MAINTENANCE CHECKS AND LUBRICATION

Model 18000

TABLE OF CONTENTS
Maintenance Checks ......................................................................................... 2
Maintenance Intervals ........................................................................................ 2
Maintenance Instructions ................................................................................... 2
Initial Run-In Services ........................................................................................ 2
Maintenance Checklist ....................................................................................... 3
General lubrication ............................................................................................. 7
Lubrication Intervals ........................................................................................... 7
Over-Lubrication ................................................................................................ 7
Lubrication Tips.................................................................................................. 7
Oil Can Points .................................................................................................... 7
Wire Rope Lubrication........................................................................................ 8
Reference Instructions ....................................................................................... 8
CraneLUBE........................................................................................................ 8
Approved Lubricants For Normal Operation....................................................... 8
Grease ........................................................................................................... 8
Open Gear Oil ................................................................................................ 8
Gear Oil.......................................................................................................... 8
Hydraulic Oil................................................................................................... 9
Hydraulic Filter Replacement ............................................................................. 9
Lubrication Points ............................................................................................ 10
Fluid Capacities ............................................................................................... 10
Approved Lubricants For Arctic Operation ....................................................... 11
Upper and Lower Lubrication Points — Location ............................................. 12
Upper and Lower Lubrication Points — Identification....................................... 16
Boom Rigging Lubrication ................................................................................ 23
Extended Upper Boom Point Lubrication ......................................................... 25
Luffing Jib Lubrication ...................................................................................... 27
#44 Luffing Jib ........................................................................................... 27
#79A Luffing Jib......................................................................................... 27
Periodic Check of Jib Stop Positioner Hydraulic Oil Level................................ 28
MAX-ER™ Lubrication ..................................................................................... 31
Automatic Lubrication System.......................................................................... 32
Operation .................................................................................................. 32
Daily Inspection ......................................................................................... 32
Automatic Lubrication System Troubleshooting ........................................ 34

© 2008 Manitowoc
Published: 06-20-2008 F2104-1
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

MAINTENANCE CHECKS
This publication contains a list of inspection and
maintenance checks and the recommended interval at
WARNING
which each check should be made. Performing the checks at
the recommended intervals will help maintain the safety, To prevent serious or fatal injury while servicing crane:
dependability, and productivity designed into your crane. • Lower all loads to ground.
NOTE: Service and maintain the engine according to the • Move all controls to off.
engine manufacturer’s instructions. • Stop engine and wait until all moving parts stop
before servicing crane.
MAINTENANCE INTERVALS Maintenance checks which require engine to be
The letters at the top of the checklist columns correspond to running are identified with a bold dot (•).
the below listed intervals. Use extreme care to avoid contact with moving
parts when servicing crane with engine running.
Perform the checks either at the hourly interval or at the
calendar interval, whichever comes first. At each interval, • Attach WARNING sign to engine start control to warn
perform all previous checks in addition to the ones listed. personnel that crane is being serviced and must not
be started.
A Every 8 Hours or Daily
• Do not operate crane until all safety guards and
B Every 40 Hours or Weekly (includes A Checks) covers are securely reinstalled and all maintenance
equipment is removed.
C Every 200 Hours or Monthly (includes A - B Checks)
Do not place crane into service until all defects are
D Every 500 Hours or Quarterly (includes A - C Checks) corrected.
E Every 1,000 Hours or Semiannually (includes A - D Checks)
NOTE: Completed checklists and repair receipts may be
F Every 2,000 Hours or Annually (includes A - E Checks) required for warranty claims. Keep these items on
The intervals are based on average operating conditions and file at all times. Give the checklists to the new
should be used only as a guide until adequate experience is owner if the crane is sold.
obtained to establish intervals which meet the specific Additional copies of this publication can be obtained
operating conditions of your crane (frequency and duration from Technical Publications Department at factory.
of operation , loa dings involved , du st y or corrosive
atmosphere, outside air temperature, etc.).
MAINTENANCE INSTRUCTIONS
Before lengthening or shortening the recommended
intervals, study the crane’s performance. Carefully examine S ee S e r vi ce M a n u al f o r sp e ci f ic ma i n te n a n ce a n d
previous checklists and service records to determine if past adjustment procedures.
component failures have been caused by inadequate See Lubrication topic in this Manual for lubrication intervals,
maintenance. types of fluids, and lube point locations.
Perform an oil analysis at regular intervals for each fluid used See Parts Manual for specific torque values of nuts, bolts,
in the crane to determine oil-change intervals. and screws.
This checklist covers 200 hours of operation (approximately
one month working one shift a day); therefore, a new INITIAL RUN-IN SERVICES
checklist must be started each time 200 hours of operation or
one month is completed. The gear boxes and pump drive must be serviced after the
first 200 hours of operation (See Lubrication in this manual).
NOTE: Depending on the options your crane has, some
checks given in this checklist may not apply. The turntable bolts must be serviced after the first 50 hours
of operation (see Turntable Bearing Adjustments in the
■ A black box in any column indicates that the item does Service Manual).
not require service at the corresponding interval.

❏
S If further service of any item is required, indicate so in
the box next to the item (for example: ‘S’ indicates
Service Required); furthermore, make a detailed report
of the type of service required (parts replacement,
adjustment, overhaul, etc.). Space is provided on at the
end of this folio for this purpose.

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MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

MAINTENANCE CHECKLIST
ENGINE HOUR METER READING:
Checkers
Initials
at Start of Checklist ______________
at End of Checklist _______________
A A A A B A A A A B A A A A B A A A A C D E F
SCHEDULE
Check for damaged or missing fiberglass covers.
Clean and check all windows for cracks.
Clean all debris from crane.
Check for leaks (fuel, coolant, gear oil, engine oil,
hydraulic oil); correct cause and fill faulty unit to
proper level.
Grease 8 hour lube points.
Apply open gear oil to ring gear.
Check pump drive oil level.
Check fuel tank level and drain water from bottom
of tank.
Check hydraulic tank level and drain water from
bottom of tank.
Check radiator coolant level when cold.
Service engine (see manufacturer’s instructions).
Check that fire extinguisher (s) is on crane and
fully charged.
Check that Operator’s Manual and Capacity
Charts are in operator’s cab.
• Check operating limit and system fault alerts for
proper operation – red and yellow lights, buzzer,
and beeper should come on for an instant when
ignition switch is moved to RUN position
(NOTE 1).
• Check seat switch for proper operation — all
control handles and corresponding functions
should be inoperable when operator is out of
seat.
• Check digital display on control console for
proper readings.
• Replace hydraulic filter elements if system fault
alert is on (oil at operating temperature) and
digital display indicates filter name.
• Check engine air cleaner service indicator.
• Check swing lock for proper operation; must
hold crane in position when engaged and allow
crane to swing when disengaged.
• Check all drum pawls for proper operation; must
fully engage and disengage ratchets. Controlled
by park switches.

