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OPERATOR MANUAL

Supplement

Crane Warm-up Procedures

An untrained operator subjects himself and others to death or 
serious injury. Do not operate this crane unless:

•

You are trained in the safe operation of this crane. 

Manitowoc is not

responsible for qualifying personnel.

•

You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.

•

You are sure that all safety signs, guards, and other safety features are
in place and in proper condition. 

•

The Operator Manual and Load Chart are in the holder provided on
crane.

DANGER

!

© 2017 Manitowoc

 Published 3-30-2017, Control # 516-04

Reference Only

Summary of Contents for CD25

Page 1: ...onnel You read understand and follow the safety and operating recommendations contained in the crane manufacturer s manuals and load charts your employer s work rules and applicable government regulations You are sure that all safety signs guards and other safety features are in place and in proper condition The Operator Manual and Load Chart are in the holder provided on crane DANGER 2017 Manitow...

Page 2: ...SECTION CONTENTS Crane Warm up Procedures 1 Engine 1 Transmission 1 Hoist 1 Swing Drive and Turntable Bearing 1 Axles 2 Hydraulic Oil System 2 R e f e r e n c e O n l y ...

Page 3: ...errain RT and Industrial Cranes 1 Engage the parking brake and apply the service brake 2 Shift the transmission into the highest gear and increase the engine RPM to 1500 for 15 seconds then allow the engine RPM to return to idle 3 Repeat Step 2 until the temperature of the transmission sump reaches normal operating temperature Alternate Warm up Procedures for Rough Terrain RT and Industrial Cranes...

Page 4: ...l drive selected if equipped and allow crane to run at idle until the temperature of the transmission sump reaches normal operating temperature NOTE Warm up operation of 4 wheel drive transmission engaged in 2 wheel drive only could cause transmission damage Hydraulic Oil System Operating Limits and Warm up Procedures From 4 C to 10 C 40 F to 15 F Crane operation without a load is allowed with med...

Page 5: ...Operator Manual CD25 R e f e r e n c e O n l y ...

Page 6: ...R e f e r e n c e O n l y ...

Page 7: ... furnish crane serial number when ordering parts or communicating service problems with your distributor or the factory An untrained operator subjects himself and others to death or serious injury Do not operate this crane unless You are trained in the safe operation of this crane Manitowoc is not responsible for qualifying personnel You read understand and follow the safety and operating recommen...

Page 8: ...e State of California to cause cancer birth defects and other reproductive harm CALIFORNIA PROPOSITION 65 WARNING Battery posts terminals and related accessories contain chemical lead and lead compounds chemicals known to the State of California to cause cancer birth defects or other reproductive harm Wash hands after handling R e f e r e n c e O n l y ...

Page 9: ...Working Area Limiter If Equipped 2 5 Crane Stability Structural Strength 2 6 Load Charts 2 6 Work Site 2 6 Wind Forces 2 7 Wind Speeds 2 7 Lifting Operations 2 20 Counterweight 2 21 Outrigger Lift Off 2 21 Multiple Crane Lifts 2 21 Tilt Up Panel Lifting 2 21 Pile Driving and Extracting 2 22 Crane Equipment 2 22 Crane Inspection 2 22 Electrocution Hazard 2 23 Set Up and Operation 2 24 Electrocution...

Page 10: ...ontrols 3 3 Right Dash Controls 3 4 Indicator and Gauge Display 3 6 Crane Level Indicator 3 8 Engine Warning and Stop Lights 3 8 Rated Capacity Indicator RCI 3 9 Air Conditioning Heater Controls 3 9 Boom Angle Indicator 3 9 Outrigger Controls 3 10 Steering Controls 3 10 Operator s Cab 3 11 Heater Air Conditioner 3 11 Defroster 3 11 Seat Adjustment 3 12 Seat Belt 3 12 Cab Door Enclosed Cab 3 12 Fir...

Page 11: ...ook Block 5 4 Removing the Hook Block 5 4 Installing the Hook Block 5 4 Boom Extension 5 5 Installing the Boom Extension 5 5 Stowing the Boom Extension 5 5 Down Haul Weight 5 7 Installing the Down Haul Weight 5 7 Removing the Down Haul Weight 5 7 Installing Cable On The Hoist 5 8 Wire Rope Wedge Socket 5 8 SECTION 6 Maintenance Introduction 6 2 Spark Arresting Mufflers 6 2 Wire Rope 6 2 General 6 ...

Page 12: ... 26 Lubricate the Swing Gear and Pinion 6 26 Torque Critical Bolts 6 26 Replace the Crankcase Oil 6 27 Replace the Engine Oil Filter 6 28 Clean the Radiator 6 28 500 Hours of Operation Three Months 6 28 Inspect the Tires 6 28 Inspect the Parking Brake Pads 6 28 Replace Fuel Filter Water Separator 6 28 Replace the Secondary Fuel Element 6 28 Replace Air Cleaner Element 6 29 Add Rust Inhibitor to En...

Page 13: ...6 37 Diesel Exhaust Fluid DEF Tank 6 39 SECTION 7 Adjustments SECTION 8 Specifications Lubricants and Capacities 8 1 Engine Oil Specifications 8 1 Cummins Oil Registration List 8 1 Oil Performance Recommendations 8 2 Oil Viscosity Recommendations 8 2 New Engine Break In Oils 8 2 Diesel Fuel 8 2 General Specifications 8 3 R e f e r e n c e O n l y ...

Page 14: ...TABLE OF CONTENTS CD25 OPERATOR MANUAL TOC 6 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 15: ...e Operating and routine maintenance procedures for the engine Rated Capacity Limiter RCL are supplied in separate manuals and should be referred to for detailed information Crane lifting capacities are found in the Load Chart Manual located in the cab along with this Operator Manual Serial Number When contacting Manitowoc Cranes or its distributor about this machine always refer to the machine s s...

Page 16: ...owoc crane please register it with Manitowoc Crane Care so we have the ability to contact you if the need arises Go to http www manitowoccranes com MCG_CARE Includes EN changeofownership cfm and complete the form SAFETY INFORMATION A Safety CD which includes sections on operation safety and maintenance for crane operators and owners is supplied when the crane is purchased new Additional copies are...

Page 17: ...ers for lift telescope steering and outriggers Hydraulic Tank 60 gal 227 L capacity steel construction with internal baffles WIRE ROPE Wire Rope Hoist Diameter 5 8 in 16 mm Type XXIPS Length 390 ft 118 9 m Wire Rope Optional Below Deck Winch Diameter 1 4 in 6 mm Length 100 ft 30 5 m TORQUE CONVERTER TRANSMISSION Manufacturer Dana Transmission Type Hydraulic FRONT AXLE DRIVE Type International Tran...

Page 18: ...INTRODUCTION CD25 1 4 Published 1 06 2017 Control 579 01 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 19: ...6 Environmental Protection 2 27 Maintenance 2 27 Service and Repairs 2 27 Lubrication 2 28 Tires 2 29 Hoist Rope 2 29 Synthetic Hoist Rope 2 29 Wire Rope 2 29 Sheaves 2 30 Batteries 2 31 Super Capacitor If Equipped 2 31 General Maintenance 2 31 Transporting the Crane 2 32 Travel Operation 2 32 Work Practices 2 33 Personal Considerations 2 33 Crane Access 2 33 Job Preparation 2 33 Working 2 34 Lift...

