Manitowoc 2250 Service Maintenance Manual
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Manitowoc 2250 Service Maintenance Manual

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Service/Maintenance Manual

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  • Page 1 Manitowoc 2250 Service/Maintenance Manual...
  • Page 3 The serial number of the crane and applicable attachments (Luffing Jib, MAX-ER ) is the only method your Manitowoc dealer or the Manitowoc Crane Care Lattice Team has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator’s cab and each attachment.
  • Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH...

  • Page 5: Table Of Contents

    2250 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1 ..........Introduction Continuous Innovation.
  • Page 6 TABLE OF CONTENTS 2250 SERVICE/MAINTENANCE MANUAL Storing and Handling Parts ............2-2 Inspecting the System .
  • Page 7 Model 2250 MAX-ER 2000® Test Voltages ........
  • Page 8 TABLE OF CONTENTS 2250 SERVICE/MAINTENANCE MANUAL Drum 9 (MAX-ER 2000 load drum) ..........3-28 Swing (crane) .
  • Page 9 2250 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Load Block Level Transmitter ............5-4 Installation .
  • Page 10 TABLE OF CONTENTS 2250 SERVICE/MAINTENANCE MANUAL Battery Disconnect Switch............7-3 Engine Diagnostics .
  • Page 11 2250 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Basic Troubleshooting..............10-1 Safety Summary .
  • Page 12 TABLE OF CONTENTS 2250 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK TOC-viii Published 07-19-16, Control # 249-01...
  • Page 13 General ............1-41 Manitowoc...
  • Page 14 2250 SERVICE/MAINTENANCE MANUAL Brake and Pawl ..........1-41 Raising the Boom Hoist/Luffing Jib .
  • Page 15 2250 SERVICE/MAINTENANCE MANUAL Counterweight Switch ......... . . 1-90 Counterweight Strap Cylinders Lower .
  • Page 16 2250 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-iv Published 07-19-16, Control # 249-01...

  • Page 17: Section 1

    Without the safety alert symbol, identifies potential If there is doubt about any procedure, contact your hazards that could result in property damage. Manitowoc Cranes dealer or the Manitowoc Crane Care Lattice Team. NOTE: Highlights operation or maintenance procedures.

  • Page 18: Maintenance Instructions

    Place a warning sign at the start controls, alerting other personnel that the crane is being serviced and the To ensure safe and proper operation of Manitowoc cranes, engine must not be started. Do not remove the sign until they must be maintained according to these maintenance it is safe to return the crane to service.
  • Page 19 Hydraulic oil can also be flammable. Do not smoke alignment. or allow open flames in the area when filling the • Unless authorized in writing by Manitowoc Cranes, hydraulic tanks. do not alter the crane in any way that affects the •...

  • Page 20: Environmental Protection

    • Do not store flammable materials on the crane. Potentially harmful waste used in Manitowoc cranes Perform the following procedure before returning the crane includes, but is not limited to, oil, fuel, grease, coolant, air to service.

  • Page 21: Identification And Location Of Components

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION IDENTIFICATION AND LOCATION OF COMPONENTS P891 P889 P887 Item Description #44 Heavy Lift Boom P892 Physical Air Cushioned Boom Stop (qty 2) Gantry Gantry Backhitch (telescopic) (qty 2) Boom Stop Limit Switch Rotating Bed Upper Counterweight...
  • Page 22 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL See View B P894 P895 See View A P896 P897 See View A See View B A468 P898 See View B See View C P899 FIGURE 1-2 Published 07-19-16, Control # 249-01...
  • Page 23 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description Crawler Drive Motor Travel Brake (disc) Crawler Connecting Pin Cylinder (hydraulic) P890 View A Boom Hoist Boom Hoist Motor Typical at Boom Hoist and Boom Hoist Brake (disc) Drum Drive Motors Boom Hoist Planetary...
  • Page 24 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL P888 P902 P903 See View A See View C See View B A468 P601 P905 P904 FIGURE 1-3 Published 07-19-16, Control # 249-01...
  • Page 25 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION P906 A470 View B Typical Four Places P907 View A Typical Outboard End of View C Each Drum Shaft Item Description Hydraulic Tank Hydraulic Tank Filter (under grate in tank) (qty 2) Hydraulic Tank Vacuum and Temperature Sender...
  • Page 26 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL See the Operator Manual for complete list of operating controls P908 P909 P911 Behind Seat Under Right Console FIGURE 1-4 P910 A974 1-10 Published 07-19-16, Control # 249-01...
  • Page 27 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION P912 Under Operator’s Cab Item‘ Description Rated Capacity Indicator/Limiter Console Front Console Crane Mode (select and confirm) Digital Display Cab Power Switch Brake Treadle Valve Right Console Load Drum Controller Handle Center Switch Foot Throttle Pedal...
  • Page 28 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL P913 P914 P915 A1064 P916 P913 FIGURE 1-5 1-12 Published 07-19-16, Control # 249-01...
  • Page 29 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description Front Drum Clutch Solenoid Valve Front Drum Park Brake Solenoid Valve Rear or Right Rear Drum Clutch Solenoid Valve Rear or Right Rear Drum Park Brake Solenoid Valve Left Rear Drum Clutch Solenoid Valve...
  • Page 30 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL View A View B View C P917 P918 P919 View F P920 View F View D View E See View P921 P923 P922 FIGURE 1-6 1-14 Published 07-19-16, Control # 249-01...
  • Page 31 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description View G MAX-ER Hydraulic Quick-Couplers 192115_3a MAX-ER Electric Receptacle MAX-ER Load Sensing Storage Receptacle Auxiliary Valves Junction Box Switch (not used) Jacking Remote Control Receptacle Not Used Setup Remote Control Jacking Remote Control Engine Air Cleaner...
  • Page 32 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL P926 Left Side Boom Hoist Drum P925 Under Rear of Rotating Bed Inside Carbody P924 Under Rear of Rotating Bed P929 A468 Inside Carbody P927 P928 Under Rear of Rotating Bed FIGURE 1-7 1-16 Published 07-19-16, Control # 249-01...
  • Page 33 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description Boom Hoist Brake Solenoid Valve Return Oil Check Valve (qty 3) Drum Brake Relay Valve (qty 2) Drum Brake Lever Drum Brake Quick-Release Valve (qty 2) Adapter Frame Connecting Pin Cylinder (qty 4) Hydraulic Swivel...

  • Page 34: Tier 4 Final Engine Components

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL TIER 4 FINAL ENGINE COMPONENTS 112195-2 81017295_1 Under Rear of Rotating Bed P930 See View A P587 A468 FIGURE 1-8 1-18 Published 07-19-16, Control # 249-01...
  • Page 35 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION View A FIGURE 1-8 continued Manitowoc 1-19 Published 07-19-16, Control # 249-01...
  • Page 36 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Item Description Item Description Diagnostic Gauge Coupler (typical each sender) Engine Starter (qty 2) Right Travel Pressure Sender Alternator Spares Air Cleaner Boom Hoist Pressure Sender Diesel Exhaust Fluid (DEF) Dosing Unit Load Drum System Pressure Sender...

  • Page 37: Crane Description Of Operation

    Figure 1-9 for the following. pumps through a pump drive transmission. In a closed-loop The model 2250 is powered with the Cummins QSX15 hydraulic system, high-pressure hydraulic fluid from the engine. Standard and optional equipment available for the system pump drives a hydraulic motor. Pressure develops crane is included.

  • Page 38: Hydraulic Components

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Hydraulic Components level sensor. The digital display indicates temperature and pressure (vacuum) of the fluid in the reservoir. Hydraulic fluid Hydraulic and Air Systems Section 2 for the hydraulic vacuum is displayed as a pressure between 0.5 and 1.2 bar schematic.

  • Page 39: Charge Pressure

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION The auxiliary pump provides hydraulic fluid pressure for the Each pump has two multifunction valves that consist of a accessory valve’s operation. The fan pump provides fluid system-relief valve and a charge flow make-up check valve.

  • Page 40: Monitoring The Main Pressure

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Monitoring the Main Pressure The pressure limiting-relief valve (1) serves as a pilot valve to open the system-relief valve (5) when the desired relief Each system’s digital display screen displays the monitored pressure setting is reached. For example, if a pressure system pressure.
  • Page 41 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION supplied pressure to perform the shifting operation. Servo Motor case fluid drainage lubricates the motor and provides control fluid is supplied from the high-pressure line of motor a recirculation of hydraulic fluid to control the heat in the port A or B and shifts the shuttle valve and the servo control closed-loop system.
  • Page 42 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RF-03 Pump Motor 23 bar Output (340 psi) Max. Disp. Input Item Description Pressure-Limiting Relief Valve Servo Check Valve Displacement Control Valve Servo Control Cylinder System-Relief Valve Charge Pump Relief Valve Charge Flow Make-up Check Valve...

  • Page 43: Accessory Systems

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Accessory Systems The suction manifold supplies hydraulic fluid to the fan pump. The fan pump supplies hydraulic fluid to drive the two Figure 1-12 for the following. fan motors. The fan’s relief valve protects the fan pump and two fan motors from damage by limiting the fan’s system...

  • Page 44: Pressurized Air Supply

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Pressurized Air Supply Each air solenoid valve is assigned an AS number. The AS number identifies each air solenoid valve. Figure 1-13 for the following. Table 1-3. Air Solenoid (AS) Valves Pressurized air is provided to the crane's air cylinder...

  • Page 45: Engine Controls

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Engine Controls Use the engine stop push button only in an emergency as all of the brakes apply and any function stops abruptly. See the engine manufacturer’s manual for instructions. Three engine diagnostic lights are mounted on the front The engine is started and stopped with the engine key console.

  • Page 46: Epic® Programmable Controller (Pc)

    The Model 2250 crane’s boom, load lines, swing, crawler monitored by the PC. Access information by scrolling to the t r a c k s , a n d a c c e s s o r y c o m p o n e n ts a r e c o n t r o l l e d desired display screen with the scroll switch.

  • Page 47: Electrical Power To Operator's Cab

    The PC also controls the load drum brake When the Engine RUN/STOP/RUN key switch is placed in application. Contact the Manitowoc Crane Care Lattice the RUN position, voltage is available at the key-operated Team for information on Clamshell modes.
  • Page 48 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Battery M104198 Disconnect 120 Amp 24 V 12 V Starter Motors 200A Starter Solenoids Converter Start Hour Meter IGNR Fan Relay 8ECM Motor Coolant 8 Amp Level Ignition IGNR Relay Engine Control Module 30 Amp Engine...

  • Page 49: Pressure Senders And Speed Sensors

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Pressure Senders and Speed Sensors for the required load-holding pressures for the load drums, boom hoist drum, or luffing hoist drum. Figure 1-17 for the following. The drum speed sensors on the drum shafts or flanges The pressure senders monitor the drum system pressures, detect speed and direction of the drum’s movement.

  • Page 50: Load Drum Air Brakes

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RF-11 87FA Regulated 10V Out Main Main Lower Upper Operating Limit Alarm Block-Up Limit WB-06 WC-35 Max. Working Angle Limit WB-17 Light WA-35 Maximum Angle Limit System Fault Alarm Minimum Angle Limit WB-16 WC-34 Light WA-17 Hydraulic Fluid Temp.