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MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

ENGINE HOUR METER READING:

Checkers
Initials
at Start of Checklist ______________
at End of Checklist _______________
A A A A B A A A A B A A A A B A A A A C D E F
SCHEDULE
• Check park modes for proper operation —
control handle and corresponding function (all
drums, swing, travel) must be inoperable when
park switch is on.
• While slowly hoisting or lowering, move control
handle to off. Load must come to complete stop
and not slip through brake. Brake must hold
load in position.
• Test boom hoist brake while slowly raising or
lowering boom. Move control handle to off.
Boom must come to complete stop and not slip
through brake. Brake must hold boom in
position.
• Test travel brake while slowly traveling in either
direction. Move control handles to off. Crane
must come to complete stop and not slip
through brake. Brake must hold crane in
position.
• Check that swing holding brake holds
upperworks in position when swing control is off.
Swing handle should be inoperable.
• Test drum rotation indicators for proper
operation.
• Check Rated Capacity Indicator/Limiter for
proper operation.
• Check auto lube systems for proper operation
(crawlers and turntable bearing).
Check that boom and load hoist wire rope is
spooled properly on drums and through sheaves
before raising boom and loads from ground.
Check that jacking cylinder rods have not
extended more than one inch (25 mm). See decal
on cylinders for instructions. Check at start of each
shift and mid-way through each shift.
NOTE 1 Operating limit and system fault alerts (lights, buzzer and beeper) will stay on if a limit has been reached or a fault
exists.

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MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

SCHEDULE B B B C D E F
Grease 40 hour lube points.
Oil all pins not equipped with grease fittings.
Check battery electrolyte level.
Inspect rotating bed, carbody, and crawlers for cracks or other damage.
Check that all pins and bolts are in place and tight in rotating bed, carbody, and crawlers (see
separate checks for turntable bolts).
Check crawler treads for proper adjustment.
Inspect boom and mast for cracked or deformed members.
Check that all boom and mast pins and bolts are in place and tight.
Inspect all sheaves for wear and damage.
Inspect all wire rope for broken wires or excessive wear and for proper spooling on drums
and reeving through sheaves; lubricate wire rope if needed.
Inspect each hook for cracks or deformation.
Clean breathers on applicable gear boxes and on pump drive.
• Test all disc brakes (load drums, boom hoist, swing, travel) for proper operation.
• Test each limit device for proper operation:
Boom up limit.
Boom down limit.
Minimum bail limit.
Maximum bail limit.
Block-Up limit.
Any other limit crane is equipped with.

Grease 200 hour lube points.

Check level of each gear box.
Inspect air cleaner.
Engage and disengage engine clutch several times with engine running to clean discs.
Inspect all hydraulic hoses and tubes for abrasion, swelling, kinking, cracks, and other damage.
Inspect all electrical harnesses and cables for abrasion, cracks, or other damage.
Inspect CAN nodes and junction boxes for corrosion, loose connectors, and loose mounting hardware.

Check tension of V-belts (see Engine Manual).

Service battery (clean and inspect).

Grease 1,000 hour lube points.

Drain and refill each gear box.
Drain and refill hydraulic system.
Replace hydraulic filter elements.
Drain and refill cooling system.
Drain and refill pump drive.

Torque turntable bolts.

Perform magnetic particle or other suitable crack detecting inspection for each hook.
Check Rated Capacity Indicator/Limiter for proper calibration.
Replace hydraulic hoses after 4,000 to 8,000 hours as recommended in Service Manual.
Replace electrical harnesses and cables after 8,000 to 10,000 hours as recommended in Service Manual.

F2104-5
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

NOTES

F2104-6
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

LUBRICATION SYMBOLS frequent or long operating cycles) may require shortening

the lubrication intervals. Follow the intervals given in this
The following symbols are used in decals on the crane to Lubrication Guide until adequate experience is obtained to
identify lubrication points. establish intervals which meet your operating conditions.
Bearings and bushings that are too warm, excessive play in
Hydraulic moving parts, binding in moving parts, excessive or
Engine Oil
Filter abnormal wear in gears and chains, and rust accumulation
Level
indicate a lack of lubrication. If these conditions are found
Hydraulic Pump Drive during regular inspection, the lubrication interval for the
Oil Oil Level faulty parts should be shortened.

Engine Diesel
Coolant Fuel
CAUTION
Machinery Damage!
FIGURE 1
Before lengthening lubrication intervals, check that all
parts are receiving an adequate supply of clean lubricant;
GENERAL LUBRICATION o th e r w is e , pa r ts wi ll b e da m a ge d f r o m a la ck o f
lubrication. C ontact your Manitow oc Cra ne Care
distributor or for recommendations on lengthening
lubrication intervals.
WARNING
Personal Injury Hazard! OVER-LUBRICATION
Personal injury can occur if safety precautions which Over-lubrication is not only wasteful but also harmful:
follow are not taken before and after servicing machinery.
• Excess lubrication can work its way onto friction
• Stop engine and wait until all moving parts have surfaces and result in faulty operation.
completely stopped (if necessary, position any grease
• Oil or grease which drips onto walkways can cause
fittings on moving parts at access point; then stop
personnel to slip and be hurt.
engine).
• Attach WARNING “out-of-order” sign to engine start • Too high an oil level can cause churning and foaming of
control in operator’s cab to warn all personnel that the oil and result in excessive heat and over-flow from
crane is being serviced. the reservoir.

• Do not operate crane until all safety guards and • An extra shot of grease, if too stiff or under too much
covers have been securely reinstalled and all pressure, can pop out a bearing seal.
maintenance equipment has been removed.
LUBRICATION TIPS
This section describes the major lubrication considerations
• Check all oil levels before start-up so the oil has had a
for this crane. Some points requiring lubrication (linkage in
chance to run down from the reservoir walls and moving
control members not equipped with grease fittings) have
parts.
been omitted, but they should be lubricated in accordance
with good maintenance practices (see Oil Can Points). • Avoid introducing dirt into reservoirs. Carefully clean the
area around dipsticks, level plugs, fill plugs, and
The lubrication intervals for vendor-supplied parts (engine,
breathers before removing.
light plant, etc.) have also been omitted from this Lubrication
Guide; service vendor-supplied parts according to the • Replace level plugs, fill plugs, drain plugs, and breathers
“original equipment manufacturers’ manuals.” snugly and wipe up any spillage.
Depending on the options your crane is equipped with, some • Keep oil and grease dispensers and containers tightly
lube points given in this Lubrication Guide may not apply to closed and stored in a dirt and moisture-free locations.
your crane.
• Clean grease fittings before and after applying grease.

