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GCD25

Product catalog summary

Introduction
This document supplements the Operator Manual for Manitowoc cranes, focusing on warm-up procedures for operating cranes in cold climates. It highlights the importance of operator training and adherence to safety protocols.

Crane Warm-up Procedures
Specific warm-up procedures for crane components are outlined to ensure safe operation in cold temperatures, preventing damage and ensuring functionality.

Engine
Operators should idle the engine for 3 to 5 minutes upon startup. Gradually increase engine speed after initial idling to stabilize oil pressure and ensure adequate lubrication.

Transmission
Warm-up procedures vary by crane type. For Rough Terrain and Industrial Cranes, engage the parking brake, apply the service brake, and cycle the transmission to reach normal operating temperature. For Truck Mount Cranes, similar procedures apply with the crane set on outriggers.

Hoist
Warm-up is recommended at every startup, especially below 4°C (40°F). Warm the hydraulic oil first, then operate the hoist at low speeds to circulate warm oil and lubricate gear sets.

Swing Drive and Turntable Bearing
For temperatures above -7°C (20°F), rotate the superstructure slowly in both directions. For temperatures below -7°C, reduce the rotation speed and increase the number of revolutions.

Axles
For temperatures below -35°C (-30°F), set up the crane on outriggers and engage the transmission with 4-wheel drive to warm the axles.

Hydraulic Oil System
Operating limits are specified for various temperature ranges. Below 10°C (50°F), operate without a load until the fluid warms. Above 95°C (200°F), cease operations to allow the oil to cool.

Safety and Compliance
The document reiterates the importance of using recommended lubricants and following prescribed warm-up procedures to avoid equipment failure and ensure safety.

Specifications and Systems
Your crane may be equipped with a Rated Capacity Limiter (RCL) system, which monitors radius, load weight, and load rating to prevent overload conditions. It is crucial to test the RCL system daily and not rely solely on it, as it does not replace the use of Load Charts and operating instructions. Always verify the load weight and crane capacity before lifting.

Anti-Two-Blocking Device
This device prevents two-blocking, which occurs when the load block contacts the boom, potentially causing rope failure and accidents. Operators should be cautious when lowering or extending the boom and ensure load lines are let out simultaneously to prevent two-blocking.

Working Area Limiter
If equipped, this system aids the operator but does not replace safe operating practices. Operators must familiarize themselves with the system's operation and symbols.

Crane Stability and Structural Strength
Ensure the crane is on a firm surface and within capacity limits as per the Load Chart. Properly extend and pin outriggers, and use cribbing to distribute weight. Check crane stability before lifting, ensuring the crane is level and the load is properly rigged.

Load Charts
Load Charts indicate maximum allowable loads based on crane conditions. Operators must know the precise load radius, boom length, and angle. Load capacities are based on freely suspended loads, and the appropriate Load Chart must be used.

Work Site Inspection
Inspect the work site for ground conditions and ensure surfaces can support the crane's weight and capacity. Be aware of potential stability issues and restrict unnecessary personnel from the crane's vicinity.

Wind Forces
Wind can significantly affect crane operations. Operators must use caution in windy conditions and never exceed rated capacities. Wind forces can cause instability and structural damage, and lifting should be avoided if wind conditions could lead to loss of control.

Wind Speed and Load Calculations
The document provides a method to calculate permissible wind speeds and load adjustments based on wind conditions. Lifting is not permitted if wind speeds exceed certain thresholds, and operators must consider wind resistance areas and drag coefficients when planning lifts.

Specifications
The document outlines the calculation of allowable load based on wind resistance and drag coefficients. It provides formulas for both metric and non-metric systems to determine the allowable wind resistance area (Awr) and permissible wind speeds.

Procedures
1. Calculate the projected wind area (Ap) using given dimensions.
2. Determine the wind drag coefficient (Cd) from Table 2-2 or assume a default value if unknown.
3. Use the Awr ratio to find permissible wind speeds from Table 2-3 (non-metric) and Table 2-5 (metric).
4. Apply capacity reduction factors for wind speeds exceeding certain thresholds.

Norms and Recommendations
- If the wind resistance area of the load exceeds the allowable area, lifting is not permitted.
- Use the maximum value of the wind drag coefficient range if the exact value is unknown.
- Ensure the crane is positioned on a firm surface with properly extended outriggers before lifting.