  • Page 51: Working (Service) Brakes

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Working Brake Pedal Not Used Regulator Working Brake Relay Brake Solenoid Brake Relay AS7 (drum 1) AS9 (drum 2) AS11 (drum 3) Quick Quick Release Release Valve Brake Valve Cylinders 89V (drum 1) 89U (drum 2)

  • Page 52: Swing System Operation

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL which clutches are released, depending on the control An orifice across the swing pump and motor ports A and B handle command and the mode selected. allow smoother fluid flow when shifting the swing from one direction to the other.
  • Page 53 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION As the swing control handle is moved to the neutral position, changing engine speed. The PC sends a 0 V output to adjust the PC compensates for hydraulic system leakage or the swashplate to the centered position.

  • Page 54: Travel System Operation

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Travel System Operation pressure or electrical power is lost when operating, the brakes apply. General Two-Speed Travel Operation Figure 1-22 Figure 1-23 for the following. The travel 2-speed switch allows the operator to select LOW Each travel hydraulic pump drives one crawler system motor speed when a smoother start is required.
  • Page 55 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION The travel pump’s EDC tilts the pump’s swashplate in the pump’s EDC that is relative to the selected control handle’s forward direction. Hydraulic fluid flow is from the pump port movement. of the selected travel pump through a quick disconnect and Travel motors are variable-displacement and shift internally swivel to the travel motor.
  • Page 56 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RF-16 Right Travel Pump Forward Shuttle Valve Right Pressure Pilot Pressure from Sender 24 bar Boom Hoist Charge (350 psi) Pump at 24 bar (350 psi) Reverse Suction Manifold Left Travel Pump Forward HS-1 HS-35 Shuttle...

  • Page 57: Boom Hoist/Luffing Jib System Operation

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Boom Hoist/Luffing Jib System Operation Raising the Boom Hoist/Luffing Jib The following description is for the boom hoist system. The General luffing jib system is similar. Figure 1-24, Figure 1-25, and Figure 1-26 for the When the left side console control handle is moved back for following.

  • Page 58: Lowering The Boom Hoist/Luffing Jib

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RF-17 Ground 50 Amp WD-19 87FA 10 V Regulated Supply WA-01 Crane Display WD-20 Raise Lower WC-14 Boom Hoist Pump Left Side Control Handle WA-05 Boom Hoist Motor WE-29 Boom Angle WA-20 Indicator Luffing Jib Motor WD-24 Luff.
  • Page 59 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION (4,930 psi), the valve shifts to direct the flow from the shuttle position restricts the returning fluid flow. Pressure builds on valve into the maximum displacement side of the servo the fluid return side of the closed-loop system, acting as a cylinder.

  • Page 60: Load Drum System-Full Power

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RF-19 Boom Hoist Boom Hoist (luffing jib) (luffing jib) Pawl In Pawl Out Boom Hoist (luffing jib) Pawl Cylinder AS-14 AS-13 AS-16 (luffing jib) AS-15 (luffing jib) Boom Hoist (luffing jib) Drum Flange Main Air Manifold FIGURE 1-26 Load Drum System—Full Power...
  • Page 61 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION solenoid AS-10 air pressure is exhausted so the clutch control handle is moved back, the pump’s swashplate angle remains spring-applied to the drum shaft. is increased. When system pressure exceeds the pressure- compensating override (PCOR) valve setting of 340 bar The pump’s EDC tilts the swashplates in the UP direction to...

  • Page 62: Lowering The Load Drum

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RF-20 Ground WD-19 50 Amp 87FA 10 V Regulated Supply Crane Display WA-01 WD-20 WC-11 Raise Lower Right Handle Drum 2 Light Green Left (drum 1) Control Handle WA-03 WD-36 Has No Function Amber Main Pump Control 1...

  • Page 63: Dual Load Drum Motor Operation

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION clutches from the drum shaft. The right rear drum clutch increased as the control handle is moved forward. As more solenoid AS-10 air pressure is exhausted so the clutch fluid is returned to the pumps, more fluid is pumped to the remains spring-applied to the drum shaft.
  • Page 64 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Load Drum Pump 2 Load Drum Pump 1 RF-20 Pressure Sender .060 23 bar 23 bar (340 psi) (340 psi) DOWN DOWN Suction Suction Manifold Manifold Charge Manifold Pressure 30 L/min Sender (8 gpm) 14 bar...
  • Page 65 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION RF-22 Working Brake Pedal Not Used Regulator Working Brake Relay Drum 1 Brake Cylinders Brake Brake Solenoid AS9 (drum 2) Relay Drum 1 Clutch Cylinder Quick Release Valve Quick Drum 2 Release Brake Valve Cylinders 89V (drum 1)

  • Page 66: Load Drum System-Free Fall

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Load Drum System—Free Fall hoisting of the other load drums is the same, except for different drum, brake, clutch, and working brake pedal. General The procedure for hoisting in Free Fall mode is the same as...
  • Page 67 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION WARNING WARNING Falling Load Hazard! Falling Load Hazard! Avoid possible injury. When the working brake pedal is Avoid possible injury. The load will fall uncontrolled if released, the load on the drum free falls. The working working brake pedal is not applied before moving control brake pedal controls lowering speed.
  • Page 68 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RF-24 Working Brake Pedal Not Used Regulator Working Brake Relay Brake Brake Solenoid AS9 (drum 2) Relay Drum 1 Brake Cylinders Drum 1 Clutch Cylinder Quick Release Valve Quick Drum 2 Release Brake Valve Cylinders Drum...

  • Page 69: Upper Accessory System Components

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Upper Accessory System Components General WARNING The upper accessory system components include four Collapsing Hazard! jacking cylinders, front and rear adapter frame pin cylinders, and gantry raising cylinders. During normal operation the Avoid possible injury. Keep the rotating bed as level as upper accessory solenoid valves are “motor spooled”...
  • Page 70 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL pressure. This allows the valves to open when the pressure return manifold. If more power is needed to extend the jacks, in the rod end of the cylinders is approximately 69 bar engine speed can be increased with the remote engine (1,000 psi).
  • Page 71 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Jacking Cylinders Retract Fluid exhausting from the piston end of the jacking cylinders is blocked by the free-flow check valve sections of the The following operating description is for the front jacks. counterbalance valves. From the counterbalance valve, fluid...
  • Page 72 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL M104182 HS12 Left Rear Jack Left Front Jack Right Front Jack Right Rear Jack Auxiliary Pump Fan Pump Auxiliary System Disable-Relief Valve Suction Manifold HS-30 HS-28 HS-26 HS-32 To Lower Accessory Valves PILOT PRESSURE HS-27 HS-29...

  • Page 73: Adapter Frame Pin Cylinders

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Adapter Frame Pin Cylinders Fluid from the rod end of the pin cylinders flows back through the upper accessory valve to the tank. Figure 1-32 Figure 1-34 for the following. When the power button or front adapter frame pins switch is...
  • Page 74 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL M104184 HS12 Auxiliary Pump Rear Adapter Frame Pins Front Adapter Frame Pins Engaged Engage Fan Pump Auxiliary System Disable-Relief Valve Suction HS-21 HS-23 Manifold To Lower Accessory Valves Pilot Pressure HS-22 HS-24 276 bar 21 bar...

  • Page 75: Gantry Cylinders

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Gantry Cylinders When the power button or the gantry cylinder switch is released, fluid to the gantry cylinders is stopped. The free- Figure 1-35 Figure 1-36 for the following. flow check valve sections trap the fluid in the rod and piston ends of the cylinders to lock the gantry in position.
  • Page 76 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL M104186 Gantry Raising Cylinders Extend 240 bar (350 psi) HS12 Auxiliary Pump Fan Pump Auxiliary System Disable-Relief Valve Suction Manifold HS-4 To Lower Accessory Valves Pilot Pressure HS-5 276 bar 21 bar Upper Accessory Valve (4,000 psi)

  • Page 77: Lower Accessory System Components

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Lower Accessory System Components Boom Hinge Pins Engage When the power button is pressed and the boom hinge pins General switch is held in the DOWN (engage) position, an input The lower accessory system components include the boom signal is sent to the PC.
  • Page 78 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RF-32 Ground WD-19 50 Amp Programmable Crane Display WD-20 Controller WC-27 Auxiliary System Disable-Relief Valve Power Upper Counterweight Pins Disengage Lower Counterweight Pins Disengage Backhitch Pins Disengage Left Crawler Frame Pins Engage Left Crawler Frame Pins Disengage...

  • Page 79: Boom Butt Handling Cylinder

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION HS12 M104188 Auxiliary Pump Upper Accessory Valve Boom Hinge Pins Engage Fan Pump Auxiliary System Disable-Relief Valve Suction HS-11 Manifold To Fan Circuit Variable Output Valve HS-10 0 to 57 L/min (0 to15 gpm) Lower Accessory Valve...
  • Page 80 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL When the power button or boom butt cylinder switch is Hydraulic fluid exits the valve assembly and flows through released, the PC sends a 0 V output to shift the spool of the free-flow check valve section of the counterbalance solenoid HS-15 to the center position.

  • Page 81: Rigging Winch

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION M104190 Boom Butt Handling Cylinder Extend HS12 Auxiliary Pump Upper Accessory Valve Fan Pump Auxiliary System Disable-Relief Valve Suction HS-16 Manifold To Fan Circuit Variable Output Valve HS-15 0 to 57 L/min (0 to15 gpm) Lower Accessory Valve...

  • Page 82: Crawler Frame Pins

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Rigging Winch Haul In The rigging winch haul in solenoid valve HS-17 is enabled by the PC to shift the valve in the selected position. Hydraulic When the power button is pressed and rigging winch switch...
  • Page 83 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION signal is sent to the PC. The PC sends a 12 V output signal Crawler Frame Pins Disengage to the auxiliary system’s disable-relief valve HS-12 that When the power button is pressed and the left crawler frame adjusts system pressure to 276 bar (4,000 psi).

  • Page 84: Air System Components

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Air System Components while air from the rod end of the cylinders exhausts to the atmosphere. Counterweight/Backhitch Pins Counterweight/Backhitch Pins Retract Figure 1-36 Figure 1-41 for the following. When the power button is pressed and the counterweight...

  • Page 85: Hydraulic Quick Disconnect

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Hydraulic Quick Disconnect remote start junction box on the right side of the rotating bed. The hydraulic quick disconnect is operational after the General following connections are made. A self-contained hydraulic system makes the mechanical Connect the boom stop electrical cable from the rotating...
  • Page 86 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RF-44 Coupling Cylinders Engaged RF-45 Coupling Cylinders Disengaged Frame Cylinder Extended Frame Cylinder Retracted Sleeve Plate Sleeve Plate Coupling Plate Coupling Plate Frame Frame 14 bar 14 bar (200 psi) (200 psi) HS-34 HS-33 HS-34 HS-33...

  • Page 87: Max-Er® 2000 Description Of Operation

    MAX-ER Hydraulic Attachments The line legend for all schematic is shown in Figure 1-44. The MAX-ER 2000 combines a model 2250 crane with mast Hydraulic and Air Systems Section 2 for the Hydraulic and boom-butt-mounted load drum with a wheeled Schematic.

