Manitowoc Carrydeck Crane 5540F YB5515 Service Manual

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Manitowoc Carrydeck Crane 5540F YB5515 Service Manual
Size: 19.71 MB
Format: PDF
Language: English
Brand: Manitowoc, Grove
Type of Machine: Carrydeck Crane
Type of Manual: Service Manual
Model: Manitowoc 5540F YB5515 Carrydeck Crane
Publication Date: 2011
Number of Pages: 412 Pages

Contents:
Introduction

Directional Reference​

Identification Plates​

Specifications​

General Maintenance​

Cleanliness​

After Cleaning​

Removal and Installation​

Disassembly and Assembly​

Pressing Parts​

Locking Devices​

Wires and Cables​

Shims​

Hoses and Tubes​

Bearings​

Gaskets​

Batteries​

Hydraulic Systems​

Electrical System​

Fatigue of Welded Structures​

Loctite​

Fasteners and Torque Values​

Weld Studs (Table 1-10)​

Hydraulic Fitting​

Wire Rope​

General​

Environmental Conditions​

Dynamic Shock Loads​

Lubrication​

Precautions and Recommendations During Inspection or Replacement​

Wire Rope Inspection (Running Ropes and Pendant Cables)​

Keeping Records​

Frequent Inspection​

Wire Rope Inspection (Boom Extension and Retraction Cables)​

Wire Rope Inspection/Replacement (All Wire Rope)​

Seizing Wire Rope​

Installing Flex-X 35 Wire Rope​

Procedures for Cutting and Preparing Flex-X 35​

O-ring, Seal and Elastic Nut Replacement​

Hydraulic Pressure Testing​

Safety Practices

Introduction​

Signal Words​

Personal Considerations​

Equipment Considerations​

General Considerations​

Operational Considerations​

Final Word​

Electric System

General​

Comparing Electrical System to a Hydraulic System​

Magnetism​

Main Electrical System​

General​

Wire Harnesses​

Fuses​

Charging System​

Alternator and Voltage Regulator​

Batteries​

Voltmeter​

Pressure Switch​

Special Precautions​

Battery Maintenance and Charging​

Starting Circuit​

General Inspections​

Starting Circuit Check​

Instrument and Light Circuits​

General​

Light Bulbs​

Gauges​

Wire Harnesses​

Engine Wire Harness​

Instrument Panel Wire Harness​

Accessory Circuits​

Anti-Double Blocking System (Figure 3-6)​

Load Moment Indicator (LMI) System (Figure 3-1)​

Optional Engine Shutdown​

Heater​

Troubleshooting​

Hydraulic System

Technical Data​

General Description​

General​

Hydraulic System​

Troubleshooting​

Troubleshooting Aids​

Troubleshooting Procedures​

Troubleshooting Guides​

Suction, Pressure and Return Circuits​

General​

Hydraulic Pump​

Main Relief Valves​

Main Control Valve​

Adjusting Main Relief Valve Pressure Settings​

Lift Circuit​

General​

Oil Flow​

Holding Valve​

Lift Cylinder Leakage Check​

Hydraulic Swivel​

Crowd Circuit​

General​

Oil Flow​

Holding Valve​

Crowd Cylinders Leakage Test​

Hydraulic Swivel​

Main Winch Circuit​

General​

Oil Flow​

Brake Holding Valve​

Hydraulic Swivel​

Swing Circuit​

General​

Oil Flow​

Anti-Double Blocking System​

General​

System Function​

Outrigger Circuit​

General​

Oil Flow​

Load Holding Valves​

Outrigger Cylinder Leakage Check​

Axle Lockout Circuit​

General​

Oil Flow​

Component Repair​

Hydraulic Pump Repair​

Main Control Valves​

Swing Motor​

Hydraulic Swivel​

Hydraulic Cylinders​

Preventative Maintenance

Introduction​

Spark Arresting Mufflers​

Safety List​

Lubricants​

Maintenance Records​

Special Maintenance​

Delivery Inspection​

After First 50 Hours of Operation (New Cranes)​

Cranes Not In Regular Use​

Preventive Maintenance​

Maintenance Schedule and Checklist​

Lubrication Points​

Scheduled Maintenance​

Daily (Walk-around) Inspection​

50 Hours of Operation (Weekly)​

100 Hours of Operation (Two Weeks)​

250 Hours of Operation (Monthly)​

500 Hours of Operation (3 Months)​

1000 Hours of Operation (6 Months)​

2000 Hours of Operation (Yearly)​

Miscellaneous Maintenance​

Batteries/Charging System​

Fuel System​

Fuse Replacement​

Carwell® Rust Inhibitor​

Protecting Cranes From Rusting​

Cleaning Procedures​

Inspection and Repair​

Application​

Areas of Application​

Engine and Engine Systems

General​

Engine Types​

Engine Performance​

Engine RPM​

Governor​

Engine Crankcase System​

Crankcase Oil Data​

Engine Cooling System​

Coolant Requirements​

Radiator Cap and Overflow Bottle​

Thermostat​

Engine Electrical System​

Engine Fuel System​

Diesel Engine Fuel System Description​

QSB Engine Electronic Controlled Fuel System Units​

Types of Fuel to Use​