Page 20: ... injury to personnel or damage to equipment You are responsible for the safety of yourself and those around you Warning Signs Refer to the Parts Manual for a drawing indicating the location of warning signs on the crane ACCIDENTS Following any accident or damage to equipment the Manitowoc dealer must be immediately advised of the incident and consulted on necessary inspections and repairs Should t...

Page 21: ...0 5 American National Standard or in any other applicable federal state or local laws Ensure that all personnel working around the crane are thoroughly familiar with safe operating practices You must be thoroughly familiar with the location and content of all placards and decals on the crane Decals provide important instructions and warnings and must be read prior to any operational or maintenance...

Page 22: ...the designated person responsible for supervising the lifting operations shall establish procedures for determining load weights and shall ascertain that the weight of the load does not exceed the crane ratings at the radius where the load is to be handled When a Boom Angle or Radius Indicator is inoperative or malfunctioning the radius or boom angle shall be determined by measurement When an Anti...

Page 23: ...g up Let out load line s simultaneously to prevent two blocking the boom tip s and the hook block etc The closer the load is carried to the boom nose the more important it becomes to simultaneously let out hoist rope as the boom is lowered Keep load handling devices a minimum of 107 cm 42 in below the boom nose at all times Two blocking can be prevented Operator awareness of the hazards of two blo...

Page 24: ...iggers or tires if lifting on rubber are firmly positioned on solid surfaces Ensure the crane is level brakes are set and the load is properly rigged and attached to the hook Check the Load Chart against the weight of the load Lift the load slightly off the ground and recheck the stability before proceeding with the lift Determine the weight of the load before you attempt the lift Unless lifting w...

Page 25: ...n wind speed at 10 m 33 ft elevation over a period of 10 minutes Table 2 1 Beaufort Wind Scale Wind Speeds The maximum permissible wind speed referred to in the load charts is the 3 second wind gust speed measured at the boom tip height and is designated as V z This value is either recorded at boom tip or calculated based on mean wind speed recorded at crane operation site For lift planning purpos...

Page 26: ...city Reduction Factor from Table 2 4 metric or non metric NOTE This condition is limited to operation with the main boom on fully extended outriggers only c If V z is 20 1 m s 45 mph then lifting is NOT permitted Cease lifting operations and lower and retract the boom In both cases a and b above the lift may also be limited by the projected wind area of the load Ap and by the wind drag coefficient...

Page 27: ...Awr load Ap X Cd Determine Cd of Load Ap maximum height X maximum length See Figure 2 2 Lifting is not permitted Cease Lifting Operations V z 20 1 m s 45 mph 13 4 m s V z 20 1 m s 30 mph V z 45 mph Use Main Boom on Fully Extended Outriggers ONLY V z 13 4 m s 30 mph Main Boom Allowable load Published Rated Capacity Allowable Load Published Rated Capacity X Capacity Reduction Factor from Load Chart ...

Page 28: ...Size and Shape of the load These rated capacities are also based on the assumption that the Wind Resistance Area of load Awr load is not more than 0 0012 square meters per kilogram 0 0059 sq ft per pound of load See below Formulas 2 4 and 2 5 The load capacities shall be reduced to account for the larger wind resistance area of load and 3 second wind gust speed at boom tip height Use tag lines whe...

Page 29: ...ag Coefficient Cd values If the exact Wind Drag Coefficient of a shape is not known use the maximum value of the shape s range Table 2 2 If the wind drag coefficient of the load cannot be estimated or determined it shall be assumed that Cd 2 4 Ap 24 m2 Ap 8 m2 Wind Wind 8 m 1 m 3 m 8 m 1 m 3 m Ap 250 ft2 Ap 75 ft2 Wind Wind 25 ft 3 ft 10 ft 25 ft 3 ft 10 ft 8384 1 FIGURE 2 2 R e f e r e n c e O n ...

Page 30: ...ad using Table 2 3 Table 2 3 Awr Ratio and Permissible Wind Speed V z Non metric 8384 2 Shape Cd 1 1 to 2 0 0 3 to 0 4 0 6 to 1 0 0 8 to 1 2 0 2 to 0 3 0 05 to 0 1 Approximately 1 6 Turbine Blade or Complete Rotor Note Permissible and rated wind speeds in this table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed mph For Rated Capacity at...

Page 31: ...2 13 CD25 SAFETY INFORMATION 2 Published 1 06 2017 Control 579 01 Rated Load Chart Example Metric FIGURE 2 3 8383 1 R e f e r e n c e O n l y ...

Page 32: ... the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed m s For Rated Capacity at 13 4 m s 12 2 11 4 10 6 10 0 9 5 For Allowable Capacity at 20 1 m s 18 3 17 0 15 9 15 0 14 2 Table 2 4 Example Capacity Reduction Factors for Wind Speed V z Greater than 13 4 m s Metric Only for lifting with main boom on fully extended outriggers with or without stowed...

Page 33: ...nclusion This load is permissible to lift in wind speed up to 20 1 m s Load example 1 3a With large wind resistance area of the load Awr load Load to be lifted of 14 000 kg Projected Wind Area Ap 21 85 m2 Wind Drag Coefficient Cd 1 2 the wind resistance area of load can be estimated as Awr load Ap X Cd 21 85 x 1 2 26 22 m2 Refer to the above Lifting Limits at wind speed V z 13 4 m s and 20 1 m s C...

Page 34: ...5 m2 NO Conclusion This load is NOT permissible to lift in wind speed up to 20 1 m s but permitted to lift at a reduced wind speed calculated as follows Ratio 1 37 From Table 2 5 the maximum permissible wind speed at ratio of 1 37 rounded to next higher table value of 1 4 is 17 0 m s Conclusion This load is permissible to lift in wind speed up to 17 0 m s only R e f e r e n c e O n l y ...

Page 35: ...2 17 CD25 SAFETY INFORMATION 2 Published 1 06 2017 Control 579 01 Rated Load Chart Example Non metric FIGURE 2 4 8382 1 R e f e r e n c e O n l y ...

Page 36: ...0 160 119 ft2 Note Permissible and rated wind speeds in this table are the 3 second gust wind speeds at boom tip height Ratio 1 2 1 4 1 6 1 8 2 Maximum Permissible Wind Speed mph For Rated Capacity 30 mph 27 4 mph 25 4 mph 23 7 mph 22 4 mph 21 2 mph For Allowable Capacity 45 mph 41 1 mph 38 0 mph 35 6 mph 33 5 mph 31 8 mph Table 2 6Example Capacity Reduction Factors for Wind Speed V z Greater than...

Page 37: ...lusion This load is permissible to lift in wind speed up to 45 mph Load example 2 3a With large wind resistance area of the load Awr load Load to be lifted of 22 000 lb Projected Wind Area Ap 180 ft2 Wind Drag Coefficient Cd 1 2 the wind resistance area of load can be estimated as Awr load Ap x Cd 180 x 1 2 216 ft2 Refer to the above Lifting Limits at wind speed V z 30 mph and 45 mph Comparing the...