LUBRICATION INTERVALS • Apply grease until the bushing or bearing is purged so

dirt and water cannot enter. Wipe up excess grease.
The intervals listed in this Lubrication Guide are for “average
operating conditions” based on experience gained by testing
OIL CAN POINTS
lubricants at the factory and on recommendations given by
the lubricant suppliers. Severe operating conditions Oil all pins not equipped with grease fittings with engine oil
(excessively dusty or corrosive atmosphere, unusually high every 40 hours of operation (even if the crane is not being
or low outside temperature, extreme loadings, uncommonly operated).

F2104-7
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

WIRE ROPE LUBRICATION between wires and strands. This buildup will inhibit rope
inspection and could trap moisture in rope’s interior.
New wire rope is lubricated during manufacturing, but this
lubricant is only adequate for initial storage and the early
REFERENCE INSTRUCTIONS
stages of operation. To prevent the damaging effects of
corrosion and to reduce wear, the wire rope must be See Crane Service Manual for detailed information on
lubricated at regular intervals. specific maintenance checks and procedure.
Contact your wire rope manufacturer/dealer for lubrication
recommendations. The lubrication interval and the type of CraneLUBE
lubricant used depends on the type of wire rope, the severity Manitowoc highly recommends the use of CraneLUBE
of duty, and the type of corrosive elements the wire ropes is l u b ri c a n ts t o i n c re a s e y o u r cr a n e ’s r e l i a b i l i t y a n d
subjected to. pe rf orma nce. C on tact yo ur Ma nit ow oc C rane C are
The wire rope must be properly protected at all times. The distributor for detailed information about our CraneLUBE
lubricant must be fluid enough to fully penetrate the strands lubrication program.
and rope core. Use one of the methods shown in Figure 2 to
lubricate the wire rope. For maximum penetration, apply APPROVED LUBRICANTS FOR NORMAL
lubricant where the wire rope “opens up” as it travels around OPERATION
a sheave or winds onto a drum.
Grease
Casing Filled with
Table 1 Grease
Swab and Lubricant.
Turntable Bearing Temperature
Application
and Crawlers Range
CraneLUBE XHP 0°F (-18°C) Automatic Lubrication
320 Mine and above Systems *
Pouring onto Slow
Moving Sheave.
CraneLUBE XHP 0°F (-18°C)
Manual Lubrication
322 Mine and above
*CraneLUBE XHP 321 Mine can be used for automatic
lubrication systems in temperatures 40°F (4°C) and above.
Other Grease Temperature
Application
Points Range
Bathing
0°F (-18°C) All Other Grease
CraneLUBE E.P. # 2
and above Points

NOTE For all operation below 0°F (-18°C) use arctic

Brushing grease specified in Approved Lubricants for Arctic
Operation topic in this section.

Hand Open Gear Oil

Swabbing
This type oil requires heating or thinning for proper
S139 application to gear teeth. Apply a light film of oil to each gear
tooth; do not rely on gear rotation to distribute oil.

WARNING • CraneLUBE NC.

Moving Rope Hazard! Gear Oil
Take every precaution to protect hands from injury
when rope is moving. Wear heavy gloves and move • CraneLUBE 75W-90 for all gear boxes, except crawler
rope as slowly as possible. output gear boxes.
• CraneLUBE 80W-140 for crawler output gear boxes.
FIGURE 2

The wire rope must be clean and dry before applying

lubricant; an air jet, or wire brush are some cleaning
methods.
Do not use grease to lubricate wire rope. Grease will not
penetrate rope properly and will buildup in valleys

F2104-8
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

Table 2 Gear Oil maximum of 25% with little effect on the oil’s low and high
temperature characteristics.
Ambient
SAE Grade None of the oils listed in the table have the same operating
Temperature Gear Boxes Used In
Gear Oil
Range limits as Flomite. Therefore, dilution beyond the 25%
maximum could effect the crane’s operating performance at
Drums, Swing, Boom Hoist,
Below -10°F certain temperatures.
75W-90 * Luffing Hoist, Crawler Input,
(-23°C)
Rigging Winch If you are in doubt about how much make-up oil has been
All Temperatures added, we recommend that a laboratory viscosity test be
75W-90 * Pump Drive performed or that the system be completely drained and
to 100°F (38°C)
refilled.
Drums, Swing, Boom Hoist,
-10°F to 100°F
80W-90 Luffing Hoist, Crawler Input, Table 4 Make-Up Oils Compatible with Benz Oil Flomite
(-23°C to 38°C)
Rigging Winch 46SS
Drums, Swing, Boom Hoist,
Above 100°F Brand Summer Oil Winter Oil
80W-140 Luffing Hoist, Crawler Input,
(38°C)
Rigging Winch, Pump Drive Amoco 1000 Fluid None Available
80W-140 All Temperatures Crawler Output Exxon Torque Fluid 56 Univis J13
Mobil Mobilfluid 424 Aero HFA
Hydraulic Oil
Shell Donax TD Aeroshell Fluid 4
• Benz Oil Flomite 46SS (MCC #549433)
Texaco THD Oil Rando HD Z-15 HV-1
Filter new oil through a 10 micron portable filter.

Table 3 Hydraulic Oil HYDRAULIC FILTER REPLACEMENT

ISO Grade The hydraulic filter elements on this crane are specially
Hydraulic Ambient Temperature Range designed to withstand high pressure as the elements fill with
Oil dirt. This feature prevents the elements from collapsing.

15 -30°F to 30°F (-34°C to -1°C) See Table 5 for the Manitowoc part numbers of replacement
filter elements. See lubrication charts in this section for
32 -10°F to 60°F (-23°C to 16°C) identification and location of the filter elements.
46 0°F to 85°F (-18°C to 29°C)
Table 5 Replacement Filter Elements
68 10°F to 110°F (-12°C to 43°C)
MCC No. System
100 30°F to 120°F (-1°C to 49°C)
A00652 Charge Pumps and In-Tank Return
Flomite is an all-weather hydraulic oil suitable for use in
ambient temperatures from 0 – 110°F (-18 – 43°C).
Flomite can cloud up (form wax crystals) at ambient CAUTION
temperatures below 0°F (-18°C). This condition can result in Hydraulic System Damage!
damage to hydraulic components during start-up.
Original Equipment Manufacturers’ filter elements –
When the expected ambient temperature will be below 0°F available from Manitowoc – must be used on this crane.
(-18°C), the hydraulic oil must be heated to at least 0°F Substituting with any other brand or type filter element is
(-18°C) prior to start-up. Tank heaters are available from prohibited.
Manitowoc Cranes. An alternative to heating the oil is to Filter elements made by other manufacturers may
change to an ISO grade oil which meets the expected collapse under pressure. This action will allow unfiltered
ambient temperatures given in Table 3). oil to be drawn into hydraulic system — pumps, motors,
Cloud point of oil selected must be equal to or less than and valves can be destroyed.
expected ambient temperature. Manitowoc will reject warranty claims for damaged
hydraulic components if proper hydraulic filter elements
Field Make-Up are not used.
Table 4 lists hydraulic oils compatible with Benz Oil Flomite
46SS. Flomite can be diluted with an oil from the table to a

