Manitowoc 18000 Service Maintenance Manual Download Page 22

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Reference

Only

INTRODUCTION

18000 SERIVCE/MAINTENANCE MANUAL

1-10

Published 12-05-17, Control # 035-23

Rear

Item

Description

Hydraulic Fluid Cooler

Fuel Cooler

Node 9 Controller

Fuel Level Gauge

Fuel Tank Fill Cap

Fuel Tank

Hydraulic Tank Return Filters

Hydraulic Tank Breather

Access Tank Clean-Out Cover

Air Bleed Valves

Hydraulic Liquid Level Gauge

Hydraulic Tank

Liquid Level Switch

Hydraulic Tank Shut Off Valves (2)

Live Mast Straps

Mast Sheaves

Live Mast

Hydraulic Tank Heater

P1905

1910

P19

1975

P1991

FIGURE 1-7

Past Production

P1925a

18CSM1-103

1910

S/N18001082 & Newer

Prior to s/n 18001082

S/N18001082 & Newer

Prior to s/n 18001082

S/N18001082 & Newer

IMG

746

IMG
_4740

Summary of Contents for 18000

Page 1: ...R e f e r e n c e O n l y Service Maintenance Manual Manitowoc 18000 ...

Page 2: ...R e f e r e n c e O n l y ...

Page 3: ...al for the exact location of the crane identification plate Always furnish serial number of crane and its attachments when ordering parts or discussing service problems with your Manitowoc dealer or the Manitowoc Crane Care Lattice Team To prevent death or serious injury Avoid unsafe operation and maintenance Crane and attachments must be operated and maintained by trained and experienced personne...

Page 4: ...R e f e r e n c e O n l y THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH ...

Page 5: ...t 1 17 Description of Operation 1 18 General Abbreviations 1 18 Solenoid Valve Identification 1 18 General Operation 1 19 Hydraulic Components 1 20 Main Pressure Monitoring 1 22 Accessory Systems 1 22 Basic Operation 1 23 Engine Controls 1 24 Drum Identification 1 25 Epic Control System 1 26 CAN Bus 1 26 Digital Display 1 26 Rated Capacity Indicator Limiter RCL 1 26 Crane Modes 1 27 Electrical Pow...

Page 6: ...st Hoist System Components 1 54 Mast Hoist Brake and Pawl 1 54 Mast Raising Cylinders 1 54 Mast Hoist Raising from Transport Position 1 54 Mast Hoist Raising to Transport Position 1 58 Luffing Jib Drum 6 Optional System 1 60 Luffing Jib System Components 1 60 Luffing Jib Brake and Pawl 1 60 Luffing Jib Raise 1 60 Luffing Jib Lower 1 62 Accessory System Components 1 63 Accessory Systems 1 63 Jackin...

Page 7: ...8 Control Calibration 2 30 Pump Pressure Test 2 31 Charge Pressure Check 2 32 Hydraulic System Adjustment Procedures 2 36 High Pressure Adjustment 2 36 Charge Pressure Adjustment 2 37 Pump Neutral Adjustment 2 37 Motor Leakage Test 2 38 Loop Flushing Valve Adjustment 2 38 Manual Override Tests 2 38 Counterbalance Valves Adjustment 2 40 Hydraulic Tank Level Sensor Calibration 2 43 Empty Calibration...

Page 8: ...nance 4 1 Bypass Limit Test 4 2 Adjustment 4 5 Actuator Rod Replacement 4 5 Physical Boom Stop 4 6 Boom and Luffing Jib Angle Indicator Calibration 4 7 Mast Angle Indicator Adjustment 4 7 Mast Angle Indicator 4 7 Strap Inspection and Maintenance 4 9 Inspection 4 9 Identifying Straps 4 9 Replacement Specifications 4 10 Storing Straps 4 12 Removing Straps from Service 4 12 Inspection Checklist 4 12 ...

Page 9: ... 19 Sheave Roller and Drum Inspection 5 19 Load Block and Hook and Weight Ball Inspection 5 22 Daily Inspection 5 22 Yearly Inspection 5 24 SECTION 6 Swing Manual Release of Swing Brake and Lock 6 1 Manual Release Procedure 6 1 SECTION 7 Power Train Battery Maintenance 7 1 Safety Information 7 1 Causes Of Battery Failure 7 1 Multiple Battery System 7 1 Maintenance 7 2 Open Circuit Voltage Test 7 2...

Page 10: ...Particulate Filter Tier 4 7 17 General 7 17 Regeneration 7 17 Maintenance 7 18 SECTION 8 Under Carriage Turntable Bearing Bolt Torque 8 1 Torque Requirements 8 1 Crawler Adjustment 8 3 Maintenance 8 3 Tread Slack Adjustment 8 3 Hydraulic Hand Pump 8 5 Assembly 8 5 Maintenance 8 5 Air Removal 8 5 Operation 8 5 SECTION 9 Lubrication Lubrication 9 1 SECTION 10 Troubleshooting General Troubleshooting ...

Page 11: ... 4 1 14 Boom Butt and Insert 1 16 Mast Butt 1 17 Description of Operation 1 18 General Abbreviations 1 18 Solenoid Valve Identification 1 18 General Operation 1 19 Hydraulic Components 1 20 Hydraulic Tank 1 20 Shutoff Valves 1 20 Charge Filters Past Production 1 20 Suction Manifolds 1 20 Return Manifolds 1 20 Hydraulic Fluid Cooler 1 20 Supercharge Pumps Past Production 1 20 Charge Pressure 1 21 H...

Page 12: ...Whip Line Hoist Drum 3 System 1 46 Whip Line Hoist System Components 1 46 Whip Line Drum Brake 1 46 Whip Line Hoist Raising 1 46 Whip Line Hoist Lowering 1 49 Main Hoist 2 System 1 50 Main Hoist 2 System Components 1 50 Main Hoist 2 Drum Brake 1 50 Main Hoist 2 Raising 1 50 Main Hoist 2 Lowering 1 53 Mast Hoist Drum 5 System 1 54 Mast Hoist System Components 1 54 Mast Hoist Brake and Pawl 1 54 Mas...

Page 13: ...sel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain chemical lead and lead compounds chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling California Spark Arrestor Operation of th...

Page 14: ...ar appropriate eye protection and approved hard hat 5 Never climb onto or off a moving crane Climb onto and off crane only when it is parked and only with operator s permission Use both hands and handrails steps and ladders provided to climb onto and off crane Lift tools and other equipment which cannot be carried in pockets or tool belts onto and off crane with hand lines or hoists 6 Boom and gan...

Page 15: ...round with or without support of boom rigging pendants or straps securely block each section to provide adequate support and alignment Do not go under boom jib or mast sections while connecting bolts or pins are being removed 28 Unless authorized in writing by Manitowoc do not alter crane in any way that affects crane s performance to include welding cutting or burning of structural members or cha...

Page 16: ... Drums 6 Operator s Cab 7 Upperworks 8 Lowerworks 9 Right Side Crawler 10 Upper Counterweights 11 Live Mast 12 Mast Stop 13 Mast Straps 14 Main Mast 15 Main Hoist Wire Rope 16 Whip Line Wire Rope 17 Boom Hoist Wire Rope 18 Equalizer 19 Boom Straps 20 Telescopic Boom Stop 21 Adapter Frame 22 Jacks 23 Main Hoist Drum 1 24 Luffing Jib Hoist Drum 6 25 Main Hoist Drum 2 26 Mast Hoist Drum 5 27 Whip Lin...

Page 17: ...n 6 Swing Gearbox 7 Mast Hinge Pin Cylinder 8 Rotating Bed 9 Adapter Frame Pins Cylinder 10 Right Front Swing Drive 11 Left Front Swing Drive 12 Operator s Cab 13 Carbody Front and Rear Counterweights 14 Grease Crawler and Turntable Bearing Reservoir 15 Turntable with External Ring Gear Bearing 16 Right Swing Drive Gear 17 Adapter Frame 18 Node 6 Controller 19 Crane Level Sensor P1930a 4 6 Typical...

Page 18: ...Pressure Switch 4 Engine Coolant Radiator 12 Whip Line Hoist Drum 3 20 Swivel 5 Mast Assist Arms 13 Engine Cover 21 Node 7 Controller 6 Live Mast 14 Swing Brake Solenoid Valve 22 Pump Inlet Manifold 7 Mast Stop 15 Swing Lock Solenoid Valve 23 Mast Hoist Motor Drum 5 8 Mast Butt 16 Travel Brake Solenoid Valve 24 Mast Hoist Drum 5 P1997 P1912a P2000 P2003 P2002 P2004 24 19 18 Inside Adapter Frame 7 ...

Page 19: ...ft Front Jack Solenoid Valves 20 Main Hoist Pump Drum 2 33 Left Travel Pressure Sender 8 Left Rear Jack Solenoid Valves 21 Swing Pump 34 Right Travel Pressure Sender 9 Right Rear Jack Solenoid Valves 22 Left Travel Pump 35 Load Drums 1 and 3 Pressure Sender 10 Right Front Jack Solenoid Valves 23 Luffing Jib Hoist Pump Drum 6 36 Boom Hoist Pressure Sender 11 Live Mast Solenoid Valves 24 Right Trave...

Page 20: ... Accessory Pump 25 Main Hoist Pump Drums 2 and 5 17 Boom Hoist B Pump Drum 4 26 Main Hoist Pump Drum 1 18 Pump Drive 27 Boom Hoist A Pump Drum 4 19 Main Hoist Pump Drums 1 and 3 28 Swing Pump Optional 20 Main Hoist Pump Drum 2 29 Engine Drive Accessory Pump 21 Swing Pump 30 Cooler Fan Pump Tier 4 Equipped 22 Left Travel Pump FIGURE 1 5 18CSM1 104 S N18001082 Newer 13 S N18001082 Newer 30 17 18 19 ...

Page 21: ...5 Boom Stop Maximum Up Limit Switch 6 Hand Held Radio Remote Receiver 7 Node 5 Controller 8 Charge Filter Alarm Sensor 9 Charge Filter 2 10 Hydraulic Thermo Bypass Valve 11 Engine Oil Dipstick 12 Ether Starting Aid 13 Engine Oil Fill 14 Jack Pad 15 Jack Pad Support Rod 16 Rotating Bed Jack 2 Cranes prior to s n 18001082 P1995 P1760 P1994 2 9 1 P1962 Pump Reference 5 11 10 16 15 14 3 4 P1978 8 9 12...

Page 22: ...her 9 Access Tank Clean Out Cover 10 Air Bleed Valves 11 Hydraulic Liquid Level Gauge 12 Hydraulic Tank 13 Liquid Level Switch 14 Hydraulic Tank Shut Off Valves 2 15 Live Mast Straps 16 Mast Sheaves 17 Live Mast 18 Hydraulic Tank Heater 6 P1905 P1910 P1911 P1975 12 8 9 16 13 11 5 4 15 P1991 10 1 2 3 9 17 FIGURE 1 7 Past Production 7 P1925a 18CSM1 103 14 P1910 12 10 9 11 13 9 8 7 18 S N18001082 New...

Page 23: ...Input Gearbox 2 7 Crawler Idler Roller 14 each Crawler 8 Crawler Output Gearbox 2 9 Crawler Track 10 Crawler Motor 2 each Crawler 11 Travel Brake 2 each Crawler 12 Crawler Drive Gearbox 2 13 Crawler Pins Cylinder 2 14 Carbody Pedestal 15 Right Crawler Pins Handle 16 Left Crawler Pins Handle Typical 2 Places Typical 2 Places P1939 P1922 P1941b 7 8 9 12 2 2 13 14 Typical 2 Places P1927 P1945 P1963 P...

Page 24: ...rols Console 18 Hand Held Radio Remote 7 Crawler Left and Right Handles 19 Circuit Breaker A8CB1 24 12 Volt Converter 8 Windshield Wiper Switches 20 Circuit Breaker A8CB2 A C Heater Power 9 Customer Panel Optional 21 Circuit Breaker A8CB3 Windshield Wipers 10 Radio Optional 22 Circuit A8CB4 Panel Lights 11 12 Volt Power Receptacle 2 23 24 12 Volts Converter 12 Foot Activated Horn On Floor in Front...

Page 25: ... system power 24 Battery 2 9 Circuit Breaker CB2 Engine ECM 25 Air Conditioning Low High Pressure Switch 10 Circuit Breaker CB3 Engine ECM 26 Fuel Pump 11 Circuit Breaker CB4 Engine Bus Run Stop 27 Fuel Shut Off 12 Circuit Breaker CB5 Engine Ether Start 28 ECM Engine Control Module 13 Circuit Breaker CB6 Engine Start Solenoid 29 Engine Oil Dipstick 14 Circuit Breaker CB7 CAN System Power 30 Radiat...

Page 26: ...iption Item Description 1 Engine Air Cleaner 7 Engine Oil Fill Tube 2 Diesel Particulate Filter DPF 8 Diesel Particulate Filter DPF 3 Engine Exhaust Stack 9 Engine Oil Filter 4 PreCleaner 10 Cooler Surge Tank 5 Engine Node 11 Cooler Fill Cap 6 Battery Disconnect 12 Cooler Drain FIGURE 1 11 1 3 2 6 8 5 9 11 12 7 10 4 81017663 81017656 81017661 ...

Page 27: ...olenoid 2 Air Filter Indicator 9 Circuit Breaker CB7 CAN System Power 3 Circuit Breaker CB1 main system power 10 Circuit Breaker CB8 Cab Power 4 Circuit Breaker CB2 Engine ECM 11 Ether Bottle 5 Circuit Breaker CB3 Engine ECM 12 Fuel Filter High Pressure 6 Circuit Breaker CB4 Engine Bus Run Stop 13 Water In Fuel Filter Low Pressure 7 Circuit Breaker CB5 Engine Ether Start 3 1 2 7 8 9 10 4 6 5 FIGUR...

Page 28: ...b Hoist Motor Drum 6 3 Main Hoist Drum 2 11 Electrical Boom Cable 4 Wire Rope Sheave 12 Electrical Cable Reel 5 Boom Insert 13 Hydraulic Manifold Block 6 Boom Insert Accumulator 14 Boom Butt Accumulator 7 Main Hoist Motor Drum 1 15 Boom Angle Indicator 8 Main Hoist Drum 1 P2017 P2010 P2015 P2016 P2014 P2012 P2011 11 12 13 14 15 6 7 5 4 8 3 2 1 10 9 Motor Each Side of Drum Motor Each Side of Drum L...

Page 29: ...tem Description 1 Mast Butt Accumulator 2 Boom Hoist Drum 4 3 Motor Control 4 Boom Hoist Motor Drum 4 5 Boom Hoist Brake Inside Gearbox 6 Motor Speed Sensor 7 Loop Flushing Valve 8 Pawl Electrical Junction Box 9 Boom Hoist Pawl P2007 P2008 P2009 P2013a 4 3 9 Motor Each Side of Drum Typical All Drums 5 7 6 2 FIGURE 1 13 1 8 18CSM1 114 ...

Page 30: ...olenoid SS Starter Solenoid VDC Volts Direct Current W White Light HS 1 Swing Brake HS 2 Swing Lock In HS 3 Swing Lock Out HS 4 Travel Brake HS 5 Travel Two speed HS 6 Boom Hoist Drum 4 Brake HS 7 Main Hoist 1 Drum 1 Brake HS 8 Whip Line Hoist Drum 3 Brake HS 9 Whip Line Hoist Drum 3 Diverting HS 10 Main Hoist 2 Drum 2 Brake HS 11 Mast Hoist Drum 5 Brake HS 12 Mast Hoist Drum 5 Pawl Out HS 13 Mast...

Page 31: ... motor Pressure develops within the closed loop system while resistance to movement of the load on motor is overcome When movement begins pump volume displacement maintains motor speed The spent hydraulic fluid from motor outlet returns directly to pump input The crane closed loop systems are swing right travel left travel boom hoist load drums 1 and 2 and luffing jib hoist The whip line hoist Dru...

Page 32: ...display indicates that charge filters need to be serviced Suction Manifolds Suction manifolds supply hydraulic fluid to all system pumps Each hydraulic system draws hydraulic fluid from a suction manifold as needed Return Manifolds Return fluid from closed loop relief valves brake valves motor servos cylinders pump case drain and motor case drain is routed to main return manifold or cooler return ...

Page 33: ...ure Charge pressure in each closed loop system is preset at approximately 350 psi 24 bar with a relief valve in charge pump Charge pressure must be at preset value as lower pressures can cause a slowing or stopping of operation If the charge pressure is set too high the hydraulic system could be damaged When a system control handle is in neutral the digital display indicates system charge pressure...