Page 38: ... crane and as close to the ground as possible Do not overload the crane by exceeding the capacities shown on the appropriate Load Chart Death or serious injury could result from the crane tipping over or failing structurally from overload The crane can tip over or fail structurally if The load and crane s configuration is not within the capacity as shown on the applicable Load Chart and notes The ...

Page 39: ...rvices of a designated person to direct the operation Use one qualified signal person Coordinate lifting plans with the operators designated person and signal person prior to beginning the lift Maintain communication between all parties throughout the entire operation If possible provide approved radio equipment for voice communication between all parties engaged in the lift Use outriggers on cran...

Page 40: ...d outriggers with all tires clear of the ground The combined weight of the driver or extractor piling leads attachments etc shall not exceed 80 of the published load chart values for on outriggers operation The pile driver or pile extractor and attachments shall be kept clear of the boom nose at all times The pile driver and piling shall be suspended from a hoist cable with sufficient line speed t...

Page 41: ...th the crane Crane operation is dangerous when close to an energized electrical power source Exercise extreme caution and prudent judgement Operate slowly and cautiously when in the vicinity of power lines Before operating this crane in the vicinity of electrical power lines or equipment notify the power utility company Obtain positive and absolute assurance that the power has been turned off This...

Page 42: ...s Any tag line that is wet or dirty can conduct electricity Do not store materials under power lines or close to electrical power sources Electrocution Hazard Devices The use of insulated links insulated boom cages guards proximity warning devices or mechanical limit stops does not assure that electrical contact will not occur Even if codes or regulations require the use of such devices failure to...

Page 43: ...vice until it is thoroughly inspected for any evidence of damage and all damaged parts are repaired or replaced as authorized by your Manitowoc distributor or Manitowoc Crane Care Special Operating Conditions and Equipment Never operate the crane during an electrical thunderstorm When operating near transmitter communication towers where an electrical charge can be induced into the crane or load T...

Page 44: ...conditions Additional requirements for crane operations are stated in ASME B30 5 Mobile and Locomotive Cranes ASME B30 8 Floating Cranes and Floating Derricks and in OSHA regulations 29CFR1910 180 for General Industry and 29CFR1926 1431 for Construction Use of a Manitowoc crane to handle personnel is acceptable provided The requirements of the applicable national state and local regulations and sa...

Page 45: ...contain Always fill or add fluids with a funnel or a filling pump Immediately clean up any spills MAINTENANCE The crane must be inspected prior to use on each work shift The owner user and operator must ensure that routine maintenance and lubrication are being dutifully performed Never operate a damaged or poorly maintained crane Manitowoc continues to recommend that cranes be properly maintained ...

Page 46: ... stop moving before servicing crane Pinch points which result from relative motion between mechanical parts are areas of the machine that can cause personal injury or death Do not place limbs or your body in contact with pinch points either on or around the machine Care must be taken to prevent motion between pinch points when performing maintenance and to avoid such areas when movement is possibl...

Page 47: ... diameter or more than four 4 broken wires in a length of rope equal to thirty 30 times the rope diameter For running ropes other than rotation resistant six 6 broken wires in one rope lay or three 3 broken wires in one strand One valley break where the wire fractures between strands in a running rope is cause for removal Abrasion of the rope resulting in a 5 reduction in the original wire diamete...

Page 48: ...d cause damage to a wire rope Broken wires mean a loss in strength Kinks permanently damage a rope and must be avoided Ropes are damaged by knots Rope with knots must never be used Environmental factors such as corrosive conditions and heat can damage a wire rope Lack of lubrication can significantly shorten the useful life of a wire rope Contact with electrical wires and resulting arcing will dam...

Page 49: ...ECM power fuse d Remove negative battery cables Do not break a live circuit at the battery terminal Disconnect the ground battery cable first when removing a battery and connect it last when installing a battery Do not short across the battery posts to check charge Short circuit spark or flame could cause battery explosion If applicable maintain battery electrolyte at the proper level Check the el...

Page 50: ... hookblock tie down the cable should be merely snugged up with adequate slack provided at the center line of sheave to anchor point Do not draw cable taut Care must be exercised anytime any crane function is being performed while the cable is hooked into the hookblock tie down TRAVEL OPERATION Only the crane operator shall occupy the crane when traveling When traveling the boom should be completel...

Page 51: ...intain a three point contact when getting on or off the crane If necessary use a ladder or aerial work platform to access the boom nose Do not make modifications or additions to the crane s access system that have not been evaluated and approved by Manitowoc Crane Care Do not step on surfaces on the crane that are not approved or suitable for walking and working All walking and working surfaces on...

Page 52: ... and or engine exhaust can cause an explosion Do not operate this crane in an area with flammable dust or vapors unless good ventilation has removed the hazard Carbon monoxide fumes from the engine exhaust can cause suffocation in an enclosed area Good ventilation is very important when operating the crane Before actuating swing or any other crane function sound the horn and verify that all person...

Page 53: ...id lowering or swinging the boom and load into ground personnel equipment or other objects Lift one load at a time Do not lift two or more separately rigged loads at one time even if the loads are within the crane s rated capacity Never leave the crane with a load suspended Should it become necessary to leave the crane lower the load to the ground and stop the engine before leaving the operator s ...

Page 54: ... cannot clearly see the load at all times Moving the crane in an area or direction in which the operator cannot clearly see the path of travel At all times use standardized hand signals previously agreed upon and completely understood by the operator and signal person If communication with the signal person is lost crane movement must be stopped until communications are restored Keep your attentio...

Page 55: ...2 37 CD25 SAFETY INFORMATION 2 Published 1 06 2017 Control 579 01 8496 1 FIGURE 2 10 R e f e r e n c e O n l y ...

Page 56: ...le superstructure orientation jib angle etc In high winds the boom and jibs should be lowered or secured Changing weather conditions including but not limited to wind ice accumulation precipitation flooding lightning etc should be considered when determining the location and configuration of a crane when it is to be left unattended SHUT DOWN Use the following steps when shutting down the crane Eng...

Page 57: ...5 C 60 F would retract approximately 196 mm 7 3 4 in see Table 2 9 and Table 2 8 The rate at which the oil cools depends on many factors and will be more noticeable with a larger difference in oil temperature verses the ambient temperature Thermal contraction coupled with improper lubrication or improper wear pad adjustments may under certain conditions cause a stick slip condition in the boom Thi...

Page 58: ...0 2 58 5 16 7 74 10 32 12 90 15 48 18 06 20 64 23 22 25 80 55 2 84 5 68 8 51 11 35 14 19 17 03 19 87 22 70 25 54 28 38 60 3 10 6 19 9 29 12 38 15 48 18 58 21 67 24 77 27 86 30 96 Length change in inches Stroke Ft X Temperature Change F X Coeff in 3 in 3 F X 12 in ft Coeff 0 000774 1 C STROKE Temperature Change C m 5 10 15 20 25 30 35 40 45 50 55 1 5 6 12 17 23 29 35 41 46 52 58 64 3 12 23 35 46 58...

Page 59: ...for corrective action The following illustrations may not be an exact representation of your crane and are to be used for reference only NOTE If your crane is equipped with CraneSTAR an overload warning will be posted to the web site for review by the crane owner Overload warnings do NOT indicate real time events Warnings could be sent 24 hours or more after the actual event WARNING Overload Hazar...