F2104-9
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

LUBRICATION POINTS • M = Monthly

• See Figure 3 through Figure 6 for location of the • Q = Quarterly

lubrication points for crane. • S = Semiannually
• See Figure 7 for location of the lubrication points for the • O = At Overhaul
boom.
• Y = Yearly
The letters before the item numbers in the illustrations
correspond to the following intervals:
FLUID CAPACITIES
• A = At Assembly
Fluid capacities are approximate and should be used only as
• D = Daily a guide for ordering sufficient fluid at oil change intervals.
Always fill each system to level plug opening or to
• W = Weekly
specified point on sight gauge or dipstick.

Capacity Approved
System
Gallons Liters Lubricant

Cooling System 21 79 See NOTE 1

Crawler Input Gearbox (each) 4.5 17 Gear Oil
Crawler Output Gearbox (each) 30 114 Gear Oil
Crawler Grease Reservoir 1 4 Grease
Drum 1 (Main Load Hoist) 27 102 Gear Oil
Drum 2 (Main Load Hoist) 27 102 Gear Oil
Drum 3 (Whip Load Hoist) 20 76 Gear Oil
Drum 4 (Boom Hoist) 25 95 Gear Oil
Drum 5 (Mast Hoist) 5 19 Gear Oil
Drum 6 (Luffing Hoist) 13 49 Gear Oil
Fuel 275 1 041 See NOTE 1
Hydraulic Tank 270 1 022 Hydraulic Oil
Pump Drive (without circulating oil system) 2.25 8.5 Gear Oil
Pump Drive (with circulating oil system) 3.5 13 Gear Oil
Swing 5.5 21 Gear Oil
Turntable Bearing Grease Reservoir 1 4 Grease

NOTE 1 See engine manual for fuel, antifreeze, and

engine oil specifications.
NOTE 2 Brake housings for swing, boom hoist, and load
drums are filled automatically with oil from gear
boxes.
Brake housings for crawlers are flushed with oil
from hydraulic system.

F2104-10
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

APPROVED LUBRICANTS FOR ARCTIC

OPERATION CAUTION
The lubricants listed in Table 6 are recommended for use in Hydraulic Pump Damage!
Manitowoc’s line of hydraulic cranes when operating in an To prevent damage to hydraulic pumps, warm hydraulic
arctic-type climate — outside temperature continuously oil to at least 60°F (16°C) before operating crane
0°F (-18°C) to -40°F (-40°C). functions during arctic-type conditions.
Use these lubricants in place of the lubricants listed for Structural Damage!
normal operation in this section. Cold weather can affect structural integrity of crane and
Additionally, the crane should be equipped with the hydraulic attachment. Before operating in cold weather, read
tanks heaters available from Manitowoc. Preparation for Cold Weather - Crane Limitations in Crane
Operator’s Manual.

CAUTION
Machinery Damage!
Do not operate main crane functions (swing, travel,
drums, boom hoist) with approved arctic lubricants when
ambient temperature is above 60°F (16°C). Crane
machinery will be damaged.
When ambient temperature is above 60°F (16°C), limit
operation to crane setup functions (i.e. jacking cylinders).
Switch back to standard lubricants listed in lubrication
guide when ambient temperature will be above 60°F
(16°C).

Table 6 Lubricant for Arctic Operation

System Approved Arctic Lubricants

Grease Points Chevron RPM Arctic Grease NLGI 1
All Gear Cases, Pump Drives, and Gear Boxes Mobil SHC 626
Hydraulic System Petro-Canada Hydrex XV
Duron XL Synthetic 0W-30
Engine Oil System (see NOTE) OR
Mobil Delvac 1
Engine Fuel (see NOTE) No. 1 Diesel
Engine Cooling System (see NOTE) Mix anti-freeze (Ethylene Glycol) and water 60/40 by volume.
This mixture will provide coolant protection to -65°F (-54°C).
Pure antifreeze freezes at -10°F (-23°C).
NOTE See engine manufacturer’s manual for specifications and cold weather operating guidelines.

F2104-11
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

UPPER AND LOWER LUBRICATION POINTS — LOCATION

A1
P1917
A2

D1

W1

P1800 A05614
P1081b

Typical:
• 4 Places in Carbody for Crawlers
• Both Mast Hinge Pins
• Both Front Rotating Bed Pins

D9

2 Places at Front
of Adapter Frame D2

D4
D10

P1918

D8 4-115

D3
P1905

P1908
D7 P1907 P1906
D6 D5

S1 FIGURE 3

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MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

W2 Left End Drum 5 W3

M11

M10

P1930a
P1919

M2
P1812
M1 S2
S4
W4
M12

P1916

Right End Drum 5

P1920
W5 M15

Filter 1 Filter 2

M13

M14

4-115 P1915

M3
S3
P1912a

D18
S5
S6 D17 W8
S6 D15

Filter 8
D19
Inside
D16b Hydraulic Tank
P1910

D16a

P1911 P2228
Filters 4 Left Side of Rotating Bed FIGURE 4

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MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

D21
P1818b
W6

P1807
M4
S7

P2327
Current Production
S7a

D20 P1807c

D20
P1807

Current Production
Past Production
S7b
P2328 4-115

Current Production pump drives

have a circulating oil system.

