Manitowoc Cranes 18000 Supplement Operator Manual F2305 PDF

Model 18000 LS801490 for Newport News Shipbuilding Operator Manual Supplement

Published 12-10-18

F2305-1

18000 Operator Manual Supplement

© 2018 Manitowoc.

Due to continuing product innovation, specifications in this manual are subject to change without notice.

THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH

F2305-2

Published 12-10-18

18000 Operator Manual Supplement

TABLE OF CONTENTS General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Identification of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Crane Access Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Operator Cab Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hook Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Live Mast Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Boom Top Pin Retainers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Drum Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Drum Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Pawl Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Bail Limit Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Drum 3 (whip hoist). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Drum 2 and 4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lubrication Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic Oil Level Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Drum Ratchet and Pawls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 RCL External Light Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Battery Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 SetUp Remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Connecting Remote Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disconnecting Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Operating Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 LMI Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ATB Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Brake Test Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Brake Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Wind Speed Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Swing Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Backup Power Unit Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Backup Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Backup Power Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Manitowoc

Published 12-10-18

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18000 Operator Manual Supplement

Backup Power Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Crane Power Plant Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Backup Power Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Right Rear Console Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 8 – Swing Park Lockout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 9 – Travel Park Lockout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 10 – Backhitch Tension Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Operator Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Digital/Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Reference Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

F2305-4

Published 12-10-18

18000 Operator Manual Supplement

18000 OPERATOR MANUAL SUPPLEMENT GENERAL

with your Model 18000 for complete operation, maintenance, and crane assembly/disassembling instructions.

This operator manual supplement: •

Identifies modifications that have been made to the Model 18000 to meet the requirements of Newport News Shipbuilding (NNS) Lift Solution 801490

•

Contains operation and maintenance instructions for those modifications

Refer to Drawing 84053048 for assis t crane lifting arrangements during crane assembly/disassembling.

IDENTIFICATION OF COMPONENTS See Figure 1 for identification of the crane and boom components.

Refer to the Operator Manual and Service Manual supplied

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Description Upper Boom Point Lower Boom Point Hook and Weight Ball Hook (Load) Block #55A Boom Physical Boom Stop 18000 Crawler Crane Mast Stop Support Frame Assembly Wheeled Counterweight Assembly Counterweight Cylinders Spreader Beam Live Mast Counterweight Straps Mast Straps 140 ft #56 Fixed Mast Load Lines Boom Hoist Wire Rope Boom Hoist Equalizer Boom Straps

Drum D1 D2 D3 D4 D5

Description Main Hoist 1 Main Hoist 2 Whip Line Hoist Boom Hoist (in mast butt) Mast Hoist

FIGURE 1

Manitowoc

Published 12-10-18

F2305-5

18000 Operator Manual Supplement

CRANE ACCESS POINTS Refer to Figure 2 for identification of the access points on the crane and MAX-ER® attachment. Additional walkways are also provided on the boom sections as shown in Section 2 of the 18000 Operator Manual.

Refer to the Boom Ladder Assembly topic in Section 4 of the 18000 Operator Manual for installation and use of the boom ladders.

Read and thoroughly understand the Crane Access and Personnel Fall-Protection Anchor topics in Section 2 of the 18000 Operator Manual before attempting to get on or off the crane.

Plan View of 18000 Crane

FIGURE 2

F2305-6

Published 12-10-18

18000 Operator Manual Supplement

Item Description 1 Anchor for Personnel Fall-Protection Equipment: • 4 on Front of Rotating Bed • 3 on Engine Covers • 3 on Rear of Rotating Bed (under mast) • 2 on each Upper Counterweight tray 2 Steps Both Sides of Both Carbody Counterweights 3 Ladder 4 Non-Skid Surface on Counterweight Boxes and Tray 5 Shaded Areas Indicate Steps and Walkways on Crane 6 Non-Skid Surfaces Both Sides of Carbody 7 Platform Both Sides of Carbody 8 Steps with Self-Closing Gate Both Sides of Rotating Bed 9 Ladder Both Sides of Rotating Bed 10 Non-Skid Surface on Crane Counterweight Boxes and Tray 11 Backup Power Unit 12 Operator Cab 13 Steps with Chain Barrier Both Sides of MAX-ER Beam 14 Shaded Areas Indicate Steps and Walkways on MAX-ER 15 Non-Skid Surface on MAX-ER Counterweight Boxes 16 Ladder with Self-Closing Gate

Plan View of 18000 MAX-ER

FIGURE 2 continued

Manitowoc

Published 12-10-18

F2305-7

18000 Operator Manual Supplement

Item 1

Description Hook Block: 36 US Ton, 5:1 Design Factor, 2,660 lb Approximate Weight 1

1

2

Dead End Lug

3

Sheave: 28 mm Groove Greased through Shaft

4

Grease Drip Guard

5

Thrust Bearing

6

Trunnion

7

Hook Latch

8

Hook

See scaled weight on nameplate.

Item 9

Description Hook Block: 360 US Ton, 5:1 Design Factor, 22,000 lb Approximate Weight 1

10

Dead End Lug (2)

11

Sheave: 32 mm Groove Greased through Shaft

12

Grease Drip Guards

13

Thrust Bearing

14

Trunnion

15

Hook Swivel Lock

16

Hook Latch (2)

17

Hook

1 See scaled weight on nameplate.

FIGURE 3

F2305-8

Published 12-10-18

18000 Operator Manual Supplement

See the Load Block and Hook-and-Weight Ball topic in Section 5 of the 18000 Service Manual for hook block inspection and maintenance points.

See the Boom Rigging Lubrication topic in Lubrication Guide, F2104 for the hook block lubrication requirements.

Thoroughly clean the grease drip guards in the hook blocks when the need arises.

LIVE MAST SHEAVES FIGURE 4

The live mast plastic sheaves have been replace with steel sheaves.

OPERATOR CAB EMERGENCY EXIT There are two options for existing the operator cab in an emergency: •

Description

Through the right side window. For instructions, see the Opening Window for Emergency Exit topic in Section 3 of the 18000 Operator Manual.

Maintenance •

See Inspection and Maintenance Checklist, F2097 for sheave inspection and maintenance intervals.

•

See the Sheave, Roller, and Drum Inspection topic in Section 5 of the 18000 Service Manual for sheave inspection and maintenance points.

