Manitowoc 18000 - Page 209

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Manitowoc Published 12-05-17, Control # 035-23 4-13

18000 SERVICE/MAINTENANCE MANUAL BOOM

Inspector’s Name Signature Date

STRAP INSPECTION CHECKLIST

Dents

Length Part Number

Length

Kinks Cracks

Breaks

Corrosion

Abrasion

Elongated Holes

Flatness

Other

mm (ft)

Straightness

Dents

Length Part Number

Length

Kinks Cracks

Breaks

Corrosion

Abrasion

Elongated Holes

Flatness

Other

mm (ft)

Straightness

Dents

Length Part Number

Length

Kinks Cracks

Breaks

Corrosion

Abrasion

Elongated Holes

Flatness

Other

mm (ft)

Straightness

Dents

Length Part Number

Length

Kinks Cracks

Breaks

Corrosion

Abrasion

Elongated Holes

Flatness

Other

mm (ft)

Straightness

Dents

Length Part Number

Length

Kinks Cracks

Breaks

Corrosion

Abrasion

Elongated Holes

Flatness

Other

mm (ft)

Straightness

Main Page

Table of Contents5
Section 113
Continuous Innovation13
Safety Messages13
General13
Safety Alert Symbol13
Signal Words13
Safe Maintenance Practices14
Maintenance Instructions14
Environmental Protection15
Identification and Location of Components16
Basic Crane16
Front17
Top18
Left Side19
Left Side - S/N18001082 & Newer20
Right Side21
Rear22
Carbody/Crawler23
Operator Cab/Controls24
Cummins Engine Tier 325
Cummins Engine Tier 426
Boom Butt and Insert28
Mast Butt29
Description of Operation30
General Abbreviations30
Solenoid Valve Identification30
General Operation31
Hydraulic Components32
Hydraulic Tank32
Shutoff Valves32
Charge Filters (Past Production)32
Suction Manifolds32
Return Manifolds32
Hydraulic Fluid Cooler32
Supercharge Pumps (Past Production)32
Charge Pressure33
Hydraulic Motors33
Main Pressure Monitoring34
Accessory Systems34
Basic Operation35
Engine Controls36
Drum Identification37
Epic® Control System38
CAN-Bus38
Digital Display38
Rated Capacity Indicator/Limiter (RCL)38
Crane Modes39
Electrical Power to Operator's Cab39
Pressure Senders and Speed Sensors39
System Faults40
Engine Faults (Tier 4)40
Operating Faults and Limit Switches40
Brake and Drum Pawl Operation40
Swing System Operation42
Swing System Components42
Swing Brake and Swing Lock42
Swing Right or Left42
Swing Holding Brake Switch43
Travel System Operation46
Travel System Components46
Travel Brakes46
Travel Forward and Reverse46
Two-Speed Travel Operation49
Travel Cruise49
Boom Hoist System Operation50
Boom Hoist System Components50
Boom Hoist Brake and Pawl50
Boom Hoist Raise50
Boom Hoist Lower53
Main Hoist 1 System54
Main Hoist 1 System Components54
Main Hoist 1 Drum Brake54
Main Hoist 1 Raising54
Main Hoist 1 Lowering57
Whip Line Hoist (Drum 3) System58
Whip Line Hoist System Components58
Whip Line Drum Brake58
Whip Line Hoist Raising58
Whip Line Hoist Lowering61
Main Hoist 2 System62
Main Hoist 2 System Components62
Main Hoist 2 Drum Brake62
Main Hoist 2 Raising62
Main Hoist 2 Lowering65
Mast Hoist Drum 5 System66
Mast Hoist System Components66
Mast Hoist Brake and Pawl66
Mast Raising Cylinders66
Mast Hoist Raising from Transport Position66
Mast Hoist Raising to Transport Position70
Luffing Jib Drum 6 (Optional) System72
Luffing Jib System Components72
Luffing Jib Brake and Pawl72
Luffing Jib Raise72
Luffing Jib Lower74
Accessory System Components75
Accessory Systems75
Jacking Cylinders76
Rotating Bed Jacking - Raise76
Rotating Bed Jacking - Lower77
Boom Hinge Pins80
Adapter Frame Pins82
Mast Pins84