Spring
P2328a Element

Current Production Y-Fitting

Plug
FIGURE 5

F2104-14
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

M18

Typical View:
• Left End Drum 3 in Crane
• Right End Drums 1, 2, 6 in Boom Butt
• Right End Drum 4 in Mast

M17

M16

P1921
M18
Right End Drum 3

M5
M13
S81

P1950
S82 P1926

M19 Past Production On Top

W7 M22 M21

P1922
4-115
M7 M8 P1817
M19 M19
S11 S12
Current Production
On Bottom

M20
M6
S9
P1687
P1914
Q1
S10

P1939

FIGURE 6

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MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

UPPER AND LOWER LUBRICATION POINTS — IDENTIFICATION

Item Description Required Service

Prior to Use When Crane is Assembled
A1 Self-Erect Connecting Pins: Grease each only with cylinders retracted.
• Upperworks (1 fitting, 4 places)
• Crawlers (1 fitting, 4 places)
A2 Carbody Pedestal (1 fitting, 4 places) Grease each only with jack screw fully retracted.
Every 8 Hours of Operation or Daily (whichever comes first)
D1 Ring Gear Check for proper lubrication; coat with open gear oil if needed.
D2 Grease Reservoir (2 places at front of adapter Check reservoir level. Fill to proper level with approved grease
frame; 1 for crawlers and 1 for turntable bearing) (see NOTE 1).
D3 Fuel Level Gauge Check level; fill to high mark (see NOTE 2).
D4 Fuel Tank Fill Cap Fill to proper level with fuel oil.
D5 Fuel Tank Drain Valve Drain water (see NOTE 3).
D6 Hydraulic Tank Drain Valve Drain water (see NOTE 3).
D7 Radiator Sight Gauge Check level; should be at full cold mark (see NOTE 4).
D8 Radiator Fill Cap Fill to proper level with coolant.
D9 Air Cleaner Service Indicator Check; replace element when indicated.
D10 Engine Service according to manufacturer’s instructions.
Items D11-D14 Not Used

NOTE 1 Fill through fitting in base of reservoir using a

hand-operated grease gun or pump. Refill
reservoir when grease reaches MIN mark. Fill
reservoir to MAX mark.
Crawlers and turntable bearing are greased
automatically by electric pumps when ignition
switch is on.
NOTE 2 Monitor fuel level on display in operator’s cab.
NOTE 3 Drain any accumulated water from fuel and
hydraulic tanks at start of each work day.
Crack open drain valves. Securely close drain
valves as soon as water stops draining and a
steady stream of fuel or hydraulic oil appears.
NOTE 4 Check coolant level when coolant is cold.

F2104-16
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

Item Description Required Service

Every 8 Hours of Operation or Daily Continued
D15 Hydraulic Tank Sight Gauge Check level (see NOTE 1).
Fill to proper level with hydraulic oil through power fill
D16a Hydraulic Tank Fill
coupler (NOTE 2).
Fill to proper level with hydraulic oil through stand pipe
D16b Hydraulic Tank Fill
(NOTE 2).
D17 Hydraulic Tank Return Filter (2 each mounted in tank) Replace BOTH elements when indicated and at each
oil change interval (NOTE 3).
D18 Hydraulic Charge Filter (2) Replace specified element when indicated and at each
oil change interval (NOTE 3).
D19 Suction Filter (2 each inside hydraulic tank) Clean BOTH when indicated and at each oil change
interval (NOTE 4).
D20 Pump Drive Sight Gauge or Dipstick Check level. Oil should be at middle of gauge or at full
mark on dipstick.
D21 Pump Drive Fill Plug/Breather Fill to proper level with gear oil.

NOTE 1 Check hydraulic oil level when oil is cold and filters). See Section 2 in the Service Manual for
upperworks jacking cylinders are retracted. filter replacement procedure.
Fill tank to FULL COLD mark on decal. System
It is normal for system fault alert to come on at
fault alert in operator’s cab will come on when
start-up when hydraulic oil is cold. Alert should
hydraulic oil is at an unsafe level; Fill Tank
shut off as oil warms up.
Immediately.
NOTE 4 Clean both filters when system fault alert (yellow
light and buzzer) comes on and digital display
reads FILTER 8 (must drain tank).
WARNING
Burn Hazard!
Oil in hydraulic tan k may be under pressure and
extremely hot.
Hot oil can escape when you remove stand pipe plug,
either filter cover, or breather.
RELIEVE PRESSURE through air valve on side of
hydraulic tank before servicing.

NOTE 2 Fill tank through power fill coupler (D16a) or

through stand pipe (D16b).
When adding hydraulic fluid RELIEVE
PR ES SU RE t hr o ug h a ir v alve on si de o f
hydraulic tank before servicing.
Do not fill tank through top of either filter or
through breather port. See Service Manual
Section 2 for fill procedure.
NOTE 3 Replace corresponding filter element when
system fault alert (yellow light and buzzer)
comes on and digital display reads FILTER 1 or
FILTER 2 (charge filter) or FILTER 4 (return

F2104-17
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

Item Description Required Service

Every 40 Hours of Operation or Weekly (whichever comes first)
W1 Swing Shaft Bearing (1 fitting, 4 places) Grease each.
W2 Drum 5 Gear Box Breather Clean (see NOTE 1).
W3 Swing Gear Box Fill Cap/Breather (4 places) Clean each (see NOTE 1).
W4 Drum Pawl and Cam (each drum so equipped) Apply open gear oil to sliding surfaces.
W5 Batteries Check electrolyte level.
W6 Pump Drive Fill Cap/Breather Clean (see NOTE 1).
W7 Crawler Input Gear Box Breather (1 each crawler) Clean each (see NOTE 1).
W8 Hydraulic Tank Breather Clean (see NOTE 1 and NOTE 2).

NOTE 1 Soak breathers in non-flammable solvent and

blow dry with compressed air. For hydraulic tank,
this service applies only to the past production
metal-type breather.
NOTE 2 Hydraulic tank on current production cranes has
a desiccant breather. The breather does not
require servicing until indicated.
Inspect desiccant breather weekly. Replace
cartrid ge w ith a ne w on e w he n all of th e
desiccant beads turn dark green (they are gold
when new).
P2348

Desiccant
Beads

Service
Indicator

Current Production
Desiccant Breather

F2104-18
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

Item Description Required Service

After First 200 Hours of Operation
(see NOTE 1)
M1 Drum 5 Brake Drain Plug (lowest outermost plug) Drain with Drum 5 (refilled by Drum 5 gear box).
M2 Swing Gear Box Drain Plug (4 places) Drain and refill each with gear oil.
M3 Drum 5 Gear Box Drain Plug Drain and refill with gear oil (see NOTE 2).
M4 Pump Drive Drain Plug Drain and refill with gear oil.
M5 Drum Gear Box Drain Valve (Drums 1-4 and 6) Drain and refill each with gear oil.
M6 Crawler Output Gear Box Drain Plug (1 each crawler) Drain and refill each with gear oil.
M7 Crawler Input Gear Box Drain Plug (1 each crawler) Drain and refill each with gear oil.
M8 Crawler Brake Drain Plugs Drain each with input gear box (refilled by hydraulic
(lowest outermost plug) (2 each crawler) system).
Item M9 Not Used

NOTE 1 Service after first 200 hours of operation is NOTE 2 Rotate drum so drain and fill plugs are located
required to remove metal particles and other on vertical center line of drum and level plug is
impurities collected during initial run-in of gear located toward rear of crane on horizontal center
boxes. line of drum.