Page 34: ...nd held radio remote control include Rotating bed jacking cylinders four Boom hinge pin cylinders Front and rear adapter frame pin cylinders Mast pins cylinders Mast raising cylinders Rigging winch Drum 7 Engine speed Each hydraulic solenoid valve of the accessory system is open circuit type where return fluid goes directly to tank Accessory system and high pressure accessory pressure senders moni...

Page 35: ...valve 2 is spring loaded with an opening pressure of 750 psi 52 bar Hydraulic fluid from pressure limiting relief valve flows through exhaust port of displacement control valve 3 The exhaust port has a restricted orifice that develops pressure for servo control cylinder 4 to pressurize and de stroke pump to limit system pressure When rapid loading produces pressure spikes system relief valve 5 shi...

Page 36: ...rvo PC valve The travel motor servo is opposite of other system motors The travel variable displacement motors begin operation at minimum displacement low torque high speed The motor shifts to maximum displacement high torque low speed when starting torque is required and back to minimum displacement when in motion if load is below a preset pressure of 3770 psi 270 bar Depending on motor system se...

Page 37: ... push button stops the engine in an emergency only as all brakes apply and any functions stop abruptly Three engine diagnostic lights are mounted on front console see Engine Diagnostics in Section 10 of the Service Maintenance Manual for diagnostic light information Drum Identification See Figure 1 19 for the following procedure Seven wire rope drum drives are on the Model 18000 crane The location...

Page 38: ...es represent electrical inputs outputs to node 1 controller See Crane Diagnostics in Section 10 of the Service Maintenance Manual Universal nodes on the boom monitor the boom luffing jib or fixed jib components and input the information to node 1 controller Boom components include angle sensors block up limits and load pin sensors The mast angle position is also monitored The system nodes controll...

Page 39: ...elays Engine control module relay CU ECM Engine ether start relay CU ES Cab power relay CAB PWR CAN system ground relay CAN GND Air conditioning system relay A C CLUTCH Engine starter solenoid relays MS1 MS2 CAN system power relay CAN PWR When cab power relay is enabled power is available to operate crane controls see Electrical Schematics in this manual Pressure Senders and Speed Sensors Pressure...

Page 40: ...the limits for crane setup or maintenance only For example to add wire rope on load drum or to remove wire rope from load drum after an operating limit is enabled Node 1 controller monitors crane systems and enables a yellow operating limit light and alert if any limit switch is open or any programmed limit is reached To identify and display operating limit use scroll switch to access fault screen...

Page 41: ...N GROUND 0 0C 6A CU 8C 8 6C8A 3 JI939L 8C JI939H RIGHT STARTER SOLENOID 6C12B MS2 S S 3 ES S M RIGHT STARTER MOTOR S S LIMIT BYPASS P11 13 0 RCL DISPLAY WCP SYSTEM FAULT ALARM P11 07 P11 09 OPERATING LIMIT LIGHT GND ALARM LIGHT P12 37 P12 38 CRANE DISPLAY P11 19 RCL CAB FAULT ALARM P12 24 P12 24 FROM ENGINE START RUN RCL DISPLAY SCROLL JIB UP P11 14 UP DOWN P11 03 P11 04 SELECT CONFIRM P11 05 P11 ...

Page 42: ...huttle valve at 500 psi 34 bar For swing brake and swing lock operation the system pressure must be above 200 psi 14 bar for full release brake and lock If system pressure is below 200 psi 14 bar swing brake or swing lock could be partially applied and damage the swing system If brake pressure or electrical power is lost when operating the swing brake is applied After startup place swing brake swi...

Page 43: ...riods when operating To prevent damage to swing system swing holding brake switch must only be applied when crane is at a standstill When holding brake switch is pressed in and held an input voltage is sent to node 1 controller Node 7 controller sends a zero output voltage to shift swing brake solenoid HS 32 Swing brake solenoid valve shifts to block fluid to brake and swing brake is applied When ...

Page 44: ...L HANDLE SWING HOLDING BRAKE SWITCH W56 G W56 H SWING TRAVEL ALARM GND DO HS 1 HS 2 HS 3 NODE 3 SWING LEFT PRESSURE SWING RIGHT PRESSURE NODE 2 P22 07 WIP52 07 DI EDC PUMP 2 RIGHT W54 X W54 a LEFT CONTROL W54 Z W54 b GND GND DO DO EDC W76 V W76 n W76 p W76 j SPEED SENSOR GND 5 VOLTS EC1A EC1B SWING W74 Z W74 X BEARING GND DO AUTO LUBE NODE 7 PUMP NODE 5 0 CRANE DISPLAY 10 AMP 6C8 6A CB4 ENGINE STO...

Page 45: ...SWING SUCTION MANIFOLD CHARGE PUMP LOCK HS 3 SWING OUT IN SWING 2 PUMP B A 350 PSI 24 BAR SUCTION MANIFOLD CHARGE PUMP A B BRAKE SWING LOCK SWING A B BRAKE SWING LOCK A B BRAKE SWING LOCK SWING SWING SWING LEFT SWING RIGHT 060 060 PRESSURE VALVE REDUCING FROM 500 PSI 34 BAR 060 060 EQUALIZING LINE EQUALIZING LINE X MOTOR MOTOR MOTOR MOTOR FIGURE 1 23 18CSM1 121 HIGH PRESSURE ACCESSORY PUMP SYSTEM ...

Page 46: ...ane in position Travel brake solenoid valve HS 35 is open to allow hydraulic flow from the brake to tank When travel brake switch is in off park position an input signal is sent to node 1 controller Travel system circuit is active waiting for a travel control handle command When travel control handle is moved node 7 controller sends a 24 volt output to enable travel brake solenoid valve HS 35 Brak...

Page 47: ...W54 D GND GND DO DO EDC TRAVEL W74 W W74 V GND DO AL NODE 7 PUMP NODE 5 LEFT TRACK PUMP CONTROL RIGHT TRACK SENDER RIGHT TRACK PRESSURE SENDER P11 23 TRAVEL P11 25 TRAVEL CRUISE SWITCH SPEED PARK BRAKE P22 36 W1P52 36 DO P22 27 W1P52 27 DO DI P21 18 W1P51 18 P22 28 W1P52 28 5 VOLTS P22 40 W1P52 40 AI P21 14 W1P51 14 GND P21 22 W1P51 22 RIGHT TRAVEL CONTROL HANDLE DO P22 29 W1P52 29 DO NODE 2 0 CRA...

Page 48: ...RS TRAVEL BRAKE LEFT TRAVEL PUMP RIGHT TRAVEL PUMP B A HS 4 290 PSI 20 BAR RIGHT PRESSURE SENDER B PILOT SUPPLY FORWARD TRAVEL 2 SPEED HS 5 TRAVEL BRAKE FROM HIGH PRESSURE PUMP ACCESSORY SUCTION MANIFOLD A 290 PSI 20 BAR B 340 PSI 23 BAR B A REVERSE FORWARD 340 PSI 23 BAR B A 290 PSI 20 BAR B A TRAVEL BRAKE TRAVEL BRAKE LEFT PRESSURE SENDER PILOT PRESSURE TO BOOM REVERSE FORWARD PRESSURE REDUCING ...

Page 49: ... valve HS 5 shifting valve and directing hydraulic pilot pressure to P C Pressure Compensated valve The P C valve shifts PCOR Pressure Compensated Over Ride spool placing travel motor in maximum displacement high torque low speed position Travel motors remain in this position until travel speed switch is placed in high speed position and engine speed is more than 1500 RPM When travel speed switch ...

Page 50: ...on boom hoist brake remains applied to boom hoist drum until node 6 controller sends a 24 volt output to brake solenoid valve HS 6 to release brake Node 6 controller sends 24 volt output to enable boom hoist pawl electric motor K2 relay in the pawl out direction Boom system circuit is active waiting for a control handle command Boom Hoist Raise When boom hoist control handle is moved back for boom...

Page 51: ...S P21 31 W1P51 31 AI P21 15 W1P51 15 GND P21 22 W1P51 22 THROTTLE ENGINE DO P22 31 W1P52 31 NODE 2 INDICATOR PUMP LOWER W54 L W54 K RAISE CONTROL W54 M W54 S GND GND DO DO EDC DRUM 4 1 PUMP LOWER W54 T W54 V RAISE CONTROL W54 U W54 W GND GND DO DO EDC DRUM 4 2 W56 V W56 n W56 p W56 j SPEED SENSOR GND 5 VOLTS EC1A SS EC1B NODE 5 W64 X DRUM 4 1 W64 Z GND DO M C MOTOR CONTROL W64 a DRUM 4 2 W64 b GND...

Page 52: ...23 BAR B A PRESSURE SENDER X X A B SUCTION MANIFOLD DOWN UP 340 PSI 23 BAR B A DRUM 4 2 PUMP BOOM HOIST DRUM 4 1 PUMP PILOT PRESSURE FROM LEFT X BRAKE DRUM BRAKE PM ELECTRIC DRUM PAWL BOOM HOIST DRUM 4 060 060 TRAVEL CHARGE PUMP MAKE UP FLUID MAKE UP FLUID EQUALIZING LINE EQUALIZING LINE 15 m l OPENS AT 200 PSI 14 bar 4 GPM 15 m l OPENS AT 200 PSI 14 bar FIGURE 1 27 18CSM1 125 ...

Page 53: ...Compensating Over Ride valve setting of 4 930 psi 340 bar the valve shifts to direct flow from shuttle valve into maximum displacement side of servo cylinder The PCOR valve over rides the command from servo PC valve increasing motor displacement and output torque and reducing output speed When PCOR valve closes control of the motor returns to servo PC valve Node controllers are continuously balanc...

Page 54: ...ed Brakes remain applied until node 8 controller sends a 24 volt output to release the brake The drum circuit is active waiting for a control handle command Main Hoist 1 Raising The following drum raising operation is for main hoist 1 Drum 1 while operating in Standard mode When main hoist 1 control handle is moved back for raising an input voltage of 2 4 volts or less is sent to node 1 controller...

Page 55: ... ALARM LIGHT CAB PWR 50 AMP CB7 6C13 CAN POWER 8C WCP P12 37 P12 38 CB8 NODE 0 NODE 1 Master ROTATION P22 01 W1P52 01 W33 c DRUM 1 W86 F W86 E W33 F HANDLE P22 23 W1P52 23 W33 E BRAKE GND AI GND DO DO GND HS 7 W86 J W86 H W86 G DI DO GND P22 07 W1P52 07 DO P21 07 W1P51 07 P22 09 W1P52 09 5 VOLTS P22 33 W1P52 33 AI P21 03 W1P51 03 GND P21 22 W1P51 22 THROTTLE ENGINE DO P22 10 W1P52 10 DO NODE 2 IND...

Page 56: ...DRUM 1 3 PUMP MAIN HOIST 1 DRUM 1 PUMP SERVO PILOT PRESSURE FROM RIGHT TRAVEL CHARGE PUMP MAKE UP CHARGE PRESSURE X BRAKE DRUM BRAKE TO DRUM 3 SELECTOR VALVE DIVERTER MAKE UP CHARGE PRESSURE LOW PRESSURE SIDE HIGH HIGH PRESSURE SIDE LOW PRESSURE SIDE SIDE MAIN HOIST DRUM 1 060 060 PRESSURE EQUALIZING LINE EQUALIZING LINE HS 9 LOW PRESSURE ACCESSORY SUPPLY 4 GPM 15 m l OPENS AT 4 GPM 15 m l OPENS A...

Page 57: ...swashplate angle When system pressure exceeds the PCOR valve setting of 4 930 psi 340 bar the valve shifts to direct flow from shuttle valve into maximum displacement side of servo cylinder The PCOR valve over rides the command from servo PC valve increasing motor displacement and output torque and reducing output speed When PCOR valve closes control of the motor returns to servo PC valve Node con...

Page 58: ...t output to release the brake Whip line hoist circuit is active waiting for a control handle command Whip Line Hoist Raising The following drum raising operation is for whip line hoist while operating in Standard mode When whip line hoist control handle is moved back for raising an input voltage of 2 6 volts or more is sent to node 1 controller Node 4 controller sends a 24 volt output to drum 3 di...

Page 59: ...2 07 P21 09 W1P51 09 P22 18 W1P52 18 5 VOLTS P22 35 W1P52 35 AI P21 05 W1P51 05 GND P21 22 W1P51 22 THROTTLE ENGINE DO P22 19 W1P52 19 DO NODE 2 INDICATOR PUMP LOWER W34 A W34 C RAISE CONTROL W34 B W34 D GND GND DO DO EDC PUMP LOWER W34 L W34 N RAISE CONTROL W34 M W34 S GND GND DO DO EDC W36 V W36 n W36 p W36 j GND 5 VOLTS EC1A SS EC1B NODE 3 DRUM 3 MOTOR CONTROL NO NC PARK BRAKE WHIP LINE DRUM 3 ...

Page 60: ...DOWN UP 340 PSI 23 BAR A B DRUM 1 3 PUMP MAIN HOIST DRUM 1 PUMP MAKE UP CHARGE PRESSURE BRAKE SELECTOR VALVE DIVERTER MAKE UP CHARGE PRESSURE TO MAIN HOIST 1 TO MAIN HOIST 1 LEFT SIDE MOTOR DRUM 3 WHIP LINE A B SERVO PILOT PRESSURE FROM LEFT TRAVEL PUMP HIGH PRESSURE LOW PRESSURE 060 060 RIGHT SIDE MOTOR X SIDE SIDE HS 9 4 GPM 15 m l OPENS AT 200 PSI 14 bar LOW PRESSURE ACCESSORY SUPPLY FIGURE 1 3...

Page 61: ...lease brake When brake is released node 3 controller sends a 24 volt output voltage to pump EDC to tilt swashplate to stroke pump in the lower direction In the lower direction hydraulic fluid flow is from port B of pump to port A of motor Return fluid is from port B of motor to port A of pump Controller output voltage to pump EDC and motor PCP is relative to control handle movement As drum control...

Page 62: ...es not stroke in response to control handle movement When selected main hoist drum brake switch is placed in off park position brake solenoid valve HS 10 Drum 2 remains applied Brakes remain applied until node 6 controller sends a 24 volt output to release the brake The drum circuit is active waiting for a control handle command Main Hoist 2 Raising The following drum raising operation is for main...

Page 63: ... AMP 6C8 6A CB4 ENGINE STOP 6C8A P12 24 P12 14 SYSTEM FAULT ALARM P11 07 P11 09 OPERATING LIMIT LIGHT GND START STOP ENGINE RUN 3 7 X 24 VOLTS ALARM LIGHT CAB PWR 50 AMP CB7 6C13 CAN POWER 8C WCP P12 37 P12 38 CB8 NODE 0 NODE 1 Master ROTATION P22 02 W1P52 02 DRUM 2 W66 F W66 E HANDLE P22 24 W1P52 24 BRAKE GND DO DO GND W66 J W66 H W66 G DI DO GND P22 07 W1P52 07 DI P22 08 W1P51 08 P22 16 W1P52 16...

Page 64: ...NIFOLD DOWN UP 340 PSI 23 BAR B A PUMP 2 5 MAIN HOIST 2 PUMP 2 SERVO PILOT PRESSURE FROM RIGHT TRAVEL CHARGE PUMP MAKE UP CHARGE PRESSURE X BRAKE DRUM BRAKE TO DRUM 5 VALVE DIVERTER MAKE UP CHARGE PRESSURE LOW PRESSURE SIDE HIGH PRESSURE HIGH PRESSURE SIDE LOW PRESSURE SIDE SIDE 060 060 ACCESSORY SUPPLY HS 14 LOW PRESSURE 4 GPM 15 m l OPENS AT 4 GPM 15 m l OPENS AT 200 PSI 14 bar 200 PSI 14 bar FI...

Page 65: ...ump swashplate angle When system pressure exceeds the PCOR valve setting of 4 930 psi 340 bar the valve shifts to direct flow from shuttle valve into maximum displacement side of servo cylinder The PCOR valve over rides the command from servo PC valve increasing motor displacement and output torque and reducing output speed When PCOR valve closes control of the motor returns to servo PC valve Node...

Page 66: ...led and drum brake is applied Mast hoist drum pawl in solenoid valve HS 12 is enabled to keep pawl applied to mast hoist drum flange The pawl in solenoid is open to charge pressure from pump 2 5 to piston end of cylinder to extend pawl to drum flange Mast hoist pump does not stroke in response to mast hoist control handle movement When mast hoist Drum 5 brake switch is placed in off park position ...