  • Page 88: Max-Er Accessory Valve

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL MAX-ER Accessory Valve sequence valve closes the inlet port to pump flow. System pressure is limited by a pressure-relief valve in the inlet Figure 1-45 for the following. section through the section’s shuttle valve. Both cylinder ports on each valve section have flow limiter valves that are The MAX-ER’s accessory valve manifold is mounted on the...
  • Page 89 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION A1152 Item Description 2250 Crawler Crane Crane Counterweight Extender Frame Wheeled Counterweight MAX-ER Counterweight Gantry Mast Hoist Equalizer #44 Mast Boom Hoist Equalizer Main Strut Jib Strut Wire Rope Guide Upper Jib Point Lower Jib Point...

  • Page 90: Epic® Programmable Controller

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL ® Operating controls or control handles send input voltage EPIC Programmable Controller command signals to the MAX-ER’s or the crane’s PC. The PC compares these input voltages with feedback voltages Figure 1-46 for the following. received from system monitoring sensors, memory The MAX-ER’s solenoid valves, cylinders, and motors are...

  • Page 91: Max-Er Modes

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION MAX-ER Modes • Flange speed sender • Minimum bail limit switch In Setup mode, the PC operates the same as in Standard mode, but the boom-up limit is bypassed. • Drum pawl In Luffing Jib mode, drum 5 cannot operate unless drum 4 is •...

  • Page 92: Pressure Senders And Speed Senders

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Pressure Senders and Speed Senders When a MAX-ER operating limit is enabled, the PC displays the following messages: Figure 1-47 for the following. • BOOM MAXIMUM UP: A counterweight strap cylinder pressure sender is located at Mast stops hoisting at 80°, operable only in...
  • Page 93 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION RM-02 LH Rod End Strap 90QL Cylinder 15 Amp Sender System Fault RH Rod End Strap 90QR Alarm Cylinder Sender Light RH Piston End Strap 90RP Operating Limit Cylinder Sender Alarm Mast Light 90QM Accumulator Sender...

  • Page 94: Backhitch Pins

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Backhitch Pins Backhitch Pins Extend/Retract Each backhitch pin cylinder is spring-returned to the Figure 1-48 for the following. extended position. In this position, the backhitch pins The backhitch pins are retracted from the telescopic normally closed air solenoid AS-1 is disabled and normally backhitch strap during assembly or disassembly.

  • Page 95: Tongue Cylinder

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Tongue Cylinder Tongue Cylinder Extend When the power button is pressed and the tongue cylinder Figure 1-49 Figure 1-50 for the following. switch is enabled and held in the UP (extend) position, an The tongue cylinder aligns the wheeled counterweight trailer input signal is sent to the programmable controller (PC).

  • Page 96: Tongue Cylinder Retract

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Tongue Cylinder Retract Accessory system fluid enters the MAX-ER’s accessory valve and flows to the free-flow check valve section of the When the tongue cylinder switch is held in the UP (retract) counterbalance valve, entering the rod end of the tongue position, an input signal is sent to the PC.

  • Page 97: Counterweight Jack Cylinders

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Counterweight Jack Cylinders With the engine running, power is available to the MAX-ER’s remote switch assembly when the power cable (W28) is Figure 1-51 Figure 1-52 for the following procedure. p l u gg e d i nt o t he r ec e p tac l e o n t h e l eft s i de o f th e counterweight trailer.

  • Page 98: Jack Cylinder(S) Retract

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL RM-07 Auxiliary System 15 Amp Crane Disable-Relief Valve Programmable Power Controller 54MLA Left Jack Extend 54MLB Left Jack Retract Center Jack Extend 54MCA 54MCB Center Jack Retract Right Jack Extend 54MRA Right Jack Retract 54MRB 54MA...
  • Page 99 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION RM-08 From Mast To Mast Stop Cylinders Stop Cylinders Right Jack To Jib Strut Cylinders 152 bar (2,200 psi) From Jib Strut Cylinders Accumulator 207 bar (3,000 psi) Extend Retract 13,8 bar (200 psi) Mast Accumulator...

  • Page 100: Steering Pin Cylinders

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Steering Pin Cylinders Steering Pin Cylinders Disengage When the steering pins switch is held in the UP (disengage) Figure 1-53 Figure 1-54 for the following. position, an input signal is sent to the PC. A 12 V output Steering pin cylinders disconnect the MAX-ER’s steering...

  • Page 101: Steering Pin Cylinders Engage

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Steering Pin Cylinders Engage valve’s bypass. Accessory system pressure increases to operate the accessory items. Accessory system fluid enters When the steering pins switch is held in the DOWN (engage) the MAX-ER’s accessory valve and flows to the piston end of position, an input signal is sent to the PC.

  • Page 102: Steering Arm Cylinders

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Steering Arm Cylinders Steering Cylinders Extend (Swing/Crab) The steering pins must be disengaged first, before the Figure 1-55 Figure 1-56 for the following. steering arms can be positioned. Move the stop pins to the Steering arms and stop pins must be properly positioned desired steering position.

  • Page 103: Steering Cylinders Retract (Straight)

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Steering Cylinders Retract (Straight) operate the accessory items. An inline relief valve set at 183 bar (200 psi) reduces the auxiliary system’s pressure to The steering pins must be disengaged first, before the the steering arm cylinders.

  • Page 104: Counterweight Strap Cylinders

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Counterweight Strap Cylinders is on the ground, the wheels must be properly positioned before swinging or traveling the crane. Figure 1-57 Figure 1-58 for the following. When the MAX-ER mode is selected, the load-sensing pin in...
  • Page 105 2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION The PC enables the MAX-ER’s electronic and hydraulic • If the calculated strap cylinder load drops below 7.5 tons s y s t e m s t o a u t o m a t i c a l l y e x t e n d a n d r e t r a c t t h e...

  • Page 106: Counterweight Switch

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Counterweight Switch valves, entering the piston end of the strap cylinders to start extending the cylinder rods. The counterweight switch is operative only in Standard or Fluid from the rod end of the cylinders is blocked by the free- Setup modes.

  • Page 107: Mast Stop Raising And Boom Stop

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Mast Stop Raising And Boom Stop Boom Stop Cushion Cylinders Figure 1-59 for the following. Mast Stop Raising Cylinders The boom stop cushion cylinders pneumatically cushion the Figure 1-59 for the following. boom against the mast when at or near maximum boom The mast stop raising cylinders pneumatically position the angle.

  • Page 108: Mast Stop

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Mast Stop Mast Stop System Operation Figure 1-60 for the following. Mast Stop Cylinders The crane’s auxiliary pump supplies pressurized hydraulic Figure 1-60 for the following. fluid to the mast stop cylinders and jib strut cylinders at The mast stop cylinders are connected to the mast and 152 to 200 bar (2,200 to 2,900 psi).

  • Page 109: Luffing Jib Stop Cylinders

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION After the accumulator is filled, the mast stop cylinders and jib Jib Stop System Operation strut cylinders are filled with pressurized hydraulic fluid, Figure 1-60 for the following. monitored by the mast accumulator pressure sender. A pressure-relief valve opens at 207 bar (3,000 psi).

  • Page 110: Drum 9 Operation

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL Drum 9 Operation The motor loop flushing valves open when system pressure exceeds 14 bar (200 psi). The sequence/flow control valve Figure 1-61 through Figure 1-64 for the following. removes 15 L/min (4 gpm) of hot fluid from the system by dumping the fluid in the motor’s case where it returns to the...

  • Page 111: Drum 9 Brake

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Drum 9 Brake The crane’s PC also sends a negative output signal to stroke each of the crawler travel pump’s EDC in the RAISE direction Drum 9 motors have hydraulic disc brakes that are spring- and a positive output signal to each motor’s PCP. The applied and hydraulically released.
  • Page 112 INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL The crane’s PC controls raising speed by varying the voltage When the left control handle is moved to the neutral position, to both pumps’ EDC and motor’s PCP in relation to the the crane’s PC sends an output signal to the travel pump’s handle’s movement.

  • Page 113: Drum 9 Lowering (Max-Er Mode)

    2250 SERVICE/MAINTENANCE MANUAL INTRODUCTION Drum 9 Lowering (MAX-ER Mode) direction. Hydraulic fluid at system pressure up to 407 bar (5,900 psi) maximum flows from pump ports B to port B of Figure 1-63 Figure 1-64 for the following. the motors. Fluid from motor ports A returns to pump ports A.

  • Page 114: Hydraulic Cooler Fan Drive

    INTRODUCTION 2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC COOLER FAN DRIVE See the engine manufacturer’s operating instructions manual for diagnostic information. Figure 1-65 for the following. Maintenance Description Fan speed is determined by the greatest demand of four The cooler fan drive assembly includes two hydraulic-driven inputs: motor variable-speed fans.
  • Page 115 Gantry Cylinders ..........2-23 Manitowoc...
  • Page 116 2250 SERVICE/MAINTENANCE MANUAL Checking the System Speed ........2-24 Travel Straightness .
  • Page 117 2250 SERVICE/MAINTENANCE MANUAL Operation ............2-40 Maintenance .
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  • Page 119: Hydraulic Schematics

    At the same service interval, visually inspect all other instructions in Section 3 of the Operator Manual. Contact hydraulic components and valves for the following. your Manitowoc Cranes dealer for an explanation of any Leaking ports procedure not fully understood.

  • Page 120: Hydraulic System Maintenance

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL Storing and Handling Parts Hydraulic hose assemblies operating in Zone D and Zone E (cold climates) should expect a degradation of mechanical Adhere to the following when storing and handling parts: properties. Long-term exposure to these cold temperatures will negatively impact service life.

  • Page 121: Servicing The Pumps

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS • Replace tubes that are cracked, kinked, or bent. Handle Open Install Bolt and Nut or Padlock • Replace hoses that are cracked, split, or abraded. (pull toward you to close) to Lock Handle Open •...

  • Page 122: Replacing The Suction Filter Element

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL Thoroughly clean the fill cap and screen in a clean, Remove the bypass spring (13). nonflammable solvent and blow dry the parts with Remove the filter element (14) by twisting it off and compressed air.

  • Page 123: Changing The Oil

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Changing the Oil Disconnect the air piping at the connections to fully access the clean-out cover (2). Drain and refill the hydraulic system every 1,000 hours or Clean all dirt off the clean-out cover.
  • Page 124 HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL Table 2-2. Hydraulic System Specifications System System Charge Pump-Motor Port Speed Function Direction Pressure Pressure 1 Pressure 2 Connections bar (psi) bar (psi) bar (psi) Lower Pump B to Motor B 40 to 48...

  • Page 125: Tightening The Hydraulic Connections

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS TIGHTENING THE HYDRAULIC Cause Cure CONNECTIONS Straight thread used instead of Use proper type and size tapered thread thread General Female threads expanded from Tighten when hot heat Make sure the fittings and O-rings being used are the proper size and style.

  • Page 126: Ors® Connection

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL Tighten the jam nut. When the fitting is properly installed, Cause Cure the O-ring will completely fill the seal cavity and the O-ring wrong size Replace with proper size washer will be tight against the spot face (View B).

  • Page 127: Sae Flare Connection

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Using wrenches, tighten the connector nut the number Dimension A Torque of flats shown in Table 2-9. inch Misalignment of the marks will show how much the nut Flange has been tightened. Size in-lb Table 2-9.

