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Shuttlelift CD5515-2
Manitowoc Shuttlelift CD5515-2 Service And Maintenance Manual
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1
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Table of Contents
Table of Contents
5
Section 1 1
13
Default Chapter
13
Directional Reference
13
Identification Plates
13
Fuel Tank
15
General Specifications
15
Engine
15
Tires
15
Electrical System
15
Hydraulic System
15
Boom
15
Mast Rotation - 360
16
Wire Rope
16
Hydraulic System
16
Weight
16
Travel Speeds
16
Operating Dimensions
17
General Maintenance
18
Cleanliness
19
After Cleaning
19
Removal and Installation
19
Disassembly and Assembly
19
Pressing Parts
19
Locking Devices
19
Wires and Cables
20
Shims
20
Hoses and Tubes
20
Bearings
20
Gaskets
21
Batteries
21
Hydraulic Systems
21
Electrical System
23
Fatigue of Welded Structures
23
Loctite
24
Fasteners and Torque Values
24
Weld Studs (Table 1-10)
28
Hydraulic Fitting
28
Wire Rope
30
General
30
Environmental Conditions
30
Dynamic Shock Loads
30
Lubrication
30
Precautions and Recommendations During Inspection or Replacement
30
Wire Rope Inspection (Running Ropes and Pendant Cables)
31
Keeping Records
31
Frequent Inspection
31
Wire Rope Inspection
31
Pendant Cables)
31
Wire Rope Inspection (Boom Extension and Retraction Cables)
32
Wire Rope Inspection/Replacement (All Wire Rope)
32
Wire Rope Inspection/Replacement
32
Seizing Wire Rope
33
O-Ring, Seal and Elastic Nut Replacement
34
Hydraulic Pressure Testing
34
Section 2 Safety Practices 2
35
Section 2
35
Introduction
35
Signal Words
35
Signal Word
35
Personal Considerations
36
Equipment Considerations
36
General Considerations
37
Operational Considerations
37
Environmental Protection
38
Final Word
38
Section 3 Electric System
39
Section 3
39
General
39
Comparing Electrical System to a Hydraulic System
40
Magnetism
40
Main Electrical System
40
General
40
Wire Harnesses
40
Fuses
40
Charging System
43
Alternator and Voltage Regulator
43
Batteries
43
Battery Disconnect Switch
43
Voltmeter
43
Pressure Switch
43
Special Precautions
43
Battery Maintenance and Charging
43
Starting Circuit
44
General Inspections
44
Starting Circuit Check
44
Instrument and Light Circuits
45
General
45
Light Bulbs
45
Gauges and Indicators
45
ECM Display Toggle Switch
45
Wire Harnesses
46
Engine Wire Harness
46
Main Frame Wire Harness
46
Dash Wire Harness
46
Cab Wire Harness
46
Boom Wire Harness
46
Accessory Circuits
58
Anti-Double Blocking System
58
Rated Capacity Limiter (RCL) System
58
Optional Engine Shutdown
58
Heater
58
Troubleshooting
59
Section 4 Hydraulic System
62
Section 4
62
General Description
62
General
62
Hydraulic System
62
Troubleshooting
63
Troubleshooting Aids
63
Troubleshooting Procedures
63
Hydraulic System
63
Hydraulic System
64
Hydraulic System
65
System Description
69
Description of Operation
69
Troubleshooting Guides
64
Hydraulic Swivel
70
General
70
Functions
71
Troubleshooting
71
Lift Circuit
71
Oil Flow
72
Holding Valve
72
Lift Cylinder Leakage Check
72
Telescope Circuit
74
General
74
Oil Flow
74
Holding Valve
74
Port Relief Valve
74
Telescope Cylinder Leakage Test
75
Hydraulic Swivel
75
Hoist Circuit
75
General
75
Oil Flow
75
Brake Holding Valve
76
Hydraulic Swivel
76
Swing Circuit
76
General
76
Oil Flow
76
Pilot Control System
76
Pilot System Relief Valve
76
Pressure Setting Procedures
76
Checking and Adjusting Hydraulic Pressure Settings
76
Outrigger and Axle Lock out Circuits
80
Independently Controlled Outrigger Hydraulic System
80
Oil Flow
80
Outrigger Valves
80
Load Holding Valves
83
Vertical Outrigger Cylinder Leakage Check
83
Anti-Double Blocking System
80
General
80
System Function
80
Component Repair
83
Hydraulic Pump Repair
83
Outrigger Control Valve
84
Swing Motor
84
Hydraulic Swivel
91
Hydraulic Cylinders
94
Under Deck Winch
101
Section 5 Preventative Maintenance
102
Maintenance
103
Preparation
103
Hydraulic System Maintenance Precautions
103
Label Parts When Disassembling