Page 67: ...5 W1P52 25 BRAKE GND DO DO GND P22 07 W1P52 07 P21 09 W1P51 09 P22 18 W1P52 18 5 VOLTS P22 35 W1P52 33 AI P21 05 W1P51 05 GND P21 22 W1P51 22 THROTTLE ENGINE DO P22 19 W1P52 19 DO NODE 2 INDICATOR PUMP LOWER W34 E W34 G RAISE CONTROL W34 F W34 H GND GND DO DO EDC DRUM 2 PUMP LOWER W34 J W34 K RAISE CONTROL W34 P W34 R GND GND DO DO EDC DRUM 2 5 W36 V W36 r W36 s W36 Z GND 5 VOLTS EC2A SS EC2B PARK...

Page 68: ...ESSURE SENDER SUCTION MANIFOLD DOWN UP 340 PSI 23 BAR B A PUMP 2 5 MAIN HOIST 2 PUMP 2 MAKE UP CHARGE PRESSURE VALVE DIVERTER MAKE UP CHARGE PRESSURE 060 060 HS 11 DRUM BRAKE TO MAIN HOIST 2 RIGHT SIDE MOTOR DRUM 5 MAST HOIST A B HIGH PRESSURE LOW PRESSURE SIDE SIDE TO MAIN HOIST 2 LEFT SIDE MOTOR HS 12 HS 13 LOW PRESSURE ACCESSORY SUPPLY HS 14 X FIGURE 1 35 18CSM1 133 ...

Page 69: ...low restrain sections preset for a relief pressure of 3 500 psi 240 bar Counterbalance valves operate with a 5 1 pilot ratio of the relief valve pressure permitting valve to open when pressure in rod end of the cylinders is approximately 700 psi 48 bar Hydraulic fluid from side B sections of both counterbalance valves combines and the free flow check valve section on side B of load equalizing valv...

Page 70: ...3 000 psi 207 bar at the beginning and 4 000 psi 276 bar after the mast cylinders start moving down From the accessory valve the fluid pressure enters free flow check valve sections on side B of load equalizing valve From equalizing valve fluid enters counterbalance valves and rod end of mast cylinders retracting cylinder rods Fluid flow from piston end of mast raising cylinders is blocked by free...

Page 71: ...LVE BANK LOAD EQUALIZING VALVE 4500 PSI 310 BAR MAST RAISING CYLINDERS EXTEND 3500 PSI 240 BAR VALVE BANK LOAD EQUALIZING VALVE 4500 PSI 310 BAR 3500 PSI 240 BAR HS 33 HS 34 HS 34 HS 33 MAST RAISING CYLINDERS RETRACT FIGURE 1 36 18CSM1 134 18CSM1 135 From High Pressure Accessory Manifold From High Pressure Accessory Manifold ...

Page 72: ...ontroller checks that luffing jib up limit switch is closed and no hydraulic system fault is present If a block up limit or RCL operating fault occurs while luffing node 1 controller sends an output signal to stop luffing jib drum Corrective action for these operating faults is to raise the jib When luffing jib control handle is moved back for luffing up an input voltage of 2 4 volts or less is se...

Page 73: ...INDICATOR PUMP LOWER W54 E W54 G RAISE CONTROL W54 F W54 H GND GND DO DO EDC DRUM 6 W86 V W86 r W86 s W86 j SPEED SENSOR GND 5 VOLTS EC1A SS EC1B NODE 5 W84 A DRUM 6 W84 B GND DO M C MOTOR CONTROL PRESSURE DRUM 6 MOTOR K1 K2 W84 G DRUM 6 PAWL MOTOR 0 CRANE DISPLAY 10 AMP 6C8 6A CB4 ENGINE STOP 6C8A P12 24 SYSTEM FAULT ALARM P11 07 P11 09 OPERATING LIMIT LIGHT GND START STOP ENGINE RUN 3 7 X 24 VOL...

Page 74: ...rides the command from servo PC valve increasing motor displacement and output torque and reducing output speed When PCOR valve closes control of the motor returns to servo PC valve Node controllers are continuously balancing the system pressure and the motor displacement angle so the motor displacement goes to minimum when control handle is all the way forward if the motor torque requirement is n...

Page 75: ...pressure are monitored by separate pressure senders During normal operation the relief valve is set at approximately 150 psi 10 bar Excess supply flow from fixed displacement accessory pump is dumped through valve to tank When a component of either accessory system is enabled an input signal is sent to node 1 controller Node 5 controller sends a variable 0 to 24 volt signal to accessory system pro...

Page 76: ...tional control valve HS 20 and shifts valve to the raise position Node 5 controller sends a variable zero to 24 volt output voltage to enable accessory system proportional relief valve Hydraulic fluid pressure at approximately 3 000 psi 204 bar flows to selected jacking cylinder s proportional control valve Hydraulic fluid exits valve and enters free flow check valve section of jacking cylinder co...

Page 77: ...ped by the cylinder counterbalance valve at piston end of the jacking cylinder supports the weight and gravitational force of rotating bed Node 4 controller monitors accessory system pressure sender to control jacking cylinder lowering speed rate Hydraulic fluid returning to tank from piston end of the jacking cylinder is blocked by the free flow check valve section of counterbalance valve From co...

Page 78: ...S GND DO HS 18 CAB TILT RIGHT FRONT W44 H W44 G JACK RETRACT GND DO LEFT FRONT W44 P W44 J JACK EXTEND GND DO BOOM HINGE PINS W44 R W44 K JACK RETRACT GND DO HS 21 W46 E W46 F GND DO W46 G W46 H GND DO HS 34 LEFT REAR JACK EXTEND RIGHT REAR W44 U W44 T JACK EXTEND GND DO HS 22 RIGHT REAR W44 W W44 V JACK RETRACT GND DO HS 23 W44 Z W44 X GND DO HS 24 LEFT REAR W44 b W44 a JACK RETRACT GND DO HS 25 ...

Page 79: ...JACKS LEFT FRONT JACK RETRACT PROPORTIONAL ACCESSORY VALVES RIGHT FRONT JACKS LEFT FRONT JACK EXTEND HS 17 HS 18 HS 19 HS 20 HS 21 HS 22 HS 23 HS 24 HS 17 HS 18 HS 19 HS 20 HS 21 HS 22 HS 23 HS 24 PROPORTIONAL ACCESSORY VALVES FIGURE 1 40 18CSM1 139 18CSM1 140 From High Pressure Accessory Manifold From High Pressure Accessory Manifold ...

Page 80: ... accessory system pressure sender monitors accessory system pressure Hydraulic fluid pressure at approximately 3 000 psi 204 bar flows to boom hinge pins accessory valve Hydraulic fluid leaves the accessory valve and enters rod end of boom pin cylinder retracting cylinder rod to engage the boom hinge pins Hydraulic fluid from piston end of boom pin cylinder leaves accessory system valve and return...

Page 81: ... 1 69 18000 SERIVCE MAINTENANCE MANUAL INTRODUCTION 1 HS 26 HS 25 ACCESSORY VALVES BOOM HINGE PINS ENGAGE HS 26 HS 25 ACCESSORY VALVES BOOM HINGE PINS DISENGAGE FIGURE 1 41 18CSM1 152 18CSM1 141 From High Pressure Accessory Manifold From High Pressure Accessory Manifold ...

Page 82: ...cessory system pressure Hydraulic fluid pressure at approximately 3 000 psi 204 bar flows to adapter frame pins accessory valve Hydraulic fluid leaves the accessory valve and enters piston end of selected pin cylinders extending cylinder rod to engage the adapter frame pins Hydraulic fluid from rod end of pin cylinders leaves accessory system valve and returns to tank When adapter frame pins switc...

Page 83: ... HS 30 HS 29 ACCESSORY VALVES FRONT ADAPTER FRAME PINS REAR ADAPTER FRAME PINS HS 28 HS 27 FRONT ADAPTER FRAME PINS REAR ADAPTER FRAME PINS HS 30 HS 29 ACCESSORY VALVES HS 28 HS 27 DISENGAGE DISENGAGE ENGAGE ENGAGE FIGURE 1 42 18CSM1 142 18CSM1 143 From High Pressure Accessory Manifold From High Pressure Accessory Manifold ...

Page 84: ...ry system pressure sender monitors accessory system pressure Hydraulic fluid pressure at approximately 3 000 psi 204 bar flows to mast pins accessory valve Hydraulic fluid leaves the accessory valve and enters piston end of mast pin cylinders extending cylinder rods to engage the mast pins Hydraulic fluid from rod end of mast pin cylinders leaves accessory system valve and returns to tank When mas...

Page 85: ...035 23 1 73 18000 SERIVCE MAINTENANCE MANUAL INTRODUCTION 1 HS 32 HS 31 ACCESSORY VALVES MAST PINS ENGAGE HS 32 HS 31 ACCESSORY VALVES MAST PINS DISENGAGE FIGURE 1 43 18CSM1 144 18CSM1 145 From High Pressure Accessory Manifold From High Pressure Accessory Manifold ...

Page 86: ...y system pressure sender monitors accessory system pressure Hydraulic fluid pressure at approximately 3 000 psi 204 bar flows to rigging winch accessory valve Hydraulic fluid leaves the accessory valve and enters pay out side of winch motor to pay out wire rope at a fixed speed Return hydraulic fluid from motor leaves accessory system valve and returns to tank When rigging winch switch is released...

Page 87: ... 23 1 75 18000 SERIVCE MAINTENANCE MANUAL INTRODUCTION 1 HS 36 HS 35 ACCESSORY VALVES RIGGING WINCH HAUL IN ACCESSORY VALVES RIGGING WINCH PAY OUT HS 36 HS 35 FIGURE 1 44 18CSM1 146 18CSM1 147 From High Pressure Accessory Manifold From High Pressure Accessory Manifold ...

Page 88: ...valve and enters free flow check valve before entering piston end of cylinder extending cylinder rod to raise the cab front Hydraulic fluid from rod end of cylinder enters free flow check valve before entering accessory valve and returns to tank When cab tilt switch is released solenoid valve HS 37 returns to center position When bottom of cab tilt switch lower front of cab is pushed and held an i...

Page 89: ...00 SERIVCE MAINTENANCE MANUAL INTRODUCTION 1 HS 37 HS 38 ACCESSORY VALVES ACCESSORY VALVES CAB TILT CYLINDER HS 37 HS 38 RAISE CAB FRONT CAB TILT CYLINDER LOWER CAB FRONT FIGURE 1 45 18CSM1 148 18CSM1 149 From High Pressure Accessory Manifold From High Pressure Accessory Manifold ...

Page 90: ...approximately 3 000 psi 207 bar The high pressure accessory systems pressure increases to operate selected component Node 1 controller monitors system pressure Pull crawler pin handle down to engage crawler pins into crawler track frame This shifts selected crawler pins lower accessory valve to block supply through valve and opens supply port to cylinders Hydraulic fluid enters piston end of cylin...

Page 91: ...E REDUCING VALVE LEFT CRAWLER PINS EXTEND RIGHT CRAWLER PINS LOWER ACCESSORY VALVE SWIVEL 500 PSI 34 BAR X PRESSURE REDUCING VALVE LEFT CRAWLER PINS RETRACT RIGHT CRAWLER PINS LOWER ACCESSORY VALVE SWIVEL 500 PSI 34 BAR X FIGURE 1 46 18CSM1 150 18CSM1 151 From High Pressure Accessory Manifold From High Pressure Accessory Manifold ...

Page 92: ...R e f e r e n c e O n l y INTRODUCTION 18000 SERIVCE MAINTENANCE MANUAL 1 80 Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 93: ...ure Sender Replacement 2 17 Disc Brake Operational Test 2 18 Shop Procedures 2 20 Initial Oil Fill 2 20 Initial Engine Start Up 2 20 Pressure Sender Calibration 2 20 Charge Pressure Check 2 20 Control Calibration 2 21 Hoist Pumps Pressure Test 2 21 Travel Pressure Check 2 21 Swing Pressure Check 2 21 Accessory System Checks 2 21 High Pressure Accessory System 2 21 Low Pressure Accessory Components...

Page 94: ...trol 035 23 Motor Leakage Test 2 38 Loop Flushing Valve Adjustment 2 38 Manual Override Tests 2 38 Pump or Motor Override 2 39 Solenoid Valve Override 2 39 Counterbalance Valves Adjustment 2 40 Hydraulic Tank Level Sensor Calibration 2 43 Empty Calibration 2 43 Full Cold Calibration 2 43 ...

Page 95: ... exist evaluate the hose assemblies for correction or replacement 2 At the same service interval visually inspect all other hydraulic components and valves for the following a Leaking ports b Leaking valve sections or manifolds and valves installed into cylinders or onto motors c Damaged or missing hose clamps guards or shields d Excessive dirt and debris around hose assemblies If any of these con...

Page 96: ...f it Also clean faucet or pump to remove oil from drum Only use clean transfer containers Do not take oil from storage until oil is needed If oil cannot be used immediately keep transfer container tightly covered Storing and Handling Parts Store new parts valves pumps motors hoses tubes in a clean dry indoor location Do not unpack parts or remove port plugs until parts are needed Once unpacked car...

Page 97: ...air leak can be pinpointed by flooding inlet fitting hose or tube with oil If there is an air leak the oil will cause a noticeable reduction in noise Correct cause for any air leak or pump motor will be ruined NOTE A high pitched whine or scream from the pump can also indicate cavitation pump being starved of oil This condition is caused by the following problems Collapsed or plugged suction line ...

Page 98: ...Production CLOSED on Current Production Rotate DOWN to CLOSE UP to OPEN 1 Filter 1 2 P1923 Typical 2 Places 10 P1910 11 12 13a 13b 1 Filter 2 7 Filters 2 P2228 Past Production 15 P1910 14 Under Rear of Rotating Bed 8b P1911 9 6 3 5 8a 16 Filter 8 15 18CSM1 103 S N18001082 Newer 7 Filters 3 9 8a 6 17 17 S N18001082 Newer Prior to s n 18001082 Prior to s n 18001082 IMG_4742 IMG_4748 Legend on follow...

Page 99: ...Cover 7 Return Filter 2 or 3 each 8a Fill Cap 8b Power Fill Coupler 9 Breather 10 Hydraulic Tank 11 Temperature Gauge oil in tank 12 Sight Gauge oil level 13a Coupler 13b Air Valve depress valve stem to vent hydraulic tank before servicing 14 Drain Valve 15 Tank Shutoff Valve 2 each 16 Filter 8 2 each suction filter 17 Oil Level Sensor NOTE 1 On S N18001082 and newer Supercharge pump and charge fi...

Page 100: ...rt to come on at start up when the oil is cold If the filters are not plugged the alert will turn off after the hydraulic oil warms up FIGURE 2 3 Outlet Past Production Charge Filter Inlet Current Production Charge Filter prior to S N 18001082 Item Description 1 Vent Plug 2a Cover 2b Handle part of cover 3 O Ring with Back Up Ring 4 O Ring 5 Element 6 Tube 7 Head 2a 2b 1 4 3 5 6 4 7 Outlet Inlet 1...

Page 101: ...lter 8 Lubricate element O ring s 4 with clean hydraulic oil and securely install element in tube 6 9 If necessary replace O ring and back up ring 3 or O ring 4 in cover 2a and lubricate with clean hydraulic oil 10 Reinstall cover 2a until threads bottom out Securely hand tighten only Disregard steps step 11 through step 14 if you are also changing oil 11 Remove vent plug 1 from filter cover 2a 12...

Page 102: ...se element Do not operate crane without return filter elements installed 7 Lubricate element O ring s 2 with clean hydraulic oil and securely install element in shell 8 If necessary replace O ring in cover and lubricate with clean hydraulic oil 9 Reinstall cover 1 until threads bottom out Securely hand tighten only 10 Start engine and allow hydraulic system to return to normal operating pressure a...

Page 103: ...nsert end of hose into a suitable container to catch hydraulic oil Tank capacity to FULL COLD mark on sight gauge is 270 gallons 1 022 liters 4 Open drain valve 14 and drain tank completely 5 Clean all dirt off access covers 6 in top and bottom of tank Then remove covers Take care to prevent dust and wind blown dirt from entering tank while covers are off 6 Flush out any sediment inside tank 7 Car...

Page 104: ...k through fill port 8a or through power fill coupler 8b 17 Apply 3 5 psi owner supplied air pressure to coupler 13a or air valve 13b in side of hydraulic tank Some air will leak from breather cap 18 Observe vent ports a Securely install vent plug 1 when oil starts flowing from vent port in each charge filter 2 on cranes prior to s n 18001082 NOTE S N18001082 and newer Supercharge pump and charge f...