Examples and Calculations
The document provides detailed examples illustrating how to calculate the allowable load and wind resistance area under different conditions. It includes scenarios with known and unknown wind drag coefficients and demonstrates how to adjust for large wind resistance areas.

Key Tables and Figures
- Table 2-2: Wind Drag Coefficient values for different shapes.
- Table 2-3 and 2-5: Awr Ratio and Permissible Wind Speed for non-metric and metric systems.
- Table 2-4 and 2-6: Capacity Reduction Factors for wind speeds greater than specified limits.

Critical Information
- Maximum permissible wind speeds are based on 3-second gust speeds at boom tip height.
- The document emphasizes the importance of adhering to specified lifting limits to ensure safety during crane operations.

Crane Leveling and Setup
The crane must be level, using a bubble level or the load line for verification. Ensure the electrical cable and Anti-Two-Block Switch are installed correctly, and the Rated Capacity Limiter (RCL) is programmed for the crane configuration. Verify the crane's capacity with the Load Chart before lifting.

Lifting Procedures
Ensure the load is properly rigged and its weight is known. Measure the load radius and stay within approved lifting areas. Keep the load close to the crane and ground. Avoid overloading the crane as it can lead to tipping or structural failure.

Crane Stability
The crane can tip over if the load exceeds capacity, the ground is unstable, outriggers are not properly set, or the crane is improperly operated. Do not rely on tipping to determine lifting capacity. Avoid side loading and ensure the hoist line is vertical.

Outrigger Lift Off
An outrigger pad may lift off the ground due to crane frame flex but does not necessarily indicate instability. Ensure the crane is properly set up and all operator aids are functional.

Multiple Crane Lifts
Not recommended unless precisely planned and coordinated. Use a designated person to direct operations, maintain communication, and ensure proper weight distribution.

Tilt-Up Panel Lifting
Follow specific precautions for tilt-up panel lifting, including proper setup and operation according to Grove's instructions. Ensure the load is balanced and controlled to prevent rotation.

Pile Driving and Extracting
Approved by Manitowoc if operated within guidelines. Use fully extended outriggers and ensure the combined weight does not exceed 80% of load chart values. Avoid shock loads and keep load lines vertical.

Crane Equipment and Inspection
Ensure hoists have cable followers, all retainer pins are in place, and jibs are removed before pile driving. Conduct daily inspections and maintain records during pile driving operations.

Electrocution Hazard
Maintain a safe distance from power lines, at least 6 meters (20 feet) for lines up to 350 kV. Notify the power utility if operation within 3 meters (10 feet) is unavoidable, and ensure lines are de-energized and grounded.

Safety Precautions
The manual emphasizes the importance of maintaining a safe distance from electrical power lines and equipment, even if they are de-energized. It highlights the risk of electrocution from electricity arcing to the crane or load. Operators should assume all lines are energized and maintain a minimum distance of 6 meters (20 feet) from power lines. A barricade should be erected to prevent the crane from entering unsafe distances, and a flagman is required when operating near power lines.

Electrocution Hazard Devices
The manual discusses the limitations of insulated links, boom cages, and proximity warning devices. These devices do not guarantee safety from electrical contact, and operators should not rely solely on them. Proper maintenance and testing of these devices are crucial to ensure their effectiveness.

Electrical Contact Procedures
In case of contact with an energized power source, operators should stay in the crane cab, warn others to stay away, and attempt to move the crane away from the source. The power company should be contacted to de-energize the source before anyone approaches the crane.

Special Operating Conditions
The manual advises against operating cranes during thunderstorms and near transmitter towers without proper precautions. It also outlines additional safety measures when using cranes with electromagnets.

Earthing the Crane
Instructions are provided for grounding the crane to prevent static electricity buildup, especially when using insulating materials for outrigger pads.

Personnel Handling
The manual references ASME B30.23-2011 standards for personnel lifting systems and outlines conditions under which cranes can be used to lift personnel. It stresses that cranes should not be used for personnel handling unless it is the least hazardous option and all safety requirements are met.

Environmental Protection
Proper disposal of waste materials such as oil, fuel, and batteries is emphasized to prevent environmental harm. Waste fluids should be drained into leak-proof containers and spills cleaned immediately.

Maintenance
Regular inspection and maintenance of the crane are required before each work shift. The manual advises against operating damaged or poorly maintained cranes and recommends upgrading cranes with safety systems like rated capacity limiters.