104
Hydraulic Oil Recommendations
104
Draining and Flushing
104
Removing Air from the Hydraulic System
105
Parts Replacement
105
Lubricants
103
Maintenance Records
103
Special Maintenance
105
Delivery Inspection
105
After First 50 Hours of Operation (New Cranes)
106
Cranes Not in Regular Use
106
Preventive Maintenance
106
Maintenance Schedule and Checklist
106
Lubrication Points
109
Scheduled Maintenance
113
Daily (Walk-Around) Inspection
113
Hours of Operation (Weekly)
118
Hours of Operation (Two Weeks)
120
Hours of Operation (Monthly)
121
Hours of Operation (3 Months)
124
1000 Hours of Operation (6 Months)
127
2000 Hours of Operation (Yearly)
132
Miscellaneous Maintenance
133
Batteries/Charging System
133
Fuel System
134
Carwell® Rust Inhibitor
134
Protecting Cranes from Rusting
134
Cleaning Procedures
135
Inspection and Repair
135
Application
135
Areas of Application
136
Section 6 Engine and Engine Systems
140
Engine Cooling System
141
Coolant Requirements
141
Radiator Cap and Overflow Bottle
142
Thermostat
142
Engine Fuel System
142
Diesel Engine Fuel System Description
142
QSB Engine Electronic Controlled Fuel System Units
143
Types of Fuel to Use
143
Engine Electrical System
142
Engine Exhaust System
144
Checks and Adjustments
144
Throttle Linkage Adjustment
144
Engine Air Intake System
144
Removal and Installation
146
Removal
146
Installation
147
Description of Operation
150
Section 8 Axles/Drive Shafts/Wheels and Tires
176
Axles/Drive Shafts/Wheels and Tires
179
Front Drive Axle Repair
179
Removal
179
Installation
179
Special Tools
179
Replacing the Pinion Oil Seal
181
Axle Hub Repair
182
Drive Head Repair
186
Rear Axles Repair
194
Removal
194
Installation
194
Service Tools
194
Replacing the Pinion Oil Seal
194
Axle Hub Repair
194
Drive Head Repair (Drive Axles Only)
199
Drive Shafts
202
Disassembly
202
Removal
202
Assembly
203
Inspection
203
Installation
204
Lubrication Procedure
205
Tire Inflation
205
Wheel & Tires
205
Wheel Stud Nuts
205
Section 9 Brake System
206
Default Chapter
207
Accumulator
207
Priority Flow Control Valve
207
Description
208
Service Brake System
208
Parking Brake System
211
Maintenance and Adjustments
211
Service Brake Bleeding
211
Parking Brake Bleeding
212
Parking Brake Adjustment
212
Accumulator Charging
213
Residual Brake System Pressure
213
Tests
213
Brake Piston Seal Leakage Test (Front Axle Only)
213
Service Brake Repair
214
Front Axle Brakes
214
Rear Axle Brakes
218
Parking Brake Repair
219
Lining Kit Replacement
219
Repair Kit Installation
220
Seal Kit Installation
222
Brake Modulating Valve Repair
223
Removal
223
Disassembly
223
Assembly
224
Installation
224
Troubleshooting
225
Service Brakes
225
Section 10 10
226
Default Chapter
229
Crab Steering
229
Steering Proximity Switches
232
General
232
Principle of Operation
232
Sensor Operation and Spacing Checks
234
Steering System
234
Steering Orbitrol
237
Description
237
Steering Cylinder
249
Technical Data
249
Special Tools
249
Cylinder Repair
249
Section 11 11
254
Default Chapter
262
Disassembly
262
Wire Rope, Sheaves and Hoist Blocks
265
Wire Rope Description
265
Wire Rope Safety
265
Inspecting Wire Rope
266
Inspection of Sheaves
266
Wire Rope Lubrication
266
Wire Rope Installation
267
Main Hoist
269
Description
269
Maintenance
269
Drum Rotation Indicator
269
Hoist Repair
271
Hoist Service
272
Troubleshooting
276
Bearing, Mast and Related Parts
277
General
277
Mast Bearing
277
Mast Bearing Bolts
278
Inspection for Bearing Wear
278
Replacing the Mast Bearing
279
Swing Gearbox and Pinion
279
Hydraulic Swivel
281
Swing Gearbox Repair
282
Outriggers
284
Outrigger Monitoring System (OMS)
284
(Optional-Standard in North America)
284
Removal
285
Disassembly
285
Assembly
285
Installation
285
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Manitowoc Shuttlelift CD5515-2 Specifications
General
Brand
Manitowoc
Model
Shuttlelift CD5515-2
Category
Construction Equipment
Language
English
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