Page 105: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL HYDRAULIC SYSTEM Manitowoc Published 12 05 17 Control 035 23 2 11 2 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 106: ... as shown in Figure 2 9 View B Tighten SAE straight thread connections as follows 1 Back up jam nut and washer to end of smooth portion on fitting as shown in Figure 2 10 View A 2 Lubricate O ring with clean oil this is very important 3 Thread fitting into port until washer bottoms against spot face as shown in Figure 2 10 View B NOTE If an elbow is being used back it out as necessary to align it ...

Page 107: ... pinched Replace O ring and tighten fitting properly O ring cut Replace O ring wrong size Replace with proper size Sealing surfaces gouged or scratched Repair if possible or replace damaged parts Sealing surfaces dirty Clean and lubricate Nut Size inch across flats Fitting Size Torque In Lb N m 5 8 04 120 145 14 16 13 16 06 203 245 23 28 15 16 08 380 470 43 53 1 1 8 10 550 680 62 77 1 3 8 12 763 9...

Page 108: ...16 325 425 37 48 2 5 16 20 425 550 48 62 2 3 4 24 550 700 62 79 3 1 16 32 650 800 73 90 3 1 8 24 1400 1600 158 181 3 13 16 32 2400 2600 271 294 Port Shoulder Flange O Ring FIGURE 2 12 S104 1 2 3 4 S101 Tube A S102 High Pressure Series 1 9 16 08 175 225 20 25 2 12 300 400 34 45 2 1 4 16 500 600 57 68 2 5 8 20 750 900 85 102 3 1 8 24 1400 1600 158 181 3 13 16 32 2400 2600 271 294 Causes Cures Flange...

Page 109: ...ned and best of all that it has been tightened Table 2 8 SAE 37 Flare Tightening Table 2 9 SAE 37 Flare Leakage Connector Nut Size inch across flats Fitting Size Adapter Flats to Rotate 9 16 04 2 1 2 5 8 05 2 1 2 11 16 06 2 7 8 08 2 1 10 1 1 2 2 1 1 4 12 1 1 1 2 16 3 4 1 2 20 3 4 1 2 1 4 24 1 2 3 4 FIGURE 2 13 Turn connector nut required number of flats Table 2 8 View B S108 Adapter Line Connector...

Page 110: ...r 2 Drum 6 Luffing Hoist 9 Accessory System 3 Load Drums 1 and 3 10 Swing Right 4 Right Travel 11 Swing Left 5 Left Travel 12 Cooler Fan Tier 4 Equipped 6 Load Drums 2 and 5 13 Swing Brake Cranes Without Swing Lock 7 Not Used 14 Pump Drive Cooler FIGURE 2 14 Under Engine at Rear of Crane Gauge Coupler typical Electric Plug typical 8 P1929b 9 7 6 3 1 2 5 10 11 P1930 Right Rear Swing Motor 4 12 Cool...

Page 111: ...e threads Be sure to install thread sealant 9 Bleed pressure senders all except swing as follows a Connect bleed lines equipped with shut off valves to couplers on pressure sender manifold Open shut off valves Use a suitable container to catch oil flow b With all control handles off start engine and allow it to idle at 1 050 1 150 rpm c Observe oil flowing from bleed lines d Close shut off valves ...

Page 112: ...or function being checked 5 Access diagnostic screen Figure 2 15 for function being checked DRUM BOOM HOIST SWING or TRAVEL Monitor system PRESS pressure and PUMP command while moving control handles 6 Slowly move handle for function being checked Specified system pressure must be reached before 50 pump command is reached and brake must not slip 7 Repeat steps 3 5 for each function 8 Reconnect ele...

Page 113: ...lenoid Valve 5 Electrical Plug typical 6 Travel Motor 4 places 7 Travel Brake 4 places 8 Drum 5 Mast Hoist Motor 9 Drum 5 Brake 10 Drum 5 Brake Solenoid Valve Following items for Drums 1 2 3 4 and 6 11 Drum Motor 12 Drum Brake inside gear box 13 Drum Brake Solenoid Valve P1930a P1995a 10 5 P2013b 9 8 3 5 13 3 11 12 Drum 6 Luffing Hoist Shown Typical for Drum 1 Main Hoist Both Ends Drum 2 Main Hois...

Page 114: ...rs As suction lines are filling monitor vent port at top of charge filters on cranes prior to s n 18001082 2 Figure 2 2 When clear oil appears install vent plugs 1 NOTE S N18001082 and newer Supercharge pump and charge filters 1 and 2 replaced with accessory pump and additional return filter 9 Monitor vent ports in end of each charge pressure manifold 3 Figure 2 2 Install vent caps 4 when clear oi...

Page 115: ... cylinders boom hinge pin cylinders mast raising cylinders and rigging winch For operating these items select and confirm SETUP REMOTE mode 1 Rotating bed jacking cylinders a Access hand held radio remote control b Use jack toggles to fully extend jacks c Scroll to accessory screen on diagnostic screen to verify that 3 000 psi 206 bar is present when cylinders are extended and retracted d When ret...

Page 116: ... accessories at a pressure of 350 psi 24 bar The low pressure accessories includes swing brake swing lock travel brake and travel 2 speed 1 Swing brake and swing lock a Scroll to swing diagnostic screen b With swing park brake and swing lock OFF attempt to swing the crane by moving control handle in both directions c Crane must respond and indicate on swing screen that swing park brake and swing l...

Page 117: ... speed at high idle 3 Push both crawler control handles fully FORWARD to travel crane at full speed 4 Have an assistant count number of revolutions timing mark makes 5 Number should be 5 3 to 5 8 revolutions in one minute 6 If count is not within this range determine cause of problem and take corrective action Swing and Drum Speed Checks Check operating speeds for functions listed in Table 2 10 wi...

Page 118: ...nch Haul In Open Loop to Tank 3 000 204 N A N A 85 to 90 Pay Out Open Loop to Tank Swing 1 Left Pump A to Motors B B 6 090 420 Right or Left N A 350 24 1 1 to 1 2 Right Pump B to Motors A A Swing 2 6 Left Pump B to Motors B B Right Pump A to Motors A A Left Side Travel Forward Pump B to Motors A A 6 090 420 Forward or Reverse 5 3 to 5 8 at Tumbler Reverse Pump A to Motors B B Right Side Travel For...

Page 119: ... Engine Pump Drive 2 18CSM1 105 FIGURE 2 21 Pump Identification S N 18001082 newer Item Description 1 Accessory Pump 2 Boom Hoist B Pump Drum 4 3 Main Hoist Pump Drums 1 and 3 4 Swing Pump 5 Left Travel Pump 6 Main Hoist Pump Drum 2 7 Luffing Jib Hoist Pump Drum 6 8 Right Travel Pump 9 Main Hoist Pump Drum 2 and 5 10 Main Hoist Pump Drum 1 11 Boom Hoist A Pump Drum 4 12 Swing Optional 13 Cooler Fa...

Page 120: ...de Control 3 Case Drain Port Note 1 4 Charge Pressure Relief Valve 5 Multi Function Valve Note 2 6 Charge Pressure Gauge Port 7 Charge Pump Inlet Port 8 Pump Port B 9 Pump Port B Gauge Port 10 Pump Port A 11 Pump Port A Gauge Port 12 Neutral Adjusting Screw NOTE 1 Both Sides of Pump NOTE 2 Valve is Directly Opposite Port it Protects 11 10 4 9 3 2 1 4 5 7 4 1 5 6 12 8 18CSM2 107 FIGURE 2 21 continu...

Page 121: ...in System Pressure 12 M8 Control Pressure Minimum Displacement 3 L1 Case Pressure Drain 13 M9 Servo Pressure Supply 4 L2 Case Pressure Drain 14 X1 External PCP Supply Pressure 5 M1 Gauge Port A 15 Minimum Displacement Limiter 6 M2 Gauge Port B 16 Charge Pressure Relief Valve 7 M3 Servo Pressure Gauge Port Maximum Displacement 17 Pressure Compensator Adjuster 8 M4 Servo Pressure Gauge Port Minimum ...

Page 122: ...ay pressure reading in the cab may not reflect actual system pressure See Note on page 2 29 Every 6 months To perform pressure sender calibration proceed as follows 1 Stop engine and turn ignition switch to RUN position 2 Access calibration screen as follows a Select and confirm SETUP mode to activate calibration program b Turn LIMIT BYPASS switch clockwise and hold c SCROLL UP at least one screen...

Page 123: ...umn of Table 2 11 All shaded boxes to the right of the number indicate senders that failed calibration Refer to Figure 2 24 to identify the pressure senders i Troubleshoot the particular system to determine the cause of the fault NOTE The cause of a failed calibration or faulty display pressure reading in the cab may not be the pressure sender The cause of the fault could be trapped air or hydraul...

Page 124: ...bottom of CRANE MODE switch until appears next to CONTROL CAL f Increase engine speed to HIGH IDLE Engine must be running at high idle before calibration will start Calibration will stop if engine speed is decreased during calibration g Press top end of CRANE MODE switch to CONFIRM Calibration will start h When calibration starts percent of completion is displayed on screen i When calibration stop...

Page 125: ...calibration g Press top end of CRANE MODE switch to CONFIRM Testing will start h When testing starts percent of completion is displayed on screen i When testing stops check binary number If 0 appears all pumps have passed the test If any number other than 0 appears use Table 2 11 to determine which pumps have failed the test Each pump is assigned a number in the binary system power of two After ru...

Page 126: ...0 appears all charge pumps are okay If any number other than 0 appears use Table 2 11 to determine which pumps have failed the test Each pump is assigned a number in the binary system Outputs that are ON failed for any pump are added together To identify the failed pumps find the binary number displayed on the screen in the first column of Table 2 11 All shaded boxes to the right of the number ind...

Page 127: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL HYDRAULIC SYSTEM Manitowoc Published 12 05 17 Control 035 23 2 33 2 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 128: ...0 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 2 4 8 16 32 64 128 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 1 2 4 8 16 32 64 128 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129...

Page 129: ...1 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 1 2 4 8 16 32 64 128 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 1 2 4 8 16 32 64 128 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 ...

Page 130: ...esponding multi function valve a Remove protective cap 3 from multi function valve 1 or 2 See Table 2 10 and Figure 2 21 for pump port identification b Loosen lock nut 4 DO NOT tamper with bypass hex 6 See pump manufacturer s instructions c Using an internal hex wrench adjust multi function valve adjusting screw 5 Turn IN to INCREASE pressure Turn OUT to DECREASE pressure 7 Repeat steps until spec...

Page 131: ... is too high adjust charge pressure relief valve If you cannot raise charge pressure excessive system leakage is indicated 5 To adjust charge pressure See Figure 2 29 for the following procedure a Loosen lock nut 1 b Adjust adjusting plug 2 Turn in to increase pressure Turn out to decrease pressure c Once specified pressure is indicated hold adjusting plug 2 in position and securely tighten lock n...

Page 132: ...ng as follows a Disconnect loop flushing hose 2 from elbow in loop flushing valve 1 b Install an 08 ORS cap on end of elbow and an 08 ORS plug in end of hose 4 Start and run engine at high idle 5 Monitor flow meter Under all operating conditions leakage should not be more than 1 1 2 to 2 1 2 gpm 5 7 to 9 5 L m 6 Stop engine and enable loop flushing by reconnecting hose to elbow in loop flushing va...

Page 133: ... Insert a rigid steel rod through hole in end of valve cap 3 Depress valve spool with rod 4 If valve is operating properly corresponding side of circuit should operate DANGER Falling or Moving Load Hazard To prevent unexpected movement of loads or crane when operating any manual override Park crane in an area where it will not interfere with other job site equipment or structures Land all loads an...

Page 134: ...as a guide and never turn a counterbalance valve more than 1 2 turn in either direction To adjust a counterbalance valve Loosen the adjusting lock nut Rotate counterbalance adjusting screw 1 2 turn clockwise in to lower holding pressure Rotate counterbalance adjusting screw 1 2 turn counter clockwise out to raise holding pressure While holding counterbalance adjusting screw with hex wrench tighten...

Page 135: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL HYDRAULIC SYSTEM Manitowoc Published 12 05 17 Control 035 23 2 41 2 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 136: ...DRAULIC SYSTEM 18000 SERIVCE MAINTENANCE MANUAL 2 42 Published 12 05 17 Control 035 23 FIGURE 2 33 18CSM1 103 Item Description 1 Level Sensor 2 Adapter 3 Hydraulic Tank 4 Electric Cable W2 5 CAL Button 6 Sight Gauge 6 4 5 1 2 3 3 ...

Page 137: ...12 Securely install adapter 2 and level sensor 1 Apply Loctite 569 to the threads of the adapter and the level sensor 13 Connect electric cable 4 to level sensor 1 14 Perform the Full Cold Calibration procedure Full Cold Calibration Perform the following calibration procedure when the hydraulic oil is cold 1 In the operator cab turn the engine stop run start switch to the STOP position 2 If not al...

Page 138: ...R e f e r e n c e O n l y HYDRAULIC SYSTEM 18000 SERIVCE MAINTENANCE MANUAL 2 44 Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 139: ...E 8 Drum 1 and Drum 6 3 22 NODE 9 MAX ER 3 24 NODE 20 Boom Block Up Block Sensor Limits 3 26 NODE 21 Luffing Jib Block Up Block Sensor Limits 3 27 NODE 0 Power Engine Controls and Diagnostics 3 28 Abbreviations 3 29 Checking Electrical Inputs Outputs 3 30 Control Handle Voltages 3 30 Dielectric Grease 3 33 Digital Display 3 34 Crane Operating Conditions 3 34 Operating Limits 3 34 System Faults 3 3...

Page 140: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL 3 ii Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 141: ...ng items 3 Harness and battery cables operating in Zone C are recommended to be replaced after 10 000 hours of service life 4 Harness and cables operating in Zone A and B with high ambient temperatures and high duty circuits could see electrical service life reduced by 25 to 40 It is recommended to replace these assemblies after 8 000 hours of service life 5 Harness and cable assemblies operating ...

Page 142: ...ol Module Cummins CB 3 10 6C6 Electronic Control Module Cummins Tier 3 CB 3 30 6C6 Electronic Control Module Cummins Tier 4 CB 4 10 6C8 Engine Stop CB 4 10 6C8 Engine Stop Run Start CB 4 10 6C8 Dome Light CB 4 10 6C8 Horn CB 4 10 6C8 Radio CB 5 15 6C11 Ether Start CB 5 15 6C11 Air Conditioner Clutch CB 5 15 6C11 Heater Air Conditioner Compressor CB 6 30 6C12 Start Solenoid CB 7 50 6C13 Can Buss Po...

Page 143: ...ts of each node A wireless hand held radio remote is used for operating setup items Test voltages are sorted by nodes reference Electrical Schematic A06374 The nodes are listed and identified in Figure 3 1 Node Number Node 1 Master Front Console 2 Handles and Cab Controls 3 Drum 3 and Pressure Senders 4 Jacking Connecting Pins and Mast 5 Alarms Limits and Pump Controls 6 Drums 2 4 5 and Adapter Fr...

Page 144: ...otor control solenoid is de energized the pressure compensator will shift the motor to min displacement The Master Node will only de energize the coil if the 2 Speed Travel Switch is in the high speed position and the engine RPM is above 1500 The pressure compensator override will begin to shift motor back to max displacement low speed as the closed loop pressure reaches or exceeds 3915 to 4200 PS...

Page 145: ...have packet numbers Master front console node node 1 FCN 2 4 Limit Bypass Switch indicates where the inputs output are located on the master node 1 FCN is the packet location number Number 2 is the bank where information is stored Number 4 is the identifier for that item Node 2 universal nodes 3 though 9 boom node 20 and luffing jib node 21 CAN38 1 32 Return Filter Alarm Switch indicates where the...

Page 146: ... 1115 P11 15 DI 32 Drum 3 Whip Line Park Switch On 0 Volts Off 24 Volts On FCN 4 128 1116 P11 16 DI 10 Drum 5 Mast Hoist Park Switch On 0 Volts Off 24 Volts On FCN 2 2 1119 P11 19 DO 7 RCL Fault Alarm in Cab 0 Volts Off 24 Volts On FCN 5 64 1121 P11 21 Ground Backlight Ground Ground 1122 P11 22 Ground Crane Display Contrast Control Low Ground 1123 P11 23 DI 28 Travel 2 Speed Switch 0 Volts Off 24 ...