Page 60: ...SAFETY INFORMATION CD25 2 42 Published 1 06 2017 Control 579 01 2 42 Boom Inspection 4 1 7 5 6 1 2 3 8 9 10 R e f e r e n c e O n l y ...

Page 61: ...amage 3 Collar welds Inspect all for damage 4 Pinning Areas Inspect all for cracks 5 Telescopic Sections Inspect for bent or twisted sections Check the boom for straightness 6 Lift Cylinder Head Area Inspect for bends or cracked welds 7 Turret Base Section Inspect for cracked welds 8 Jib Section Inspect for bent or twisted section Check for straightness 9 Welds Inspect for cracks 10 Paint Inspect ...

Page 62: ...SAFETY INFORMATION CD25 2 44 Published 1 06 2017 Control 579 01 2 44 Superstructure Inspection 2 1 3 8 9 6 5 4 7 10 11 R e f e r e n c e O n l y ...

Page 63: ... See topic in Introduction section of Service Manual 3 Turntable Bearing Check bolts for proper torque See topic in Swing section of Service Manual 4 Hoist Drums Inspect each for damage 5 Hoist Brakes Brakes must hold rated line pull 6 Bearing Main Boom Pivot Pin Inspect for deformation cracked welds 7 Lift Cylinder Lower Mount Inspect pin and welds 8 Turret Area Inspect for deformation cracked we...

Page 64: ...SAFETY INFORMATION CD25 2 46 Published 1 06 2017 Control 579 01 2 46 Carrier Inspection 3 1 1 1 2 2 2 3 3 4 4 5 6 R e f e r e n c e O n l y ...

Page 65: ...ds Overload from 25 to 49 1 jack Cylinders Inspect for leaking 2 Outrigger Pads Inspect for deformation and cracked welds 3 Outrigger Beams Inspect for deformation and cracked welds 4 Outrigger Boxes Inspect for deformation and cracked welds 5 Welds Inspect for cracks 6 Paint Inspect for cracked paint which could indicate twisted stretched or compressed members R e f e r e n c e O n l y ...

Page 66: ...SAFETY INFORMATION CD25 2 48 Published 1 06 2017 Control 579 01 2 48 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 67: ...topping Travel 3 18 Operating the Outrigger Controls 3 18 Outrigger Monitoring System OMS Optional Standard in North America 3 20 Operating the Boom Controls 3 20 Optional Controls Operation 3 26 Operating Practices 3 27 Handling a Load 3 27 Attaching the Load 3 27 Holding the Load 3 27 Moving the Load 3 27 Traveling with a Load Pick and Carry 3 28 Elevating Personnel 3 28 Turning Clearances 3 29 ...

Page 68: ...ssed in order to place the transmission into gear Foot Controls Accelerator Pedal Accelerator Pedal 1 Figure 3 2 controls the travel speed and hydraulic work function speeds of the crane Pressing down on the accelerator pedal increases the engine speed The pedal is spring loaded to return to idle speed Brake Pedal Pressing down on the Brake Pedal 2 applies the service brakes located in the front a...

Page 69: ...etract the outrigger jack selected with the Outrigger Jack Select Switch Refer to Outrigger Controls page 3 10 The park brake must be applied before outriggers will function Headlights Work Lights Switch The Headlights Work Lights Switch 7 is a three position switch Press the bottom of the switch to turn on the head and tail lights Press the top of the switch to turn on the work lights In the cent...

Page 70: ...10 The park brake must be applied before outriggers will function Hazard Lights Switch The Hazard Lights Switch 5 causes all four turn signal lights to flash Crane Function Switch The Crane Function Switch 6 is a two position switch Press the top of the switch to enable all crane functions Press the bottom of the switch to disable crane functions Parking Brake Switch The Parking Brake Switch 7 is ...

Page 71: ...the switch 360 Swing Lock Switch This switch 10 engages the 360 swing lock to lock the turntable in any position Press the bottom of the switch to engage the lock press the top of the switch to disengage the lock Differential Lock Switch This switch 11 engages the differential lock to lock the axles together Press the top of the switch to lock the differentials and press the bottom of the switch t...

Page 72: ...tmeter 4 Hour Meter 5 Diesel Exhaust Fluid Level Gauge 6 Tachometer 7 Right Turn Signal 8 Coolant Temperature 9 Crane Functions Enabled 10 Outrigger Monitoring 11 Third Wrap 12 Low Battery 13 Diesel Exhaust Fluid Low DEF 14 High Exhaust System Temperature HEST 15 Inhibit Exhaust System Cleaning 16 Exhaust System Cleaning Needed 17 Engine Wait to Start 18 Engine Warning 19 Engine Stop 20 Parking Br...

Page 73: ...ion Enabled Indicator 9 illuminates amber when the crane functions hoist telescope boom lift and swing are activated Outrigger Monitoring Indicator The Outrigger Monitoring Indicator 10 illuminates green when all the outriggers have been fully extended The jacks can be extended to level the crane Third Wrap Indicator The Third Wrap Indicator 11 illuminates red when the wire rope is down to the las...

Page 74: ...ion Oil High Temperature Indicator The Transmission Oil High Temperature Indicator 23 illuminates red during high transmission oil temperature conditions A warning buzzer will also sound Four Wheel Drive 4WD Indicator The 4WD Indicator 24 illuminates amber when the Drive Select Switch is in four wheel drive and all four wheels are driving the crane Hydraulic Oil High Temperature Indicator The Hydr...

Page 75: ...r these variables For operating instructions refer to the RCI manual provided Air Conditioning Heater Controls The Fan Switch 1 Figure 3 9 is a four position switch which controls the speed of the fan The A C Thermostat Control 2 is used to regulate the temperature of the air that is delivered The Heater Thermostat Control 3 is used to regulate the temperature of heated air that is delivered The a...

Page 76: ...eel Steering Mode Crab Steering Mode These modes are selected using the Steering Selector Switch 1 Figure 3 12 Because proximity switches are used in the steering system after a steering mode is selected and the steering wheel is turned the steering mode will automatically switch when the tires are aligned in straight ahead direction The steering modes are shown in Figure 3 13 3 14 and 3 15 Two Wh...

Page 77: ...n the engine is open To operate the heater use the fan switch 2 Figure 3 16 in conjunction with the heater control 3 to select the desired fan speed and amount of heat To operate the air conditioner use the fan switch 2 Figure 3 16 in conjunction with the air conditioner control 4 to select the desired fan speed and amount of air conditioning Position the vents on the heater air conditioner for de...

Page 78: ...at belt Use this belt at all times when operating the crane Cab Door Enclosed Cab Opening the Cab Door from Outside Pull the door handle out to release the cab door latch Figure 3 18 Opening the Door from Inside Pull the door handle back to release the cab door latch Figure 3 19 Locking the Cab Door The cab door can be locked from the outside Insert the key and turn it to the left to lock the door...

Page 79: ...Procedures for Industrial Cranes 1 Engage the parking brake and apply the service brake 2 Shift the transmission into the highest gear and increase the engine RPM to 1500 for 15 seconds then allow the engine RPM to return to idle 3 Repeat Step 2 until the temperature of the transmission sump reaches normal operating temperature Alternate Warm up Procedures for Industrial Cranes 1 Setup the crane o...