Rigging Winch (Drum 7)86
Cab Tilt88
Crawler Pin Cylinders90
Hydraulic Schematics95
Hydraulic System - General95
Checking and Replacing Hydraulic Hoses95
Hydraulic System Maintenance96
Safety96
Storing and Handling Oil96
Storing and Handling Parts96
Inspecting System96
Hydraulic Tank Heater97
Replacing Filters100
Charge Filters101
Return Filters102
Replacing Desiccant Breather103
Changing Oil103
Servicing Pumps104
Tightening Hydraulic Connections106
Pipe Thread Connection106
SAE Straight Thread Connection106
ORS Connection107
Split Flange Connection108
SAE Flare Connection109
Pressure Sender Replacement111
Disc Brake Operational Test112
Shop Procedures114
Initial Oil Fill114
Initial Engine Start-Up114
Pressure Sender Calibration114
Charge Pressure Check114
Accessory System Checks115
Control Calibration115
Hoist Pumps Pressure Test115
Travel Pressure Check115
Swing Pressure Check115
High Pressure Accessory System115
Low-Pressure Accessory Components116
Lower Accessory Valve116
Travel Handle and Speed Check117
Swing and Drum Speed Checks117
Hydraulic System Specifications - 18000118
Pumps119
Motors121
Hydraulic System Calibration Procedures122
Calibration Description122
Pressure Sender Calibration122
Control Calibration124
Pump Pressure Test125
Charge Pressure Check126
Hydraulic System Adjustment Procedures130
High Pressure Adjustment130
Charge Pressure Adjustment131
Pump Neutral Adjustment131
Motor Leakage Test132
Loop Flushing Valve Adjustment132
Manual Override Tests132
Pump or Motor Override133
Solenoid Valve Override133
Counterbalance Valves Adjustment134
Hydraulic Tank Level Sensor Calibration137
Empty Calibration137
Full Cold Calibration137
Electrical Schematics141
Checking and Replacing Electrical Components141
Circuit Breaker Identification142
Test Voltages143
CAN Bus Nodes143
Pumps and Motors144
Alphabetical Index of Components145
Node Heading Descriptions145
NODE 1 - Master Node (Front Console)146
NODE 2 - Handles and Cab Controls148
NODE 3 - Drum 3 and Pressure Senders151
NODE 4 - Connecting Pins, Jacking, and Mast153
NODE 5 - Alarms, Pump Controls, and Limits154
NODE 6 - Drums 2, 4, & 5, and Adapter Frame158
NODE 7 - Swing, Travel and Auto Lube160
NODE 8 - Drum 1 and Drum 6162
Node 9 - Max-Er164
NODE 20 - Boom Block Up, Block Sensor, & Limits166
NODE 21 - Luffing Jib, Block Up, Block Sensor, Limits167
NODE 0 - Power, Engine Controls, and Diagnostics168
Abbreviations169
Checking Electrical Inputs/Outputs170
Control Handle Voltages170
Dielectric Grease173
Digital Display174
Crane Operating Conditions174
Operating Limits174
System Faults175
Function Speed/Torque Adjustment180
Adjustment180
Crane Diagnostics180
General180
Drum 1180
Drum 2180
Drum 3180
Drum 4180
Drum 2181
Drum 3181
Drum 4181
Drum 5182
Drum 6182
Swing (Crane)182
Trk (Travel)183
FCN (Front Console Node)183
CAN (Can Bus)184
Hydraulic System Calibration185
Speed/Torque185
Accessory System185
Wireless186
Block Level Sensor186
Crane Mode186
Hydraulic Fan (Tier 4 Only)186
Digital Input and Output Item Tables187
Section 4195
Automatic Boom Stop Adjustment197
Maximum Operating Angles197
Operation197
Maintenance197
Bypass Limit Test198
Adjustment201
Actuator Rod Replacement201
Physical Boom Stop202
Operation202
Boom and Luffing Jib Angle Indicator Calibration203
Mast Angle Indicator Adjustment203
Mast Angle Indicator203
Adjusting Angle203
Sending Unit Assembly203
Strap Inspection and Maintenance205
Inspection205
Identifying Straps205