Page 147: ...2 P12 22 Ground RCL Display Contrast Control Low Ground 1223 P12 23 DI 20 Air Conditioning Compressor Clutch On 0 Volts Off 24 Volts On FCN 3 8 1224 P12 24 DI 22 Engine Start 0 Volts Off 24 Volts On FCN 3 32 1225 P12 25 DI 7 Travel Park Switch On 0 Volts Off 24 Volts On FCN 1 64 1226 P12 26 DI 17 Seat Switch 0 Volts Off 24 Volts On FCN 3 1 1228 P12 28 Ground Engine Diagnostics Red L E D Ground 122...

Page 148: ...AI 4 Left Travel Handle Output Signal Forward 2 6 4 5 Volts Reverse 2 4 0 5 Volts CAN0 8 1 2114 P51 14 AI 6 Right Travel Handle Output Signal Forward 2 6 4 5 Volts Reverse 2 4 0 5 Volts CAN1 4 1 2115 P51 15 AI 9 Handle A Output Signal Raise 2 4 0 5 Volts Lower 2 6 4 5 Volts CAN2 2 1 2116 P51 16 AI 13 Swing Handle Output Signal Left 2 4 0 5 Volts Right 2 6 4 5 Volts CAN3 2 1 2117 P51 17 DI 9 Left T...

Page 149: ...ction 24 Volts Nominal CAN32 2 2 2219 P52 19 DO 18 Handle D Raise Direction 24 Volts Nominal CAN32 3 2 2220 P52 20 Ground Handle D Display Ground 2221 P52 21 DO 8 3 Handle D Display 24 Volts Nominal CAN32 1 128 2222 P52 22 DO 8 4 Handle C Display 24 Volts Nominal CAN32 1 128 2223 P52 23 Ground Handle B Rotation Indicator Ground 2224 P52 24 Ground Handle C Rotation Indicator Ground 2225 P52 25 Grou...

Page 150: ...Ground Setup Receiver Ground P53 B Ground Left Console Ground P53 C Ground Cab Ground Ground P53 E 28 Volts Setup Receiver 28 Volts Nominal P53 F 28 Volts Bar Graph Display 28 Volts Nominal 1 Lower four bits are the most significant bit of the analog value Can ID Connector Function Type Description Test Voltage Packet No ...

Page 151: ...ack Pressure Sender 0 Volts Off 24 Volts On CAN33 1 16 33 T DI 3 Super Charge Hydraulic Pressure Prior to S N 18001082 0 Volts Off 24 Volts On CAN59 1 4 33 b AI 2 Drum 2 5 Pressure Sender 1 Volt at 0 psi 5 Volts at 7 500 psi CAN4 4 1 33 c AI 3 Drum 1 3 Pressure Sender 1 Volt at 0 psi 5 Volts at 7 500 psi CAN4 6 1 33 d AI 4 Accessory System Pressure Sender 1 Volt at 0 psi 5 Volts at 7 500 psi CAN4 ...

Page 152: ...e Ground 36 F DO 9 Pump Drive Cooler Pressure 0 Volts Off 24 Volts On CAN33 2 1 36 G Ground Drum 3 Minimum Bail Limit Switch Ground 36 H DO 10 Drum 3 Minimum Bail Limit Switch 0 Volts Off 24 Volts On CAN33 2 2 36 J DI 8 Drum 3 Minimum Bail Limit Switch 0 Volts Off 24 Volts On CAN59 1 128 36 L NS 2 Node Select 2 Jumper to Ground 0 Volts With Jumper 36 U Ground Jumper to Node Select Ground 36 V 5 Vo...

Page 153: ...Off 24 Volts On CAN35 1 32 43 R DO 5 Cab Tilt Down Solenoid 0 Volts Off 24 Volts On CAN35 1 16 43 g Ground Cab Tilt Up Solenoid Ground 43 h Ground Cab Tilt Down Solenoid Ground J4 Receptacle Jacking Solenoids 44 A Ground Drum 7 Payout Solenoid Ground 44 B DO 11 Drum 7 Payout Solenoid 0 Volts Off 24 Volts On CAN35 2 4 44 C Ground Drum 7 Haul In Solenoid Ground 44 D DO 12 Drum 7 Haul In Solenoid 0 V...

Page 154: ...round 46 V 5 Volts Mast Angle Sensor 5 Volts 46 W Ground Mast Angle Sensor Ground 46 a AI 9 Mast Angle Sensor 5 Volts DC Mast at Vertical CAN14 2 1 1 Lower four bits are the most significant bit of the analog value Can ID No Function Type Description Test Voltage Packet No WN16 A WN14 A 24 Volts From Node 0 to Node 9 24 Volts Nominal WN16 C WN14 C CANH Can High Wire Transmission N A WN16 D WN14 D ...

Page 155: ...s On CAN24 6 1 53 d AI 4 Return Line Filter 1 Alarm Switch 0 Volts Off 24 Volts On CAN24 2 128 53 e AI 5 Hydraulic Vacuum Switch 0 Volts Off 24 Volts On CAN25 2 16 53 f AI 6 Hydraulic Fluid High Temperature Switch 185o Tier 2 and Tier 3 only 0 Volts Off 24 Volts On CAN25 2 32 53 f AI 6 Cooler Fan Pressure Transducer Tier 4 1 Volt at 0 psi 5 Volts at 7 500 psi CAN25 2 1 53 g Ground Hydraulic Fluid ...

Page 156: ...ts On CAN38 3 64 54 e Ground Accessory System Proportional Solenoid Ground 54 f DO 24 Accessory System Proportional Solenoid 0 Volts Off 24 Volts On CAN38 3 128 54 g Ground Jumper to Node Select 4 Ground 54 m NS 4 Node Select Jumper to Ground 0 Volts With Jumper J6 Receptacle Limits 56 A Ground Drum 6 Pressure Sender Ground 56 B DO 7 Drum 6 Pressure Sender 0 Volts Off 24 Volts On CAN38 1 64 56 C G...

Page 157: ...t Not Moving 2 2 Volts Moving CAN68 2 1 56 p ENC1B Drum 4 Motor Speed Sensor 1 2 or 3 2 Volts Not Moving 2 2 Volts Moving CAN68 2 2 1 Lower four bits are the most significant bit of the analog value 2 The number in the indicated bank should increase with device rotation and decrease with rotation in opposite direction Can ID No Function Type Description Test Voltage Packet No ...

Page 158: ...Frame Level Sensor Pitch 0 to 10 Volts CAN8 2 1 63 b AI 2 Rotating Frame Level Sensor Roll 0 to 10 Volts CAN8 4 1 63 g Ground Rotating Frame Level Sensor Ground 63 j 5 Volts Rotating Frame Level Sensor 5 Volts DC J4 Receptacle Adapter Frame Drum 4 Controls 64 A Ground Rear Adapter Frame Pins Engage Sol Ground 64 B DO 11 Rear Adapter Frame Pins Engage Sol 0 Volts Off 24 Volts On CAN34 2 4 64 C Grou...

Page 159: ...2 Minimum Bail Limit Switch 0 Volts Off 24 Volts On CAN61 1 128 66 K NS 1 Node Select 1 Jumper to Ground 0 Volts With Jumper 66 L NS 2 Node Select 2 Jumper to Ground 0 Volts With Jumper 66 U Ground Jumper to Node Select 2 Ground 66 V 5 Volts Drum 2 and Drum 7 Motor Speed Sensor 5 Volts DC 66 W Ground Jumper to Node Select 1 Ground 66 Z Ground Drum 2 Motor Speed Sensor Ground 66 j Ground Drum 7 Mot...

Page 160: ... Ground Track Auto Lube Pump Ground 74 W DO 20 Track Auto Lube Pump 0 Volts Off 24 Volts On CAN36 3 8 74 X Ground Swing Bearing Auto Lube Pump Ground 74 Z DO 21 Swing Bearing Auto Lube Pump 0 Volts Off 24 Volts On CAN36 3 16 74 g Ground Jumper to Node Select 1 Ground 74 h NS 1 Node Select 1 Jumper to Ground 0 Volts With Jumper 74 k NS 3 Node Select 3 Jumper to Ground 0 Volts With Jumper 74 r Groun...

Page 161: ...8 6 1 76 j Ground Swing Motor Speed Sensor Ground 76 n ENC 1A Swing Motor Speed Sensor CH A 1 2 or 3 2 Volts Not Moving 2 2 Volts Moving CAN64 2 2 76 p ENC 1B Swing Motor Speed Sensor CH B 1 2 or 3 2 Volts Not Moving 2 2 Volts Moving CAN64 2 2 1 Lower four bits are the most significant bit of the analog value 2 The number in the indicated bank should increase with device rotation and decrease with...

Page 162: ... 86 B DO 7 Drum 1 Motor Control 1 See Table 3 3 for Values CAN39 1 64 86 C Ground Drum 1 Motor Control 2 Ground 86 D DO 8 Drum 1 Motor Control 2 See Table 3 3 for Values CAN39 1 128 86 E Ground Drum 1 Brake Solenoid Ground 86 F DO 9 Drum 1 Brake Solenoid 0 Volts Off 24 Volts On CAN39 2 1 86 G Ground Drum 1 Minimum Bail Limit Switch Ground 86 H DO 10 Drum 1 Minimum Bail Limit Switch 0 Volts Off 24 ...

Page 163: ...R e f e r e n c e O n l y Manitowoc Published 12 05 17 Control 035 23 3 23 18000 SERIVCE MAINTENANCE MANUAL ELECTRIC SYSTEM 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 164: ...lts On CAN37 1 16 93 T DI 3 Counterweight Limit Switch Right Side 0 Volts Off 24 Volts On CAN67 1 4 93 W DI 4 Counterweight Limit Switch Left Side 0 Volts Off 24 Volts On CAN67 1 8 93 X 24 Volts MAX ER Right Side CWT Carrier Load PIn 24 Volts 93 Z 24 Volts MAX ER Left Side CWT Carrier Load PIn 24 Volts 93 a AI 1 Remote Active 24 Volts Nominal CAN20 2 16 93 b AI 2 CWT Pendant Cylinder Remote Lower ...

Page 165: ...Jack Extend 54RB W51 E Right Front Jack Retract 54LC W51 F Left Rear Jack Extend 54LD W51 G Left Rear Jack Retract 54RC W51 H Right Rear Jack Extend 54RD W51 J Right Rear Jack Retract 54AC W51 KW All Jacks Extend 54BD W51 LX All Jacks Retract 58RD W51 M Right Steering Pins Disengage 58RE W51 N Right Steering Pins Engage 58LD W51 P Left Steering Pins Disengage 58LE W51 Q Left Steering Pins Engage 5...

Page 166: ...Cable Reel 24 Volts Nominal CAN 136 6 4 204 F CANL Can Low Wire Transmission N A J5 Receptacle Block Level Sensor 205 A 24 Volts Load Pin 1 Lower Boom Point 24 Volts Nominal 205 B AI 1 Load Pin 1 Lower Boom Point 0 47 V No Load 5 7 V Full Load 205 D Ground Load Pin 1 Lower Boom Point Ground J6 Receptacle Block Level Sensor 206 A 24 Volts Load Pin 2 Lower Boom Point W Tandem Drum 24 Volts Nominal 2...

Page 167: ... 128 212 B DI 2 Block Up Limit Luffing 79A or Fixed Jib Upper Point 0 Volts Off 24 Volts On CAN135 6 128 J3 Receptacle Lower Block Up 213 A 24 Volts Block Up Limit Luffing 44 or 79A or Fixed Jib Lower Point 24 Volts Nominal 213 B DI 1 Block Up Limit Luffing 44 or Fixed Jib Lower Point 0 Volts Off 24 Volts On CAN132 6 64 213 B DI 1 Block Up Limit Luffing 79A or Fixed Jib Lower Point 0 Volts Off 24 ...

Page 168: ...lts Nominal P111 0 Ground Battery Ground P112 0112 Ground Can System Bus Ground P114 0114 Ground ECM Power Relay Coil Negative Ground P117 0117 Ground Air Conditioning Clutch Relay Coil Negative Ground P119 0119 Ground Ether Relay Coil Negative Ground P120 0120 Ground MS1 MS2 Start Relay Coil Negative Ground P121 OC Ground Can System Bus Output Wire Ground P122 0122 Ground Can Power Relay Coil Neg...

Page 169: ...ax Maximum AO Analog Output Min Minimum CAN Controller Area Network MS Motor Starter CANH Controller Area Network High N A Not Applicable CANL Controller Area Network Low N C No Connection CHA or CHB Channel A or B NO Number DC Direct Current NS Node Select DI Digital Input Opt Optional DO Digital Output psi Pressure EC Encoder Control RCL Rated Capacity Indicator Limiter ENC Encoder Number Count ...

Page 170: ...d problem component terminal Enable test component and check ampere reading on meter Test a for a communication problem on a universal node with communication in line test board 1 Engine must be off and engine key switch in run position with all brakes and locks engaged 2 Access desired node to install communication in line test board 3 Remove cable from node at W1 or W7 connector 4 Connect the co...

Page 171: ...in Front Console 11 Node 21 At Jib Top 2 Node 2 In Right Side Console 12 Universal Node Controller 3 through 9 3 Node 3 Left Side of Crane in Machinery Enclosure 13 Node In line Test Board 3 Separate Boards 4 Node 4 Left Side of Crane in Machinery Enclosure 14 W4 Connector 110 Degree Key 5 Node 5 Right Side of Crane in Machinery Enclosure 15 W3 Connector Zero Degree Key 6 Node 6 Right Front Side o...

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Page 173: ...O ring for a pin male connector The size of the grease bead on the O ring is as follows On a 3 pin connector a 1 16 inch 1 59 mm bead is required On a 24 pin connector a 1 8 inch 3 18 mm bead is required On a 37 pin connector a 3 16 inch 4 76 mm bead is required Place a small amount of grease on your finger for the application on the connector s face Wipe your finger across the face leaving grease...

Page 174: ...nd pump drive screen Figure 3 11 displays the hydraulic tank fluid level the current steady wind speed or maximum gust wind speed in parenthesis and pump drive operating conditions For hydraulic tank level 0 empty 100 full cold 110 is full hot MAX WIND SPEED resets when crane power is off Operating Limits Table 3 6 lists operating limits which can be displayed When one or more operating limit is r...

Page 175: ...t stopping at each for approximately three seconds The system fault alert turns off when the cause of each fault is corrected Each active fault that has occurred during operation is retained in memory until two things happen 1 Name of fault appears on display at least once 2 Cause of fault is corrected For this reason it is normal for the names of inactive faults to appear when you scroll to the s...

Page 176: ... is angle or degrees that crane is out of level in indicated direction from horizontal Second number is inches of blocking to level crane in required direction HYD TANK FLUID LEVEL Indicates hydraulic tank fluid level in full CURRENT WIND SPEED MPH Indicates current steady wind speed MAX WIND SPEED MPH Indicates maximum gust wind speed PUMP DRIVE TEMP DEG F indicates temperature of oil in pump dri...

Page 177: ...d load on load drum or raise boom or jib MAST BELOW 2 DEGREES Stops down movement of live mast when lowering mast to transport position Pin live mast in place before retracting mast arms cylinders fully MAST TOO FAR FORWARD Boom hoist live mast inoperable in lowering direction occurs if mast is below 160 Raise live mast Further lowering is not intended mast will fall MAX DOWN 1 Stops boom from low...

Page 178: ...ngine coolant temperature above 205 F 96 C FILTER FAULT 1 or 2 All functions operable Replace charge filter 1 or 2 as soon as possible Cranes prior to S N 18001082 Filter is dirty FILTER FAULT 4 All functions operable Replace return filters as soon as possible Cranes prior to S N 18001082 Filter is dirty FILTER FAULT 1 All functions operable Replace return filter 2 as soon as possible Crane S N 18...

Page 179: ...si 0 34 bar Check pump for proper operation Check pump drive oil level PUMP DRIVE TEMP HIGH 2 Does not affect operation Shut down and correct cause as soon as possible to prevent gear or bearing damage Gear oil temperature above 250 F 121 C Check oil cooler for proper operation Check pump drive oil level SUPERCHARGE PRESSURE Prior to S N 18001082 Does not affect operation Shut down and correct cau...

Page 180: ...operating screens To disable the diagnostic screens turn limit bypass key switch clockwise and scroll down The operating screens remain active The diagnostic screens provide information about the status of all main crane components as well as the controller inputs and outputs during operation The diagnostic screens display the following information Particular crane functions DRUMS SWING and TRACK ...