F2104-19
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

Item Description Required Service

Every 200 Hours of Operation or Monthly (whichever comes first)
M10 Swing Gear Box Level Plug (4 places) Check level; should be up to plug opening.
M11 Swing Gear Box Fill Plug (4 places) Fill each to proper level with gear oil.
M12 Drum Pawl Pin (1 fitting each drum so equipped) Grease each 1/2 shot.
M13 Drum Journal Bearing (1 fitting Drum 3 and 5) Grease each.
M14 Drum 5 Gear Box Level Plug Check level; should be up to plug opening (see NOTE 1).
M15 Drum 5 Gear Box Fill Plug Fill to proper level with gear oil.
M16 Drum Gear Box Sight Gauge (Drums 1-4 and 6) Check level; should be at middle of gauge.
(see NOTE 2)
M17 Drum Gear Box Fill Plug (Drums 1-4 and 6) Fill each to proper level with gear oil.
M18 Cab Support Grease Fittings (2 fittings) Grease each 1/2 shot.
M19 Engine Clutch Lever and Bearing (3 fittings) Past production – Grease each (2 left side, 1 right side).
Current production – Grease 1 each side and 1 on bottom.
M20 Crawler Output Gear Box Fill/Level Plug (1 each Check level; oil should be up to plug opening. Fill each as
crawler) required with gear oil.
M21 Crawler Input Gear Box Level Gauge (1 each crawler) Check level; should be at middle of gauge.
M22 Crawler Input Gear Box Fill Plug (1 each crawler) Fill each to proper level with gear oil.

NOTE 1 Rotate drum so drain and fill plugs are located • CHECK LEVEL of drums 1, 2, 4, and 6 using
on vertical center line of drum and level plug is drain pipe S82. Rotate drum so drain pipe S82
located toward front of crane on horizontal is horizontal. Oil should be up to drain pipe
center line of drum. opening. If required, add oil to drum through
NOTE 2 Check level of drums 1, 2, 4, and 6 using plugs drain valve S81.
M16 and M17 with drums in horizontal position
• DRAIN drums 1, 2, 4, and 6 using drain pipe
prior to raising mast and boom each time crane
is assembled. S82. Rotate drum so drain pipe S82 is
VERTICAL.
During operation with mast and boom raised:

Item Description Required Service

Every 500 Hours of Operation or Quarterly (whichever comes first)
Q1 Crawler Drive Shafts (4 fittings both crawlers) Grease (see Note 1).

NOTE 1 See manufacturer’s instructions for proper

greasing.
Must slide guards clear of drive shafts to expose
grease fittings. Be sure to securely reattach
ends of guards in operating position after
greasing.

F2104-20
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

Item Description Required Service

Every 1,000 Hours of Operation or Semiannually (whichever comes first)
S1 Hydraulic Tank Drain Valve Drain and refill with hydraulic oil.
S2 Swing Gear Box Drain Plug (4 places) Drain and refill each with gear oil.
S3 Drum 5 Gear Box Drain Plug Drain and refill with gear oil (see NOTE 1).
S4 Drum 5 Brake Drain Plug (lowest outermost plug) Drain with Drum 5 gear box (refilled by Drum 5 gear box).
S5 Hydraulic Tank Breather Replace element or entire breather (see NOTE 2).
S6 Hydraulic Filters (four) Replace elements when indicated on screen.
S7 Pump Drive Drain Plug Drain and refill with gear oil.
S7a Pump Drive Oil Cooler Thoroughly pressure clean fins. Make sure there are not
obstructions to air flow.
S7b Pump Drive Oil Filter Replace.
S81 Load Drum Gear Box Primary Drain Valve Drain and refill each with gear oil.
(Drums 1-4 and 6) (see NOTE 3).

S82 Load Drum Gear Box Secondary Drain Valve Drain. This drain drains remaining oil from bottom of drum
(Drums 1-4 and 6) barrel.
S9 Crawler Gear Box Drain Plug (2 places) Drain and refill each with gear oil.
S10 Radiator Drain Valve Drain and refill with coolant.
S11 Crawler Input Gear Box Drain Plug (1 each crawler) Drain and refill each with gear oil.
S12 Crawler Brake Drain Plug Drain each with input gear box (refilled by hydraulic
(lowest outermost plug) (2 each crawler) system).

NOTE 1 Rotate drum so drain and fill plugs are located

on vertical center line of drum and level plug is
located toward front of crane on horizontal
center line of drum.
NOTE 2 This service applies only to the past production
metal-type breather. For current production
desiccant breather, see page 18.
NOTE 3 Lower boom so Drums 1, 2, and 6 are horizontal
when changing oil.
For Drum 4 when mast is raised:

• DRAIN Drum 4 using drain pipe S82. Rotate

drum so drain pipe S82 is vertical.

• FILL Drum 4 through drain valve S81. Rotate

drum so drain pipe S82 is horizontal. Oil should
be up to drain pipe opening.

F2104-21
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

* M2

W1

W3

W2
Plastic
Plug
Y1

Drum
Seal

A3 Y1

D2

A4

A2

M1
5-102

* A1

A2

1-100 D1

FIGURE 7

F2104-22
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

BOOM RIGGING LUBRICATION

Item Description Required Service

Prior to Use When Crane is Assembled
A1 Fixed Mast Self-Erect Connecting Pin (1 fitting, 2 places) Grease each only with cylinders retracted.
A2 Boom Butt Fleeting Sheaves (Rigging Winch) Grease each. Make sure entire length of both shafts
are coated with grease.

If equipped, roller in luffing jib strut and sheave in

luffing butt do not require lubrication.
A3 Rigging Winch Bearing Grease until grease seeps out drum seal.
A4 Rigging Winch Inspect for oil leaks prior to using. If found, repair
and refill unit with gear oil.
Every 8 Hours of Operation or Daily (whichever comes first)
D1 Boom Hinge Pin (1 fitting, 2 places) Grease each.
D2 Wire Rope Guide Sheave (1 fitting each) Grease each.
Every 40 Hours of Operation or Weekly (whichever comes first)
W1 Load Block Sheaves (1 fitting, each sheave) Grease each.
W2 Hook Swivel and Trunnion Bearings Grease.
W3 Weight Ball Swivel (not shown) Grease.
Every 200 Hours of Operation or Monthly (whichever comes first)
M1 Live Mast Cylinder Ends (2 fittings each cylinder) Grease each.
M2 Block-Up Limit Switch (1 fitting inside each switch) Grease each.
Every 2,000 Hours of Operation or Yearly (whichever comes first)
Y1 Rigging Winch Drain and refill with 17 oz (0,5 L) of gear oil.
Wire rope must be removed before drum can be
drained.
• Remove plastic plug and drain plug from bottom
of drum barrel to drain oil. Securely reinstall
plugs.
• Remove plastic plug and fill plug from top of
drum barrel to add oil. Securely reinstall plugs.
Sheaves in locations marked with an asterisk (*) do not require greasing at regular intervals. Repack these
* sheaves with grease when sheaves are overhauled.