  • Page 128: Programmable Controller Calibration Procedures

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL PROGRAMMABLE CONTROLLER Repeat step 3 if the engine is running or if the engine is started. CALIBRATION PROCEDURES When calibration starts, the screen shown in Figure 2-12 General appears to indicate the percentage of completion. It takes approximately 1 minute to complete this process.

  • Page 129: Calibrating The Controls

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Calibrating the Controls speed is decreased during calibration. In either case, the screen shown in Figure 2-14 appears. The controls must be calibrated at the following instances and/or intervals: CONTROL CALIBRATION HIGH IDLE REQUIRED •...

  • Page 130: Replacing A Pressure Sender

    Load Drum Charge Pressure Sender Load Drum System Pressure Sender Boom Hoist System Pressure Sender Swing Right System Pressure Sender Swing Left System Pressure Sender Optional 2250 Left Inboard Side of Rotating Bed (forward of pumps) FIGURE 2-16 2-12 Published 07-19-16, Control # 249-01...
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  • Page 132: Disc Brake Operational Test

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL DISC BRAKE OPERATIONAL TEST General WARNING There is no physical way to check the disc brakes for travel, Falling Load/Moving Crane Hazard! boom hoist, luffing hoist, front/rear drums, and swing. An operational test of each brake must be performed weekly.
  • Page 133 2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS P927 P898 P899 P913 P897 P924 P894 A468 Typical 2 Places P895 P896 Typical 2 Places FIGURE 2-17 Manitowoc 2-15 Published 07-19-16, Control # 249-01...

  • Page 134: Shop Procedure

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL SHOP PROCEDURE Comply with the pressure and flow settings specified. Altering settings without the approval of the Manitowoc General Crane Care Lattice Team can damage crane components or cause the crane to operate improperly. Procedures for This section covers hydraulic adjustments for the hydraulic connecting hydraulic fittings are provided in this section.

  • Page 135: Initial Oil Fill

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Initial Oil Fill Pipe Case Drain NOTE: Use new hydraulic oil of the proper viscosity filtered Plug Return Pipe P969 through at least a 10-micron filter. Fill each motor case with clean oil to the level of the case...

  • Page 136: Initial Startup

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL Adjusting Screw Fan Bypass Valve (optional) Electric Plug (with lock nut and protective cap) Fan Relief Valve Fan Relief Valve P971 Access at Left End of Radiator P970 3,2 mm (1/8 in) Gauge Coupler...

  • Page 137: Calibrating The Controls

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Calibrating the Controls Calibrate the pressure transducers, if not already done. CAUTION Start and run the engine at high idle. Equipment Damage! Inadequate oil pressure can damage hydraulic pumps. Depress and hold the swing holding brake switch (on the swing handle) for one minute.

  • Page 138: Checking The Operating Pressure

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL Stop the engine. Start and run the engine at 1,500 rpm and operate the boom hoist in the down direction (no wire rope or load on 10. Remove the gauges and install protective caps over the the drums).

  • Page 139: Checking The Auxiliary System Pressure

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Scroll to the Drum 4 (boom hoist) Diagnostic screen. 50% pump command is reached, and the brake must not Monitor the pump pressure and pump command while slip. moving the control handle. If the specified pressure is not indicated in either Slowly pull the boom hoist control handle back.
  • Page 140 HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL At the main relief valve (6) on the auxiliary system Loosen the lock nut on the adjusting screw for the control valve (5), loosen the lock nut and turn the auxiliary system relief valve.

  • Page 141: Rotating Bed Jacking Cylinders

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Rotating Bed Jacking Cylinders Crack open the bleed screw (4) on the proportional flow control valve (3). Figure 2-26 for the following procedure. b. Securely close the bleed screw when a steady Stop the engine.

  • Page 142: Checking The System Speed

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL Piston End Rod End Counterbalance Valve Rod End Counterbalance Valve Counterbalance Valve (with lock nut and adjusting screw) (with lock nut and adjusting screw) (with lock nut and adjusting screw) On Inboard Side...

  • Page 143: Unloader Pilot Valve Maintenance

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS UNLOADER PILOT VALVE MAINTENANCE mechanism then exhausts, and the compressor starts compressing air. General Adjustment Figure 2-28 for the following. The unloader pilot valve has a 0,83 bar (12 psi) range The unloader pilot valve automatically controls air system between the cut-out and cut-in pressures.

  • Page 144: Maintenance

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL MOISTURE EJECTOR VALVE Operational Checks MAINTENANCE Make the following checks after the engine is started at the beginning of each work shift. General Check for air leaks. There must be no leaks in the pilot Figure 2-29 for the following.

  • Page 145: Air System Filter Maintenance

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS AIR SYSTEM FILTER MAINTENANCE Monthly Maintenance Figure 2-31 for the following procedure. General Replace the filter element as follows. Two styles of air filters are used on cranes—Type A and Type B. This section describes maintenance of both filters.

  • Page 146: Automatic Drain Valve Operation

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL Wash all parts in soap and water and dry. backflow of antifreeze into the reservoir during periods of no flow. For the Type A filter, wash the element in alcohol and blow it out from the inside with air. For the Type B filter, The flow sensor functions as a variable restriction in the discard the element.

  • Page 147: Adjusting

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Adjusting Tighten the reservoir (9) by hand until the arrowhead on the reservoir is in line with or to the right of the Figure 2-32 for the following procedure. arrowhead on the body.

  • Page 148: Air Dryer Maintenance

    For operation, leak testing, disassembly and assembly, cleaning, inspection, and preventive maintenance, see the Retain the mounting hardware. vendor manual and contact the Manitowoc Crane Care Lattice Team. Remove the air dryer assembly (15) from the crane. 2-30...
  • Page 149 2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Item Description End Cover Purge Valve Assembly Capscrew Sleeve Nut Mounting Strap Mounting Saddle Adjusting Nut Mounting Strap Isolator Upper Bracket Capscrew (qty 2) Lock Nut (qty 2) Special Washer (qty 4) Lower Mounting Bracket...

  • Page 150: Breather Vent Maintenance

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL BREATHER VENT MAINTENANCE Inspect the breather vents weekly to make sure they are not obstructed by any debris. If necessary, remove and clean (or Figure 2-36 for the following procedure. replace) them as needed.

  • Page 151: Maintenance

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Maintenance plate, down in place on the body (12) with a slight twisting motion. Troubleshooting Hold the housing plate down and replace the screws (7). Figure 2-38 for the following procedures. Tighten the screws to 2 ± 0,3 Nm (18 ± 3 in-lb). Place...

  • Page 152: Quick Release Valve Maintenance

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL QUICK RELEASE VALVE MAINTENANCE Adjustment General The quick release valve does not require adjustment. Maintenance Figure 2-39 for the following. The quick release valve shortens the time required to vent air By removing the screws and washers, the cover can be pressure from a cylinder or other pneumatic device.
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  • Page 154: Maintenance

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL AIR PRESSURE SAFETY SWITCHES NOTE: Always confirm by crane serial number the specific pressure at which the limit switch is set and the MAINTENANCE operation for which the limit switch is wired by...

  • Page 155: Adjustment

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Adjustment Turn the switch adjustment screw (5) all the way in and then out until it just touches the plunger. Figure 2-41 for the following procedure. b. Increase air pressure to the specified point. The Shut down the crane.

  • Page 156: Shuttle Valve Maintenance

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL SHUTTLE VALVE MAINTENANCE opposite port of the valve and air flows out the common OUT port. The low pressure IN port is sealed from both the OUT General port and the opposite side IN port.

  • Page 157: Type A Air Regulator Maintenance

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS TYPE A AIR REGULATOR MAINTENANCE NOTE: To clean, it is not necessary to remove the regulator from the lines. Installation If the air supply is kept clean, the regulator should provide long periods of uninterrupted service.

  • Page 158: Maintenance

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL N-1 PRESSURE-REDUCING VALVE enough to close the inlet valve and keep the exhaust valve closed. As long as air pressure at the OUT port and spring MAINTENANCE force are balanced, the inlet and exhaust valve remain closed.

  • Page 159: Maintenance

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Maintenance Rinse each part thoroughly and blow dry them with a low-pressure air jet. Figure 2-45 for the following procedure. Arrange the parts on a clean surface in the order of the Maintenance periods should be scheduled in accordance exploded view.

  • Page 160: Type S Relay Valve Maintenance

    HYDRAULIC AND AIR SYSTEMS 2250 SERVICE/MAINTENANCE MANUAL TYPE S RELAY VALVE MAINTENANCE Balanced Position Figure 2-47 for the following. General Pressure at the OUT port (below diaphragm assembly) Figure 2-46 for the following. becomes equal to pressure at the pilot port (above diaphragm assembly).

  • Page 161: Maintenance

    2250 SERVICE/MAINTENANCE MANUAL HYDRAULIC AND AIR SYSTEMS Decreasing Pressure Figure 2-47 for the following procedure. CAUTION As the brake pedal is eased up to release the drum brake, reduced pressure at the pilot port unbalances the pressure Flying Debris Hazard! across the diaphragm assembly.
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  • Page 163 Model 2250 MAX-ER 2000® Test Voltages ....... . . 3-16...
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  • Page 165: Electrical Drawings And Schematics

    2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM SECTION 3 ELECTRICAL SYSTEM ELECTRICAL DRAWINGS AND • Excessive corrosion or dirt on the junction boxes SCHEMATICS • Loose junction box mounting hardware Applicable electrical system drawings and schematics are If any of these conditions exist, address them appropriately.

  • Page 166: Circuit Breaker And Fuse Id

    ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL CIRCUIT BREAKER AND FUSE ID Circuit breakers are mounted in the following locations: • Fuse junction box (Figure 3-1) General • Engine junction box (Figure 3-2 Figure 3-4) This section identifies the fuses and circuit breakers.
  • Page 167 2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Circuit Amps Wire No. Description of Items Protected Breaker Engine Controller Module Breakers for Tier 4 Cummins QSX-15 Power Plant CB Numbers Are per the Electrical Schematic CB-2 Engine Control Module (ECM) CB-3 Engine Diagnostics...
  • Page 168 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Circuit Amps Description of Items Protected Breaker Cold Weather Package Circuit Breakers Cold Weather Package Main Load Center Circuit Breaker Engine Coolant Heater Control Console and Treadle Valve Heaters Hydraulic Reservoir, Engine Oil, and Battery Pad Heaters...
  • Page 169 2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Circuit Amps Wire No. Description of Items Protected Breaker MAX-ER 2000 Junction Box Enclosure Main Junction Box Drum 9 Pawl Relays MAX-ER Programmable Controller MAX-ER 2000 Junction Box Enclosure MAX-ER Programmable Controller Main Junction Box...
  • Page 170 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Fuse Amps Wire No. Description of Items Protected Inline Fuses for TCU Harness Located at Battery Terminals Master Node 24VDC Supply P15-24 TCU 24VDC Supply 81011979 Fuse Amps Description of Items Protected Aftertreatment Junction Box Enclosure...

  • Page 171: Test Voltages For Crane Controller

    2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM TEST VOLTAGES FOR CRANE Abbreviations CONTROLLER The following abbreviations are used in this section: General Analog Input This section contains test voltages sorted into the following Analog Output four categories: CHA or CHB Channel A or B •...