Page 181: ...OR command in percent with 0 maximum displacement and 100 minimum displacement Measured hoist PRESSURE psi at high side pressure port Measured drum SPEED in rpm with raise and lower Park BRAKE command with 0 engaged and 1 released DOS digital output status displays a binary number or total if digital output signal is disabled to pump A drum 2 1 pump B drum 2 and 5 2 motor 1 4 motor 2 8 or drum bra...

Page 182: ...URE psi at high side pressure port Measured drum SPEED in rpm with raise and lower Park BRAKE command with 0 engaged and 1 released DOS digital output status displays a binary number or total if digital output signal is disabled to pump A drum 5 1 not used 2 drum brake 4 drum pawl 8 or diverter 16 Drum 6 DRUM 6 screen displays the following information Control HANDLE command in percent from neutra...

Page 183: ...Front Console Node The status of the digital inputs and outputs of the front console controller is displayed in the FCN screen Each bank can indicate the state of up to 255 individual digital inputs or outputs The FCN screen displays the following information Front console digital input DI BANKS 1 2 3 and 4 Front console digital output DO BANKS 5 and 6 Only programmers use TF BANKS 1 2 3 and 4 Eac...

Page 184: ...acket item status Digital input or digital output BANKS 1 2 3 and 4 Digital input or digital output BANKS 5 6 7 and 8 Each individual input output is assigned a number identifier in the binary system powers of two The identifiers of all inputs outputs that are ON active for each bank are added for a total of 0 255 The number displayed for each bank is the sum of all identifiers that are ON in that...

Page 185: ...ext screen Hydraulic System Calibration See Hydraulic System Calibration Procedures in this section Speed Torque See Function Speed Torque Adjustment in this section Accessory System The ACC system screen displays the following information Drum 5 mast hoist control HANDLE command in percent from neutral with raise and lower Accessory valve ACC VLV command in percent Drum 5 mast hoist pump DM 5 PMP...

Page 186: ...on Block Level Sensor The LEVEL screen displays the following information when BLOCK LEVEL SENSOR where the block identification code is entered and displayed To enter a block identification code press select The cursor appears next to Block Level Sensor Press select again to enter identification code area Scroll up or down to enter 0 to 9 press select to move through each four positions BLOCK ANG...

Page 187: ...57 1 16 Swing Handle Dead Man Option 2 FCN 1 16 Drum 2 Park Switch On 1 CAN57 2 1 Left Track Direction Signal 2 FCN 1 32 Crane Display Scroll Down Switch 1 CAN57 2 2 Handle B Direction Signal 2 FCN 1 64 Travel Park Switch On 1 CAN57 2 4 Handle C Direction Signal 2 FCN 1 128 Cab Tilt Up Switch 1 CAN57 2 8 Right Track Direction Signal 2 FCN 2 1 RCL Mode Confirm Switch 1 CAN59 1 4 Super Charge Hydrau...

Page 188: ...rack Pump Control Reverse 3 CAN32 3 64 Foot Throttle Output 2 CAN33 3 16 Swing 1 Pump Control Left 3 CAN33 3 32 Swing 1 Pump Control Right 3 CAN37 1 32 CWT Right Cylinder Extend Solenoid 9 CAN34 1 2 Drum 5 Brake Solenoid 6 CAN37 1 64 Power to MAX ER Remote Control 9 CAN34 1 4 Drum 5 Pawl Out Solenoid 6 CAN37 1 128 Power to MAX ER Remote Control 9 CAN34 1 8 Drum 5 Pawl In Solenoid 6 CAN37 2 1 Power...

Page 189: ...ft Rear Jack Extend Solenoid 4 CAN39 2 16 Drum 6 Pawl In Motor 8 CAN35 3 32 Right Rear Jack Retract Solenoid 4 CAN39 2 32 Drum 6 Pawl Out Motor 8 CAN36 1 64 Swing Left Pressure Sender 7 CAN36 1 128 Swing Right Pressure Sender 7 FCN 5 1 Operating Limit Alarm Beeper and L E D 1 CAN36 2 2 Accessory System Hydraulic Pressure Sw 7 FCN 5 4 RCL Warning L E D 1 CAN36 2 4 Swing Brake Solenoid 7 FCN 5 32 RC...

Page 190: ...9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 2 4 8 16 32 64 128 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 1 2 4 8 16 32 64 128 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 12...

Page 191: ...43 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 1 2 4 8 16 32 64 128 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 1 2 4 8 16 32 64 128 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232...

Page 192: ... 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 300 1 2 4 8 16 32 64 128 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 343 1 2 4 8 16 32 64 128 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 3...

Page 193: ... 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 429 1 2 4 8 16 32 64 128 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 472 1 2 4 8 16 32 64 128 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 4...

Page 194: ...R e f e r e n c e O n l y ELECTRIC SYSTEM 18000 SERIVCE MAINTENANCE MANUAL 3 54 Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 195: ...b Angle Indicator Calibration 4 7 Mast Angle Indicator Adjustment 4 7 Mast Angle Indicator 4 7 Adjusting Angle 4 7 Sending Unit Assembly 4 7 Strap Inspection and Maintenance 4 9 Inspection 4 9 Frequent Inspection 4 9 Periodic Inspection 4 9 Cranes Not In Regular Use 4 9 Identifying Straps 4 9 Replacement Specifications 4 10 Corrosion Or Abrasion 4 10 Straightness 4 11 Flatness 4 11 Elongated Hole ...

Page 196: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL 4 ii Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 197: ...ically because the open limit switch turns off power to the boom hoist electric circuit The boom hoist pump shifts to neutral and the brake applies to stop boom movement Maintenance At least once weekly check that the automatic boom stop stops the boom at the specified maximum angle If not replace any worn or damaged parts and or adjust the boom stop Once the automatic boom stop is properly adjust...

Page 198: ...ey and the adjusting rod to the normal operating positions Table 4 1 Automatic Boom Stop Angles Angle A see Figure 4 1 Attachment 83 1 55 79A 55 or 55A Boom without Luffing Jib OR 84 2 55 79A 55 or 55A Boom without Luffing Jib When Boom Up Limit Can be Bypassed 85 44 or 79A Luffing Jib on 140 180 ft 42 7 54 9 m of Boom 87 44 or 79A Luffing Jib on 200 340 ft 61 0 103 6 of Boom When Boom Up Limit Ca...

Page 199: ... Description 1 Boom Butt 2 Switch Assembly Right Side of Crane See Table 4 2 2a or 2b FIGURE 4 1 Table 4 2 Adjusting Rods Adjusting Rod Length 2a Boom Only 2b With Luffing Jib When Boom Up Limit Can be Bypassed 4 3 4 in 121 mm for 83 4 1 2 in 114 mm for 84 3 3 4 in 83 mm When Boom Up Limit Cannot be Bypassed 4 3 4 in 121 mm for 83 4 1 2 in 114 mm for 84 3 1 4 in 83 mm ...

Page 200: ...r 4 Coupling 11 Actuator Rod 5 Limit Switch 12 Digital Level see Figure 4 5 6 Cover VIEW A SWITCH OPENED Roller Over Travel LED ON 7 8 9 10 11 2a or 2b LED OFF STORED 5 5 6 VIEW B SWITCH CLOSED 2a or 2b 4 3 Limit Switch Wiring Past Production Receptacle Switch Terminals Function 1 green 22 B 14 Max Angle 2 black A 13 LED 3 white 21 12 VDC Supply 1 11 Past Production Current Production Limit Switch...

Page 201: ... Turn adjusting rod 2a or 2b out against boom butt 1 until limit switch 5 clicks open and the LED is OFF View A e Tighten jam nut 3 7 If the boom reaches the specified angle before it stops a Loosen jam nut 3 View B b Turn adjusting rod 2a or 2b out against boom butt 1 until limit switch 5 clicks open and the LED is OFF View A c Tighten jam nut 3 8 Check that actuator rod 11 over travels the limit...

Page 202: ... 89 Operation See Figure 4 4 for the following procedure 1 When boom is raised to 77 springs in boom stop tubes begin to compress 2 As boom is raised higher spring compression increases to exert greater force against boom 3 If for any reason boom is raised to 89 boom stop springs fully compress to provide a physical stop WARNING Falling Attachment Hazard Physical boom stops must be installed and p...

Page 203: ...ustment steps at initial installation after installing a new sending unit or potentiometer and during assembly Mast angle should be 0 when mast is fully lowered to the rear transport position NOTE Mast must be in transport position when checking or adjusting angle indicator 1 Park crane on a solid level surface 2 Lower mast to transport position 3 Place an electronic level on mast Figure 4 6 4 Rec...

Page 204: ...t new sensor in existing holes as shown in View B 5 Refer to wiring chart in View B and parallel splice sensor wires to existing input wires with crimp solder and heat shrink tubing 6 Seal green wire on sensor with heat shrink tubing and coil up 1 2 3 NOTE Current through potentiometer must not exceed 10 milliamperes 120 Pendulum Type Potentiometer Black Pin 2 Ground Bus White Pin 3 5V DC System B...

Page 205: ... wear and other damage is likely to occur Look for straps that are disconnected loose or sagging excessively and for distortion such as kinking or twisting If any strap looks like it is damaged strap must be checked to make sure it is within specifications given in this section Periodic Inspection Periodic inspection must be performed at least monthly During this inspection entire length of strap ...

Page 206: ...eference Allowable Tolerance or Deviation Corrective Action Dent Figure 4 9 0 12 in 3 175 mm Monitor condition 0 12 in 3 175 mm Remove strap from service Kink Figure 4 10 None Remove strap from service Crack or Break Figure 4 11 None Remove strap from service Corrosion or Abrasion Figure 4 12 6 of strap thickness Sandblast and paint to maintain continuous protective coating 6 of strap thickness Re...

Page 207: ...sure distance from line to strap If deviation from straight is greater than maximum allowed remove strap from service 6 Remove line Turn strap over 7 Repeat steps 1 5 above Elongated Hole See Figure 4 15 for the following procedure 1 Insert pin into hole 2 Push pin tight against edge of hole along horizontal center line Measure dimension between pin and hole View A Strap Length L Maximum Deviation...

Page 208: ...is provided at the end of this section The checklist can be reproduced as needed Signed and dated copies of the Strap Inspection Checklist must be kept on file at all times for each strap as the checklists may be required to verify warranty or product liability claims If no damage is found or damage is within specification check the box next to the item to indicate that its specific condition was ...

Page 209: ...htness 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 Lengt...

Page 210: ...R e f e r e n c e O n l y NOTES SKETCHES AND PHOTOGRAPHS ...

Page 211: ...blished 12 05 17 Control 035 23 4 15 18000 SERVICE MAINTENANCE MANUAL BOOM 4 LATTICE SECTION INSPECTION AND LACING REPLACEMENT Refer to Folio 1316 at the end of this section for lattice section inspection and lacing replacement instructions ...

Page 212: ...R e f e r e n c e O n l y BOOM 18000 SERVICE MAINTENANCE MANUAL 4 16 Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 213: ...ontrol Deactivated 5 8 Block Up Limit Control Activated 5 8 Installation 5 8 Load Block Level Transmitter 5 8 Disconnecting Block Up Limit Control 5 12 Removing Upper Boom Point or Jib Point 5 13 Storing Electric Cable 5 13 Maintenance 5 13 Adjustment 5 14 Wire Rope Inspection and Replacement 5 15 Wire Rope Lubrication 5 15 Maintain a Wire Rope Condition Report 5 15 Required Inspection Intervals 5...

Page 214: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL 5 ii Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 215: ...from actuator 3 3 Loosen jam nut 5 and back out adjusting screw 6 until leaf spring 7 is fully relaxed 4 Carefully remove pins 8 securing actuator 3 to lug 9 and bracket 10 5 If necessary loosen bracket nuts 11 to loosen actuator pins 8 6 Remove actuator 3 Actuator Installation and Adjustment See Figure 5 1 for the following procedure 1 Turn ignition key to RUN position Do not start engine 2 If ne...

Page 216: ... 3 is fully extended and fully retracted and that pawl 1 fully engages and disengages ratchet tooth 2 CAUTION Flying Part Hazard Actuator must be free to fully extend and retract Motor will overheat and be ruined if actuator stroke is restricted in either direction Item Description 1 Pawl 2 Ratchet Tooth 3 Actuator 4 Electrical Cord 5 Jam Nut 6 Adjusting Screw 7 Leaf Spring 8 Actuator Pin 9 Lug 10...

Page 217: ...ulic cylinder retracts and the cam rotates to disengage the pawl from the ratchet It may be necessary to hoist slightly to fully disengage the pawl from the ratchet Maintenance The only maintenance required is to visually check the pawl for proper operation This should be done daily when the mast hoist is in use If necessary adjust the eye bolts so the spring has sufficient tension to fully engage...

Page 218: ...Bring corresponding function to a complete stop land suspended load if load drum is being serviced and PARK function 2 Remove faulty sensor Do not connect sensor cable to crane wire harness until initial adjustment is made 3 Loosen lock nut and carefully turn sensor in clockwise by hand until it gently contacts speed ring inside motor 4 Back sensor out counterclockwise 1 4 turn or more until flat ...

Page 219: ...3 Loosen lock nut and carefully turn sensor in clockwise by hand until it gently contacts speed ring inside motor 4 Back sensor out 1 turn or more until notch is positioned 180 from motor shaft facing outboard side of motor 5 Connect sensor cable to crane wire harness 6 Operate drum motor and check for a steady drum speed rpm signal on drum screen in cab If necessary turn sensor out slightly until...

Page 220: ...ayer LED off Adjust limit switch if necessary 2 Check that cap screws holding rollers on lever shaft are tight 3 Check tension of return springs If necessary adjust eyebolts so springs hold rollers snug against bare drum Adjustment 1 Pay out wire rope until rollers are against bare drum with 3 to 4 wraps of wire rope remaining on first layer 2 Turn adjusting screw in toward mounting plate until LE...

Page 221: ...cription 1 Lever 2 Rollers 3 Cap Screw 4 Drum 5 Jam Nut 6 Adjusting Screw 7 Limit Switch 8 LED 9 Mounting Plate 10 Return Spring 11 Eyebolt 1 2 3 11 10 2 1 7 4 6 1 34 in 34 0 mm When New 1 71 in 43 4 mm 8 9 5 NOTE Dimensions given above apply to all drums 18CSM5 105 18CSM5 104 Past Current Limit Switch Wiring Receptacle Switch Terminals Function 1 green 22 B 14 Max Angle 2 black A 13 LED 3 white 2...

Page 222: ...es the corresponding limit switch to open the load drum UP and boom DOWN electric circuits The load drum and boom hoist pumps stroke to off At the same time the load drum and boom parking brakes apply to stop load drum from hoisting and boom from lowering Installation See Figure 5 8 for installation of the weights The block up limit controls must be installed according to the Boom Wiring and Limit...

Page 223: ...ck level controller assembly box as needed such that box mounting surface backside is 90 degrees to the horizontal mounting surface of the load block assembly d Turn cab power on and scroll to the Level screen for the block level sensor and block level angle diagnostic display readings see Section 3 Crane Diagnostics Block Level Sensor topic e While one person is monitoring the block level diagnos...

Page 224: ...Assembly 7 Lower Boom Point 8 Boom Node 9 Load Cell Receiver 10 Electric Cable From Reel 11 Lift Plate 12 Load Block 13 Chain 12 ft 3 7 m 14 Block Angle Transmitter optional 15 Angle Sensor 16 Batteries 17 Press to Install Button 1 2 3 4 5 6 Weight Multiple Part Chain 12 3 7 m 11 10 9 6 8 3 13 12 Block Up Limit at 55 79A Boom Point Shown Block Up Limit at 79 Boom Point at 55 Boom Point and at Luff...

Page 225: ...s 1 2 3 4 5 18CSM5 108 See Load Block Reeving for Suggested Location of Weight Two Chains Prevent Weight from Turning FIGURE 5 8 Lower or Upper Boom Point multiple part Upper Boom Point 1 part Upper Jib Point 1 part Lower Jib Point 1 part 3 ft 0 9 m to Top of Weight Ball 1 Part Reeving Dead End Load Line or Slowest Live Line Item Description 1 Weight 2 Shackle 3 Chain 4 Connecting Pin 5 Lift Plate...

Page 226: ...tric Cable WNE14 4 Electric Cable WBM150 from Cable Reel 5 Boom Node Controller 6 Sealing Cap 14 each 7 Terminating Plug 5 each 8 Wind Speed 9 Digital Output 10 Block Level Switch 1 Past Production 11 Block Level Switch 2 Past Production 12 Electric Cable from Boom Cable Reel 13 Block Up Limit Lower Point Boom or Jib 14 Block Up Limit Upper Point Boom or Jib 15 Electric Cable Out to Jib 16 Luffing...