Page 80: ...ngine immediately and contact a Manitowoc distributor From 10 C to 4 C 50 F to 40 F Crane operation with a load is allowed with medium engine RPM and medium function speed joystick position until the fluid reaches at least 10 C 50 F From 95 C to 10 C 200 F to 50 F Crane operation with a load is allowed with no restrictions Above 95 C 200 F No crane operation is allowed Let the crane s hydraulic oi...

Page 81: ... steering and all controls for proper operation If a malfunction is found shut down the engine immediately and park the crane until the malfunction is corrected or the crane can be safely towed See Towing a Disabled Crane page 3 29 8 Disengage the parking brake before you travel with the crane See Traveling with the Crane page 3 17 Towing or Pushing the Crane to Start the Engine If the battery is ...

Page 82: ...ed to the positive post on the discharged battery See Figure 3 24 8 Connect the other end of the positive cable to the positive post on the booster battery 9 Connect one end of the negative jumper cable usually black to the negative post on the booster battery 10 Connect the other end of the negative cable to the engine block or a ground point furthest away from the discharged battery 11 Follow th...

Page 83: ... heavy load as this may cause lugging on the engine Use a lower gear when moving a heavy load higher gear when moving a lighter load SELECTING THE CORRECT TRAVEL SPEED WILL PROLONG ENGINE LIFE NOTE Check the instrument panel gauges frequently during operation Any abnormal readings should be investigated and corrected as soon as possible CAUTION If travel sight is restricted do not attempt to trave...

Page 84: ...snow commonly called rocking Shifting to reverse or forward while operating the engine at high speed in neutral Operating the transmission at or near stall speed for more than 10 seconds at a time Stall condition is when the engine runs at high speed while the transmission is in forward or reverse and the drive wheels are not moving For example when the wheels are mired in deep sand or mud or when...

Page 85: ...ge the parking brake 3 Run the engine at idle speed accelerator pedal released 4 Push the top of the Extend Retract Switch 2 5 Press the accelerator pedal to increase the engine speed which will accelerate the outward movement of the outriggers Figure 3 26 Release the accelerator pedal and the switch when the outriggers are fully extended Lowering the Jacks 1 Place the Outrigger Jack selector swit...

Page 86: ...he indicator to not illuminate indicating outrigger beams are not fully extended and lifts can only be made per the outriggers retracted or on rubber Load Charts Outrigger beam position monitor is not interfaced with the rated capacity indicator system if equipped the crane operator is responsible for selecting the correct load chart Raising the Jacks 1 Place the Outrigger Jack selector switches 1...

Page 87: ...To Rotate the Mast to the Left Counterclockwise Press the accelerator pedal to increase the engine speed to maximum RPM Slowly pull back on the swing control lever Figure 3 33 until the desired swing speed is obtained The further the control is pulled back the faster the mast will rotate To Stop Rotation Slowly move the control lever to the neutral position and decrease the engine speed to idle To...

Page 88: ...ire rope when extending the boom Do not let the drop block touch the boom head An automatic cutout device is installed on this crane to inhibit the drop block from being pulled into the boom head When the drop block touches the anti double blocking bracket Figure 3 34 hanging from the boom head a switch is activated and the hydraulic flow to extend the telescope cylinder is stopped A horn will sou...

Page 89: ...dal to increase the engine speed to maximum RPM Slowly pull back on the boom control lever Figure 3 36 until the desired raising speed is obtained The further the control is pulled back the faster the boom will raise To Stop Boom Movement Slowly move the control lever to the neutral position and decrease the engine speed to idle 1100254 w0030 w0028 1200144 FIGURE 3 36 a0866 WARNING When lifting at...

Page 90: ...load can cause injury or death Always have a flagman give assistance if you can not see a moving load Be sure you can see the flagman at all times Agree in advance to hand signals to be used see Hand Signals page 2 36 A moving load can cause injury or death and or property damage w0024 1100254 w0030 CAUTION Never put side loads on the boom Side loads can damage the swing gearbox Move the boom so t...

Page 91: ...3 25 CD25 OPERATING CONTROLS AND PROCEDURES 3 Published 1 06 2017 Control 579 01 FIGURE 3 37 a0583 a0584 R e f e r e n c e O n l y ...

Page 92: ... caused if the wire rope breaks or the hook becomes disconnected To Extend the Wire Rope Push and hold the top of the switch Figure 3 38 Keep tension on the wire rope to prevent twisting of the wire rope on the winch drum For fast unwind release the free spool lever on the right side of the winch To Stop the Winch Release the switch To Retract the Wire Rope Push and hold the bottom of the switch F...

Page 93: ...he wire rope it must be determined that the rope is seated on the hoist drum and in the sheaves as the slack is removed The effect of ambient wind on the load and crane stability During lifting operations care must be taken that There is no sudden acceleration or deceleration of the moving load Load boom and other parts of the crane do not contact any obstruction The load must not be lowered below...

Page 94: ... outside the criteria defined in the above guidelines contact Manitowoc Crane Care for further guidance Traveling with a Load Pick and Carry When traveling with a load a designated person must be responsible for the operation Decisions such as the necessity to reduce crane ratings load position boom location ground support travel route and speed of movement must be in accordance with that person s...

Page 95: ...ct switch is located on the right side of the cab in front of the seat To disconnect the batteries turn the battery disconnect switch to OFF Turn the switch to ON to connect the batteries Unattended Crane The configuration in which the crane should be left while unattended shall be determined by a qualified designated individual familiar with the job site configuration conditions and limitations T...

Page 96: ...OPERATING CONTROLS AND PROCEDURES CD25 3 30 Published 1 06 2017 Control 579 01 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 97: ...serve when Using the Capacity Chart The rated loads are the maximum lift capacities as determined by operating radius boom length and boom angle The operating distance from a projection of the axis of rotation to the supporting surface before loading to the center of the vertical hoist line or tackle load applied The rated loads shown in the Capacity Chart on Outriggers do not exceed 85 of actual ...

Page 98: ...pacity when using the boom extension observe the angle at which the main boom is positioned use the angle indicator on the boom see Figure 4 1 Find this angle on the Capacity Chart Read across the line to the amount of offset on the boom extension The capacity given is the capacity that can be lifted DO NOT lift more than what the Capacity Chart states Pick and Carry Ranges Figure 4 2 illustrates ...

Page 99: ...4 3 CD25 CAPACITY CHART 4 Published 1 06 2017 Control 579 01 FIGURE 4 3 FOR REFERENCE ONLY USE THE LOAD CHART IN THE OPERATOR S CAB a0624 R e f e r e n c e O n l y ...

Page 100: ...CAPACITY CHART CD25 4 4 Published 1 06 2017 Control 579 01 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 101: ...he pivoting boom head can be adjusted to five angle positions four of which are used when there is no boom extension attached and two when a boom extension is attached There are limitations to the boom elevation when the boom head is pivoted Refer to Figure 5 1 Pivot Hole Pattern decal also attached to boom nose for these limitations Positions When No Boom Extension is Attached The 0 boom head pos...

Page 102: ...or the desired angle see Figure 5 2 Insert the pivot lock pin through the holes and install the lynch pin 6 Install the rope retention pin and retaining clip into the top of the boom head Figure 5 4 7 Using the hoist control raise the block or hook ball off of the ground Check that the wire rope is engaged in all the sheaves in the boom hoist block and hoist drum Retaining Pin Locations Offset Boo...