  • Page 172: Crane Controller Pin, Wire, And Description Identification

    ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Crane Controller Pin, Wire, and Description Identification Test Voltage Board Wire Description (DC unless otherwise specified) (signal type) A-01 10 VDC Regulated Supply Out 10 Volts CPU (VDC) A-02 Not Used CPU (AI) 0 Volts Neutral, 1.4 to 5 Volts Lower,...
  • Page 173 2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Test Voltage Board Wire Description (DC unless otherwise specified) (signal type) 1 Volt at 762 mm (30 in) of Mercury (Hg), A-31 Hydraulic Vacuum Switch I/O 3 (AI) 2.3 Volts at 0 psi 5 Volts at 0°, A-32 Level Sensor—X Dimension...
  • Page 174 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Test Voltage Board Wire Description (DC unless otherwise specified) (signal type) B-35 Not Used I/O 3 (DI) B-36 Not Used I/O3 (DI) B-37 Not Used C-01 Computer Input 12 Volts Nominal C-02 Computer Ground 0 Volts...
  • Page 175 2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Test Voltage Board Wire Description (DC unless otherwise specified) (signal type) C-35 Operating Limit Buzzer & Light 12 Volts Nominal I/O 2 (DO) C-36 Jacking Remote Level Alarm & Light 12 Volts Nominal I/O 2 (DO)
  • Page 176 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Test Voltage Board Wire Description (DC unless otherwise specified) (signal type) D-32 Not Used I/O 3 (DO) D-33 Front Drum Pawl-In Solenoid 12 Volts Nominal I/O 3 (DO) D-34 81MC Main Hoist Motor Control (Rexroth)
  • Page 177 2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Test Voltage Board Wire Description (DC unless otherwise specified) (signal type) E-32 Not Used E-33 MAX-ER 2000 Power Relay 12 Volts Nominal I/O 4 (DO) E-34 Not Used E-35 80CA Front Drum Pawl-Out Solenoid 12 Volts Nominal...

  • Page 178: Master Node Pin Identification

    ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Master Node Pin Identification CraneSTAR equipped machines are included. Test Voltage Function Type Description (DC unless otherwise specified) Receptacle—Front Console Master Node (unused terminals are omitted) P11-01 24 Volts 24VDC Power Bus 24 Volts Nominal...
  • Page 179 2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Test Voltage Function Type Description (DC unless otherwise specified) P12-30 DO-12 Grd CAN System Ground Ground P12-31 CANH CAN-Hi Data Line (CraneSTAR) P12-32 CANL CAN-Low Data Line (CraneSTAR) P12-33 DI-19 Diesel Particulate Filter (DPF) Regeneration Disable...

  • Page 180: Model 2250 Max-Er 2000® Test Voltages

    ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Abbreviations ® MODEL 2250 MAX-ER 2000 TEST VOLTAGES The following abbreviations are used in this section: General Analog Input This section contains MAX-ER 2000 test voltages sorted into Analog Output the following three categories: CHA or CHB Channel A or B •...

  • Page 181: Max-Er Controller Pin Identification

    2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM MAX-ER Controller Pin Identification Test Voltage Board Wire Description (DC unless otherwise specified) (signal type) A-01 87FM 10 Volt Regulated Supply 10 Volts A-03 89F4 Mast Angle Limit 12 Volts Nominal (AI) A-04 89G4 Drum 9 Minimum Bail Limit Switch...
  • Page 182 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Test Voltage Board Wire Description (DC unless otherwise specified) (signal type) C-22 MAX-ER PC Ground Ground C-30 MAX-ER PC Power 12 Volts Nominal C-31 MAX-ER PC Ground Ground 7.5 or 0 Volts Not Moving, 3.5 Volts...

  • Page 183: Digital Display Readings

    This section identifies display readings for all The cause of the limit is corrected. modes and configurations in which the 2250 can be For this reason, it is normal for the names of limits to appear used (to include MAX-ER). Therefore, some of the...

  • Page 184: System Faults

    ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL System Faults To erase the names of inactive faults, scroll to the system fault group. Wait until the display scrolls through the name of Table 3-4 lists system faults that can be displayed. each fault. The names of inactive faults will be erased automatically.
  • Page 185 AUX SWING Display TRACKS Screens A1, A2, A3 The Manitowoc Crane Care Lattice Team will request these numbers when troubleshooting the crane. D1, D2, D3 2 Rows of Numbers are used to monitor the operation of the programmable controller Numbers and system functions for MAX-ER 2000 only.
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  • Page 187 2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-3. Operating Limits Listed below are the limits that turn on the operating limit alert (yellow light and continuous buzzer) in the operator’s cab. When the alert comes on, scroll to the OPERATING LIMIT group of the digital display to determine which limit has been reached.
  • Page 188 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Display Reading Function Response Corrective Action LUFFING JIB MAX DOWN The luffing jib stops lowering when the boom- Raise the luffing jib. to-jib angle is 60° (70° on #44 luffing jib). EQUALIZER BOOM STOP The boom hoist stops hoisting when the...
  • Page 189 2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-4. System Faults Listed below are the faults that turn on the system fault alert (red light and beeper) in the operator’s cab. When the alert comes on, scroll to SYSTEM FAULT group of the digital display to determine which fault has been reached. Take corrective action.
  • Page 190 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Display Reading Cause of Fault Function Response MAST ACCUMULATOR The mast stop cylinders, MAX-ER luffing See ACCUM diagnostic screen to determine jib stop cylinders, or accessory system the cause of fault and correct the problem as pressure is not in range.

  • Page 191: Drum Identification

    2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Drum Identification Drum 2250 MAX-ER 2000 32,000 lb Clam Number Front Load Drum No Drum Available Front Load Drum Rear or Right Rear Full Width Rear Load Boom Hoist Load Drum Drum Left Rear Load Drum Rear Load Drum —...

  • Page 192: Diagnostic Display

    ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL DIAGNOSTIC DISPLAY The motor command in percent (0% max displacement, 100% min displacement) General The measured drum speed in rpm (+ raise, – lower) The diagnostic display provides information about the status The command to park brake (1 release, 0 apply)

  • Page 193: Swing (Crane)

    2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Swing (crane) The left pump command in percent from neutral (+ forward, – backward) The measured system pressure right track in psi SWING The measured system pressure left track in psi FIGURE 3-18 The command to park break (1 release, 0 engage) The handle command in percent from neutral (+ right, –...

  • Page 194: A1 (Handles)

    Any other number indicates a problem with MAX-ER • Handle 3—Boom/luffing/mast hoist controller communication to the crane controller. Contact the Manitowoc Crane Care Lattice Team. • Handle 5—Right track Right strap cylinder rod side pressure (0 to 207 bar [0 to •...

  • Page 195: D1 And D2 (Digital Outputs And Inputs)

    2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM D1 and D2 (digital outputs and inputs) Tab le 3-7 a nd Tab le 3-8 to ide ntify the cra ne components assoc iated with the identifiers for the The status of the digital outputs from the controller and the corresponding bank.
  • Page 196 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Table 3-7. D1 (digital outputs) Table 3-8. D2 (digital inputs) Binary Binary Component Component Identifier* Identifier* Bank 1 Bank 1 Drum 1 Brake Travel Detent Drum 2 Brake Drum 1 Max Air Pressure/Swing Right Limit Switch...
  • Page 197 2250 SERVICE/MAINTENANCE MANUAL ELECTRICAL SYSTEM Table 3-9. 8-Bit Binary System Dark shaded boxes indicate ON, white boxes OFF. Manitowoc 3-33 Published 07-19-16, Control # 249-01...
  • Page 198 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL Table 3-10. 8-Bit Binary System (continued) Dark shaded boxes indicate ON, white boxes OFF. 3-34 Published 07-19-16, Control # 249-01...

  • Page 199: Programmable Controller (Pc) I/Oboard Fault Troubleshooting

    General To assist in troubleshooting, it is imperative the crane’s This section will assist in troubleshooting the model 2250 operator or field service technician follows these steps programmable controller (PC) for communication errors. before calling the Manitowoc Crane Care Lattice Team for The PC communication errors activate the system’s fault IO...

  • Page 200: Troubleshooting Procedure

    12. Note the active I/O Board Fault as it may have changed seat. Note the state of the LED on each board if from the previous fault and call the Manitowoc Crane equipped. Care Lattice Team for technical support and additional troubleshooting procedures.

  • Page 201: Cpu Eprom Replacement

    Tier 4 Final engines—no longer has erasable programmable read- only memories (EPROMs) (computer chips). For information on updating crane software, contact your Manitowoc dealer or the Manitowoc Crane Care Lattice Team. DIELECTRIC GREASE The following figures show the proper application of dielectric grease on J-tech type of connectors.
  • Page 202 ELECTRICAL SYSTEM 2250 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-38 Published 07-19-16, Control # 249-01...

  • Page 203: Section 4

    Lattice Section Inspection and Lacing Replacement ......4-20 Manitowoc Published 07-19-16, Control # 249-01...
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  • Page 205: Automatic Boom Stop

    2250 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM AUTOMATIC BOOM STOP Centerline of Boom WARNING Falling Attachment Hazard! Death or serious injury may occur if attachments fall from the crane. Table 4-1 If the boom fails to stop for any reason, stop the engine immediately.

  • Page 206: Operation

    BOOM 2250 SERVICE/MAINTENANCE MANUAL Operation Travel the crane onto a firm level surface or level the crane by blocking under the crawlers. Figure 4-2 for the following. If necessary, adjust the position of the limit switch (2a) When the boom is below the maximum angle, the limit with relation to the actuator bracket (4) as instructed in switch (2a) is closed.
  • Page 207 2250 SERVICE/MAINTENANCE MANUAL BOOM 2a or 2b View B CAUTION Equipment Damage! The limit switch could be damaged from over-travel if it is positioned too high in the slots or if either end of the actuator is cocked. The limit switch will also not trip open if it is positioned too low in the slots.

  • Page 208: Setup Boom Stop Angle

    BOOM 2250 SERVICE/MAINTENANCE MANUAL Adjusting the Minimum Automatic Boom Stop The boom should stop at the desired minimum angle. If it does not stop at the desired angle: Figure 4-2 for the following procedure. Stop lowering the boom. NOTE: The slots in the actuator (3b) allow the minimum Raise the boom several degrees above the boom angle to be adjusted to any angle between 4°...
  • Page 209 2250 SERVICE/MAINTENANCE MANUAL BOOM THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc Published 07-19-16, Control # 249-01...

  • Page 210: Physical Boom Stop

    BOOM 2250 SERVICE/MAINTENANCE MANUAL PHYSICAL BOOM STOP If for any reason the boom is raised to 90 , the boom ° stop cylinders fully compress the air and bottom out to provide a physical stop. Maintenance WARNING Weekly Boom Hazard! The physical boom stop does not automatically stop the Inspect the air cylinders and piping for air leaks.
  • Page 211 2250 SERVICE/MAINTENANCE MANUAL BOOM A488 The rod end must be snug against the shoulder of the cylinder rod. Plug Socket Rod End Engagement with the boom stop pin Guide should take place 1/3 to 1/2 of the way down the rear side of the saddle in both boom stop rod ends.