Maintenance and Inspection
Routine maintenance and inspection of the crane must be conducted by qualified personnel as per the Manitowoc Crane Care Maintenance and Inspection Manual. For any procedural or specification queries, contact the Manitowoc distributor.

Service and Repairs
Only qualified individuals should perform service and repairs, adhering to the manufacturer's recommendations and manuals. Unauthorized modifications invalidate warranties and may lead to accidents.

Safety Warnings
Proper fall protection is mandatory when working at heights. Hydraulic systems should be handled with care to prevent injuries from pressurized fluids. Moving parts pose risks of amputation; ensure the engine is off before servicing.

Hydraulic Fluid Precautions
Do not check for leaks with bare hands. Use cardboard or paper and wear gloves. Never repair hydraulic components under pressure. Allow fluid to cool before disconnecting lines.

Wire and Synthetic Hoist Rope
Daily inspections are crucial. Remove ropes from service if they show significant wear or damage. Follow specific criteria for wire rope removal, including broken wires and abrasion.

Tires
Inspect for damage and ensure proper inflation. Under-inflated tires must be deflated, inspected, and re-inflated as per OSHA standards.

Sheaves and Hoist Rope
Inspect sheaves regularly for wear and damage. Use nylon sheaves to extend rope life, but establish retirement criteria based on experience.

Batteries and Super Capacitors
Handle with care to avoid contact with skin or eyes. Follow proper procedures for disconnecting and maintaining batteries and capacitors.

Safety Procedures and Precautions
1. Always wear safety glasses during servicing.
2. Disconnect the battery using the battery disconnect switch before removing the ground battery cable, especially for cranes with a Cummins engine using an ECM.
3. Avoid short-circuiting capacitor posts to prevent damage and potential explosion.
4. Use appropriate test equipment to check capacitor charge levels.

General Maintenance
1. Fuel the crane only when the engine is off and avoid smoking during refueling.
2. Be aware of the nearest fire extinguisher location.
3. Allow the engine to cool before checking coolant levels.
4. Disconnect the battery before maintenance and keep clear of moving parts.
5. Avoid using ether to start engines with intake manifold grid heaters.
6. Be cautious of high exhaust temperatures during engine exhaust cleaning mode.

Transporting the Crane
1. Verify route suitability considering crane dimensions and weight.
2. Check bridge load limits on the travel route.
3. Use appropriate ramps for loading/unloading.
4. Secure the crane properly to the transport vehicle.
5. Follow state and local transport regulations.

Travel Operation
1. Only the crane operator should be in the crane during travel.
2. Retract and lower the boom to the travel position and engage locks.
3. Adhere to Load Chart guidelines for pick and carry operations.
4. Avoid high-speed travel on rough ground to prevent loss of control.
5. Use signal persons for guidance in tight spaces.
6. Ensure air-operated brakes are at operating pressure before moving.

Work Practices
1. Adjust and lock the seat, and fasten the seat belt before starting the engine.
2. Wear appropriate protective clothing and gear.
3. Use proper fall protection when working at heights.
4. Use designated access systems for entering/exiting the crane.
5. Keep walking surfaces clean and slip-resistant.

Job Preparation
1. Barricade the work area and keep unnecessary personnel out.
2. Conduct visual inspections for damage and ensure proper equipment setup.
3. Check the functionality of controls and operator aids.
4. Ensure outriggers are properly extended and set.

Working and Lifting Operations
1. The operator is responsible for all operations and should stop if safety is in doubt.
2. Ensure all personnel are clear before starting the engine.
3. Avoid operating in unsafe conditions like poor visibility or thunderstorms.
4. Use proper rigging and ensure the load is secure before lifting.
5. Do not exceed crane capacity and avoid side loading.
6. Never leave a load suspended when leaving the crane.
7. Be cautious of boom deflection and sudden movements that could tip the crane.

Safety Information
1. Load Handling and Hand Signals: Ensure all personnel are clear of the crane area before lifting. Use a qualified signal person when visibility is limited or near power lines. Standardized hand signals must be used, and crane movement should stop if communication is lost.

2. Jib Operations: Follow procedures for erection, stowage, and use of the jib to avoid injury. Secure all pins and control jib movement. Inspect and maintain the jib and its mounting.

3. Parking and Securing: When parking on a grade, apply the parking brake and chock the wheels. Follow specific instructions for securing the crane when unattended, considering weather conditions and ensuring the crane is in a stable configuration.

4. Shut-Down Procedures: Engage the parking brake, retract and lower the boom, and secure the crane by turning off power and locking the cab.

