Manitowoc YB5520 Operator Manual – PDF DOWNLOAD
FILE DETAILS:
Manitowoc YB5520 Operator Manual – PDF DOWNLOAD
Language : English
Pages : 174
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Manitowoc YB5520 Operator Manual – PDF DOWNLOAD
SECTION 1 11
Introduction 11
The Manual 11
Directional Reference 11
Serial Number Plate 11
Delivery Report 11
Customer Support 12
New Owners 12
Vibration Level Test Results 12
Safety Information 12
General Crane Design 12
Nomenclature 13
SECTION 2 15
Safety Information 15
Safety Messages 15
General 15
Safety Alert Symbol 16
Signal Words 16
General 16
Safety Decals 16
Accidents 16
Operator Information 16
Operator Qualifications 17
Operational Aids 18
Rated Capacity Limiter (RCL) Systems (If Equipped) 18
Anti-Two-Blocking Device 18
Working Area Limiter (If Equipped) 19
Crane Stability/Structural Strength 19
Load Charts 20
Work Site 20
Wind Forces 21
Wind Speeds 21
Determination of 3-second wind gust speed at boom tip height: 24
Size and Shape of the load: 24
Determining Wind Drag Coefficient (Cd) 25
Maximum Permissible Wind Speed 26
Example and Sample Calculations (metric) 28
Example 1: Crane Configuration: 28
Load example 1 1: 29
Load example 1 2: 29
Load example 1 3a: 29
Load example 1 3b: 29
Example and Sample Calculations (Non-metric) 32
Example 2: 32
Load example 2 1: 33
Load example 2 2: 33
Load example 2 3a: 33
Load example 2 3b: 33
Lifting Operations 34
Counterweight 35
Outrigger Lift Off 35
Multiple Crane Lifts 35
Tilt-Up Panel Lifting 35
Electrocution Hazard 36
Set-Up and Operation 37
Electrocution Hazard Devices 37
Electrical Contact 38
Special Operating Conditions and Equipment 38
Grounding the Crane 39
Personnel Handling 39
Environmental Protection 40
Maintenance 40
Service and Repairs 41
Lubrication 42
Tires 42
Hoist Rope 42
Synthetic Hoist Rope 42
Wire Rope 42
Sheaves 44
Batteries 44
Super Capacitor (If Equipped) 44
General Maintenance 45
Transporting the Crane 45
Travel Operation 45
Work Practices 46
Personal Considerations 46
Crane Access 46
Job Preparation 47
Working 47
Lifting 48
Hand Signals 49
Boom Extension 51
Parking and Securing 51
Shut-Down 51
Cold Weather Operation 51
Temperature Effects on Hook Blocks 52
Temperature Effects on Hydraulic Cylinders 52
Overload Inspection 53
Boom Inspection 55
Superstructure Inspection 57
Carrier Inspection 59
SECTION 3 61
Operating Controls and Procedures 61
Controls, Switches, and Gauges 63
Crane Controls 63
Swing Control (1) 63
Telescope Control (2) 63
Hoist Control (3) 63
Boom Lift Control (4) 63
Accelerator Pedal (5) 63
Brake Pedal (6) 63
Steering Wheel (7) 63
Turn Signal/Windshield Wiper Lever (8) 63
Left Dash Controls 64
Defroster Switch (3) 64
Fault Code Switch (4) 64
Steering Select Switch (5) 64
Two-Wheel/Four-Wheel Drive Select Switch (6) 64
Headlights/Work Lights Switch (7) 64
Outrigger Extend/Retract Switch (8) 64
Hoist Speed Select Switch (9) 64
Heater Fan Switch (10) 64
Emergency Stop Switch (11) 64
Steering Controls 65
Two-Wheel Steer Mode 65
Four-Wheel Steer Mode 65
Crab Steer Mode 65
Right Dash Controls 66
Hoist Direction Indicator (1) 66
Outrigger Beam/Jack Select or Switches (4) 66
Hazard Lights Switch (5) 66
Crane Function Switch (6) 66
Parking Brake Switch (7) 66