  • Page 212: Raising The Boom Stop To The Working Position

    BOOM 2250 SERVICE/MAINTENANCE MANUAL Raising the Boom Stop to the Working should be bottomed out against the cylinders to within 3,2 mm (1/8 in) of each other as shown in View D. Position Install the U-shaped spacers between the cylinder flanges Figure 4-4 for the following procedure.
  • Page 213 2250 SERVICE/MAINTENANCE MANUAL BOOM Item Description Luffing Jib Butt Angle Indicator Sending Unit (qty 1 or 2) Protractor Level Punch Marks Scribed Line Boom Butt FIGURE 4-6 Manitowoc Published 07-19-16, Control # 249-01...

  • Page 214: Disconnecting The Luffing Jib Angle Indicator Sending Unit Assembly

    BOOM 2250 SERVICE/MAINTENANCE MANUAL Disconnecting the Luffing Jib Angle Indicator Sending Unit Assembly Figure 4-7 for the following procedure. Disconnect the electrical cord (1) from the receptacle on the sending unit (2). Install the protective cap on the receptacle on the sending unit.

  • Page 215: Angle Indicator Sending Unit

    2250 SERVICE/MAINTENANCE MANUAL BOOM Angle Indicator Sending Unit Identify all input wires to the existing sensor. Cut the existing input wires near the terminal strip (if The angle indicator sending unit is a solid state sensor used) to allow for splicing.

  • Page 216: Adjusting The Angle Indicator Sender

    BOOM 2250 SERVICE/MAINTENANCE MANUAL Adjusting the Angle Indicator Sender Position a protractor level (3) along the scribed line. Record the angle as shown on the protractor level. Figure 4-6 for the following procedure. Scroll to the desired angle (boom, luffing jib, or boom-to- Perform the following adjustment procedure at the following luffing jib) on the digital display in the operator cab.
  • Page 217 2250 SERVICE/MAINTENANCE MANUAL BOOM Item Description Luffing Jib Butt Angle Indicator Sending Unit (qty 1 or 2) Protractor Level Punch Marks Scribed Line Boom Butt FIGURE 4-9 Manitowoc 4-13 Published 07-19-16, Control # 249-01...

  • Page 218: Boom Hoist Ratchet And Pawl Adjustment

    BOOM 2250 SERVICE/MAINTENANCE MANUAL BOOM HOIST RATCHET AND PAWL The pawl limit switch is factory set and does not require periodic adjustment. However, the limit switch must be ADJUSTMENT adjusted if any parts are replaced or checked if the drum is not operating properly.
  • Page 219 2250 SERVICE/MAINTENANCE MANUAL BOOM A1148 Item Description Eyebolt A1066 Return Spring Ratchet Pawl Limit Switch Cylinder Screw Roller Limit Switch Lever Shaft FIGURE 4-10 Manitowoc 4-15 Published 07-19-16, Control # 249-01...

  • Page 220: Strap Inspection And Maintenance

    During this inspection, the entire length of strap must be indicated. For inspection procedures not covered in this inspected to ensure that it is within specifications. service manual, contact your dealer or the Manitowoc Crane NOTE: All straps must be within specification. Any damage Care Lattice Team.

  • Page 221: Strap Replacement Specifications

    2250 SERVICE/MAINTENANCE MANUAL BOOM Strap Replacement Specifications Dent Any strap not within the specifications listed in Table 4-2 must be replaced. WARNING Falling Attachment Hazard! Depth Operating the crane with a damaged strap can cause of Dent structural failure or collapse of the boom, jib, mast, or...

  • Page 222: Corrosion Or Abrasion

    BOOM 2250 SERVICE/MAINTENANCE MANUAL Corrosion or Abrasion Straightness Figure 4-15 for the following procedure. Figure 4-16 Table 4-3 for the following procedure. Sandblast to remove the corrosion. Do not grind! Stretch a line (string or wire) from the pin storage hole at one end of the strap.

  • Page 223: Flatness

    If the line does not touch the strap, measure the distance If the dimensions are identical, but greater than 0,8 mm from the line to the strap. (0.03 in), contact the Manitowoc Crane Care Lattice Team. If the deviation from straight is greater than the maximum allowed, remove the strap from service.

  • Page 224: Storing Straps

    BOOM 2250 SERVICE/MAINTENANCE MANUAL Length Storing Straps Figure 4-19 Table 4-4 for the following procedure. Straps should be stored in a protected area. If stored in the open, a protective covering is recommended, especially in a NOTE: See the appropriate Rigging Drawing in the corrosive environment in which the straps are exposed to Operator Manual for the original length.

  • Page 225: Strap Inspection Checklist

    2250 SERVICE/MAINTENANCE MANUAL BOOM STRAP INSPECTION CHECKLIST Inspector’s Name Signature Date Length m (ft) Part Number Corrosion Kinks Cracks Dents Breaks Straightness Elongated Holes Abrasion Length Flatness Other Length m (ft) Part Number Corrosion Kinks Cracks Breaks Dents Abrasion Length...
  • Page 226 BOOM 2250 SERVICE/MAINTENANCE MANUAL NOTES DRAW SKETCHES OR ATTACH PHOTOGRAPHS HERE AND NEXT TWO PAGES 4-22 Published 07-19-16, Control # 249-01...
  • Page 227 2250 SERVICE/MAINTENANCE MANUAL BOOM Manitowoc 4-23 Published 07-19-16, Control # 249-01...
  • Page 228 BOOM 2250 SERVICE/MAINTENANCE MANUAL 4-24 Published 07-19-16, Control # 249-01...

  • Page 229: Section 5

    Wire Rope Lubrication ..........5-27 Manitowoc...
  • Page 230 2250 SERVICE/MAINTENANCE MANUAL Inspecting and Replacing Wire Rope ........5-27 General .

  • Page 231: Adjusting The Minimum Bail Limit

    2250 SERVICE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS ADJUSTING THE MINIMUM BAIL LIMIT Weekly Maintenance Figure 5-1 for the following procedure. General Check for proper operation of each minimum bail limit The minimum bail limit assembly is a protective device. It assembly, as follows.

  • Page 232: Removing The Wire Rope

    HOISTS 2250 SERVICE/MAINTENANCE MANUAL Three to Four Wraps of Wire Rope on Drum A644 A03641 View at Right Rear Drum (other drums similar) Item Description Item Description Bail Limit Lever Limit Switch Roller Roller (qty 3) Lock Nut Capscrew (qty 2)

  • Page 233: Electrical Wiring

    2250 SERVICE/MAINTENANCE MANUAL HOISTS Electrical Wiring The block-up limit control (also called an anti-two blocking d e v i c e ) i s a t w o b l o c k i n g p r e v e n t i o n d e v i c e t h a t...

  • Page 234: Load Block Level Transmitter

    HOISTS 2250 SERVICE/MAINTENANCE MANUAL Load Block Level Transmitter Use a smart level to check the level sensor zero. Follow the procedure below if a zero adjustment is required. Figure 5-2 for the following procedure. Open the enclosure. The optional load block level transmitter (12) is only used b.

  • Page 235: Installation

    2250 SERVICE/MAINTENANCE MANUAL HOISTS Installation Securely fasten the electrical cords to the boom and jib with the metal straps and nuts provided. Figure 5-3 for installation of the weights. When equipped with more than one block-up limit switch, The block-up limit control must be installed according to the wire the limit switches in series.

  • Page 236: Storing The Electrical Cords

    HOISTS 2250 SERVICE/MAINTENANCE MANUAL Storing the Electrical Cords Disengage the cable reel locking pin to allow the reel to be wound. Engage the locking pin to lock the reel in position. Figure 5-4 for the following. The power supply cord to the reel must be disconnected before the reel can be wound.

  • Page 237: Maintenance

    2250 SERVICE/MAINTENANCE MANUAL HOISTS Adjustment Reconnect the electrical cord to the proper block-up limit switch when the corresponding attachment is reinstalled. Figure 5-5 for the following procedure. Maintenance Lower the boom onto blocking at ground level and adjust each limit switch as follows.

  • Page 238: Inspecting And Adjusting The Drum Brake

    Aftermarket brake linings may not provide the proper brake torque. The brake could slip, allowing the load to Mounting Studs drop, resulting in death or serious injury. Only use Manitowoc Cranes original equipment linings. FIGURE 5-6 Published 07-19-16, Control # 249-01...
  • Page 239 Contact your Manitowoc Cranes dealer for brake band thickness. Have the band part number available at the time of the request.
  • Page 240 HOISTS 2250 SERVICE/MAINTENANCE MANUAL Figure 5-8 for the remaining steps. Turn off the drum park for the drum being serviced. The drum park brake will release. Check each brake band (6) for proper adjustment as follows. Check for clearance between the brake lining and...
  • Page 241 2250 SERVICE/MAINTENANCE MANUAL HOISTS Item Description Guard Band Support (qty 2) Jam Nut and Adjusting Nut Access Cover Band Adjusting Nut Brake Band Lining (qty 6) Live End Brake Actuator Mounting Bracket Mounting Nut (qty 2) Brake Lever Dead End...

  • Page 242: Checking The Treadle Valve

    HOISTS 2250 SERVICE/MAINTENANCE MANUAL Checking the Treadle Valve Lower the load for the treadle valve being adjusted to the ground so the load line is slack. Figure 5-9 for the following procedure. Adjust the pedal to the desired height as follows.

  • Page 243: Removal

    2250 SERVICE/MAINTENANCE MANUAL HOISTS Removal Exhaust the air from the actuator. Figure 5-8 for the following procedure. A467 Service Brake Port Spring Brake Port Lower the load block, weight ball, or bucket to the (working brake) (park brake) ground so the wire rope is slack on the drum being serviced.

  • Page 244: Adjusting The Brake Release

    HOISTS 2250 SERVICE/MAINTENANCE MANUAL Adjusting the Brake Release Adjust the regulator until the distance from the bottom of the actuator to the top of the rod end is 25,4 mm (1.0 in) Perform the following adjustment only if a new or rebuilt (Figure 5-11).
  • Page 245 2250 SERVICE/MAINTENANCE MANUAL HOISTS THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 5-15 Published 07-19-16, Control # 249-01...

  • Page 246: Inspecting And Adjusting The Drum Clutch-Standard

    HOISTS 2250 SERVICE/MAINTENANCE MANUAL INSPECTING AND ADJUSTING THE DRUM Inspection and Adjustment CLUTCH—STANDARD Description CAUTION Figure 5-13 for the following. Moving Machinery Hazard! The drum clutch is an internal, expanding band-type clutch It is necessary to rotate the load drum and apply/release that is spring-applied and air-released.
  • Page 247 2250 SERVICE/MAINTENANCE MANUAL HOISTS 38 to 54 mm (1-1/2 to 2-1/8 in) View A View B Item Description Item Description Rod End Pin (qty 2) Band Guide (qty 4) WARNING Access Hole Air Line Guard Air Cylinder Falling Load Hazard!
  • Page 248 Tighten the adjusting nut as required. Turning the drop, resulting in death or serious injury. adjusting nut one flat moves the cylinder rod (17) Only use Manitowoc Cranes original equipment linings. out approximately 14 mm (9/16 in). Apply the clutch. See the procedure in Table 5-1.