5. Cold Weather Operation: Take precautions in cold weather, such as warming hydraulic oil and avoiding contact with metal surfaces. Ensure the crane is not frozen to the ground.

6. Temperature Effects: Be aware of the effects of temperature on hook blocks and hydraulic cylinders. Avoid using hook blocks in extreme temperatures and monitor hydraulic oil expansion and contraction.

7. Overload Inspection: Conduct inspections if the Rated Capacity Limiter (RCL) indicates an overload. For overloads up to 50%, specific inspections are required. For overloads above 50%, stop operations and contact Crane Care.

Inspection Guidelines
1. Boom Inspection: Inspect sheaves, rope guides, collar-wear pads, pinning areas, telescopic sections, lift cylinder head area, turret-base section, jib section, and welds for damage or deformation.

2. Superstructure Inspection: Check lift cylinders, wire ropes, turntable bearings, hoist/drums, hoist brakes, bearing main boom pivot pin, lift cylinder-lower mount, turret area, mounting studs, and welds for damage or deformation.

3. Carrier Inspection: Inspect stabilizer cylinders, outrigger pads, beams, boxes, and welds for leaks, deformation, or cracks.

Operating Controls and Procedures
1. Controls, Switches, and Gauges: Familiarize with cab controls, foot controls, left and right dash controls, and indicator and gauge displays for effective crane operation.

Brake System Indicators
The document outlines the importance of monitoring the brake system indicators. The low brake pressure warning light requires immediate attention, and the crane should not be driven until the issue is resolved. The Axle Differentials Locked Indicator shows when the differentials are locked, and the Transmission Oil High Temperature Indicator warns of high oil temperatures with a red light and buzzer.

Hydraulic and Engine Indicators
The Hydraulic Oil High Temperature Indicator signals when the hydraulic oil exceeds 93°C (200°F). The engine warning and stop lights indicate when engine conditions are outside calibration limits, potentially leading to engine derate. If the stop light illuminates, the engine should be shut down to prevent damage.

Crane Operation Controls
The document details various controls, including the Rated Capacity Indicator (RCI) for load management, air conditioning/heater controls, and the boom angle indicator for determining boom position. The outrigger controls ensure crane stability, and steering controls offer three modes: Two-Wheel, Four-Wheel, and Crab Steering.

Operator's Cab Features
The cab includes a heater/air conditioner, defroster, adjustable seat, and a fire extinguisher. Proper use of these features is essential for operator comfort and safety.

Crane Warm-up Procedures
Warm-up procedures are crucial for crane components, especially in cold weather. The document provides detailed steps for warming up the engine, transmission, hoist, swing drive, turntable bearing, axles, and hydraulic oil system. Using the correct lubricants and following warm-up procedures prevent component failure.

Engine Starting Procedures
Before starting the engine, ensure the crane is clear of personnel. The document advises on seat adjustment, seat belt use, and parking brake engagement. The engine should not be operated at full RPM until warm, and the air intake heating system should be used in cold weather.

Engine Starting Procedure
1. Turn the ignition switch to START and release when the engine starts. Do not bypass the crane’s neutral-start system. Avoid cranking the starter motor for more than 30 seconds to prevent damage.
2. Do not press the accelerator pedal; the engine ECM will set the idle speed.
3. If the engine fails to start, wait for the starter motor to stop completely before trying again.
4. Check the engine oil pressure warning light. If illuminated, shut down the engine immediately for servicing.
5. Verify brakes, steering, and controls are functioning properly. If not, shut down the engine and park the crane.
6. Disengage the parking brake before traveling with the crane.

Jump Starting the Engine
1. Wear eye protection and engage the parking brake.
2. Place the travel select lever in Neutral and stop all electrical loads.
3. Locate the battery and connect jumper cables correctly: positive to positive, negative to a ground point.
4. Follow normal starting procedures and remove jumper cables in reverse order once the engine starts.

Traveling with the Crane
1. Enter the cab, close the door, and fasten the seat belt.
2. Start the engine and disengage the parking brake.
3. Select Forward or Reverse on the transmission shift lever.
4. Start traveling in 1st gear and shift gears as needed. Avoid high speeds with heavy loads to prevent engine lugging.
5. Do not apply the parking brake while traveling.

Changing Travel Direction
1. Stop the crane before changing direction.
2. Move the travel select lever to the opposite direction.
3. Ensure the brake pedal is depressed before placing the transmission in gear.