Ignition Switch (8) 66
Winch Switch (9) (Optional) 67
Swing Lock Switch (10) 67
Exhaust System Cleaning Switch (11) —Tier 4 Final Engine Only 67
Dual Fuel Switch (11) 67
Swing Lock Engaged Indicator (12) 67
12 volt Accessory Outlet (13) 67
Indicator and Gauge Display—Diesel Engine 69
Fuel Gauge (1) 69
Left Turn Signal Indicator (2) 69
Voltmeter (3) 69
Hourmeter (4) 69
DEF Gauge (5)—Tier 4 Final Engine Only 69
Fault Code Display (6) 69
Tachometer (7) 69
Right Turn Signal Indicator (8) 69
Engine Coolant Temperature Gauge (9) 69
Crane Function Enabled Indicator (10) 69
Outrigger Monitoring Indicator (11) 69
Minimum Wrap Indicator (12) 69
Battery Charge Indicator (13) 69
DEF Low Indicator (14)—Tier 4 Final Engine Only 69
High Exhaust System Temperature (HEST) Indicator (15)—Tier 4 Final Engine Only 69
Exhaust System Cleaning Inhibit Indicator (16)—Tier 4 Final Engine Only 69
Exhaust System Cleaning Needed Indicator (17)—Tier 4 Final Engine Only 69
Engine Wait to Start Indicator (18) 70
Engine Warning Indicator (19) 70
Engine Stop Indicator (20) 70
Parking Brake Engaged Indicator (21) 70
Low Brake Pressure Indicator (22) 70
Axle Lock Indicator (23) 70
Transmission Oil Temperature Indicator (24) 70
Four Wheel Drive Indicator (25) 70
Hydraulic Oil High Temperature Indicator (26) 70
Indicator and Gauge Display—Dual Fuel Engine 72
Gasoline Fuel Gauge (1) 72
Left Turn Signal Indicator (2) 73
Voltmeter (3) 73
Hourmeter (4) 73
Tachometer (5) 73
Right Turn Signal Indicator (6) 73
Engine Coolant Temperature Gauge (7) 73
Crane Function Enabled Indicator (8) 73
Outrigger Monitoring Indicator (9) 73
Minimum Wrap Indicator (10) 73
Headlights Indicator (11) 73
Work Lights Indicator (12) 73
Axle Lock Indicator (13) 73
Hydraulic Oil High Temperature Indicator (14) 73
Engine Warning Indicator (15) 73
Parking Brake Engaged Indicator (16) 73
Low Brake Pressure Indicator (17) 73
Engine Oil Indicator (18) 73
Battery Charge Indicator (19) 73
Transmission Oil Temperature Indicator (20) 74
Four Wheel Drive Indicator (21) 74
Operator Aids 74
Crane Level Indicator 74
Boom Angle Indicator 74
Rated Capacity Limiter (RCL) 74
Mirrors 74
Operator Cab Controls 75
Heater/Air Conditioner 75
Defroster 75
Seat Switch 76
Operator Seat 76
Seat Belt 76
Cab Door (Enclosed Cab) 76
Opening the Cab Door from Outside 76
Opening the Door from Inside 76
Locking the Cab Door 77
Cab Side Window 77
Fire Extinguisher 77
Strobe Light 77
The amber strobe light behind the operator cab comes on when the engine is started 77
Dome Light 77
The dome light has a 3-way switch: map light only, map and dome light, and off 77
Connecting/Disconnecting the Batteries 77
Starting the Engine: Normal 77
Starting the Engine: Towing or Pushing 78
Starting the Engine: Jump Start 78
Jump Starting the Crane 78
Charging 78
Warming the Crane 79
Engine 79
Warm-up Procedures for All Temperature Ranges: 79
Transmission 80
Warm-up Procedures for Industrial Cranes: 80
Alternate Warm-up Procedures for Industrial Cranes: 80
Hoist 80
Swing Drive and Turntable Bearing 80
Warm-up Procedures for Temperatures Above -7°C (20°F): 80
Warm-up Procedures for Temperatures Below -7°C (20°F): 80
Axles 80
Warm-up Procedures for Temperatures Below -35°C (-30°F): 80