•

The bearings in the live mast sheaves are packed with grease and do not require regular greasing. The bearings must be re-packed with grease when the sheaves are overhauled.

OR •

Using the life hammer provided (Figure 4), smash the front window to exit the operator cab. The life hammer is stored on the left side cab wall.

HOOK BLOCKS The hook blocks supplied by Manitowoc are shown in Figure 3.

Maintenance See Inspection and Maintenance Checklist, F2097 for hook (load) block and sheave inspection and maintenance intervals.

See the Sheave, Roller, and Drum Inspection topic in Section 5 of the 18000 Service Manual for sheave inspection and maintenance points.

Manitowoc

BOOM TOP PIN RETAINERS Description All boom top pin and shaft retainers (cotter pins and snap pins) have been replaced with screws and lock nuts.

Maintenance At least weekly when the boom is lowered, thoroughly inspect the boom to make sure all pins and shafts are properly retained. Make sure all lock nuts are in place and tight.

Published 12-10-18

F2305-9

18000 Operator Manual Supplement

Item

Description

1

Drum 3 (whip hoist)

2

Hydraulic Motor

3

Primary Planetary Gear Box with Internal Brake

4

Secondary Planetary Gear Box with Internal Brake

5

Ratchet Wheel

FIGURE 5

Item

Description

1

Swing Drive (4 places)

2

Hydraulic Motor

3

Swing Lock (internal)

4

Swing Brake (internal)

5

Planetary Gear Box

6

Oil Surge Tank

FIGURE 6

F2305-10

Published 12-10-18

18000 Operator Manual Supplement

DRUM MAINTENANCE

•

The corresponding brakes are released when the control handle is moved in either direction from off.

Lubrication

•

See the Lubrication Guide, 2104 for lubrication of all drums.

Also see "Drum 2 and 4 Lubrication" on page 13 of this publication.

The corresponding brakes are applied when the control is moved back to off.

•

The corresponding brakes are applied when the park switch is moved to the PARK position.

Brake Test

•

The brakes are applied if hydraulic pressure is lost for any reason.

See "Brake Test Switches" on page 21 of this supplement.

SWING LOCK

Drum Inspection See the Sheave, Roller, and Drum Inspection topic in Section 5 of the 18000 Service Manual.

Pawl Adjustment Se e "Drum Ratchet a nd Pawls" on page 16 of this supplement.

Bail Limit Adjustment See the Bail Limit Adjustment topic in Section 5 of the 18000 Service Manual.

DRUM 3 (WHIP HOIST)

Description To meet NNS requirements, a swing lock (3, (Figure 6) has been added to each swing planetary gear box.

Operation The swing locks are controlled by the swing PARK switch on the front console in the cab. See the Swing Controls topic in Section 3 of the 18000 Operator Manual for operation of the swing controls.

A pressure switch in the swing lock IN hydraulic system prevents the control system from allowing crane travel until all of the swing locks are disengaged.

To meet NNS requirements, Drum 3 (Figure 5) has been modified as follows: •

Secondary planetary gear box (4) added to the right end of the drum

•

Ratchet wheel (5) added to the right end of the drum

The secondary planetary gear box has an internal disc brake.

Each drum (1, 2, 3, and 4) has two disc brakes (left and right). The brakes are spring applied, hydraulically released, and controlled in conjunction with control handle movement.

Manitowoc

CAUTION Swing Drive Damage Hazard!

The swing drives can be damaged if you attempt to travel the crane while the swing locks are engaged.

If the swing locks are not fully disengage (and swing brakes released), travel will be inoperable and the operating limit alert will come on to warn the operator. SWING PARK will appear in the Crane Faults/Limits screen of the digital display in the cab.

Published 12-10-18

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18000 Operator Manual Supplement

Drum 2

Drum 4

FIGURE 7

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18000 Operator Manual Supplement

DRUM 2 AND 4 LUBRICATION

HYDRAULIC OIL LEVEL DECAL

To meet NNS requirements, Drums 2 and 4 have been modified to add the oil level tubes (M16) and fill plugs (M17) shown in Figure 7.

To meet NNS requirements, the hydraulic tank oil level decal (Figure 8) has been revised to add the MINIMUM (MAXER OPERATION ONLY) mark, which indicates the minimum oil level when equipped with the MAX-ER attachment.

Following is a list of components for Figure 7. The letters and item numbers correspond to the letters (intervals) and item numbers in the Model 18000 Lubrication Guide, F2104.

Item

Description

W2

Breather (on left side of drums)

M5

Primary Drain Valve

M16

Oil Level Tube (use in place of circular sight gauge)

M17

Fill Plug

S81

Primary Drain Valve

S8

2

Secondary Drain

Lubrication Intervals Perform the lubrication services at the intervals specified in the lubrication guide.

Checking Oil Level Check Drum 2 oil level when the boom is horizontal.

Check Drum 4 oil level when the mast is in the working position.

The oil for either drum must be visible in the oil level tube (M16) at a visual horizontal line (HL) drawn through the center of the drum.

If necessary, remove the fill plug (M17) and add specified gear oil. Clean and securely reinstall the fill plug.

Draining Oil

FIGURE 8

Drain Drum 2 oil when the boom is horizontal.

Drain Drum 4 oil when the mast is in the working position.

Manitowoc

Published 12-10-18

F2305-13

18000 Operator Manual Supplement

Drum 1

DISENGAGED

ENGAGED Drum 2

ENGAGED

DISENGAGED Drum 3

DISENGAGED

ENGAGED

FIGURE 9

F2305-14

Published 12-10-18

18000 Operator Manual Supplement

Drum 4

DISENGAGED

ENGAGED Drum 5

ENGAGED

DISENGAGED

Limit Switch Wiring Wire Color

Switch Terminals

Function

Black

13

Normally Open

Green

14

Input

White

21

Blue

14

Manitowoc

View A Typical Each Drum

Item 1 2 3 4 5 6 7 8 9 10

Description Hydraulic Cylinder Pawl Ratchet Cam Limit Switch Eye Bolt Spring Set Screw Shaft Lever with Roller

Normally Closed 22

Jumper

FIGURE 9 continued

Published 12-10-18

F2305-15

18000 Operator Manual Supplement

DRUM RATCHET AND PAWLS

the pawl into the root of a ratchet tooth if the drum starts to turn in the down direction.