Page 227: ...of each attachment Store excess electric cable for the boom and luffing jib by winding it onto the reel mounted on the respective butt The reel has a locking pin Disengage the locking pin to allow the reel to be wound Engage the locking pin to lock the reel in position The electric cable from the crane to the reel must be disconnected before the reel can be wound Store excess electric cable for th...

Page 228: ...ick limit switch open and hold Then securely tighten setscrew in limit switch lever 7 Test limit switch for proper operation see Maintenance topic Repeat adjustment steps until limit switch operates properly CAUTION Avoid Sheave Damage Use extreme care when testing block up limits when boom is raised If a block up limit fails to stop load immediately stop load by moving drum control handle to off ...

Page 229: ...anently attached end fittings use only pre assembled lengths of wire rope as supplied from Manitowoc Do not build lengths from individual components 2 Replace an entire wire rope assembly Do not attempt to rework damaged wire rope or wire rope ends 3 Never electroplate a wire rope assembly 4 Do not weld any wire rope assembly or component unless welding is recommended by the wire rope manufacturer...

Page 230: ...rioration of rotation resistant ropes may not be readily observable 2 Throughout the day observe the wire rope during operation particularly Pick up Points Sections of the wire rope that are repeatedly stressed during each lift such as the sections that are in contact with the sheaves End Attachments The point where a fitting is attached to the wire rope or the point where the wire rope is attache...

Page 231: ...erature Continuous excessive moisture levels Exposure to corrosive chemicals or vapors Subjecting the wire rope to abrasive material Power line contact Exposure to abuse and shock loads such as High velocity movement such as hoisting or swinging a load followed by abrupt stops Suspending loads while traveling over irregular surfaces such as railroad tracks potholes and rough terrain Moving a load ...

Page 232: ... out of service when it has the following number of broken wires See Figure 5 14 for an explanation of lay length Running Ropes six randomly broken wires in one lay length or three broken wires in one strand in one lay length Standing Ropes Pendants more than two broken wires in one lay length in sections beyond the end attachment or more than one broken wire at the end attachment see Figure 5 13 ...

Page 233: ... may have entered bearing Grease leaks indicating a faulty seal or water in grease The above problems indicate bearing damage If found the corresponding sheave roller or drum should be disassembled for further inspection New bearings should be installed For sheaves not equipped with grease fittings be sure to pack the new bearings with grease at assembly 3 For steel sheaves check the depth width a...

Page 234: ...ith grease at assembly Repack the bearings of these sheaves with CraneLUBE EP 2 grease when the sheaves are overhauled Due to application and design variations it is not possible to give specific grease repacking intervals or the life expectancy of the components 9 Make sure the sheaves drums and rollers are properly lubricated according to the instructions in the lubrication guide provided with t...

Page 235: ...17 16 5 8 631526 489 19 25 422 4 16 63 50 8 1 94 22 7 8 631527 489 19 25 422 4 16 63 50 8 1 94 16 5 8 631055 500 1 19 69 447 17 60 47 1 85 22 7 8 631067 500 1 19 69 450 9 17 75 50 1 97 19 3 4 631529 508 20 431 8 17 00 76 2 3 25 1 631519 584 2 23 511 20 13 57 2 2 25 22 7 8 631520 631084 584 2 23 511 20 13 63 5 2 50 22 7 8 A00083 631102 584 2 23 511 20 13 63 5 2 50 25 1 B tread diameter new sheave E...

Page 236: ... to structural failure of load block or hook and weight ball Only use a load block or a hook and weight ball which has a capacity equal to or greater than the load to be handled Do not remove or deface the nameplate Figure 5 19 that is attached to the load blocks and hook and weight balls See Section 4 of the Operator Manual for recommended sling angles and capacity restrictions when the load bloc...

Page 237: ...earings are damaged Side loading This can cause the swivel to turn freely in one spot and lock up in another This condition can also be checked by checking the gap 4c Figure 5 20 between the barrel and shank To check the swivel must be removed from the weight ball If the gap is wide on one side and closed on the other side damage is present NOTE The gap between the barrel and the shank is normally...

Page 238: ... and shackle at least yearly for cracks using a dye penetrant test MAG particle test ultrasonic test or by X ray WARNING Falling Load Hazard To prevent the load from dropping make sure that under slack conditions the hook latch retains the slings or other rigging in the hook The hook latch is not intended as an anti fouling device Make sure that the hook latch does not support any part of load Mak...

Page 239: ...R e f e r e n c e O n l y Manitowoc Published 12 05 17 Control 035 23 6 i 6 SECTION 6 SWING TABLE OF CONTENTS Manual Release of Swing Brake and Lock 6 1 Manual Release Procedure 6 1 ...

Page 240: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL 6 ii Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 241: ... swing brake and swing lock 1 Disconnect hoses from fitting at brake release port and if equipped at swing lock OUT port 2 Attach hand pump to each port brake release and swing lock OUT 3 Pressurize brake and swing lock to 350 psi 24 bar 4 Remove or install swing planetary 5 Relieve pressure and remove hand pumps WARNING Unexpected Crane Movement Crane can swing suddenly when swing brake is releas...

Page 242: ...R e f e r e n c e O n l y SWING 18000 SERIVCE MAINTENANCE MANUAL 6 2 Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 243: ... 4 General 7 4 On Board Engine Diagnostics 7 4 Engine Diagnostics Cummins 7 4 DPF Diagnostics Tier 4 7 4 Engine Air Cleaner Maintenance 7 6 Tier 3 and Past Production 7 6 Inspection 7 6 Service 7 6 Tier 4 Current Production 7 8 Inspection 7 8 Daily 7 8 Monthly 7 8 Service 7 8 Engine Clutch Adjustment 7 10 Operation 7 10 Adjustment 7 10 Engine Throttle Adjustment 7 12 Foot Throttle Controller 7 12 ...

Page 244: ...ol 035 23 Tier 3 Engine 7 16 Tier 4 Engine 7 16 Diesel Particulate Filter Tier 4 7 17 General 7 17 Regeneration 7 17 General 7 17 Passive Regeneration 7 17 Active Regeneration 7 17 Stationary Regeneration 7 17 Maintenance 7 18 DPF Removal 7 18 DPF Installation 7 19 DPF Re Orientation 7 19 ...

Page 245: ...ercharging can cause a type of sulfate to develop on the plates The sulfate causes strains in the positive plates which causes plate buckling Buckled plates can pinch the separators and cause a short circuit An undercharged battery is not only unable to deliver power but may freeze see Table 7 1 Table 7 1 Battery Freeze Points The sulfate condition can eventually be converted to metallic lead whic...

Page 246: ...kewise readings should not be taken after a battery has been discharged at a high rate such as cranking 4 When reading a hydrometer hold the barrel vertical with the float freely suspended 5 Draw the electrolyte in and out several times to bring the float temperature to that of the electrolyte 6 Take the reading across the bottom of the liquid level Disregard curvature of the liquid 7 Readings mus...

Page 247: ... current equal to about one half the number of plates per cell in the battery A battery with 13 plates per cell should therefore be charged at 7 amperes If a battery was discharged rapidly cranking until dead it can be recharged on a fast charger with an output of up to 40 amperes for a maximum of 2 hours If the electrolyte temperature reaches 52 C 126 F or if it gases violently the charging curre...

Page 248: ...ide of digital display until Engine Diagnostics screen appears Corresponding flash code for each active fault will appear next to FLASH CODE as shown in Figure 7 4 The screen will automatically scroll through each fault at two second intervals if more than one fault exists DPF Diagnostics Tier 4 See Figure 7 5 for the following procedure DPF High Temperature GLOWS YELLOW to alert crane operator th...

Page 249: ... to START manual stationary regeneration Release switch back to center position Cummins ECM will control a DPF regeneration if necessary It is normal for the DPF High Temperature lamp to illuminate Perform a manual stationary regeneration only if indicated by the DPF diagnostic in the Tier 4 Engine Diagnostics Cummins QSX15 Tier 4 see DPF Condition for details NOTE A guard over the top of the rock...

Page 250: ... the amount of dust dislodged There will be some initial resistance similar to breaking the seal on a jar Gently move the end of the primary filter back and forth to break the seal 2 Avoid dislodging dust from filters Gently pull primary filter off outlet tube and out of housing Avoid knocking filter against housing Repeat steps 1 and 2 for safety filter 3 Clean sealing surfaces in housing Use a c...

Page 251: ...ice cover to push filter into place 9 Check connections for tight fit Make sure that all clamps bolts and connections in entire air intake system are tight Check for holes in piping and repair if needed 14 3 Access Through Door in Left Enclosure Service Indicator 4 5 15 9 1 2 OR 6 8 7 10 12 11 13 A02258 Item Description Item Description 1 Standard Inlet Cap 9 Rubber Reducer with Clamps 2 Pre Clean...

Page 252: ...s 2 Tighten if necessary 4 Inspect engine intake pre cleaner 5 for obstructions or damage Clean as required Service Service the air cleaner and its primary and secondary filter elements per the intervals specified by the engine manufacturer and per the engine manufacturer s instructions An illustration of these instructions is located on the air filter cover see Figure 7 7 Replacement of the prima...

Page 253: ... 7 7 Item Description 1 Rubber Reducer 2 Clamp 6 3 Air Cleaner Assembly 4 Mounting Bracket 5 Pre Cleaner 6 Service Indicator 7 Reset Button 8 Filter Access Cover 9 Air Cleaner Assembly Inlet 10 Air Cleaner Assembly Outlet 11 Primary Filter 12 Secondary Filter 3 6 5 1 1 2 7 1 4 2 2 81018951 81017660 IMG_752 IMG_753 10 9 8 11 12 ...

Page 254: ...ing 3 When disengaging clutch check free travel at lower bracket Free travel should be 2 3 8 2 1 2 in 60 64 mm Readjust the clutch when free travel decreases to 1 3 8 in 35 mm Adjustment The clutch is adjusted internally through the hand hole on top of clutch housing See the manufacturer s manual for adjustment instructions CAUTION Avoid Clutch Damage Observe the following precautions for the engi...

Page 255: ...d BLK ELECTRICAL SCHEMATIC LOW IDLE HIGH IDLE Flat on Head of Shaft Pedal Position B Cab Floor Floor Mat Section B B These two holes should be aligned when initially inserting shaft and spring into housing Surface X 11 2 17 1 6 15 10 12 14 18 15 13 7 8 Ground Supply Signal 1 16 3 5 70 Pedal Position A 13 8 12 7 4 B B A A 2 14 6 10 1 12 15 8 18 14 18 16 9 5 15 17 7 9 13 11 4 11 3 RTV 162 Left End V...

Page 256: ...on housing Finish turning in setscrew 14 until it contacts flat on head of shaft Section A A Calibration Supply voltage to be 25 0 to 26 0 VDC 1 Turn potentiometer 7 shaft fully CCW as viewed from shaft end zero volts out 2 With pedal 3 in Position B insert potentiometer 7 into cavity in bottom of housing 1 as shown in View B B Insert potentiometer shaft into end of shaft 4 and tighten setscrew 22...

Page 257: ...through a vent line to the radiator Since coolant circulation is very slow in the radiator air separates from the coolant Air collects at the top of the radiator When pressure rises to 15 psi 1 03 bar the relief in the fill cap opens to exhaust air through overflow line De aerated coolant returns to the system through a make up line FIGURE 7 10 Item Description Item Description 1 Engine 6 Vent Lin...

Page 258: ...hrough cooler assembly fill cap to FULL COLD LEVEL mark on sight gauge Coolant system capacity is approximately 21 gallons 79 5 liters 2 Look for coolant leaks while engine is running Correct if found 3 Stop engine wait until engine is cool and refill cooling system to FULL COLD level mark Supplemental Coolant Additive Supplemental Coolant Additive must be added to the cooling system to prevent li...

Page 259: ...NTENANCE MANUAL POWER TRAIN 7 A14217 81017661 Item Description 1 Cooler Assembly Tier 3 and Past Production 2 Cooler Assembly Tier 4 3 Coolant Level Sight Gauge 4 Cooler Assembly Fill Cap 5 Cooler Assembly Drain FIGURE 7 11 3 4 4 5 5 3 2 5 1 Tier 4 Current Production Tier 3 and Past Production ...

Page 260: ...4 Engine Engine belt routing for the Tier 4 engine is shown in Figure 7 13 to help service personnel with installing a new fan belt FIGURE 7 12 Item Description 1 Water Pump 2 Belt 1 3 Tension Pulley 4 Alternator 5 Tension Pulley 6 Belt 2 7 Pulley 8 Tension Pulley 9 Crankshaft Flywheel 1 3 4 5 7 8 9 2 6 A13447 FIGURE 7 13 Item Description 1 Water Pump 2 Alternator 3 Belt 1 4 Tension Pulley 5 Pulle...

Page 261: ...mperatures are NOT naturally high enough to oxidize the soot faster than it is collected in the DPF If this happens the engine s controller will initiate the process see Engine Manufacturer s Manual for detailed instructions The process occurs more frequently in cranes operated at low speed light or no load or stop and go cycles Active regeneration will be transparent to the operator except that h...

Page 262: ...as needed for clearance to DPF 3 Disconnect the electrical wiring to the DPF Remove wiring harness and P clamp mounts on the DPF and lay to the side 4 Loosen but do not remove V band clamp and gasket 6 from the inlet side of the DPF Slide clamp and gasket onto inlet tube 5 Loosen screws locknuts and washers securing inlet tube support bracket or remove U bolt guillotine clamp to free inlet tube as...

Page 263: ...ection and the outlet section to the filter center section until each section can be freely rotated Do not fully remove the clamp or gasket 3 Rotate the inlet and outlet section to orientation shown in View B and C Figure 7 15 4 Tighten each V Band clamp to 20 Nm 14 48 ft lb 5 Gently tap the circumference of each clamp with a rubber mallet to ensure proper seating of the V Band Re torque to 20 Nm ...

Page 264: ...scription 1 Lifting Hook 2 Temperature Sensor 1 3 Temperature Sensor 2 4 Lifting Hook Band 5 Inlet V Band Clamp 6 Pressure Sensor 7 Outlet V Band Clamp 8 DPF Outlet Section 9 DPF Center Section 10 DPF Inlet Section 9 View A View B Outlet End 35o 63o 105o 10o 28o View C Inlet End 3 3 2 6 2 1 1 6 FIGURE 7 15 8 10 4 5 7 ...

Page 265: ...g Bolt Torque 8 1 Torque Requirements 8 1 Lubrication 8 1 Torque Values 8 1 Torque Sequence 8 1 Torque Intervals 8 1 Bolt Replacement 8 1 Crawler Adjustment 8 3 Maintenance 8 3 Tread Slack Adjustment 8 3 Adjustment Guideline 8 3 Adjustment Procedure 8 4 Hydraulic Hand Pump 8 5 Assembly 8 5 Maintenance 8 5 Air Removal 8 5 Operation 8 5 ...

Page 266: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL 8 ii Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 267: ...lways replace the washer when replacing a bolt If at the yearly inspection interval one or more bolts are found to be torqued to less than 5 280 ft lb 7 159 Nm replace each loose bolt Also replace the bolt and washer on each side of each loose bolt If at the yearly inspection interval 17 or more bolts in either ring are found to be torqued to less than 5 280 ft lb 7 159 Nm replace all of the bolts...

Page 268: ...ed Numbers Indicate Tightening Sequence FRONT of Upperworks and Carbody Access to inner ring bolts is through hole in center of adapter frame and carbody Adapter Frame Carbody Outer Ring Inner Ring Adapter Frame Carbody A B P1983 P1982 P1981 4 29 11 36 17 40 7 26 42 13 21 1 32 9 19 39 5 28 44 16 24 3 34 23 15 43 25 8 38 18 33 12 31 2 22 14 41 27 6 37 20 35 10 30 40 26 7 42 13 21 1 32 9 34 19 39 28...

Page 269: ...k Adjustment Adjustment Guideline Check tread slack at the tumbler end of each crawler Maintain equal tread slack at both crawlers 1 Travel forward or reverse on a firm level surface so all tread slack is in top of treads at tumbler end of crawlers as shown in Figure 8 2 2 Place straight edge on tread as shown in Figure 8 2 Gap between straight edge and top of tread at lowest point should be 1 1 2...