Hydraulic Oil System 80
Operating the Travel Controls 81
Starting Travel 81
Changing Travel Direction 82
Shifting Gears 82
Stopping Travel 82
Operating the Outrigger Controls 82
Leveling the Crane 83
Adjusting the Bubble Level 83
Extending the Outrigger Beams 83
Extending the Outrigger Jacks 84
Outrigger Monitoring System (OMS) (Optional—Standard in North America) 84
Raising the Jacks 84
Retracting the Outriggers 85
Operating the Crane Functions 86
Anti-Two Blocking System 86
Swing Operation 88
To Rotate the Boom to the Left (Counterclockwise) 88
To Stop Rotation 88
To Rotate the Mast Right (Clockwise) 88
Boom Telescope Operation 90
To Extend the Boom 90
To Stop Extension/Retraction 90
To Retract the Boom 90
Boom Lift Operation 92
To Raise the Boom 92
To Stop Boom Movement 92
To Lower the Boom 92
Hoist Operation 93
To Raise the Load 94
To Stop Hoist Rotation 94
To Lower the Load 94
Under Deck Winch Operation 96
To Engage/Disengage the Winch 96
To Pay Out the Wire Rope 96
To Stop the Winch 96
To Haul In the Wire Rope 96
Operating Practices 96
Handling a Load 96
Attaching the Load 96
Holding the Load 96
Moving the Load 96
Traveling on Slopes 97
Traveling with a Load (Pick and Carry) 97
Handling Personnel 98
Turning Clearances 98
Shutting Down Crane 98
Disconnecting Battery 98
Leaving Crane Unattended 98
Towing a Disabled Crane 98
SECTION 4 99
Capacity Chart 99
Using the Capacity Chart 99
Operating Boom Radius 99
Locating the Lift Capacity 99
Things to Observe When Using the Capacity Chart 99
Lifting with the Boom Extension Installed 100
Pick and Carry Ranges 100
SECTION 5 103
Attachments 103
Pivoting Boom Head 103
Boom Head Positions 103
Positions when No Boom Extension is Attached 103
Positions when Boom Extension is Attached 103
Changing the Boom Head Position (without Boom Extension) 105
Changing the Boom Extension Offset 105
Hook Block 106
Removing the Hook Block 106
Installing the Hook Block 106
Downhaul Weight 107
Installing the Downhaul Weight 107
Removing the Downhaul Weight 107
Searcher Hook Assembly 109
Installation 109
Removal 109
Boom Extension 111
Deploying the Boom Extension 111
Stowing the Boom Extension 112
Installing Wire Rope on the Hoist 112
Installing Wire Rope Wedge Socket 113
Reeving 115
SECTION 6 117
Maintenance 117
Introduction 118
Spark Arresting Mufflers 118
Safety List 118
Lubricants 118
Maintenance Records 118
Special Maintenance 119
Delivery Inspection 119
After First 50 Hours of Operation (New Cranes) 119
After First 100 Hours of Operation (New Cranes) 119
Cranes Not in Regular Use 119
Maintenance Schedule and Checklist 120
Safety 123
Environmental Protection 123
Engine Maintenance 123
Grease Points 124
Boom and Main Frame 124
Drive Train 126
Daily Walk-around Inspection 126
Inspect Wire Rope 126
Inspect Reeving, Clamps, and Connections 126
Inspect the Lifting Hook 126
Daily Operational Inspection 127
Inspect the Anti-Two-Block System 127
Inspect All Safety Devices 127
Check Controls Operation 127
Daily Component/System Checks 127
Check Diesel or Gasoline Fuel Level 127
Check LP Gas Fuel Level 127
Check Engine Oil Level 128
Check Transmission Oil Level 128
Check Transmission Filter Indicator 128
Replace Transmission Filter 129