Shifting Gears
1. Manually shift gears; the transmission is not automatic.
2. Avoid over-revving the engine when downshifting.
3. Stop the crane before shifting between forward and reverse.

Stopping Travel
1. Apply service brakes and downshift to stop the crane.
2. Place the transmission in Neutral and engage the parking brake.
3. Turn off the ignition and remove the key if unattended.

Operating the Outrigger Controls
1. Level the crane within 1% of grade using the bubble level indicator.
2. Extend and lower outriggers using the selector switches and accelerator pedal.
3. Use the Outrigger Monitoring System to ensure outriggers are fully extended.

Operating the Boom Controls
1. Use the control levers in the cab to operate boom functions.
2. Increase engine speed to maximum RPM for faster operation.
3. Ensure clearance before rotating the mast and avoid side loads on the boom.

Operating Controls and Procedures for CD25 Boom Telescope Operation

To Extend the Boom: Increase engine speed to maximum RPM and push the telescope control lever forward to extend the boom. Ensure the hoist control unwinds the wire rope to prevent the drop block from touching the boom head. An automatic cutout device will stop the hydraulic flow if the block touches the anti-double blocking bracket, triggering a warning horn.

To Stop Extension/Retraction: Move the control lever to neutral and decrease engine speed to idle.

To Retract the Boom: Increase engine speed to maximum RPM and pull back on the telescope control lever.

Warnings: Maintain proper side slide pad adjustment at high boom angles. Ensure the boom is visually straight to prevent failure.

Boom Lift Operation: Familiarize with the crane’s capacity chart. Check for overhead obstructions before raising the boom. Increase engine speed and pull back on the boom control lever to raise the boom.

Hoist Operation: Ensure all persons are clear of the load. Increase engine speed and use the hoist control lever to raise or lower the hookblock. Avoid side loads on the boom and ensure the hookblock does not touch the boom head.

Optional Controls Operation: For the under deck winch, keep hands clear of moving parts. Use the switch to extend or retract the wire rope.

Operating Practices: Do not exceed the crane’s rated load capacity. Ensure the load is properly secured and balanced. Avoid sudden movements and ensure the load path is clear.

Travel on Slopes: Limit slope travel to 15% and ensure the surface is suitable. Travel forward only, with the boom fully retracted and lowered. Use a ground person for assistance.

Traveling with a Load: A designated person must oversee operations. Maintain specified tire pressure and avoid sudden movements.

Elevating Personnel: Inspect the crane daily and ensure the platform is securely attached. Follow safety protocols and use required restraining items.

Crane Shutdown: Park on level ground, engage the parking brake, and lower the boom. Turn off the ignition and disconnect the battery if necessary.

Towing and Safety Instructions
For towing a crane over a distance of 1.5 km (one mile), use a rigid tow bar and ensure the travel select lever and transmission are in Neutral (N). Limit the speed to 25 kmph (15 mph). For distances exceeding 1.5 km, disconnect the drive shafts to prevent transmission damage. Consider weather conditions when leaving a crane unattended to avoid tipping hazards, as non-compliance may result in serious injury or death.

Capacity Chart Usage
The Capacity Chart is located inside the operator’s cab and provides maximum load limits and conditions for safe lifting. The boom's angle and extension length determine the lifting radius. Always use the next highest radius on the chart if the exact radius is not listed. Do not exceed the chart's stated capacities.

Key Observations for Capacity Chart

Rated loads are based on operating radius, boom length, and angle.
Loads on outriggers do not exceed 85% of tipping capacity; on rubber, they do not exceed 75%.
Consider weights of all load handling devices as part of the load.
Ensure proper tire condition and inflation for loads on rubber.
Do not induce external side loads to the boom.

Attachments and Adjustments
The document details procedures for adjusting the boom head and extension, including:

Changing boom head positions without extension.
Adjusting boom extension offset angles.
Installing and removing the hook block.
Stowing the boom extension.

Warnings are provided for potential crushing hazards during adjustments.

Installation and Removal Procedures:
1. Transmitter Removal: Remove the transmitter from the boom head by detaching the mounting hardware. Remove the hoist block and install the transmitter onto the down haul weight using the previously removed hardware.
2. Rope Guide Pin: Remove and reinstall the rope guide pin ensuring the wire rope is correctly positioned between the pins.
3. Transmitter Connection: Connect the transmitter wire to the load pin wire and adjust the boom head angle for the lift operation.