Description

Weekly

Each of the drums (1, 2, 3, 4, 5) has a ratchet and pawl (Figure 9) which is a positive locking device. When engaged, the pawl prevents the corresponding drum from turning in the down direction.

See Figure 9 for the following procedure.

Apply open gear lube to the sliding surfaces between the cam (4) and pawl (2).

Operation

Limit Switch Adjustment

Each ratchet and pawl is controlled by the corresponding park switch in the operator’s cab. See Figure 9 for the following operations.

See Figure 9, View A for the following procedure.

•

When the drum is PARKED, the pawl engages. The hydraulic cylinder (1) strokes in the required direction and spring force rotates the pawl (2) into engagement with the ratchet (3).

•

A limit switch is replaced

•

You suspect the limit switch is the cause of a problem

When the drum is UNPARKED, the pawl disengages.

The hydraulic cylinder (1) strokes in the required direction and the cam (4) rotates to disengage the pawl (2) from the ratchet (3).

1.

Land the load or the boom from the corresponding drum.

2.

Fully disengage the corresponding pawl by moving the park switch to the UNPARK position. It may be necessary to operate the drum in the up direction slightly before the pawl will fully disengage the ratchet.

3.

Lock out/tag out the crane.

4.

Loosen the set screw (8) so the limit switch lever (10) is free to rotate on the shaft (9).

5.

Rotate the lever (10) up and hold it so the roller is against the pawl (2).

6.

Turn the limit switch shaft (9) clockwise until the limit switch clicks open and hold.

7.

Make sure the roller is against the pawl and securely tighten the set screw (8) to lock the adjustment.

8.

Start the engine and check for proper operation:

•

It may be necessary to hoist slightly to fully disengage the pawl from the ratchet.

When the pawl disengages, the limit switch (5) trips open. This action signals the crane’s control system that the pawl is fully disengaged.

If the pawl does not fully disengage, the drum will be inoperable in the down direction and the operating limit alert will come on to warn the operator. DRUM X PAWL IN (X = corresponding drum number) will appear the Crane Faults/Limits screen of the digital display in the cab.

Maintenance

Each limit switch (5) was adjusted at factory installation.

Readjustment is required if:

To adjust a limit switch, proceed as follows:

See Figure 9 for the following procedure.

•

Engage the pawl by moving the park switch to the PARK position and try to operate the drum in the down direction. The drum should not operate in the down direction.

•

Disengage the pawl by moving the park switch to the UNPARK position and try to operate the drum in the down direction. The drum should operate in the down direction.

Daily Check each pawl for proper operation as described under the Operation topic.

If necessary, adjust each eye bolt (6) so the spring (7) has sufficient tension to fully engage the pawl (2) with the ratchet (3).

In some cases, the pawl may come to rest on the top of a ratchet tooth. Spring tension must be strong enough to pull

F2305-16

9.

Readjust the limit switch if required.

Published 12-10-18

18000 Operator Manual Supplement

RCL EXTERNAL LIGHT BAR

BATTERY DISCONNECT SWITCH

FIGURE 11 FIGURE 10 An external RCL/RCI light bar (1, Figure 10) is mounted on the lower right-front of the operator’s cab. It is a visual aid for alerting ground personnel to the load conditions of the crane during an active hoist function.

The light bar operates in conjunction with the RCL/RCI display on the console in the operator cab, and illuminates as follows: •

GREEN — the load is within the capacity configured in the RCL/RCI.

•

YELLOW — the load is near the capacity configured in the RCL/RCI.

•

RED — the load has reached the capacity configured in the RCL/RCI. The horn will sound from the light bar to alert ground personnel to an overload condition.

The light bar is also activated for the following operating conditions: •

The lights flash to test their operation at startup.

•

The red light glows and the horn sounds when any bypass switch is activated.

•

The red light flashes in the setup mode.

•

The red light flashes in the brake test mode.

Manitowoc

The battery disconnect switch (1, Figure 11) is accessible through the opening in the left-rear corner of the rotating bed.

Turn the knob CLOCKWISE to CONNECT the battery circuit.

Turn the knob COUNTERCLOCKWISE to DISCONNECT the battery circuit for the following reasons: •

When servicing the crane’s electrical control system.

•

If desired, to prevent the batteries from discharging when the crane is stored for extended periods of time.

•

If desired, to prevent the crane from being started by unauthorized personnel.

The handle can be padlocked in either position to prevent unauthorized use.

CAUTION Engine Damage!

To avoid possible engine fault codes and undesirable operation, make sure the engine ignition switch has been off two minutes before disconnecting the batteries.

Do not rely on this switch to protect the crane’s electronic systems when welding. Disconnect the battery cables at the batteries before welding.

Published 12-10-18

F2305-17

18000 Operator Manual Supplement

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Right-Front Corner of Rotating Bed

Description Power Switch Stop Switch Left Front Jacking Switch Right Front Jacking Switch Left Rear Jacking Switch Right Rear Jacking Switch All Jacking Switch Boom Pins Switch Front Rotating Frame Pins Switch Rear Rotating Frame Pins Switch Mast Pins Switch (fixed mast) Mast Switch (live mast arms) Rigging Winch Payout/Haul In Switch Rigging Winch High/Low Switch Engine Speed Switch Electric Cable (remote control) CAN Terminator Electric Cable (WNE06)

FIGURE 12

F2305-18

Published 12-10-18

18000 Operator Manual Supplement

SETUP REMOTE

Disconnecting Remote Control

Description

1.

Turn off the remote control (see Remote Controls topic in Section 3 of the 18000 Operator Manual).

2.

Stop the engine.

3.

Disconnect the electric cable (16) from the electric cable (18).

4.

Thoroughly clean the dust cap and connect it to the electric cable (16).

5.

Thoroughly clean the connectors for the electric cable (18) and the CAN system terminator (17).

6.

Apply dielectric grease as instructed in Section 3 of the 18000 Service Manual and connect the CAN system terminator (17) to the electric cable (18).

The Model 18000 wireless remote control has been replaced by the wired remote control with carrying harness shown in Figure 12.

Connecting Remote Control 1.

Stop the engine.

2.

Disconnect the CAN system terminator (17) from the electric cable (18) on the right-front corner of the rotating bed.