Page 103: ...the top of the boom head Figure 5 4 4 With the extension supported remove the lynch pin and pivot lock pin It will be necessary to remove the weight on the pin in order to remove it 5 Raise or lower the main boom until the desired offset angle is achieved Figure 5 3 6 Install the pivot lock pin and lynch pin 7 Install the rope retention pin and retaining clip into the top of the boom head Figure 5...

Page 104: ...the wire rope and dead end through the block 6 Install the three pins Installing the Hook Block 1 Remove the three pins and hook assembly from the hook block assembly See Figure 5 9 2 Thread the wire rope through the hook block so it is under the hook block sheave 3 Install the hook assembly and three pins to the hook block assembly 4 Attach the wire rope wedge assembly to boom head 5 Connect the ...

Page 105: ... install the pin from No 1 at location No 13 9 Install the wire rope over the deflector sheave at the base of the jib boom 10 Remove the two pins 1 and 2 Inset Figure 5 11 and place the wire rope over sheave 3 Install pins 1 and 2 11 Disconnect the wires from the anti double blocking switch in the boom head Connect the wire in the boom extension to the wires on the main boom 12 Attach the down hau...

Page 106: ...age arm and install pin at location No 5 8 Remove pins at No 6 and disengage boom extension from boom head Install pins from location 4 into extension link to prevent them from becoming lost 9 Remove pin at location No 13 Swing the boom extension to engage it with the bracket on boom Install pin at location No 1 a0631 FIGURE 5 11 R e f e r e n c e O n l y ...

Page 107: ...ved when removing the hoist block Install the lynch pin 7 Install the rope guide pin Be sure the wire rope is placed between the two pins 8 Connect the transmitter wire to the load pin wire 9 Adjust the boom head angle in the position required for the lift operation 10 Lift the hoist block off of the ground Be sure the wire rope is engaged in the sheave grooves in both the boom head and hoist bloc...

Page 108: ...OPE WEDGE SOCKET 1 Inspect the wedge and socket Remove any rough edges and burrs 2 The end of the wire rope should be seized using soft or annealed wire or strand If the end of the rope is welded the welded end should be cut off Do not weld on size 6X37 rope This will allow the distortion of the rope strands caused by the bend around the wedge to adjust themselves at the end of the line Refer to S...

Page 109: ... the tail length of the dead end should be a minimum of 6 rope diameters but not less that 15 2 cm 6 in for standard 6 to 8 strand ropes and 20 rope diameters but not less than 15 2 cm 6 in for rotation resistant wire ropes When using method A place a wire rope clip around the dead end by clamping a short extra piece of rope to the rope dead end DO NOT CLAMP THE LIVE END The U bolt should bear aga...

Page 110: ...ATTACHMENTS CD25 5 10 Published 1 06 2017 Control 579 01 FIGURE 5 16 Wedge Socket Specialty Clip Specialty Wedge R e f e r e n c e O n l y ...

Page 111: ...ble Sheave Lubrication 6 25 100 Hours of Operation Two Weeks 6 25 Inspect the Fan Belts 6 25 Check the Wheel Nut Torque 6 26 250 Hours of Operation Monthly 6 26 Inspect the Hydraulic Hoses 6 26 Clean the Batteries and Cables 6 26 Lubricate the Wire Rope 6 27 Lubricate the Swing Gear and Pinion 6 27 Torque Critical Bolts 6 27 Replace the Crankcase Oil 6 28 Replace the Engine Oil Filter 6 29 Clean t...

Page 112: ... rope used as load lines hoisting cables boom extension and retraction cables pendant cables tow winch cables and hook block tie down cables Environmental Conditions The life expectancy of wire rope may vary due to the degree of environmental hostility and other conditions to which these mechanical devices are subjected Variation in temperature continuous excessive moisture levels exposure to corr...

Page 113: ...he method used and amount of lubricant reaching the working parts of the rope Precautions and Recommendations During Inspection or Replacement Always lock out equipment power when removing or installing wire rope assemblies Always use safety glasses for eye protection Wear protective clothing gloves and safety shoes as appropriate Use supports and clamps to prevent uncontrolled movement of wire ro...

Page 114: ...f diameter etc General corrosion Broken or cut strands Number distribution and type of broken wires Evidence of core failure End fitting wear abrasion Pay particular attention to areas of the rope where wear and other damage is likely to occur Pick up Points Sections of wire rope that are repeatedly stressed during each lift such as those sections in contact with sheaves End Attachments The point ...

Page 115: ...ction Wire rope replacement should be determined by the following information excerpted from a National Consensus Standard as referenced by Federal Government Agencies and as recommended by Manitowoc All wire rope will eventually deteriorate to a point where it is no longer usable Wire rope shall be taken out of service when any of the following conditions exist In running ropes six randomly distr...

Page 116: ...ts observe the following Do not pour waste fluids onto the ground down any drain or into any source of water Always drain waste fluids into leak proof containers that are clearly marked with what they contain Always fill or add fluids with a funnel or a filling pump Immediately clean up any spills LUBRICANTS It is not the policy of Manitowoc Cranes Inc to publish lists of approved lubricants or gu...

Page 117: ...crankcase Remove water from fuel filters Cooling System Check coolant level Fill if level is low Hydraulic Tank Check oil level Fill if level is low Drive Axles Check axle housing lubricant level and wheel hub lubricant level Fill if levels are low Hoist Gearbox Check lubricant level Fill if level is low Tires Check tires for correct air pressure Wire Rope Cable Clamps and Connections Check for lo...

Page 118: ...250 Hour Monthly maintenance interval perform all the tasks required for Daily 50 Hour and 100 Hour maintenance Service Check Interval Daily Before Operation 50 Hours Weekly 100 Hours Two Weeks 250 Hours Monthly 500 Hours Three Months 1000 Hours Six Months 2000 Hours Yearly Inspect the Anti Double Blocking System X Inspect the Wire Rope X Inspect the Reeving Clamps and Connectors X Inspect the Lif...

Page 119: ...e Crankcase Oil1 X Replace the Engine Oil Filter1 X Clean Radiator Fins and Core X Clean Battery and Connections X Torque Critical Fasteners X Check Axle Wheel Hub Lubricant Level 4 places X Check Axle Housing Lubricant Level 2 places X Check Swing Gearbox Lubricant Level X Lubricate the Outrigger Slides X Replace Fuel Filter Water Separator Elements X Replace the In line Fuel Filter X Replace Tra...

Page 120: ...ter Option X 1 Under extremely dusty conditions the engine oil and filter as well as the air cleaner element may require replacement more frequently Service Check Interval Daily Before Operation 50 Hours Weekly 100 Hours Two Weeks 250 Hours Monthly 500 Hours Three Months 1000 Hours Six Months 2000 Hours Yearly Lube Symbol Description Specification EP MPG EP MPG Multipurpose Grease A6 829 003477 AF...