Engine Air Intake System​

Engine Exhaust System​

Checks and Adjustments​

Throttle Linkage Adjustment​

Removal and Installation​

Removal​

Installation​

Dual Fuel Engine And engine Systems​

General​

Engine Types​

Engine Performance​

Engine RPM​

Governor​

Crankcase System​

Crankcase Oil Data​

Engine Cooling System​

Coolant Requirements​

Radiator Cap and Overflow Bottle​

Thermostat​

Engine Electrical System​

Engine Fuel Systems​

Fuel Injected Dual Fuel System​

Fuel Tank​

Fuel Level Sender and Gauge​

Fuel Pump​

Types of Fuel to Use​

Engine Air Intake System​

Engine Exhaust System​

Electronic Fuel Injection System​

Fuel Injection Components​

Checks and Adjustments​

Troubleshooting​

Removal And Installation​

Transmission and Torque Converter

Technical Data​

General Technical Data​

Clutch Solenoid Technical Data​

Description of Operation​

General​

Reverser Clutch​

Hydraulic 2/4-Wheel Drive Unit - Spring ON/Pressure OFF​

Hydraulic 2/4-Wheel Drive Unit - Pressure ON/Spring OFF​

Hydraulic 2/4-Wheel Drive Unit - Pressure ON/Spring OFF (cont'd)​

Troubleshooting​

General Troubleshooting​

Hydraulic 2/4-Wheel Drive Unit (Spring ON/ Pressure OFF)​

Hydraulic 2/4-Wheel Drive Unit (Pressure ON/Spring OFF)​

Water Contamination​

Transmission Repair​

Servicing the Torque Converter​

Servicing the Transmission​

Transmission Gearbox Repair​

Assembly​

Solenoid Valve Disassembly and Assembly​

Assembly​

Hydraulic 2/4-Wheel Drive Unit Disassembly and Assembly (Pressure ON/Spring OFF Type)​

Hydraulic 2/4-Wheel Drive Unit Disassembly and Assembly (Spring ON/Pressure OFF Type)​

Hydraulic 2/4-Wheel Drive Unit Pressure Testing (Spring ON/Pressure OFF Type)​

Axles/Drive Shafts/Wheels and Tires

Description​

Front Axle​

Rear Axle​

Technical Data​

Front Drive Axle​

Rear Drive Axle​

Rear Non-Drive Axle​

Front Drive Axle Repair​

Removal​

Installation​

Special Tools​

Replacing The Pinion Oil Seal​

Axle Hub Repair​

Drive Head Repair​

Rear Axles Repair​

Removal​

Installation​

Service Tools​

Replacing the Pinion Oil Seal​

Axle Hub Repair​

Drive Head Repair (Drive Axles Only)​

Drive Shafts​

Removal​

Disassembly​

Inspection​

Assembly​

Installation​

Lubrication Procedure​

Wheel & Tires​

Tire Inflation​

Wheel Stud Nuts​

Technical Data​

Front Axle Brakes​

Rear Axle Brakes​

Accumulator​

Accumulator Charging Valve​

Priority Flow Control Valve​

Description​

Service Brake System​

Parking Brake System​

Maintenance And Adjustments​

Service Brake Bleeding​

Parking Brake Bleeding​

Parking Brake Adjustment​

Accumulator Charging​

Residual Brake System Pressure​

Tests​

Brake Piston Seal Leakage Test (Front Axle Only)​

Service Brake Repair​

Front Axle Brakes​

Rear Axle Brakes​

Parking Brake Repair​

Lining Kit Replacement​

Repair Kit Installation​

Seal Kit Installation​

Brake Modulating Valve Repair​

Removal​

Disassembly​

Assembly​

Installation​

Troubleshooting​

Service Brakes​

Steering System

Units Without Return-To-Center Steering​

Technical Data​

Description​

Two-Wheel Steering​

Four-Wheel Steering​

Crab Steering​

Relief Valve Pressure Check And Adjustment​

Pressure Check​

Pressure Adjustment​

Units With Return-To-Center Steering​

Technical Data​

Description​

General​

Steering Modes​

Two-Wheel Steering​

Four-Wheel Steering​

Crab Steering​

Relief Valve Pressure Check And Adjustment​

Steering Proximity Switches​

General​

Principle Of Operation​

Sensor Operation And Spacing Checks​

Steering Orbitrol​

Description​

Orbitrol Repair​

Steering Cylinder​

Technical Data​

Special Tools​

Cylinder Repair​

Structurals

Booms​

General​

Disassembly​

Assembly​

Wire Rope, Sheaves and Hoist Blocks​

Wire Rope Description​

Wire Rope Safety​

Inspecting Wire Rope​

Inspection of Sheaves​

Wire Rope Lubrication​

Wire Rope Installation​

Main Winch (Tulsa Model)​

Theory Of Operation​

Repair​

Troubleshooting​

Main Winch (Braden Model)​

Theory Of Operation​

Winch Operation​

Repair​

Troubleshooting​

Bearing, Mast And Related Parts​

General​

Mast Bearing​

Mast Bearing Bolts​

Inspection For Bearing Wear​

Replacing The Mast Bearing​

Swing Gearbox And Pinion​

Swing Gearbox Repair (Tulsa Gearbox)​

Swing Gearbox Repair (Braden Gearbox)​

Outriggers​

Outrigger Monitoring System (OMS)(Optional—Standard in North America)​

Cylinder Removal​

Cylinder Installation​