3.

Thoroughly clean the dust caps and connect them to the CAN system terminator.

4.

Disconnect the dust cap from the remote control electric cable (16).

5.

Thoroughly clean the connectors and apply dielectric grease as instructed in Section 3 of the 18000 Service Manual.

6.

Connect the electric cable (16) to the electric cable (18).

Manitowoc

Operating Remote Control The item numbers in Figure 12 are identical to the item numbers for the wireless remote control identified in Section 3 of the 18000 Operator Manual.

Refer to the Remote Controls topic in Section 3 of the 18000 Operator Manual for the following: •

Turning the remote control on and off

•

Identifying and operating the remote control switches

Published 12-10-18

F2305-19

18000 Operator Manual Supplement

Operator Cab

See "Right Rear Console Modification" on page 32

Item 1 2 3 4 5 6 6A 6B 6C 6D

F2305-20

Description RCL/RCI Display: See F2006 for Instructions Digital Display: See Section 3 of the 18000 Operator Manual for Instructions Standard Limit Bypass Switch: See Section 3 of the 18000 Operator Manual for Instructions LMI Bypass Switch (with key) ATB Bypass Switch (with key) Brake Test Junction Box Main Hoist 1 (Drum 1) Brake Test Switch (with key) Main Hoist 2 (Drum 2) Brake Test Switch (with key) Whip Hoist (Drum 3) Brake Test Switch (with key) Boom Hoist (Drum 4) Brake Test Switch (with key)

Published 12-10-18

FIGURE 13

18000 Operator Manual Supplement

LMI OVERRIDE SWITCH

BRAKE TEST SWITCHES

Description

Description

The LMI Bypass Switch (4, Figure 13) allows the LMI (RCL/ RCI) to be bypassed independently of the Standard Limit Bypass Switch (3, Figure 13) described in Section 3 of the 18000 Operator Manual.

The Brake Test Switches (Figure 13) allow the Drum 1, 2, 3, and 4 brakes to be tested when using the special charts (84% capacity and 1/10th line pull) requested by NNS. The brakes should be tested at intervals determined by NNS.

Operation Insert the key and turn it CLOCKWISE to BYPASS LMI. Insert the key and turn it COUNTERCLOCKWISE to ENABLE LMI. This position allows the RCL/RCI to stop functions in the normal manner. The switch must be in this position for normal operation. Otherwise, tipping or structural damage can occur.

Remove the key to prevent unauthorized operation.

ATB OVERRIDE SWITCH Description

DANGER Crush Hazard!

Capacity Chart 9512-A or 9516-A, parts of line per Wire Rope Specification 9493-A or 9495-A, and line pull per Wire Rope Specification 9493-A or 9495-A must be configured in the RCL/RCI display before conducting individual brake tests.

If the incorrect Wire Rope Specification or Capacity Chart are configured when performing individual brake tests, the boom or load may fall, potentially resulting in death or serious injury.

The ATB Bypass Switch (5, Figure 13) allows the ATB (block-up limit switches) to be bypassed independently of the Standard Limit Bypass Switch (3, Figure 13) described in Section 3 of the 18000 Operator Manual.

Operation

Operation

A slotted screw driver is required to open the cover on the Brake Test Junction Box (6).

Insert the key and turn it CLOCKWISE to BYPASS reached block-up limits.

Insert the key and turn it COUNTERCLOCKWISE to ENABLE the block-up limits. This position allows the blockup limit switches to stop the load/boom hoists in the normal manner. The switch must be in this position for normal operation. Otherwise, structural damage can occur.

See Figure 13 for the following.

Each Brake Test Switch (6A - 6D) has a key. Store the keys in a safe location that prevents unauthorized operation of the switches.

Each Brake Test Switch (6A - 6D) operates the same.

Insert the key and turn it COUNTERCLOCKWISE (from center) to TEST the corresponding LEFT brake.

Turn the key to CENTER for NORMAL OPERATION. Remove the key to prevent unauthorized operation.

WARNING Two-Blocking Hazard!

If it is necessary to hoist the load above a block-up limit, do so slowly with extreme caution to prevent two-blocking.

Do not hoist the load above the minimum block clearance given in the Range Diagram (see Capacity Chart Manual).

Do not use the ATB override switch to lower the boom or the luffing jib after a block-up limit is contacted; two-blocking could occur, causing the load to fall.

Manitowoc

Insert the key and turn it CLOCKWISE (from center) to TEST the corresponding RIGHT brake.

Continued on next page.

Published 12-10-18

F2305-21

18000 Operator Manual Supplement

Brake Test Procedure ON or OFF

M104473

BT = Brake Test

FIGURE 14 NOTE:

Read "Brake Test Switches" on page 21 before proceeding.

6.

Hoist the load/boom on the selected drum to the desired height off the ground.

7.

Move the drum control handle to off.

8.

Turn and hold the selected drum brake test switch in the desired position, LEFT or RIGHT for 10 minutes.

9.

The load/boom must not lower more than 25.4 mm (1 inch). Take immediate corrective action if it does.

10. Release the selected drum brake test switch to the NORMAL OPERATION position.

Always return the drum brake test switch to the normal operation position and wait at least 10 seconds between tests. DO NOT go directly from the left position to the right position (or vice versa) — BOTH BRAKES MIGHT RELEASE.

1.

Make sure the RCL/RCI is properly configured as instructed in the Danger on page 21.

11. Repeat steps 8 and 9 in the opposite direction.

2.

Make sure all brake test switches are in the NORMAL OPERATION position (see Figure 13 on page 20).

3.

Park all drums.

12. Release the selected drum brake test switch to the NORMAL OPERATION position and park the selected drum.

4.

Turn ON the BRAKE TEST mode (BT) as follows:

5.

13. Repeat steps 5-12 for the remaining drums.

a.

Use the SELECT switch to access the Crane Mode – BRAKE TEST OFF screen (Figure 14).

b.

Press the CONFIRM switch to turn ON the brake test mode.

-

The screen will return to the previously selected crane mode (for example, standard).

-

BT will appear in the top of the screen.

-

The operating limit light in the cab will flash yellow, the external light bar will flash red, and OPERATING LIMIT - BRAKE TEST MODE will appear when scrolled to in the Crane Faults/ Limits Display Screen.