Page 121: ...le 1 Differential 4 8 Gal 18 0 Liters HYDO 2 Planetary Hub Gears 2 1 Qts 2 0 Liters HYDO 3 Kingpin Bearings EP MPG 4 Steer Cylinder Bearing EP MPG 5 Universal Joints EP MPG 6 Brake Caliper EP MPG Rear Drive Steer Axle 7 Differential 4 8 Gal 18 0 Liters HYDO 8 Planetary Hub Gears 2 1 Qts 2 0 Liters HYDO FIGURE 6 6 8534 R e f e r e n c e O n l y ...

Page 122: ... T Gear Pinion EP OGL 18 T T Bearing EP MPG Cylinders 19 Outrigger Cylinder ASC 20 Lift Cylinder EP MPG Boom 21 Boom Nose Sheaves EP MPG 22 Jib Boom Sheave EP MPG 23 Boom Sections EP MPG See Note 6 24 Tele Cylinder Wear Pads EP MPG 25 Boom Extension Sheave EP MPG 26 Boom Ret Sheave EP MPG 27 Hook Block Swivel Bearing EP MPG 28 Boom Pivot Shaft EP MPG 29 Hook Block Sheaves EP MPG Outriggers 30 Slid...

Page 123: ... 6 8 1 Boom Head Sheaves and Pivot See Figure 6 9 2 Lift Cylinder 2 Pivots See Figure 6 10 4 Location Qty Steering Knuckles Front and Rear Axles See Figure 6 11 8 Steering Cylinder Pivot Ends Front and Rear Axles See Figure 6 12 4 Drive Shaft Front Axle See Figure 6 13 No routine lubrication is required Lubricate only after major axle overhaul 2 Drive Shaft Rear Axle See Figure 6 14 No routine lub...

Page 124: ...d Pivot Grease Points both sides 7407 43 FIGURE 6 10 Lift Cylinder Pivot Grease Points 7407 41 7407 42 p0489 FIGURE 6 11 Steering Knuckle Grease Points Front and Rear Axles Both sides p0488 FIGURE 6 12 Steering Cylinder Pivot Grease Points Front and Rear Axles Both sides R e f e r e n c e O n l y ...

Page 125: ...rol 579 01 p0490 FIGURE 6 13 Front Axle Drive Shaft Grease Points Three Lube Fittings p0491 FIGURE 6 14 Rear Axle Drive Shaft Grease Points Three Lube Fittings p0492 FIGURE 6 15 Axle Pivot Grease Points Front and Rear Axles R e f e r e n c e O n l y ...

Page 126: ...16 Published 1 06 2017 Control 579 01 p0528 FIGURE 6 16 Drop Block Grease Point Both sides p0315 FIGURE 6 17 Jib Head Sheave Grease Point p0316 FIGURE 6 18 Jib Boom Deflector Sheave Grease Point R e f e r e n c e O n l y ...

Page 127: ...not operate the crane if any of the above is found Only after correcting the problem should the crane be put back in service Inspect the Lifting Hook Daily before beginning operation inspect the lifting hook for damage cracks deformation loose retaining hardware etc If any damage is found DO NOT operate the crane until the damage is repaired Inspect All Safety Devices Daily before beginning operat...

Page 128: ...ating temperature 82 to 93 C 180 to 200 F 2 Level the crane engage the parking brake and let the engine run at idle speed 3 Remove the transmission dipstick Figure 6 19 and check the oil level Oil should be at the FULL mark on the dipstick 4 Install the dipstick 5 If the oil is low add recommended oil to bring the level up to the full mark on the dipstick 6 Shut off the engine Check the Engine Coo...

Page 129: ...utriggers are retracted and up 2 With the crane on level ground engage the parking brake and shut off the engine 3 Visually check the oil level in the sight glass Figure 6 20 The hydraulic oil should be visible in the sight gauge on the side of the tank If low fill the tank with pre filtered recommended hydraulic oil NOTE The pump used on this crane requires clean hydraulic oil for proper operatio...

Page 130: ...ld cause damage to the engine Use a clean water dampened cloth to wipe every surface clean Check it visually to make sure it is clean before installing a new element 5 Always clean the gasket sealing surfaces of the housing An improper gasket seal is one of the most common causes of engine contamination Make sure that all hardened ridges are completely removed Inspecting the Element 1 Don t be foo...

Page 131: ...lent to the inner boom surface in front of and behind the slide block Only use a small amount of lubricant for best results Extend and retract the booms to distribute the lubricant along the slide path Check the Hoist Gearbox and Brake Lubricant Levels 1 Lower the boom to its lowest position 2 Engage the parking brake and shut off the engine 3 Check the lubricant level Oil should be visible in the...

Page 132: ...ese cracks and if machines are operated daily protect the rods Machines that are stored transported or used in a corrosive environment high moisture rain snow or coastline conditions need to have the exposed rods protected more frequently by applying a protectant Unless the machine is operated daily exposed rod surfaces will corrode Some cylinders will have rods exposed even when completely retrac...

Page 133: ...ease 9 Repeat steps 3 5 Fully extend and retract the boom to spread the grease Side and Bottom Boom Wear Pad Lubrication 1 Fully extend and set the outriggers NOTE A fully extended boom at horizontal needs to have an assist from a crane or forklift to retract Lift the front of the boom enough to relieve pressure on the bottom wear pads This should be sufficient for the boom to retract 2 Lower the ...

Page 134: ...ules found in Section 2 Safety Information before performing any operation or maintenance procedures For additional engine maintenance guidelines see the engine manual furnished with this crane Inspect the Fan Belts Keep the engine and accessory belts properly tensioned for maximum engine performance and fuel economy Proper belt tension minimizes slippage and increases belt life Belts that are too...

Page 135: ...tings and worn exterior Do not use your hands to check for hydraulic leaks Hydraulic oil under pressure can cause serious injury or possible death Use a piece of cardboard or other material as a deflector to detect leaks Replace any problem hose before beginning work Clean the Batteries and Cables 1 Open the battery compartment cover to gain access to the batteries 1 Figure 6 27 2 Tighten all batt...

Page 136: ...bricate the Swing Gear and Pinion 1 Engage the parking brake and shut off the engine 2 Remove the guard covering the swing pinion 3 Using a brush apply open gear lube to the pinion and swing gear teeth 1 Figure 6 28 Rotating gears can cause injury Keep hands clear of rotating pinion and gear while the mast is rotating 4 Start the engine and rotate the mast until a non lubricated portion of the swi...

Page 137: ... them Rotate the mast through a complete cycle tightening all bolts Mast to Swing Bearing Mounting Bolts Tighten the twenty six 26 7 8 mast mounting bolts 1 Figure 6 32 to 619 Nm 455 lb ft Tighten each bolt in a crisscross pattern Replace the Crankcase Oil Change the engine oil more frequently if operating under difficult conditions for example in high or low temperatures or frequent starting and ...

Page 138: ...s are not removed the engine may overheat due to blocked air through the radiator fins and core 500 HOURS OF OPERATION THREE MONTHS NOTE You must read and understand the warnings and basic safety rules found in Section 2 Safety Information of this manual before performing any operation or maintenance procedures For additional engine maintenance guidelines see the engine manual furnished with this ...

Page 139: ...E The secondary element must be replaced after two primary element replacements 7 Install the new element in the housing and slide it all the way in 8 Make sure the gasket is seating evenly If the gasket isn t seating evenly for a perfect seal you won t have protection Recheck to see if the sealing surface in the housing is clean or if the element is not the right model number If may be too short ...