Down Haul Weight Removal:
1. Lower the down haul block and disconnect the transmitter load pin wire.
2. Remove the rope guide pin, lynch pin, and load pin from the down haul weight.
3. Reinstall the transmitter to the boom head using existing hardware.

Cable Installation on Hoist:
1. Position the cable over the boom nose sheave and route it to the hoist drum.
2. Insert the cable through the anchor slot and secure it with the anchor wedge.
3. Ensure the cable is evenly wound onto the drum.

Wire Rope Wedge Socket:
1. Inspect and prepare the wedge and socket, ensuring no rough edges.
2. Insert the wire rope into the socket, form a loop, and secure with the wedge.
3. Ensure proper seating of the wedge using the crane's hoist.

Maintenance Guidelines:
1. Preventive Maintenance: Regular maintenance is crucial for crane longevity. Adjust schedules based on operating conditions.
2. Wire Rope Inspection: Follow ANSI/ASME B30.5 guidelines for inspection and maintenance. Inspections should be more frequent as the rope nears the end of its life.
3. Lubrication: Regular lubrication of components such as the boom slides, hoist gearbox, and brake is essential.

Safety Precautions:
1. Use eye protection during maintenance tasks.
2. Ensure a person is at the controls if maintenance is performed with the engine running to prevent accidental movement.

Regulatory Compliance:
1. Some regions may require spark arresting mufflers for cranes used in specific applications.
2. Follow federal regulations and manufacturer guidelines for wire rope maintenance.

Inspection and Maintenance Procedures for Wire Ropes
Wire ropes used in Manitowoc products require annual inspection and maintenance. These ropes include load lines, boom extension and retraction cables, pendant cables, tow winch cables, and hook block tie-down cables. Environmental conditions such as temperature, moisture, and exposure to corrosive substances can affect the lifespan of wire ropes, necessitating frequent inspections to prevent premature wear.

Dynamic Shock Loads
Wire ropes subjected to abnormal loads, such as high-velocity movements or overloading, will have reduced life expectancy. Proper handling and avoiding excessive loads are crucial for maintaining rope integrity.

Lubrication
Regular lubrication is essential as factory-applied lubricant is insufficient for the rope's entire lifespan. Lubricants should be compatible with the original and should not hinder visual inspections. Proper cleaning before lubrication and applying lubricant at the top of a bend in the rope are recommended practices.

Precautions and Recommendations
During inspection or replacement, ensure equipment power is locked out, use protective gear, and avoid welding or electroplating wire rope assemblies. Replace entire assemblies rather than attempting repairs on damaged ropes.

Inspection Intervals
Wire ropes should be inspected frequently (daily) and periodically (annually) based on environmental conditions and usage. Inspections should focus on wear, corrosion, broken wires, and end fitting conditions. Records of inspections must be maintained to track rope condition over time.

Replacement Criteria
Wire ropes should be replaced when specific conditions are met, such as broken wires, significant wear, heat damage, or severe corrosion. For cable-extended booms, replacement of the entire set of cables is recommended if any single cable is damaged.

Seizing Wire Rope
Seizing prevents unraveling of wire ropes. Two methods are recommended: using soft annealed wire to wrap and secure the rope ends.

Environmental Protection
Proper disposal of waste materials like oil, fuel, and lubricants is crucial to prevent environmental harm. Follow local regulations for waste disposal.

Lubricants and Maintenance Records
Manitowoc does not endorse specific lubricants but provides guidelines for their use. Maintenance records for critical components must be kept diligently.

Maintenance Overview
This document provides detailed maintenance procedures for cranes, focusing on regular inspections and lubrication to ensure optimal performance and safety. It includes schedules for daily, weekly, monthly, and yearly maintenance tasks, emphasizing the importance of adhering to these intervals to prevent equipment failure.

Initial and Regular Maintenance
For new cranes, specific actions are required after the first 50 and 100 hours of operation, such as checking and filling fuel, oil, and coolant levels, and inspecting various components like tires and controls. Regular maintenance tasks are outlined for different intervals, ranging from daily checks to yearly inspections.

Inspection Procedures
Daily inspections include checking the anti-double blocking system, wire ropes, reeving, clamps, connections, lifting hooks, and all safety devices. Any malfunction or damage found during these inspections must be addressed before operating the crane.

Lubrication and Fluid Levels
The document specifies lubrication points and the types of lubricants required for different components, such as the drive axles, hoist gearbox, and boom sections. It also provides instructions for checking and maintaining fluid levels in the engine, transmission, and hydraulic systems.