Unpark the desired drum.

F2305-22

14. Park all drums.

15. Turn OFF the BRAKE TEST mode (BT) as follows when done: a.

Use the SELECT switch to access the Crane Mode – BRAKE TEST ON screen (Figure 14).

b.

Press the CONFIRM switch to turn OFF the brake test mode.

NOTE:

Published 12-10-18

-

The screen will return to the previously selected crane mode (for example, standard).

-

BT will disappear from the top of the screen.

-

The operating limit light in the cab the external light bar will stop flashing.

The brake test mode will always go to off when the crane power is turned off.

18000 Operator Manual Supplement

NOTE:

Refer to the 18000 Operator Manual, Section 3, for instructions on accessing the Digital Display and Diagnostic Screens.

4.

Scroll up or down to change the wind speed to the desired setting.

5.

Press the SELECT switch to store the SET wind speed and to return to the current (max) wind speed screen (View A).

6.

Adjustment is complete. The SET wind speed will remain in computer memory, even after the engine is stopped.

7.

When the SET wind speed is reached, the operating limit alert will come on and the screen shown in Figure 16 will appear when scrolled to in the Crane Faults/Limits Display Screen.

WIND SPEED INDICATOR Description The wind speed screen displays the following Information: 1

2

View A

M104468

1

3

4 M104472

FIGURE 16

SWING DIAGNOSTICS M104469

View B Item 1 2 3 4

Description Current Steady Wind Speed MAX Gust Wind Speed (since crane power turned on) Cursor SET Alarm Wind Speed

FIGURE 15

M104470

Swing Lock Pressure Switch Status

FIGURE 17

Adjustment

The SWING diagnostic screen is shown in Figure 17. Refer to the 18000 Operator Manual, Section 3, for a complete description of the information displayed in the swing screen.

The status of the SW — swing lock pressure switch — has been added to the screen for NNS.

To set the wind speed alarm, proceed as follows:

•

1 SW = swing lock pressure switch active (swing lock disengaged).

•

0 SW = swing lock pressure switch inactive (swing lock (engaged). Check to be make sure the SWING function is unparked. If it is unparked, then troubleshoot the swing lock system to determine the fault.

NOTE:

The MAX gust wind speed is reset to zero when crane power is turned off.

1.

Stop operating and park the crane functions.

2.

Access the Diagnostic Screens and scroll to the screen shown in View B, (Figure 15):

3.

Press the SELECT switch. The word SET and the cursor ( * ) will flash.

Manitowoc

Published 12-10-18

F2305-23

18000 Operator Manual Supplement

THIS PAGE INTENTIONALLY LEFT BLANK

F2305-24

Published 12-10-18

18000 Operator Manual Supplement

BACKUP POWER UNIT DIAGNOSTICS Backup power unit diagnostics is located in the FCN diagnostic screen shown in Figure 18.

0x01 0x02 0x04 0x08

Multifunction fault (Function Parked operating limit on) MAX-ER active Backup system active Hoist functions disabled while MAX-ER is moving (4 second delay before and after movement) 0x10 Drums 1 and 2 active individually (tandem mode off) Above are bitwise, so they can be a combination of numbers.

5

M104771

Item 1 2 3 4 5 6 7 8

1

2

3

4 0 1 2 4 8 16 32 64 128

Description Pump 1 Port A Pressure (psi) Pump 1 Port B Pressure (psi) Pump 2 Port A Pressure (psi) Pump 2 Port B Pressure (psi) Backup Power Unit State Backup Power Unit Active Function Backup Power Unit Pump 1 Backup Power Unit Pump 2

7

Backup systems on, all functions parked Backup systems on, Drum 1 active Backup systems on, Drum 2 active Backup systems on, Drum 3 active Backup systems on, Drum 4 active Backup systems on, swing active Backup systems on, Drums 1 and 2 active in Tandem mode Backup systems on, Drums 1 and 2 active in individually Backup systems off, normal crane function

8

A

B

A

PUMP 1 (item 7) Port A Drum 2 Up Drum 3 Down Drum 4 Down Port B Drum 2 Down Drum 3 Up Drum 4 Up PUMP 2 (item 8) Port A Drum 1 Up Swing Right Port B Drum 1 Down Swing Left

B

View Inside Backup Power Unit From FRONT of Crane

Manitowoc

6

Published 12-10-18

FIGURE 18

F2305-25

18000 Operator Manual Supplement

View B

View A

View D

View E

F2305-26

Published 12-10-18

View C

FIGURE 19

18000 Operator Manual Supplement

BACKUP POWER UNIT

Legend for Figure 19 Item 1 2 3 4 5 6 7 8 9 10 11a 11b 12 13a 13b 14 15 16

Description Backup Power Unit Lifting Lugs (qty 4) Motor Starter: 60 Hz 460V Cable Reel with 460V Cable and Plug Electric Motor Pump Drive with Pumps Valve Assembly 120VAC Power Cable for Electric Motor Heater and Cable Reel Motor Counterweight Tray (left side) Bolts with Washers (qty 14) Electric Cable W96-J1 Electric Cable W94-J1 Hydraulic Hoses (qty 6) Receptacle W96-J1 Receptacle W94-J1 Hydraulic Nipples (qty 6) Suctions Hose with Clamps Suction Tube

WARNING Electrocution Hazard!

The backup power unit is powered by 460VAC electricity.

To avoid death or serious injury: •

Perform electrical repairs only if you are trained and qualified to do so.

•

Disconnect power before working on motor starter, motor, or driven equipment.

•

Always keep hands and clothing away from moving parts.

•

Read the motor manufacturer’s manual before attempting to service the electric motor.

•

Reinstall all guards and covers before operating the backup power unit.

Backup Power Unit Installation Once the crane is assembled: 1.

Install the backup power unit (1, View A) and handrails per Backup Power Unit Assembly Drawing 84030830 at the end of this publication. An assist crane is required.

Use owner furnished lifting slings attached to the four lifting lugs (2, View A). The unit weighs approximately 9,100 lb (4 128 kg).

2.

Remove the bolts and washers (10, View C) from the mounting pads on the counterweight tray (9).

3.

Thoroughly clean the mounting pads, the bolts, and the washers.

4.