Page 140: ...e 3 If necessary add Mobil Fluid 424 or equivalent to fill the housings until the oil is level with the bottom of the fill check hole Check the Wheel Hub Lubricant Level 1 Position the fill check plug so it is horizontal with the ground at the 3 o clock position 1 Figure 6 38 2 Clean around the plug and then remove it 3 Check the lubricant level which should be even with the bottom of the hole 4 I...

Page 141: ...ance procedures For additional engine maintenance guidelines see the engine manual furnished with this crane Replacing the Transmission Oil and Filter 1 Engage the parking brake and start the engine Allow the transmission oil to obtain normal working temperature 82 2 to 93 3 C 180 to 200 F 2 Shut off the engine Remove the ignition key NOTE It is necessary to climb under the crane to drain the tran...

Page 142: ...e is shut off the ignition key is removed and chock blocks are in place before climbing under the crane 1 Place a container under the differential drain plug Figure 6 42 Remove the drain plug and drain the fluid into the container Install the drain plug 2 Clean around the check fill plug in the axle housing Figure 6 43 Remove the plug 3 Remove and clean the axle breather Figure 6 44 with a suitabl...

Page 143: ...e but leave the engine running 2 Rotate hoist drum until the drain plug is visible through the lower hole in the side mounting bracket Figure 6 47 3 Clean around the gearbox breather Figure 6 47 and the fill check plug Remove the gearbox breather and clean it in a suitable solvent after which reinstall into the gear box 4 Remove the fill check plug 5 Place a suitable container under the drain plug...

Page 144: ...ydraulic oil for proper operation Contaminated oil can cause damage to the pump Before adding any hydraulic oil to the hydraulic system be sure the oil has been filtered through a 10 micron absolute or less filter To change the hydraulic oil 1 Fully retract and lower the booms 2 Retract all outriggers 3 Operate the hydraulic system until the hydraulic oil is warm NOTE It is necessary to climb unde...

Page 145: ...nting surface on the filter head 3 Install the filter a Apply a small amount of clean hydraulic oil to the gasket of the new hydraulic filter Install the filter Install the filter to the filter head by turning it clockwise until the filter gasket makes contact Then tighten the filter 1 2 to 3 4 turn to achieve a tight seal b Start the engine and check for leaks around the filter Check the Swing Ge...

Page 146: ...eries produce flammable and explosive gases To avoid personal injury when checking testing or charging batteries DO NOT use smoking materials near batteries Keep arcs sparks and flames away from batteries Provide ventilation and wear safety glasses Never check battery charge by placing a metal object across the posts The sparks could explode battery gases and cause injury or death Use a voltmeter ...

Page 147: ...d causes accumulation of sediment dirt water and other foreign materials in the fuel Many engine problems are caused by dirty fuel and long storage periods Keep fuel in an outside location Use a shelter to keep the fuel as cool as possible The water from condensation must be removed at regular intervals from the storage tank Fuses and Relays Fuse Block 1 Fuse Relay Panel Fuse block 1 fuse relay pa...

Page 148: ...ery compartment fuse block 3 1 Figure 6 55 and fuse block 4 2 Refer to TABLE 6 1 and TABLE 6 2 for identification of the fuses FIGURE 6 53 8543 25A 7 5A AXLE OSC SWITCH FIGURE 6 54 8543 1 10A K9 HORN K10 SHIFT TABLE 6 1 Fuse Block 3 Fuse Function Size F1 Fuse Block FB 1 F10 FB 2 F3 20 F2 FB 1 F1 FB 1 F2 FB 2 F6 30 F3 ECM B 30 F4 FB 1 F7 FB 1 F8 FB 1 F9 FB 2 F1 FB 2 F4 FB 2 F8 30 F5 FB 1 F3 FB 1 F4...

Page 149: ...luid level sending unit and a heating element to keep the DEF from freezing When the indicator in the dash illuminates see Figure 3 5 add DEF into the tank TABLE 6 2 Fuse Block 4 Fuse Function Size F1 DEF Pressure Line DEF Return Line DEF Suction Line 15 F2 DEF Line Relay Coil 5 F3 DEF Supply Module Relay Coil DEF Module 15 F4 Aftertreatment Sensors 10 F5 Aftertreatment Sensor Relay Coil High Exha...

Page 150: ...MAINTENANCE CD25 6 40 Published 1 06 2017 Control 579 01 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 151: ... ADJUSTMENTS 7 Published 1 06 2017 Control 579 01 SECTION 7 ADJUSTMENTS All adjustments must be performed by a qualified mechanic Refer to the Service Manual for the proper procedures R e f e r e n c e O n l y ...

Page 152: ...ADJUSTMENTS CD25 7 2 Published 1 06 2017 Control 579 01 THIS PAGE BLANK R e f e r e n c e O n l y ...

Page 153: ... red bar Service Tools mini tab and Oil Registration Lists link within the Service Tools list This will load a list of the different Cummins Engineering Specification numbers Select the one that applies to your engine to view the registered oils COMPONENT CAPACITY LUBRICANT FLUID Engine Crankcase See engine manual See engine manual Fuel Tank 189 L 50 gal See engine manual Cooling System 21 9 L 23 ...

Page 154: ...at high operating temperatures While 15W 40 oil is recommended for most climates see the viscosity recommendations for extreme climates Figure 8 1 NOTE Limited use of low viscosity oils such as 10W 30 may be used for easier starting and providing sufficient oil flow at ambient temperatures below 5 C 23 F However continuous use of low viscosity oils can decrease engine life due to wear New Engine B...

Page 155: ... torque 499 Nm 368 lb ft Electrical System Voltage 12 VDC negative ground Batteries Two Low maintenance Cold starting amps 0 degrees 820 amp Battery rating 150 amp hr Alternator 12 volts 130 amps Wire Rope Size 15 9 mm 5 8 6 x 19 Bright EEIPS IWRC Length 114 3 m 375 0 Weight Crane Open Cab 19 786 kg 43 620 lb Closed Cab 20 285 kg 44 720 lb Travel Speeds Two wheel steer 1st gear 4 66 km hr 2 9 mph ...

Page 156: ...8 4 SPECIFICATIONS CD25 Published 1 06 2017 Control 579 01 Boom angle Maximum 80 Minimum 0 R e f e r e n c e O n l y ...

Page 157: ...nvironmental Protection 6 6 General Crane Design 1 2 General Specifications 8 3 General 1 1 General 2 2 Hoist Rope 2 29 Hook Block 5 4 Installing Cable On The Hoist 5 8 Introduction 6 2 Jib 2 38 Lubricant symbols 6 10 Lubricants and Capacities 8 1 Lubricants 6 6 Lubrication Points 6 11 Lubrication Points 6 13 Maintenance Records 6 6 Maintenance 2 27 Miscellaneous Maintenance 6 36 Operating Practic...

Page 158: ...fects on Hydraulic Cylinders 2 39 Transporting the Crane 2 32 Travel Operation 2 32 Using the Capacity Chart 4 1 Wind Forces 2 7 Wire Rope Wedge Socket 5 8 Wire Rope 6 2 Work Practices 2 33 R e f e r e n c e O n l y ...

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