F2104-23
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

A1
* M1

M1

W1

W1

W1
W2

W3

F2104-24
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

EXTENDED UPPER BOOM POINT LUBRICATION

Item Description Required Service

Prior to Use When Crane is Assembled
A1 Extended Upper Point Rollers (1 fitting each end of shaft) Grease prior to raising boom.
Every 40 Hours of Operation or Weekly (whichever comes first)
W1 Swivel (1 fitting each) Grease each.
W2 Load Block Sheaves (1 fitting, each sheave) Grease each.
W3 Hook Swivel and Trunnion Bearings Grease.
Every 200 Hours of Operation or Monthly (whichever comes first)
M1 Block-Up Limit Switch (1 fitting inside each switch) Grease each.
Sheaves in locations marked with an asterisk (*) do not require greasing at regular intervals. Repack these
* sheaves with grease when sheaves are overhauled.

F2104-25
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

* 6
#44 Luffing Jib
5

1 or
2 and 3
CAUTION
Parts Damage! * 8
2 and 3
If luffing jib is to be operated when air temperature is
below 32°F (0°C), drain and refill hydraulic systems
(crane and boom) with Petro Canada Premium Plus
hydraulic oil (MCC #549318). Be sure that jib strut 7
cylinders and supply lines are completely drained
before refilling.
* *
9
For operation below 10°F (-12°C) use a thinner fluid
such as Petro Canada Premium Arctic 15 (MCC
#A03745).

Luffing Hoist Top Wire

* Rope Guide Sheave

#79A Luffing Jib *

Optional Remote Fitting
5-100
at Base of Boom Butt
5-101
5
1 or
2 and 3
9
* 2 and 3

*
P1378

8
4 Places

7
P2147

10

Luffing Hoist
Top Wire Rope
* Guide Sheave
4

Optional Remote Fitting Jib Point Dolly

5-102 at Base of Boom Butt
FIGURE 8

F2104-26
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

LUFFING JIB LUBRICATION

#44 Luffing Jib

Item Description Required Service (see NOTE)

Every 40 Hours or Weekly (whichever comes first)
1 Weight Ball Swivel Grease.
2 Load Block Sheaves Grease if equipped with fittings.
3 Load Block Trunnion/Swivel Grease if equipped with fittings.
4 Bottom Wire Rope Guide Sheave Grease.
Every 200 Hours of Operation or Monthly (whichever comes first)
5 Block-Up Limit Switch (1 fitting inside each switch) Grease each.
Each Time Boom and Luffing Jib are Lowered to Ground
6 Luffing Jib Wheels (2 places) Grease each.
7 Luffing Jib Hinge Pins (2 places) Grease each.
8 Jib Strut Hinge Pin (2 places) Grease each.
9 Main Strut Hinge Pin (2 places) Grease each.

NOTE: Sheaves marked with an asterisk (*) have sealed

bearings and do not require periodic lubrication.
Repack sheave bearings with grease at overhaul.

#79A Luffing Jib

Item Description Required Service (see NOTE)

Every 40 Hours or Weekly (whichever comes first)
1 Weight Ball Swivel Grease.
2 Load Block Sheaves Grease if equipped with fittings.
3 Load Block Trunnion/Swivel Grease if equipped with fittings.
4 Bottom Wire Rope Guide Sheave Grease.
Every 200 Hours of Operation or Monthly (whichever comes first)
5 Block-Up Limit Switch (1 fitting inside each switch) Grease each.
Each Time Boom and Luffing Jib are Lowered to Ground
6 Jib Stop Positioner Cylinder Trunnion Grease 1 fitting, 2 places.
7 Jib Hinge Pins (2 places) Grease each (in legs of butt).
8 Wheel Hub Sight Glass Check level.
Fill to FULL ring in sight glass with same gear oil used in
9 Wheel Hub Fill Plug
drum planetaries on crane.
Once Yearly
See Periodic Check of Jib Stop Positioner Hydraulic Oil
10 Jib Stop Positioner Hydraulic System
Level in this section.

NOTE: Sheaves marked with an asterisk (*) have sealed

bearings and do not require periodic lubrication.
Repack sheave bearings with grease at overhaul.

F2104-27
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

PERIODIC CHECK OF JIB STOP 5. Stroke pump handle (4) back and forth until positioner
POSITIONER HYDRAULIC OIL LEVEL cylinders (9) are fully extended.
6. Remove dipstick (3) slowly to vent pressure in tank.
This procedure applies to the #79A Luffing Jib.
7. Wipe dipstick (3) clean and reinstall so it rests on tank
Perform the following procedure ONCE YEARLY when the
fitting for proper oil level check.
attachment is on the ground. See Figure 9.
8. Remove dipstick (3). Oil should be at top mark on
NOTE: It is normal for jib stop positioner cylinders (9) to dipstick.
extend (if retracted) when engine is stopped.
If necessary remove fill plug (2) and fill tank though fill
1. Stop engine. port with pre-filtered Arctic 15 hydraulic oil (MCC
2. Unlatch safety latches (8) with hand winch in jib top. #A03745).
3. Loosen lock nut (10) and slowly turn valve screw (11) If oi l le vel i s m ore th an 1- 2 cu ps of o il l ow,
counterclockwise to transfer oil from accumulator (5) to thoroughly inspect system for oil leaks. Repair as
hydraulic tank (1). required.
Positioner cylinders (9) will fully retract (jib stops lower) 9. Move pump handle (4) back and forth until oil level is at
when this step is performed. low mark on dipstick. Gauge reading must be 2,450 -
2,500 psi (169 - 172 bar).
4. Once cylinders are retracted, turn valve screw (11) fully
clockwise and tighten lock nut (10). 10. Apply hydraulic thread sealant to threads and securely
reinstall dipstick (3) and fill plug (2).
11 10

3 2

1
5

5-103
6 Right Side of Boom Top
P2150

Item Description
1 Hydraulic Tank
2 Fill Plug
3 Dipstick
4 Pump Handle
5 Accumulator
6 Pressure Gauge
7 Jib Stop
8 Safety Latch
8 9 Positioner Cylinder
10 Lock Nut
11 Valve Screw