Lift the power unit (1, View A) into position on the left side of the counterweight tray (9, View C) and align the mounting holes.

5.

Apply Loctite® 243 Thread Locker to the bolt threads and install the washers and bolts (10, View C).

6.

Torque the bolts to 213 ft-lb (289 Nm).

7.

Disconnect the lifting slings.

8.

Disconnect and uncoil the electric cables (11a and 11b, View D) and the hydraulic hoses (12) from the underside of the power unit (1).

9.

Disconnect the dust caps from the electric cables, from the hydraulic hoses, and from the bulkhead under the left side of the rotating bed (View E).

10. Thoroughly clean all of the electric and hydraulic connectors.

11. Apply dielectric grease to the electric connectors as instructed in Section 3 of the Crane Service Manual.

12. Connect the electric cables (11a and 11b) to the receptacles (13a and 13b, View E) on the bulkhead.

13. Connect the hydraulic hoses from the backup power unit to the nipples (14, View E) on the bulkhead. Match the numbered tags on the hoses to the numbered tags on the nipples.

14. Connect the suction hose (15, View E) to the suction tube (16) with the hose clamps provided.

Manitowoc

Published 12-10-18

F2305-27

18000 Operator Manual Supplement

View B

View C

Item

View A

Description

1 120VAC Power Cable – 46 m (150 ft) 2 460VAC Power Cab – 46 m (150 ft) CABLE REEL CONTROLS 3 Brake Knob 4 Manual Drive Shaft 5 Clutch Lever 6 Manual Handle MOTOR STARTER CONTROLS Disconnect Operating Handle (with 7 padlock bracket)

Item

Description

8 9 10 11 12 13 14 15

Recoil Power Cable Switch Motor Heater Switch Door Handle (with padlock bracket) ON Light (green) OFF Light (red) ON-OFF Power Switch START Button STOP Button

FIGURE 20

Backup Power Unit Operation

turning the crane pumps during backup power unit operation.

See Figure 20 for the following procedure.

If the crane’s engine is inoperable, the swing drive, the load drums (Drum 1, 2, and 3), and the boom hoist (Drum 4) can be powered by the backup power unit and operated with the controls in the cab.

Drums 1 and 2 can be operated at the same time.

Drums 3, 4, and swing can only be operated one function at a time.

1.

2.

3.

In the operator’s cab: a.

Park all crane functions.

b.

Turn the engine ignition switch to the stop position.

At the backup power unit: a.

Turn off the customer supplied power source.

b.

If necessary, heat the electric motor to remove condensation.

At the crane (main) engine, make sure the engine clutch is engaged to prevent the backup power unit from

F2305-28

Published 12-10-18

18000 Operator Manual Supplement

To determine if this step is needed, measure the insulation resistance of the motor stator winding as outlined in the motor manufacturer ’s manual provided in the Backup Power Unit Manual.

•

The dead-man switch on the swing control, Drum 1, and Drum 3 handle must be held down to operate all crane functions. See the 18000 Operator Manual for detailed instructions.

Heat the electric motor as follows, if the resistance is below the allowed valve:

•

Drums 1 and 2 can be operated at the same time.

•

Drums 3, 4, and swing can only be operated one function at a time.

•

When the desired function is unparked, the enable valve for the function is switched on to divert backup system oil to the function. When the function is parked, there is a 3 second delay in diverting the oil to the next function so the drum has time for the pawl to engage.

•

MAX-ER counterweight movement has priority over operation of the crane functions. When the MAX-ER needs to rise or lower, the hoist function is disabled and the BACKUP MAXER ACTIVE operating limit is turned on. After 4 seconds, the MAX-ER moves.

Then, 4 seconds after the MAX-ER stops moving, the hoist function is re-enabled and the operating limit is turned off. The operator can continue to hold the handle in the desired position during MAX-ER movement and the function will automatically resume when the MAX-ER stops moving.

-

Uncoil the 120VAC power cable (1, View B) and plug it into a 120VAC customer supplied power source.

-

Turn the motor heater switch (9, View A) to the ON position.

-

Turn the heater OFF and store the cable once the resistance is at or above the allowed valve.

c.

Disengage the cable reel clutch by pulling the clutch lever (5, View C) out.

d.

Adjust the cable reel brake with the brake knob (3, View C) so the power cable pays out at the desired speed (CLOCKWISE, tighten and COUNTERCLOCKWISE, loosen).

e.

Pay out the 460VAC power cable (2, View C) by hand and connect it to a 460VAC customer supplied power source.

Take every precaution to prevent damage to the cable while swinging the crane.

Crane Power Plant Operation

f.

Turn ON the customer supplied power source.

See Figure 20 for the following procedure.

g.

Rotate the disconnect operating handle (7, View A) up to the ON position. The OFF light (12) will glow red.

To restore operation from the crane’s power plant:

h.

Turn ON the power switch (13, View A). The OFF light (12) will continue to glow red.

i.

Depress the start switch (14, View A). The ON light (11) will glow green and the off light (12) will turn off.

1.

2.

In the operator’s cab: a.

Bring all crane functions to a complete stop.

b.

PARK all crane functions.

c.

Turn the engine ignition switch to the STOP position

At the backup power unit:

4.

In the operator’s cab, turn the engine ignition switch to the RUN position.

a.

Depress the motor stop button (15, View A). The OFF light (12) will glow red.

5.

Before releasing the selected brake, check that the selected system’s charge pressure is at least 350 psi (24 bar) in the diagnostic screen.

b.

Turn OFF the power switch (13). The OFF light (12) will continue to glow red.

6.

In the operator’s cab, UNPARK the desired function only.

c.

Rotate the disconnect operating handle (7, View A) down to the OFF position. The OFF light (12) will turn off.

The park switch determines the active function. The FUNCTION PARKED operating limit will come on if more than one function is unparked at the same time (except for Drums 1 and 2 which can be operated at same time).

d.

Turn OFF the customer supplied power source.

e.

Disconnect the 460VAC power cord from the customer supplied power source.

Operate the desired function with the control handle in the cab. The function will operate at slow speed.

f.

Store the 460VAC power cable (2, View C) on the cable reel using one of the following methods:

7.

POWER STORAGE:

OPERATING NOTES:

Manitowoc

Published 12-10-18

F2305-29

18000 Operator Manual Supplement

-

Uncoil the 120VAC power cable (1, View B) and plug it into a 120VAC customer supplied power source.