  • Page 249: Band Disassembly And Assembly Notes

    2250 SERVICE/MAINTENANCE MANUAL HOISTS Band Disassembly and Assembly Notes Removing the Cylinder Figure 5-14 for the following procedure. Figure 5-14 for the following. Read the precautionary steps given in Inspection and Each clutch band consists of two segments fastened Adjustment on page 5-16.
  • Page 250 HOISTS 2250 SERVICE/MAINTENANCE MANUAL Disassembling the Cylinder Align the holes in the bonnet with the threaded rods and install the nuts (2). Figure 5-15 for the following procedure. Working in a crisscross manner, alternately tighten the Remove the four socket head capscrews (1).

  • Page 251: Inspecting And Adjusting The Drum Clutch- Right Rear Drum Clutch (421339)

    2250 SERVICE/MAINTENANCE MANUAL HOISTS INSPECTING AND ADJUSTING THE DRUM CLUTCH— RIGHT REAR DRUM CLUTCH P805 (421339) Front Drum Clutch (if equipped) General Rear or Right Figure 5-16 for the following procedure. Rear Drum Clutch The right rear drum clutch used for operation in Clamshell mode is an internal, expanding band-type clutch that is air- applied and spring-released.

  • Page 252: Inspection And Adjustment

    Only use Manitowoc Cranes original equipment linings. Maintain constant communication between the adjuster and operator so the drum is not operated while the Inspect all pins and linkage for excessive wear and adjuster is in contact with parts.

  • Page 253: Band Disassembly And Assembly Notes

    2250 SERVICE/MAINTENANCE MANUAL HOISTS If necessary, loosen the mounting screws and 13. Reinstall the cover over the access hole. reposition the band guide to obtain the specified clearance. Securely tighten the mounting screws. A1147 Item Description Dead End Live End...

  • Page 254: Marking The Cylinder Rod

    HOISTS 2250 SERVICE/MAINTENANCE MANUAL Marking the Cylinder Rod Support the blower (2) so it cannot fall and remove the bolts with nuts and lock washers (3). Figure 5-18 for the following procedure. Remove the blower, guard (4), and inlet elbow (5).

  • Page 255: Adjusting The Slack Line Sensor

    2250 SERVICE/MAINTENANCE MANUAL HOISTS ADJUSTING THE SLACK LINE SENSOR NOTE: The yellow LED on the receiver turns on when the light beam is received by the transmitter. General Tighten the screws when the light beam is correct. Figure 5-23 for the following procedure.

  • Page 256: Adjusting The Drum Pawl

    HOISTS 2250 SERVICE/MAINTENANCE MANUAL ADJUSTING THE DRUM PAWL The pawl limit switches are factory set and do not require periodic adjustment. Either limit switch must be adjusted if General parts are replaced and checked if the corresponding drum is not operating properly.

  • Page 257: Wire Rope Lubrication

    2250 SERVICE/MAINTENANCE MANUAL HOISTS A1066 Front Drum Shown, Item Description Rear Drum Similar Pawl Roller Lever Screw Shaft Ratchet Limit Switch Cylinder Air In Disengage Pawl Connect Electrical Wires to Air In Engage Pawl Normally Open Terminals Inside Limit Switch...

  • Page 258: Inspecting Wire Rope

    HOISTS 2250 SERVICE/MAINTENANCE MANUAL Inspecting Wire Rope • Reduction in rope diameter below the nominal diameter caused by loss of core support, internal or external Frequent Inspection corrosion, or wear of the outside wires Visually inspect all running ropes in service once each work •...
  • Page 259 2250 SERVICE/MAINTENANCE MANUAL HOISTS Broken Wires percent of the outer wires fractured, or 10 percent of the total numbers, whichever comes first.” Thoroughly clean the wire rope so breaks can be seen. Relax the rope, move it off pick-up points, and flex it as much as possible.

  • Page 260: Distributing Wire Rope Wear

    Drum WARNING Crushing Falling Load Hazard! S146 Replacement wire rope can break if it does not meet Manitowoc Cranes’ specifications given in the following publications supplied with the crane: Sheaves • Wire Rope Specifications Chart located in the Too Small...

  • Page 261: Inspecting Sheaves, Rollers, And Drums

    2250 SERVICE/MAINTENANCE MANUAL HOISTS INSPECTING SHEAVES, ROLLERS, AND Inspect the sheaves to verify they do not contact another sheave or structural plate work. There should be uniform DRUMS clearance between sheaves in a cluster. Repair or Perform the following inspections weekly.
  • Page 262 HOISTS 2250 SERVICE/MAINTENANCE MANUAL Re-machine or replace steel sheaves, drums, or rollers Nylon sheave properties degrade in temperatures that have been “corrugated” by the wire rope’s print as above 60ºC (140°F). shown in (Figure 5-30). Inspect nylon sheaves to verify they have not separated a n d “...
  • Page 263 2250 SERVICE/MAINTENANCE MANUAL HOISTS Plastic Sheave Data Outside Tread Rope Sheave Width Diameter Diameter Diameter Part No. inch inch inch inch B = Tread diameter, new sheave 912738 335,0 13.19 290,1 11.42 45,0 1.77 E = Tread diameter, used sheave...

  • Page 264: Inspecting The Load Block And Hook-And-Weight Ball

    Check the load block for signs of overloading such as Block Serial Number spread side plates, elongated holes, bent or elongated Block Part Number (OEM and Manitowoc) tie-bolts, and cracks. Design Factor 10. Check all welds for defects and cracks.
  • Page 265 2250 SERVICE/MAINTENANCE MANUAL HOISTS 12. Verify that each hook has a hook latch and that the hook latch operates properly. The latch must not be wired open or removed. Item Description WARNING Socket and Wedge Center Plate (qty 2) Falling Load Hazard!
  • Page 266 Furthermore, do not weld on any load-bearing component unless proper welding methods are used (contact the Manitowoc Crane Care Lattice Team for material and welding specifications). 5-36...

  • Page 267: Section 6

    2250 SERVICE/MAINTENANCE MANUAL SECTION 6 SWING TABLE OF CONTENTS Manual Release of Swing Brake ......... . . 6-1 Manual Release Procedure .
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  • Page 269: Manual Release Of Swing Brake

    2250 SERVICE/MAINTENANCE MANUAL SWING SECTION 6 SWING MANUAL RELEASE OF SWING BRAKE Manual Release Procedure This procedure is for servicing purposes only. The swing A hydraulic hand pump with a pressure gauge is needed to brake must be fully operational when operating the crane.
  • Page 270 SWING 2250 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 07-19-16, Control # 249-01...

  • Page 271: Section 7

    Diesel Exhaust Fluid (DEF) Tank ........... . 7-13 Manitowoc...
  • Page 272 2250 SERVICE/MAINTENANCE MANUAL Coolant Solenoid Valve ............7-13 Coolant Manifold .

  • Page 273: Battery Maintenance

    2250 SERVICE/MAINTENANCE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERY MAINTENANCE Excessive heat is the result of overcharging. Overheating causes the plates to warp, which can damage separators Safety Information and cause a short circuit within a cell. This resultant bubbling and gassing of the electrolyte can wash the active material from the plates, reducing the battery’s capacity or causing an...

  • Page 274: Multiple-Battery System

    POWER TRAIN 2250 SERVICE/MAINTENANCE MANUAL Multiple-Battery System Take the reading across the bottom of the liquid level. Disregard the curvature of the liquid. In a multiple-battery system, the batteries are connected Readings must be temperature-corrected. Subtract either in series or in parallel. Always refer to your wiring 0.004 from the reading for each 10°...

  • Page 275: Charging

    2250 SERVICE/MAINTENANCE MANUAL POWER TRAIN Storage NOTE: Detailed test information is provided by the meter manufacturer. When a machine is left idle for prolonged periods, it should High Resistance Test be run periodically to charge the batteries. A voltage drop (while cranking) of more than 0.2 V between...

  • Page 276: Engine Diagnostics

    POWER TRAIN 2250 SERVICE/MAINTENANCE MANUAL ENGINE DIAGNOSTICS Engine Stop Light General CAUTION Engine Damage! The Cummins QSX15 engine has the following two types of fault codes: Permanent damage can occur if the engine is run while the red Engine Stop light is illuminated.

  • Page 277: Engine Off Diagnostics

    2250 SERVICE/MAINTENANCE MANUAL POWER TRAIN Engine Off Diagnostics b. There is a 1- to 2-second pause. The red Engine Stop light flashes a three-digit code Figure 7-3 for the following. to show which active fault has been detected. A laminated list of fault codes is located in the operator’s There is a 1- to 2-second pause between each cab.

  • Page 278: Engine Air Cleaner Maintenance

    POWER TRAIN 2250 SERVICE/MAINTENANCE MANUAL ENGINE AIR CLEANER MAINTENANCE Figure 7-4 for the following. CAUTION Engine Damage! The air cleaner (1) is connected to the engine air intake (17) with a rubber elbow reducer (3), clamps (4), steel tubes (5), Drawing contaminants into the engine while it is running a rubber elbow (6), and a rubber reducer (7).
  • Page 279 2250 SERVICE/MAINTENANCE MANUAL POWER TRAIN Item Description Item Description Air Cleaner Reset Button Intake/Pre-Cleaner Housing Rubber Elbow Reducer (qty 2) Service Cover Clamp (qty 6) Primary Filter (qty 2) Steel Tube (qty 2) Secondary Filter (qty 2) Rubber Elbow Latch (qty 6)

  • Page 280: Engine Cooling System Fill

    POWER TRAIN 2250 SERVICE/MAINTENANCE MANUAL ENGINE COOLING SYSTEM FILL Cooling System Operation Cooling system flow is illustrated in Figure 7-5. The cooling system is of the deaeration type, which continually removes air from the system, as follows: WARNING • A small percentage of total coolant flow is circulated Poison Hazard! through a vent line to the radiator.

  • Page 281: Maintenance

    2250 SERVICE/MAINTENANCE MANUAL POWER TRAIN Maintenance Look for coolant leaks while the engine is running and correct causes of leaks if any are found. WARNING Burn Hazard! Prevent personal injury. Hot coolant, coolant spray, and coolant steam can cause serious injury.

  • Page 282: Draining The Radiator

    POWER TRAIN 2250 SERVICE/MAINTENANCE MANUAL Draining the Radiator Close the drain valve once the system is completely drained. Figure 7-7, Figure 7-8, and Figure 7-9 for the following. Filling the Radiator Drain the radiator system as follows. Stop the engine.

  • Page 283: Engine Throttle Adjustment

    2250 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE THROTTLE ADJUSTMENT 75° Low Idle High Idle Ref. Item Description Spring Clip Rod End Jam Nut Low Idle Reach Rod Rod End 100 mm Jam Nut (qty 2) High Idle (3-15/16 in) Pedal Stop Screw...

  • Page 284: Engine Belt Routing

    Over time, both soot and ash are collected in the DPF and the operator if regeneration is required (see Section 3 of the must be removed as follows: 2250 Operator Manual and the engine manufacturer’s manual for detailed instructions). 7-12...