Page 270: ... for proper adjustment see Adjustment Guideline and readjust as required steps 4 through 9 11 Tighten nuts on bolts at crawler roller to 2 000 ft lb 2 710 Nm lubricated with Never Seez or an equivalent oil and graphite mixture 12 Install cover on both sides of crawler frame NOTE The extreme limit of tread adjustment occurs when the bolts are tight against the front end of the slots in the crawler ...

Page 271: ...pump higher than cylinder and position cylinder so rod is down 3 Operate pump to fully extend cylinder rod 4 Open valve and retract cylinder rod to force oil and trapped air back into pump 5 Repeat steps until cylinder operates smoothly Erratic operation indicates air in system Operation 1 Before using pump a Check that all fittings are tight and leak free b Check oil level 2 To pressurize cylinde...

Page 272: ...IAGE 18000 SERIVCE MAINTENANCE MANUAL 8 6 Published 12 05 17 Control 035 23 S135 S137 S138 Notch in Dipstick Enerpac Pump FIGURE 8 4 Hose Cylinder Vent Fill Cap Simplex Pump Extend Cylinder Close Valve Open Valve Retract Cylinder Pump OR ...

Page 273: ...R e f e r e n c e O n l y Manitowoc Published 12 05 17 Control 035 23 9 i 9 SECTION 9 LUBRICATION TABLE OF CONTENTS Lubrication 9 1 ...

Page 274: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL 9 ii Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 275: ...R e f e r e n c e O n l y Manitowoc Published 12 05 17 Control 035 23 9 1 18000 SERIVCE MAINTENANCE MANUAL LUBRICATION 9 SECTION 9 LUBRICATION LUBRICATION See F2104 at the end of this section ...

Page 276: ...R e f e r e n c e O n l y LUBRICATION 18000 SERIVCE MAINTENANCE MANUAL 9 2 Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 277: ...ch maximum speed 10 15 Problem 14 Boom will not boom up but will boom down 10 16 Problem 15 Boom will not boom down but will boom up 10 17 Problem 16 No luffing jib drum 6 operation 10 18 Problem 17 Luffing jib will not reach maximum speed 10 19 Problem 18 Luffing jib will not boom up but will boom down 10 20 Problem 19 Luffing jib will not boom down but will boom up 10 21 Problem 20 No mast hoist...

Page 278: ...R e f e r e n c e O n l y 18000 SERIVCE MAINTENANCE MANUAL 10 ii Published 12 05 17 Control 035 23 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 279: ...nce equipment is removed Perform a function check to ensure correct operation at completion of maintenance or repair operations The following warnings apply to all troubleshooting operations Manitowoc cannot foresee all hazards that may occur Technicians shall be familiar with the equipment trained in testing methods and use common sense while troubleshooting to avoid other hazards GENERAL TROUBLE...

Page 280: ...ncountered during normal operation These charts contain instructions to assist in identifying and correcting problems Follow the procedural steps in the order indicated Some steps direct you to other charts in this manual or reference a specific test that should be performed to move through the complete troubleshooting procedure If directed consult your Manitowoc dealer or the Manitowoc Crane Care...

Page 281: ...DC or less Check engine stop switch for voltage Charge or replace battery Check starter solenoid SS circuit breaker CB6 If Good If Bad Check electrical connections in starter circuit from battery to starter Connections Good Connections Bad Replace starter Clean connections Replace circuit breaker CB6 if damaged Check start solenoid MS1 MS2 relays If Good If Bad Replace start solenoid MS1 MS2 relay...

Page 282: ...er engine No Fuel Good Stream of Clear Fuel Make sure injector pump fuel shut off valve is fully open Fully Open Not Open Check for fuel in tank or line obstruction A fuel additive is recommended in cold weather Algae can occur in warm climates Make adjustments to solenoid shut off valve or check valve for correct operation Remove injector pump inlet line Turn over engine Look for momentary burst ...

Page 283: ...shut off valve or replace filter if necessary Clutch Engaged Clutch not Engaged Engage clutch Remove tank cap and check vent fluid level and viscosity In extreme cold conditions oil may not flow freely to pump inlets causing pump cavitation Tank Vent Oil Level Viscosity Ok Not Ok Service hydraulic system Check manual override on two or more pumps Does engine load when manual override is applied Se...

Page 284: ...ngine running POSSIBLE CAUSES Belt loose or broken No input to alternator terminals Damaged alternator Corroded or loose battery connection Battery is damaged CHECKS Check fan drive belt and alternator belt for correct tension See engine manual for belt specifications Ok Not Ok Zero Volts DC 27 2 Volts DC or more 20 8 Volts DC or less Tighten fan drive belt alternator belt Replace belt if worn Rep...

Page 285: ...ant level and quality Ok Not Ok Check engine oil level at dipstick Ok Not Ok Check fan drive belt or alternator belt for excessive wear Check engine oil pressure sender Ok Not Ok Add or replace coolant Check for leaks before adding oil Ok See engine manual Check if radiator is plugged Check temperature sender Ok See engine manual Adjust or replace belt s Ok Not Ok Clean or repair radiator Does Eng...

Page 286: ...ts Increase engine speed Obstruction No Obstruction Is throttle in maximum RPM position Yes No When moving travel handle fully in both directions does TRACK screen approach 100 pump control in each direction Yes No Check for control voltage of zero volts at rest and 24 at full speed at both sides of EDC coil and a resistance of around 19 ohms at pump See Section 3 Checking Electrical Inputs Output...

Page 287: ...ce wiring or switch Consult dealer factory When moving problem handle fully in both directions does TRACK screen read 0 5 to 2 4 volts in reverse or 2 6 to 4 5 volts in forward direction No Yes Replace switch or wiring When moving problem handle in both directions does TRACK screen approach 100 pump control in each direction No Yes Is voltage at problem handle greater than 0 with handle moved See ...

Page 288: ...n raise or 2 6 to 4 5 volts in lower direction Yes No When moving problem handle fully in both directions does DRUM screen approach 100 pump control for each pump Yes No Is voltage at problem handle more than 0 with handle moved Yes No Is there an operating or system fault when handle is moved Correct problem Yes No Consult dealer factory Is pressure at drum brake s and drum valve s more than 300 ...

Page 289: ...mp Control Raise Packet 33 Bank 2 changed by 4 Drum 2 Pump Control Raise Packet 33 Bank 2 changed by 16 Drum 3 Pump Control Raise Packet 33 Bank 3 changed by 1 All bank numbers increased by number shown Any bank number not increased by number shown Does selected DRUM screen approach 100 handle control with handle moved back Yes No Check for problem and repair limit switch operation wiring or circu...

Page 290: ...by 2 Drum 1 Pump Control Lower Packet 33 Bank 2 changed by 8 Drum 2 Pump Control Lower Packet 33 Bank 2 changed by 32 Drum 3 Pump Control Lower Packet 33 Bank 3 changed by 2 Bank number increased by number shown Bank number not increased by number shown Does selected DRUM screen approach 100 handle control with handle moved forward Check for problem Repair limit switch wiring or circuit breaker Do...

Page 291: ...e Check for zero volt at rest and 24 volt at full speed and coil resistance of around 19 ohms at pump EDC or 24 to 26 ohms at motor PCP See Section 3 Checking Electrical Inputs Outputs Consult dealer factory Yes Voltage and Coil Ok Remove plug at motor port M5 and check orifice for obstruction See Section 2 Motor Components Repair or replace coil or wiring Obstruction No Obstruction Clean or repla...

Page 292: ...approach 100 handle control in each direction Yes No Yes No Yes No Yes No Yes No Yes No Yes No When moving handle fully in both directions does DRUM 4 screen approach 100 pump control command for each pump Is voltage at handle more than 0 with handle moved See Section 3 Checking Electrical Inputs Outputs Consult dealer factory Correct problem Is there an operating or system fault Replace pump s ED...

Page 293: ...ng boom hoist control handle fully in both directions does DRUM 4 screen approach 100 pump control for each pump Repair wiring consult dealer Check for control voltage and coil resistance at pump EDC and motor PCP See Section 3 Checking Electrical Inputs Outputs Check for pump and motor leakage See Section 2 Motor Leakage Test Repair or replace coil or wiring Clean or replace orifice Consult deale...

Page 294: ...ist Pump Pressure Packet 38 Bank 3 changed by 1 or 4 Bank number increased by number shown Bank number not increased by number shown When moving boom hoist handle fully back directions does DRUM 4 screen read 100 handle command and 0 5 to 2 4 volts in raise direction Check for problem Repair limit switch wiring or circuit breaker Yes No Yes No Yes No Yes No Does DRUM 4 screen approach 100 pump con...

Page 295: ...Yes No Yes No Yes No Does Packet 34 bank 3 boom hoist pawl change by 4 when moving brake switch Check for problem Repair limit switch wiring or circuit breaker Visually check pawl Check pawl operation Repair or replace switch or wiring to controller Does DRUM 4 screen approach 100 pump control with handle moved fully forward Are zero volts at rest and 24 volts at full speed present at pump EDC whe...

Page 296: ...ly in both directions does DRUM 6 screen approach 100 handle control in each direction Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No When moving handle fully in both directions does DRUM 6 screen approach 100 pump control command for pump Is voltage at handle more than 0 with handle moved Is pressure at brake and brake valve 300 psi 21 bar or more Consult dealer factory Correct pr...

Page 297: ... moving boom hoist control handle fully in both directions does DRUM 6 screen approach 100 pump control Repair wiring consult dealer Check for control voltage and coil resistance at pump EDC and motor PCP See Section 3 Checking Electrical Inputs Outputs Check for pump and motor leakage See Section 2 Motor Leakage Test Repair or replace coil or wiring Clean or replace orifice Consult dealer factory...

Page 298: ... by number shown Yes No Out In Yes No Yes No Yes No Does Packet 39 bank 2 luffing jib pawl change by 32 when moving brake switch Check for problem Repair limit switch wiring or circuit breaker Visually check pawl Check pawl operation Repair or replace switch or wiring to controller Does DRUM 6 screen approach 100 pump control with handle moved fully back Are zero volts at rest and 24 volts at full...

Page 299: ...Yes No Yes No Yes No Does Packet 39 bank 2 luffing jib pawl change by 32 when moving brake switch Check for problem Repair limit switch wiring or circuit breaker Visually check pawl Check pawl operation Repair or replace switch or wiring to controller Does DRUM 6 screen approach 100 pump control with handle moved fully forward Are zero volts at rest and 24 volts at full speed present at pump EDC w...

Page 300: ...handle fully in both directions does DRUM 5 screen approach 100 handle control in each direction Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No When moving handle fully in both directions does DRUM 5 screen approach 100 pump control command for pump Is voltage at handle more than 0 with handle moved Is pressure at brake and brake valve 300 psi 21 bar or more Consult dealer factory ...

Page 301: ...Brake Packet 36 Bank 2 changed by 4 Yes No Contact factory service department Repair or replace switch or wiring Contact factory service department Is 24 volts present at swing brake solenoid W74 B or swing lock solenoid W74 F See Section 3 Checking Electrical Inputs Outputs Check accessory accumulator pressure at swing lock or brake valve with a 0 1000 psi 70 bar gauge Repair or replace swing loc...

Page 302: ... bank 2 change by 16 Consult dealer factory Replace switch or wiring Check wiring connector at pump EDC Repair connector Consult dealer factory Manually stroke swing pump See Section 2 Manual Override Tests Does platform rotate Isolate and manually the stroke pump Is system pressurized Is 0 1 to 2 0 volts present at pump s EDC Replace pump EDC Repair or replace motor Repair or replace wiring to PC...

Page 303: ...re at more than 350 psi 24 bar on screen Fill reservoir to correct level warm hydraulic oil to 15 C 60 F or open shut off valve Is suction filter displayed on system fault screen Check and replace suction filter if required Adjust charge pressure relief valve for 350 psi 24 bar See Section 2 Charge Pressure Adjustment 350 psi Obtained 350 psi not Obtained System multifunction valves operating at r...

Page 304: ...pressure sensor station Yes No System multifunction valves are operating at recommended system pressures Are suction filters clean Replace filters Yes No Adjust or replace problem valve Adjust charge pressure relief valve for 350 psi 24 bar See Section 2 Charge Pressure Adjustment 350 psi obtained System should be at correct temperature Check for internal leakage at pump and motor See Section 2 Mo...

Page 305: ... not return to neutral POSSIBLE CAUSES Control handle is worn System pump EDC is damaged or out of adjustment System pump is damaged Pump is not centered No Yes Replace system control handle or repair wiring With system handle in neutral does screen display command activity for pump Consult dealer factory Does system pump EDC manually return to neutral See Section 2 Pump Neutral Adjustment Adjust ...

Page 306: ...ed by 4 Drum 5 Pawl Out Packet 34 Bank 1 changed by 8 Drum 5 Pawl In Packet 34 Bank 1 changed by 4 Drum 6 Pawl Out Packet 39 Bank 2 changed by 32 Drum 6 Pawl In Packet 39 Bank 2 changed by 16 Damage Repair damage Test and adjust Move brake switch to apply and release positions See Crane Diagnostics topic in Section 3 to find CAN bus packet numbers When applicable function was enabled Yes No Check ...

Page 307: ...mast lower when moving mast switch from neutral to raise or lower Yes No Adjust cylinder counterbalance valve See Section 2 Counterbalance Valve Adjustments Does cylinder operate correctly Replace cylinder or consult dealer factory No Is crane setup mode selected and confirmed Yes No Consult dealer factory Select and confirm setup remote mode Check for 24 volts at mast power switch pin number W46 ...

Page 308: ... counterbalance valve 3 000 psi 207 bar Low no pressure Is crane setup remote mode selected and confirmed Yes No Exchange both counterbalance valve cartridges on problem jacking cylinder Is cylinder enabled with switch movement Adjust supercharge accessory supply pressure to 3 000 psi 207 bar when enabling jacking switch Consult dealer factory Replace counterbalance valve See Section 2 Counterbala...

Page 309: ...BLE CAUSES Not in setup mode Faulty control valve section Supercharge accessory supply pump is damaged Mechanical problem 3 000 psi 207 bar Low No pressure Repair or replace problem crawler pin cylinder Is crane setup mode select and confirmed Yes No Select and confirm setup mode Does system develop any working pressure Yes No Adjust supercharge accessory supply system for 3 000 psi 207 bar when p...

Page 310: ... screen VALVES change when moving rotating frame pin switch to engage or disengage position Front Rotating Pin In Bank 1 changed by 1 Front Rotating Pin Out Bank 1 changed by 2 Rear Rotating Pin In Bank 1 changed by 4 Rear Rotating Pin Out Bank 1 changed by 8 Yes No Is crane setup mode selected and confirmed Yes No Select and confirm setup mode Replace cylinder or consult dealer factory Repair pro...

Page 311: ...ge by 64 mast pin in or bank 3 change by 128 mast pin out when moving boom hinge pin switch to engage or disengage position Yes No Is crane setup mode selected and confirmed Yes No Select and confirm setup mode Replace cylinder or consult dealer factory Repair problem Are solenoids magnetized when switch position is enabled Yes No Is there voltage at solenoid valve Check supercharge accessory syst...

Page 312: ...nge pin cylinders Yes No Does ACC screen VALVES bank 3 change by 16 hinge pin in or bank 3 change by 32 hinge pin out when moving boom hinge pin switch to engage or disengage position Yes No Is crane setup mode selected and confirmed Yes No Select and confirm setup mode Replace cylinder or consult dealer factory Repair problem Are solenoids magnetized when switch position is enabled Yes No Is ther...

Page 313: ...ilter Tier 4 7 17 Digital Display 3 34 Digital Input and Output Item Tables 3 47 Disc Brake Operational Test 2 18 Electric System 3 1 Electrical Schematics 3 1 Engine Air Cleaner Maintenance 7 6 Engine Belt Routing 7 16 Engine Clutch Adjustment 7 10 Engine Cooling System 7 13 Engine Diagnostics 7 4 Engine Speed Calibration 7 12 Engine Throttle Adjustment 7 12 Environmental Protection 1 3 Epic Cont...

Page 314: ...ance 5 3 Physical Boom Stop 4 6 Power Train 7 1 Pressure Sender Replacement 2 17 Replacing Desiccant Breather 2 9 Replacing Filters 2 6 Safe Maintenance Practices 1 2 Safety Messages 1 1 Safety Summary 10 1 Servicing Pumps 2 10 Sheave Roller and Drum Inspection 5 19 Shop Procedures 2 20 Speed Sensor Adjustment 5 4 Strap Inspection and Maintenance 4 9 Swing System Operation 1 30 Swing 6 1 Test Volt...

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