-

Engage the cable reel clutch by pushing the clutch lever (5, View C) in.

-

Turn ON the recoil power cable switch (8, View A) to haul the cable in.

-

Adjust the cable reel brake with the brake knob (3, View C) so the power cable hauls in at the desired speed (CLOCKWISE, tighten and COUNTER-CLOCKWISE, loosen).

-

Turn OFF the recoil power cable switch (8, View A) to stop hauling in the cable.

MANUAL STORAGE:

g.

-

Remove the manual handle (6, View C) from storage and connect it to the manual drive shaft (4).

-

Turn the handle to haul in the 460VAC power cable (2, View C).

-

Remove the handle and store it when done.

Resume normal crane operation.

View B

View C View A

Item 1 2 3 4 5 6 7 8

Description Pump Drive Dipstick Pump Drive Breather Pump Drive Magnetic Drain Plug Electric Motor Grease Fitting (qty 2) Hydraulic Filter Element (qty 2) Cable Reel Drive Chain Cable Reel Bearing (qty 2) Cable Reel Drive Shaft Bearing

FIGURE 21

F2305-30

Published 12-10-18

18000 Operator Manual Supplement

Backup Power Unit Maintenance

1.

Stop the power unit.

See Figure 21 for the following procedures.

2.

Place shop rags under the filter elements and filter heads to catch oil leakage.

3.

Remove the filter elements and dispose of them according to local environmental regulations.

4.

Wipe up spilled oil.

5.

Install new filter elements:

PUMP DRIVE •

Oil Level: Check the oil level prior to each use of the backup power unit.

The oil level must be between the MAX and MIN marks on the dipstick (1).

Fill the pump drive through the breather (2) plug opening with a quality brand of 80W90 or EP 90 gear oil. The pump drive requires 3,4 L (3.6 qt) of oil.

•

Oil Change:

a.

Make sure the top of the filter elements and the filter heads on the pump drive are clean.

b.

Lubricate each filter element seal with clean hydraulic oil.

c.

Thread the filter elements onto the filter heads and hand tighten.

d.

Tighten the filter elements an additional 1/2 turn.

Per the pump drive manufacturer, change the oil initially after the first 500 hours or three months, whichever comes first.

6.

Thereafter, change the oil every 1,000 hours or three months, whichever comes first.

ELECTRIC MOTOR

Clean the breather (2) at each oil change interval.

Refer to the pump drive manufacturer’s manual for detailed instructions.

NOTE:

To determine an oil change interval that meets your operating conditions, establish a oil analysis program with your oil supplier.

HYDRAULIC FILTERS Replace the hydraulic filters (5, View B) on the power unit yearly.

Manitowoc

Start the power unit and check for oil leaks. Tighten the elements if needed.

The electric motor has two grease fittings (4, View B and C).

Grease the electric motor according to the lubrication procedures in the motor manufacturer’s manual.

CABLE REEL Apply a light coat of engine oil to the drive chain (6, View C) at each pump drive oil change interval.

The cable reel has three grease fittings (7 and 8, View C).

Grease the cable reel at the same interval and with the same grease specified for the electric motor.

Published 12-10-18

F2305-31

18000 Operator Manual Supplement

Item 1 2 3 4 5 6 7 8 9 10 *

Description RCL/RCI Display: See F2006 for Instructions Digital Display * Standard Limit Bypass Switch * LMI Bypass Switch (with key): See page 21) ATB Bypass Switch (with key): See page 21) Climate Controls * Wiper Switches * Swing Park Lockout Switch Travel Park Lockout Switch Backhitch Tension Switch See Section 3 of the 18000 Operator Manual for Instructions

FIGURE 22

RIGHT REAR CONSOLE MODIFICATION The right rear control console has been modified as shown in Figure 22 to add two lockout switches and a backhitch tension switch.

8 – Swing Park Lockout Switch Insert the key and turn it COUNTERCLOCKWISE to UNLOCK (enable) operation of the swing park switch.

Insert the key and turn it CLOCKWISE to LOCK (disable) operation of the swing park switch.

Remove the key to prevent unauthorized operation.

Refer to Section 3 of the 18000 operator manual for operation of the swing park switch.

9 – Travel Park Lockout Switch Insert the key and turn it COUNTERCLOCKWISE to UNLOCK (enable) operation of the travel park switch.

F2305-32

Insert the key and turn it CLOCKWISE to LOCK (disable) operation of the travel park switch.

Remove the key to prevent unauthorized operation.

Refer to Section 3 of the 18000 operator manual for operation of the travel park switch.

10 – Backhitch Tension Switch The crane’s control system automatically raises the MAX-ER counterweight when backhitch tension is greater than 50 US tons and lowers it when backhitch tension is less than 10 US tons.

The backhitch tension switch allows the operator to manually increase and decrease backhitch tension (lower and raise the counterweight) when backhitch tension is in either of the ranges shown in Figure 23.

Wind speed, backhitch tension, and boom angle can be monitored in the digital display screen shown in (Figure 23).

Published 12-10-18

18000 Operator Manual Supplement

MAX-ER Counterweight Position Indicator: DOWN if both of the maximum up limit switches are closed.

UP if one or both of the maximum up limit switches is open.

MAX-ER Counterweight Indicator: flashes when counterweight is rising or lowering.

Blank when counterweight is not moving.

Wind Speed (mph)

Backhitch Tension Indicator Bar: moves to right as tension increases; moves to left as tension decreases.

Boom Angle (degrees) Manually Adjustable Low Range: backhitch tension between 10 and 15 US tons.

Manually Adjustable High Range: backhitch tension between 40 and 50 US tons.

FIGURE 23 To manually adjust backhitch tension, proceed as follows.

Tension is adjustable only in the low and high ranges shown in Figure 23.

•

To DECREASE BACKHITCH TENSION: insert the key, turn it COUNTERCLOCKWISE, and HOLD. This will raise the MAX-ER counterweight.

Release the key to the center position to return to automatic operation. Remove the key from the center position to prevent unauthorized operation.

•

To INCREASE BACKHITCH TENSION: insert the key, turn it CLOCKWISE, and HOLD. This will lower the MAX-ER counterweight.