Safety Precautions
Safety is a critical aspect of crane maintenance. The document highlights the need for proper installation and inspection of components to prevent accidents. It also advises on handling flammable materials like engine fuel and provides guidelines for safe refueling practices.

Lubrication Points and Symbols
A detailed list of lubrication points is provided, along with the corresponding lubricant symbols and specifications. This ensures that the correct type of lubricant is used for each component, which is crucial for maintaining the crane's functionality and longevity.

Conclusion
Adhering to the maintenance schedule and performing thorough inspections are essential for the safe and efficient operation of cranes. The document serves as a comprehensive guide for maintenance personnel to follow, ensuring that all aspects of crane maintenance are covered.

Hydraulic Oil Check and Maintenance:
Ensure the crane is on level ground, engage the parking brake, and shut off the engine. Check the hydraulic oil level through the sight glass and fill with pre-filtered oil if necessary. Use a 10-micron filter to avoid contamination which can damage the pump.

Tire Pressure and Condition:
Check tire pressure to ensure it is at 758 kPa (110 psi). Inspect for broken studs, rim damage, loose nuts, and cracks.

Air Cleaner Maintenance:
Check the air cleaner restriction indicator while the engine is running at high idle. Replace the element if the indicator shows a restriction. Clean the housing and ensure proper gasket sealing to prevent engine contamination.

Boom and Lubrication Maintenance:
Lubricate boom slides and wear pads with bronze anti-seize. Check hoist gearbox and brake lubricant levels, ensuring oil is visible in the sight glass. Use SAE 90 EP gear lube for the gearbox but avoid using it in the brake section.

Surface Protection for Cylinder Rods:
Apply Boeshield T-9 Premium Metal Protectant to exposed cylinder rods to prevent corrosion, especially in corrosive environments.

Regular Maintenance Intervals:

50 Hours (Weekly): Lubricate all points, check air cleaner, and inspect fan belts.
100 Hours (Bi-weekly): Inspect fan belts for tension and wear, and check wheel nut torque.
250 Hours (Monthly): Inspect hydraulic hoses for leaks, clean batteries and cables, lubricate wire ropes, and apply open gear lube to swing gear and pinion.

Safety Precautions:
Always use proper fall protection when working at heights. Do not use hands to check for hydraulic leaks; use a deflector like cardboard instead.

Maintenance Procedures Overview

This document provides detailed maintenance procedures for a crane, focusing on various components such as the engine, tires, brakes, and hydraulic systems. The procedures are structured around specific intervals, such as 500 hours and 1000 hours of operation.

Engine Maintenance

Crankcase Oil Replacement: Change the engine oil more frequently under harsh conditions. Ensure the engine is off and secure before proceeding. Drain the oil when hot and replace with 11 liters of new oil.
Oil Filter Replacement: Remove the old filter, clean the mounting surface, and install a new filter with a lubricated gasket. Check for leaks after filling the engine with oil.
Radiator Cleaning: Use compressed air or water to clean radiator fins to prevent overheating.

Tire and Brake Inspection

Tire Inspection: Check for damage and replace unsafe tires.
Parking Brake Pads: Inspect and replace if thickness is 7.1 mm or less.

Fuel System Maintenance

Fuel Filter/Water Separator: Follow the engine manual for replacement procedures. Ensure the filter is filled with fuel before installation to avoid air in the system.
Secondary Fuel Element: Replace as necessary, ensuring the engine is off and secure.

Air Cleaner Maintenance

Air Cleaner Element Replacement: Remove and replace the primary and secondary elements, ensuring the housing is clean to prevent engine contamination.

Lubrication and Fluid Checks

Outrigger Slides: Clean and lubricate with Mobil EP grease.
Axle Housing and Wheel Hub Lubricant Levels: Check and fill with Mobil Fluid 424 as necessary.
Swing Gearbox Lubricant Level: Check and fill with EP 90 weight oil.

Transmission and Axle Maintenance

Transmission Oil and Filter Replacement: Drain and refill with recommended fluid, ensuring proper oil levels at operating temperature.
Axle Housing and Wheel Hub Lubricant Replacement: Drain and refill with Mobil Fluid 424.

Hydraulic System Maintenance

Hydraulic Oil Replacement: Drain and refill with Mobil Fluid 424, ensuring the system is free of contaminants.
Hydraulic Oil Filter Replacement: Replace the filter as necessary, ensuring the system is secure.