Check Hydraulic Filter Indicator 129
Replace Hydraulic Filter 129
Check Engine Coolant Level 130
Check DEF Level 131
Drain Water from Engine Fuel/Water Separator 131
Check Hydraulic Oil Level 131
Service Tier 3/Dual-Fuel Engine Air Cleaner 131
Inspecting Air Cleaner Indicator 131
Removing Air Cleaner Elements 131
Installing Air Cleaner Elements 132
Service Tier 4F Engine Air Cleaner 132
Air Intake Restriction Monitoring (AIRM) 132
Removing Air Cleaner Elements 132
Installing Air Cleaner Elements 132
Check Tire Pressure 133
50 Hours Of Operation 133
Clean Air Cleaner Dust Cup 133
Inspect Wire Rope and Sheaves 133
Inspection 133
Lubricate Grease Fittings 134
Lubricate Boom Cable Sheaves 134
The lubrication points on the sheaves are not equipped with grease fittings and will require a grease gun adapter to accomplish the task 134
Special Tools: 134
Lubricate Inner Boom Wear Pads 134
Lubricate Side and Bottom Boom Wear Pads 135
Lubricate Parking Brake 135
Clean Heater/Air Conditioner Filter 135
100 Hours of Operation or Two Weeks 136
Inspect Engine Fan Belts 136
Check Wheel Nut Torque 136
Replace Transmission Filter 136
175 Hours of Operation 136
250 Hours of Operation or Monthly 137
Lubricate Swing Gear and Pinion 137
Lubricate Wire Rope 137
Inspect Hydraulic Hoses 137
Clean Battery and Cables 138
Clean Radiator and Oil Cooler 139
Change Diesel Engine Oil and Filter 139
Torque Critical Bolts 139
Hoist Mounting Bolts 140
Counterweight Mounting Bolts 140
Swing Gearbox Mounting Bolts 140
Mast Mounting Bolts 140
Front Axle Mounting bolts 141
500 Hours of Operation or Every Three Months 141
Inspect the Tires 141
Check Wheel Hub Lubricant Level 141
Check Axle Housing Lubricant Level 142
Lubricate Drivelines 142
Inspect the Parking Brake Pads 143
Add Grease to Swing Gearbox 143
Check Hoist Gearbox and Brake Lubricant Levels 143
Replace Fuel Filter 144
Replace Air Cleaner Element 144
Add SCA to Engine 144
Replace Fuel Filters (Diesel Engine) 144
Replace Fuel Filters (Dual-Fuel Engine) 145
Lubricate the Outrigger Slides 145
1000 Hours of Operation or Six Months 146
Replace Transmission Oil, Strainer, and Filter 146
Replace the Axle Housing Oil 147
Replace Axle Wheel Hub Oil 147
Replace Hoist Gearbox Oil 148
Replace Hoist Brake Oil 148
Replace Hydraulic Oil and Filter 149
Check Swing Gear/Pinion Backlash 150
Service Dual-Fuel Engine 150
2000 Hours of Operation or Yearly 150
Replace Engine Coolant 150
Inspect Crane Structure and Boom for Damage 151
Test RCL 151
Replace LP Gas Filter 151
Service Dual-Fuel Engine 151
Miscellaneous Maintenance 151
Batteries/Charging System 151
Checking Battery Charging System 151
Charging Battery 151
Replacing Battery 152
Fuel Storage 152
Fuse Replacement 152
Carwell® Rust Inhibitor 153
Protecting Cranes From Rusting 153
Cleaning Procedures 154
Inspection and Repair 154
Application 155
Areas of Application 155
SECTION 7 159
Adjustments 159
SECTION 8 161
Specifications 161
Lubrication 162
Lubrication Schematic 162
Lubrication Symbols 163
Lubrication Legend 163
Lubrication Notes 164
Engine Lubricants 164
General Specifications 166
Travel Speeds 167
Operating Dimensions 168
Turning Radii 170
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