Release the key to the center position to return to automatic operation. Remove the key from the center position to prevent unauthorized operation.

Operator Notes •

Inadvertent manual adjustment of the backhitch tension reaching an adjustable range limit will cause the system to go into automatic operation to maintain backhitch tension within the acceptable range.

•

A backhitch tension greater than 50 US tons may occur during automatic operation when the full weight of the MAX-ER has been raised. This is a normal condition.

Manitowoc

Published 12-10-18

F2305-33

18000 Operator Manual Supplement

DIGITAL/ANALOG INPUTS AND OUTPUTS The following list of digital/analog inputs and outputs supplements those in Section 3 of the 18000 Operator Manual and in Section 3 of the 18000 Service Manual.

CAN Packet Number

Item Description

Schematic Node Number

Digital Inputs CAN57-1-32

Increase Backhitch Tension Switch

2

CAN57-1-128

Decrease Backhitch Tension Switch

2

CAN57-2-64

RCL Bypass Switch

2

CAN57-2-128

Anti-2-Block Bypass Switch

2

CAN61-2-64

Drum 4 Pawl Engaged Switch

6

CAN63-1-4

Drum 1 Left Brake Test Switch

4

CAN63-1-8

Drum 1 Right Brake Test Switch

4

CAN65-1-64

Swing Lock Pressure Switch

7

CAN67-1-128

Backup System Enabled Switch

9

CAN71-1-4

Drum 1 Pawl Engaged Switch

8

CAN71-1-8

Drum 2 Pawl Engaged Switch

8

Analog Inputs, Digital Input Data CAN12-2-16

Drum 2 Left Brake Test Switch

4

CAN12-2-32

Drum 2 Right Brake Test Switch

4

CAN12-2-64

Drum 3 Left Brake Test Switch

4

CAN12-2-128

Drum 3 Right Brake Test Switch

4

CAN13-2-16

Drum 3 Pawl Engaged Switch

4

CAN13-2-32

Drum 5 Pawl Engaged Switch

4

CAN13-2-64

Drum 4 Left Brake Test Switch

4

CAN13-2-128

Drum 4 Right Brake Test Switch

4

CAN22-1+2-NA

Backup Pump 1 A Port Transducer

9

CAN23-1+2-NA

Backup Pump 2 B Port Transducer

9

CAN23-3+4-NA

Backup Pump 1 B Port Transducer

9

CAN23-5+6-NA

Backup Pump 2 A Port Transducer

9

CAN34-2-64

Drum 3 Right Brake

6

CAN34-3-1

Drum 3 Pawl In

6

CAN34-3-2

Drum 3 Pawl Out

6

CAN34-3-4

Drum 4 Pawl In

6

CAN34-3-8

Drum 4 Pawl Out

6

CAN34-3-128

Drum 4 Right Brake

6

CAN37-2-64

Backup System Flow Combiner

9

CAN37-3-8

Backup System Swing Enable

9

CAN37-3-16

Backup System Drum 1 Enable

9

CAN37-3-32

Backup System Drum 2 Enable

9

CAN37-3-64

Backup System Drum 3 Enable

9

CAN37-3-128

Backup System Drum 4 Enable

9

CAN39-1-1

Drum 1 Pawl Out

8

CAN39-1-2

Drum 1 Pawl In

8

CAN39-1-4

Drum 2 Pawl Out

8

CAN39-1-8

Drum 2 Pawl In

8

Analog Inputs

Digital Outputs

F2305-34

Published 12-10-18

18000 Operator Manual Supplement

CAN Packet Number

Item Description

Schematic Node Number

CAN39-1-16

Drum 1 Left Brake

8

CAN39-1-32

Drum 2 Right Brake

8

CAN50-2-64

Drum 3 Right Brake Disabled

6

CAN50-3-1

Drum 3 Pawl In Disabled

6

CAN50-3-2

Drum 3 Pawl Out Disabled

6

CAN50-3-4

Drum 4 Pawl In Disabled

6

CAN50-3-8

Drum 4 Pawl Out Disabled

6

CAN50-3-128

Drum 4 Right Brake Disabled

6

CAN53-2-64

Backup System Flow Combiner Disabled

9

CAN53-3-8

Backup System Swing Enable Disabled

9

CAN53-3-16

Backup System Drum 1 Enable Disabled

9

CAN53-3-32

Backup System Drum 2 Enable Disabled

9

CAN53-3-64

Backup System Drum 3 Enable Disabled

9

CAN53-3-128

Backup System Drum 4 Enable Disabled

9

CAN55-1-1

Drum 1 Pawl Out Disabled

8

CAN55-1-2

Drum 1 Pawl In Disabled

8

CAN55-1-4

Drum 2 Pawl Out Disabled

8

CAN55-1-8

Drum 2 Pawl In Disabled

8

CAN55-1-16

Drum 1 Left Brake Disabled

8

CAN55-1-32

Drum 2 Right Brake Disabled

8

CAN53-2-48

Backup System Pump 1 Disabled

9

CAN53-3-3

Backup System Pump 2 Disabled

9

CAN77-1+2-NA

Backup System Pump 1

9

CAN77-3+4-NA

Backup System Pump 2

9

Digital Output Disables

Pump Servo Outputs

Manitowoc

Published 12-10-18

F2305-35

18000 Operator Manual Supplement

REFERENCE PUBLICATIONS The following reference material is provided at the end of this publication:

Publication

F2305-36

Description

Drawing 84030744

Boom Rigging #55A with 140 ft Mast

Drawing 84030746

Mast Rigging #56, 140 ft, MAX-ER

Drawing 84030830

Backup Power Unit

Drawing 84032345

Boom Wiring

Drawing 84035633

Electric Schematic

Drawing 84037607

Hydraulic Schematic

Drawing 84042796

Boom Rigging #55A with 100 ft Mast

Drawing 84045320

Backup Power Unit ESI

Drawing 84045655

Backup Power Unit Hydraulic Line Install

Drawing 84046178

Mast Rigging #56, 100 ft

Drawing 84053048

Lift Configuration for NNS Crane Assembly

Drawing 80114056

Console MOD NNS

Drawing 80116707

Console MOD Dead Man NNS

Sunsource NG47A

Operation Manual for Backup Power Unit

Published 12-10-18