Safety Precautions

Throughout the document, safety precautions are emphasized, such as ensuring the engine is off, the ignition key is removed, and chock blocks are in place before performing maintenance under the crane.

Maintenance Procedures

Hydraulic Filter Replacement: Engage the parking brake, shut off the engine, and use a filter wrench to remove the old filter. Clean the mounting surface and install the new filter with a small amount of hydraulic oil on the gasket. Tighten the filter and check for leaks after starting the engine.
Swing Gear/Pinion Backlash Check: Remove the cover to expose the swing pinion and ring gear. Align the high point on the swing gear with the pinion and use a feeler gauge to check for backlash. Adjust if necessary.
Engine Coolant Replacement: Ensure the engine is cool before draining and refilling the cooling system. Follow the procedures in the Engine Operation and Maintenance Manual.
Crane Structure Inspection: Check for loose hardware, cracked welds, missing decals, rust, and any damage that could affect safe operation. Repair or replace as needed.
Rated Capacity Limiter (RCL) Testing: Follow the instructions in the RCL manual to test the device.

Battery and Charging System

Battery Safety: Avoid smoking and open flames near batteries. Use a voltmeter or hydrometer to check battery charge.
Charging System Check: Normal voltmeter readings are 14-16 volts with the engine running and 10-14 volts when stopped. Low readings indicate a need for service.
Battery Charging: Use a charger if the alternator cannot recharge a completely discharged battery. Avoid charging a frozen battery.
Battery Replacement: Handle with care to avoid spillage of sulfuric acid. Use protective gear and follow first aid procedures if contact occurs.

Fuel System and Storage

Fuel Safety: Engine fuel is flammable. Avoid open flames and smoking during refueling.
Fuel Storage: Store fuel in a cool, outside location and remove condensation regularly.

Fuses and Relays

Fuse blocks are located below the dash and in the battery compartment. Refer to the manual for identification and specifications.

Specifications

Lubricants and Capacities: Lists recommended lubricants and capacities for various components.
Engine Oil Specifications: Use high-quality SAE 15W40 oil. Follow Cummins Oil Registration List for recommended oils.
Diesel Fuel: Use No. 2 diesel fuel above 0°C and No. 1 or winterized No. 2 diesel below 0°C.
General Specifications: Includes engine, transmission, tire, electrical system, and operating dimensions specifications.

Catalog excerpts

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 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. You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. The Operator Manual and Load Chart are in the holder provided

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Crane Warm-up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing Drive and Turntable Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axles . . . . . . . ....

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This Supplement provides information regarding the proper warm-up procedures for operating the crane in colder temperatures. The information provided here supplements the Operator and Service Manuals and must be used in conjunction with these manuals. COLD CLIMATE ENGINE OPERATION Engine specific cold climate operation information is available through your Cummins dealer/service center under Service Bulletin 3379009. CRANE WARM-UP PROCEDURES The following procedures detail the actions that must be taken to properly warm the different crane components before operating the crane. NOTE: For temperatures...

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Swing Drive and Turntable Bearing Warm-up Procedures for Temperatures Above -7°C (20°F): 1. Setup the crane on fully extended outriggers, with the boom fully retracted and near maximum lift angle with no load applied. 2. Rotate the superstructure at a speed of less than one RPM for at least one complete revolution in one direction, then rotate the superstructure at a speed of less than one RPM for at least one complete revolution in the opposite direction. Warm-up Procedures for Temperatures Below -7°C (20°F): 1. Ensure the boom is fully retracted and near maximum lift angle with no load applied....

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Operator Manual

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OPERATOR MANUAL This manual has been prepared for and is considered part of - Crane Model Number The crane serial number is the only method your distributor or the factory has of providing you with correct parts and service information. The crane serial number is identified on the builder’s decal attached to the operator’s cab. Always 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 read, understand, and follow...

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CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the 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. The original language of this publication is English.

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See End of this Manual for Alphabetical Index SECTION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Overview of Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Delivery Report . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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SECTION 3. . . . . . . . . . . . . . . . . . . Operating Controls and Procedures Controls, Switches, and Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Cab Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Foot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Left Dash Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Right Dash Controls. . ....

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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...

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Cranes Not in Regular Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Maintenance Schedule and Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Lubricant symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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GCD25

GCD25

Catalog excerpts

All Manitowoc Cranes catalogs and technical brochures

Archived catalogs