Frequent Inspection205
Periodic Inspection205
Cranes Not in Regular Use205
Replacement Specifications206
Corrosion or Abrasion206
Straightness207
Flatness207
Elongated Hole207
Storing Straps208
Removing Straps from Service208
Inspection Checklist208
Lattice Section Inspection and Lacing Replacement211
Section 5213
Hoist Drawings215
Boom Hoist Pawl Adjustment215
General215
Actuator Removal215
Actuator Installation and Adjustment215
Mast Hoist Pawl Maintenance217
General217
Maintenance217
Speed Sensor Adjustment218
Hydraulic Motors with Speed Sensors218
Speed Sensor Replacement218
Version 1 - Sensor with Flats218
Bail Limit Adjustment220
Weekly Maintenance220
Adjustment220
Electrical Wiring220
Block-Up Limit Adjustment222
General222
Operation222
Installation222
Load Block Level Transmitter222
Block-Up Limit Control Deactivated222
Block-Up Limit Control Activated222
Disconnecting Block-Up Limit Control226
Removing Upper Boom Point or Jib Point227
Storing Electric Cable227
Maintenance227
Adjustment228
Wire Rope Inspection and Replacement229
Wire Rope Lubrication229
Maintain a Wire Rope Condition Report229
Wire Rope Care and Replacement Guidelines229
Daily Inspection229
Periodic Comprehensive Inspection231
Replacement Criteria231
Determining the Frequency of Inspection231
Reduction in the Rope Diameter231
Broken Rope Wires232
Distributing Wire Rope Wear233
Sheave, Roller, and Drum Inspection233
Rope that Has Been Idle a Month or more233
Load Block and Hook-And-Weight Ball Inspection236
Daily Inspection236
Yearly Inspection238
Section 6239
Manual Release of Swing Brake and Lock241
Manual Release Procedure241
Section 7241
Battery Maintenance245
Safety Information245
Causes of Battery Failure245
Multiple Battery System245
Overcharging245
Undercharging245
Lack of Water245
Hold-Downs245
Overloads245
Maintenance246
Open-Circuit Voltage Test246
Weekly - Check Electrolyte Level246
Every 2 Months - Test Batteries246
High Resistance Test247
Quarterly247
Charging247
Storage247
Battery Disconnect Switch247
Engine Diagnostics248
General248
On-Board Engine Diagnostics248
Engine Air Cleaner Maintenance250
Tier 3 and Past Production250
Inspection250
Service250
Tier 4 Current Production252
Inspection252
Service252
Daily252
Monthly252
Engine Clutch Adjustment254
Operation254
Adjustment254
Engine Throttle Adjustment256
Foot Throttle Controller256
Assembly256
Calibration256
Engine Speed Calibration256
Engine Cooling System257
General257
Operation257
Coolant Flow257
Maintenance258
Daily Maintenance (Start of each Shift)258
Semiannual Checks258
Draining Cooling System258
Filling Cooling System258
Supplemental Coolant Additive258
Engine Belt Routing260
Tier 3 Engine260
Tier 4 Engine260
Diesel Particulate Filter - Tier 4261
General261
Regeneration261
Passive Regeneration261
Active Regeneration261
Stationary Regeneration261
Maintenance262
DPF Removal262
DPF Installation263
DPF Re-Orientation263
Turntable Bearing Bolt Torque267
Torque Requirements267
Lubrication267
Torque Values267
Torque Sequence267
Torque Intervals267
Bolt Replacement267
Crawler Adjustment269
Maintenance269
Tread Slack Adjustment269
Adjustment Guideline269
Adjustment Procedure270
Hydraulic Hand Pump271
Assembly271
Maintenance271
Air Removal271
Operation271
Lubrication273
Section 10273
General Troubleshooting279
Safety Summary279
Troubleshooting Charts280

Manitowoc 18000 - Page 209

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