9
Both sides of Boom Top P2149 FIGURE 9

F2104-28
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

THIS PAGE BLANK

F2104-29
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

18000MOM501
MAX-ER

W1 W1 W1

Hanging Version

W3
W1
W1 W1

Both Sides of
W3 Counterweight Carrier
40 ft (12.2 m) Radius

W5 W5

B1 B1

W4 W4

M1 M1

W2 M1 W2
Wheeled Version

FIGURE 10

F2104-30
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

MAX-ER™ LUBRICATION

Item Description Required Service (See Note)

Every 40 Hours or Weekly (whichever comes first)
W1 Cylinder Trunnions Grease 1 fitting, 4 places.
W2 Axle Pivot Pins Grease 2 fittings, each pin.
W3 Strut Bearings Grease 4 fittings.
W4 Ring Gears Inspect. Coat with open gear oil, as required.
W5 Wheel Locks Grease 1 fitting, 2 places.
Every 80 Hours or Bi-Weekly (whichever comes first)
B1 Turntable Bearings Grease 20 fittings each bearing.
Every 200 Hours or Monthly (whichever comes first)
M1 Wheel Bearings Grease 1 fitting each end of each axle.

NOTE: This section identifies only those parts of the MAX-

ER Attachment that require lubrication.

F2104-31
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

AUTOMATIC LUBRICATION SYSTEM 1. Check grease level in each reservoir.

The crane has two grease systems which automatically 2. Check and fill reservoirs when the grease level reaches
grease points on the turntable bearing and rollers on each the MIN mark.
crawler. Grease is pumped to each point at the intervals 3. Fill reservoirs to the MAX mark with a hand operated
given in Table 7 when the ignition switch is on. grease pump through grease fitting on pump housing.
Table 7 Automatic Greasing Intervals Use a recommended grease (see Table 1 for factory fill).

Item Cycle Time Interval 4. Visually inspect automatic lubrication systems:

Turntable Bearing Continuous While Swinging a. Inspect divider valve inlets, outlets, and lubrication
points for leaks.
Crawler Roller Bearings Continuous While Traveling
b. Inspect for broken or cut grease lines.
Reservoir Capacity 1 gal (4 L)
c. Inspect terminal ends of each grease line to verify
Pump Output:
there are no leaks.
Turntable Bearing 0.177 in3/min (2,9 cm3/min)
d. Tighten fittings if grease leakage is detected.
Crawlers 0.488 in3/min (8,0 cm3/min)
5. With power on, check that pumps are working by moving
Operation swing and travel handles.

See Figure 11 in following procedure. 6. Check to see if indicator pin on each valve is working
when system is cycling. Should extend and retract.
The crane’s programmable controller controls the grease
pumps. If grease is pumped out through pressure relief valve,
pressure within system is greater than 4,000 ± 250 psi (276 ±
• The pumps pump grease to the grease points 17 bar). An obstructed grease line or divider valve is
continuously when the crane is swung or traveled. indicated. Troubleshoot system (see Table 8).
• The pumps stop pumping when swing or travel is
stopped.
CAUTION
• The pumps also stop pumping if the crane’s ignition
switch is turned off. Crawler/Turntable Bearing Hazard!
In extreme cold weather operation — temperatures down
• Each divider valve — primary and secondary — has an
to -40°F (-40°C) — pumps may not pump grease through
indicator pin (16) that extends and retracts during a
automatic lubrication systems. It will be apparent that the
lubrication cycle.
lines are obstructed when the pump pushes grease out
Daily Inspection the relief valve.
If this occurs, intermediate rollers and turntable
See Figure 11 for following procedure. bearing must be greased manually using grease fittings
To ensure maximum reliability and to protect crane (5) on divider valves (12 and 15).
components, the automatic lubrication systems must be
inspected daily.

F2104-32
MODEL 18000 MAINTENANCE CHECKS AND LUBRICATION

P1942
Item Description
1 Grease Pump (Turntable Bearing)
2 Grease Pump (Crawler)
3 Grease Reservoir
4 Grease Fitting for Filling Reservoir 3
6
5 Grease Fitting for Greasing System Manually
6 Pressure Relief Valve
7 Electric Power Cable
8 Primary Divider Valve (Crawler)
9 Grease Line from Grease Pump
10 Grease Line to Secondary Divider Valve 5 4
11 Grease Line from Primary Divider Valve
12 Secondary Divider Valve (Crawler) 1
13 Grease Lines to Lube Points
7
14 Primary Divider Valve (Turntable Bearing)
15 Secondary Divider Valve (Turntable Bearing)
16 Indicator Pin View A

16 10

2
11 1
5 14
12

P1944
9 View C

16
13

16

4-115
P1943
View D 9
8
13 2 Places
15
5

16 5

P1945 View D
11
2 Places

P1943a
View E
10

FIGURE 11

F2104-33
MAINTENANCE CHECKS AND LUBRICATION MODEL 18000

Automatic Lubrication System Troubleshooting

Table 8 Troubleshooting

Symptom Probable Cause Solution

1. Pump will not operate. Not receiving 24-volt DC Check fuses and electrical supply.
input. Check electrical supply to the pump, by tracing to electrical
source. Repair.
Blocked pump cam. If voltage is available to pump, check for blockage. Repair.
Replace pump motor if blockage is not identified.
2. The pump motor is running Air pocket at pump element Disconnect main delivery hose from pump outlet.
but there is no grease being inlet. Run pump until solid grease with no bubbles flows from
discharged. outlet. If solid grease does not discharge after 20 minutes,
pump inlet is blocked.
NOTE 1 Depending on operating temperature and
grease type, it can take up to 10 minutes to
obtain full volume at outlet.
Blocked pump inlet. Remove pump element from pump body and check suction
inlet port for foreign particles.
Reassemble pump and element, then test pump. If pump
element does not discharge grease, replace element.

3. Pump operated with an Grease in reservoir is low. Fill reservoir and test system with grease gun at system
empty reservoir. manual grease fitting.
Disconnect main delivery hose from pump and watch until
solid grease with no bubbles flows from outlet.
Reconnect main delivery hose to pump outlet.
4. Grease is discharged at There is blockage in meter Test system with grease gun at system manual grease
pressure relief valve. valves, hose, tubing, or at fitting. Loosen each outlet line at primary valve, one at a
bearing. time. The blocked outlet line will start flowing grease and
indicator pin starts indexing.
Retighten all outlets at primary valve.
Trace hose that flowed to its secondary valve.
Repeat process of loosening each outlet one at a time until
blocked line is found.
Retighten all outlets.
Repair bearing blockage.
If a metering valve is causing blockage, replace valve.
5. Indicator pin on primary See item 4. See item 4.
valve does not move.
6. Lubrication point is not Cut in hose or tubing. Replace hose or tubing.
receiving grease.

F2104-34