  • Page 285: Exhaust Aftertreatment System

    2250 SERVICE/MAINTENANCE MANUAL POWER TRAIN EXHAUST AFTERTREATMENT SYSTEM Figure 7-12 for the following. The DEF tank (1) can hold 57 L (15 gal) of DEF. DEF consists of 32% urea and 68% de-ionized water. A varying, metered mist of DEF, equal to 2 to 3% of the fuel used, is injected into the decomposition reactor tube (DRT) (2).

  • Page 286: Diesel Exhaust Fluid (Def) Supply Pump

    POWER TRAIN 2250 SERVICE/MAINTENANCE MANUAL Diesel Exhaust Fluid (DEF) Supply Pump If an excessive NO x warning is issued, check anything that might cause an elevated NO x level, such as the following: Figure 7-12 for the following. • Disconnected DEF tank level or quality sensor...

  • Page 287: Diesel Exhaust Fluid (Def) Heating And Cooling System

    2250 SERVICE/MAINTENANCE MANUAL POWER TRAIN Diesel Exhaust Fluid (DEF) Heating and To keep the DEF flowing during cold temperatures, two heating elements are provided—one in the DEF supply Cooling System pump and one in DEF line. The heating elements turn on if Figure 7-12 for the following.

  • Page 288: Pump Drive Disconnect

    POWER TRAIN 2250 SERVICE/MAINTENANCE MANUAL PUMP DRIVE DISCONNECT Adjust the pump drive disconnect as follows. Set the length of the shift rod (9) to 699 mm (27-1/2 in), General lock it in place with the hex nut (8), and install the rod.
  • Page 289 2250 SERVICE/MAINTENANCE MANUAL POWER TRAIN 327 mm (12-7/8 in) 699 mm (27-1/2 in) Engage Disengage No Interference Either Side View A 3 mm (1/8 in) View B Item Description Item Description Latch Assembly Hex Nut Hook Shift Rod Base Plate...
  • Page 290 POWER TRAIN 2250 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 7-18 Published 07-19-16, Control # 249-01...
  • Page 291 Recalibrating the Level Sensor ......... 8-6 Manitowoc...
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  • Page 293: Turntable Bearing Bolt Torque

    2250 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE SECTION 8 UNDERCARRIAGE TURNTABLE BEARING BOLT TORQUE The gear tooth valley marked XX in the outer ring must be mounted on the longitudinal centerline at the front or rear of Installing the Turntable Bearing the carbody or carrier as shown.

  • Page 294: Replacing The Turntable Bearing Bolts

    UNDERCARRIAGE 2250 SERVICE/MAINTENANCE MANUAL Adjusting the Tread Slack When new bolts are installed, tighten the bolts in two steps, as follows. Crawler Adjustment Guideline Tighten all bolts to 814 Nm (600 lb-ft). Figure 8-2 for the following procedure. Tighten all bolts to 2 848 Nm (2,100 lb-ft).

  • Page 295: Adjusting The Tread Slack

    2250 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Adjusting the Tread Slack Figure 8-3 for the following procedure. CAUTION Adjust the tread slack at the front roller end of each crawler. Excessive Part Wear! Crawler parts will wear rapidly if they are not adjusted Thoroughly clean the crawler to be adjusted.

  • Page 296: Hydraulic Hand Pump

    HYDRAULIC HAND PUMP fittings or the castings to split at pressures lower than their rated capacity. Manitowoc provides a hand pump and cylinder to be used for performing the crawler adjustment procedure only. Any other Maintenance use of this tool is neither intended nor approved.

  • Page 297: Operating The Pump

    2250 SERVICE/MAINTENANCE MANUAL UNDERCARRIAGE Operating the Pump pressure in the cylinder. The pressure will be maintained until the valve is opened. Figure 8-4 for the following procedure. Make short strokes to reduce the amount of force Before using the pump, perform the following.

  • Page 298: Rotating Bed Level Sensor

    UNDERCARRIAGE 2250 SERVICE/MAINTENANCE MANUAL ROTATING BED LEVEL SENSOR Repeat step 2 through step 5 to reset to a different setting if necessary. The rotating bed level sensor senses the crane's pitch and Disconnect the power and install the cover. yaw. It is calibrated at the factory but can be reset if necessary.

  • Page 299: Section 9

    Lube and Coolant Product Guide ......... . 9-1 Manitowoc...
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  • Page 301: Lubrication Guide

    2250 SERVICE/MAINTENANCE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION GUIDE LUBE AND COOLANT PRODUCT GUIDE See F2298 at the end of this section. See the publication at the end of this section. Manitowoc Published 07-19-16, Control # 249-01...
  • Page 302 LUBRICATION 2250 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 07-19-16, Control # 249-01...
  • Page 303 Test 11—Testing for Voltage at the Fuse Box ......10-44 Test 12—Checking Voltage at the Control Handle ......10-45 Manitowoc 10-i...
  • Page 304 2250 SERVICE/MAINTENANCE MANUAL Test 13—Adjusting the Control Handle Potentiometer ....10-46 Test 14—Checking System Voltage at the Air Solenoid Panel ....10-47 Test 15—Checking System Voltage at the Hydraulic Valve Assemblies.

  • Page 305: Basic Troubleshooting

    If a problem is encountered the completion of maintenance or repair operations. that is not covered in this manual, first consult your dealer. The Manitowoc Crane Care Lattice Team can also provide The following warnings apply to all troubleshooting assistance if necessary.

  • Page 306: General Guidelines

    Check all terminal points for cleanliness and tighten the crane’s hydraulic or electrical systems. The test connections. equipment can be purchased in kit form (with or without carrying case) or separately by contacting the Manitowoc • Check pressures at the specified hydraulic component Crane Care Lattice Team.

  • Page 307: Troubleshooting Charts

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING TROUBLESHOOTING CHARTS PROBLEM 1 Engine will not turn over to start. POSSIBLE CAUSES Dead battery. Loose connection on battery. Starter, start solenoid (MS1) relay, or starter solenoid (SS) worn. CHECKS Check for voltage at battery terminals while attempting to turn over engine. (See Test 4—Testing the...
  • Page 308 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 2 Engine rotates, but will not start. POSSIBLE No fuel to or from injector pump. Water or algae in fuel. Air intake restricted or blocked. Engine load is too high. Low battery amperage to gain starting RPM. Fuel shut-off is not working correctly.
  • Page 309 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 3 Engine runs, but no hydraulic operation. POSSIBLE CAUSES Clutch not engaged. No hydraulic fluid in tank. Blocked charge inlet to pumps. Clogged tank vent. Drive train damaged from flywheel to pump mount. CHECKS Check hydraulic filter service shut-off valve.
  • Page 310 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 4 Engine runs, but battery is not charging. POSSIBLE CAUSES Belt loose or broken. No input to alternator terminals. Damaged alternator. Corroded or loose battery connection. Battery discharged. CHECKS Check drive belt for correct tension.
  • Page 311 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 5 Unable to build more than 6 bar (90 psi) air pressure. POSSIBLE CAUSES Safety valve, unloader valve, compressor, shut-off valve, or bleed valve may be damaged. CHECKS Is gauge pressure more than 6 bar (90 psi)? Replace pressure sensor.
  • Page 312 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 6 Engine fault alerts enable during engine operation. POSSIBLE CAUSES High engine coolant temperature or low engine oil pressure. High Engine Temperature Low Oil Pressure CHECKS CHECKS Check engine oil level at dipstick. Check coolant level and quality.
  • Page 313 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 7 Crawler travels at slow speed. POSSIBLE CAUSES Partial control voltage from handle to PC. Partial control voltage from PC to pump EDC. Pump or motor worn. CHECKS Check travel speed switch for high-speed selection.
  • Page 314 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 8 Crawlers will not travel in either direction (one or both tracks). POSSIBLE CAUSES Brake valve worn. Control handle worn. EDC bad. No voltage from handle to PC controller. No voltage out of PC controller to pump EDC.
  • Page 315 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 9 No front or rear load drum operation. POSSIBLE CAUSES Load drum disc brake not releasing. Load drum pawl not released or hung up. No voltage through control handle to PC controller. No voltage out of PC controller to pump EDC. Wiring or switch is bad.
  • Page 316 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 10 Front or rear load drum will not raise load, but will lower load. POSSIBLE CAUSES Block-up limit is opened. Pump is worn. Rated capacity indicator/limiter (RCL) circuit is open. Control handle is worn. Maximum bail limit is opened. Speed sender is bad.
  • Page 317 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 11 Front or rear load drum will not lower load, but will raise load. POSSIBLE CAUSES Pawl in. Control handle is worn. Minimum bail limit opened. Pump is worn. Speed sender is bad. CHECKS Check Diagnostic Screen D2. (See Diagnostic Display topic in this section of manual.) When applicable switch was enabled…...
  • Page 318 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 12 Front or rear load drum will not reach maximum speed. POSSIBLE CAUSES Partial control from handle to PC. Partial control voltage from PC to pump EDC. Pump or motor is bad. CHECKS When moving load drum control handle fully in both directions, does diagnostic display...
  • Page 319 Replace valve. Is there an operating or system fault? Is pressure at brake 21 bar (300 psi) or more? Consult the Manitowoc Crane Care Correct problem. Lattice Team. Is 10 volts at handle (87FA)? Manually stroke pump. (See Test 10—Manually...
  • Page 320 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 14 Boom hoist will not reach maximum speed. POSSIBLE CAUSES Partial control voltage from handle to PC. Partial control voltage from PC to pump EDC. Pump or motor worn. CHECKS When moving boom hoist control handle fully in both directions, does diagnostic DRUM 4 screen (bank 1) obtain 100% handle control in each direction? Repair or replace control handle.
  • Page 321 PCP.) Are -2.3 or more volts present at pump EDC when control handle is moved back? Repair or replace wiring or consult the Manitowoc Crane Care Lattice Team. Can boom pump be manually stroked down? (See Test 10—Manually Stroking the Pump.)
  • Page 322 PCP.) Are +2.3 or more volts present at pump EDC when Crane Care Lattice Team. control handle is moved forward? Repair or replace wiring or consult the Manitowoc Crane Care Lattice Team. Can boom pump be manually stroked down? (See Test 10—...
  • Page 323 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 17 No swing operation, but engine loads. POSSIBLE CAUSES Mechanical hang-up. Solenoid failure. Wiring fault. CHECKS Check swing operation in both directions with brake released. Slight Swing Movement No Swing Movement Check for voltage to brake solenoid with swing park brake switch in OFF position.
  • Page 324 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 18 No swing operation, engine does not load. POSSIBLE CAUSES No voltage through control handle to controller. No voltage out of controller to pump EDC. Wiring or switch is bad. Damaged pump or motor. Swing holding brake switch actuated.
  • Page 325 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 19 Travel system response is sluggish. POSSIBLE CAUSES Pump or motor is worn. Travel speed out of adjustment. CHECKS Use a gauge to check charge pressure at travel diagnostic station. (See Test 16— Checking the Pump Charge Pressure and Electrical Test.)
  • Page 326 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 20 Closed-loop hydraulic system response is sluggish. POSSIBLE CAUSES Low hydraulic oil level in reservoir. Low hydraulic oil temperature. Reservoir shut-off is partially closed. Dirty charge filter. System multifunction valves are not set correctly. Pump or motor problem.
  • Page 327 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 21 Hydraulic system is operating hot. POSSIBLE CAUSES Low hydraulic oil level in reservoir. Heat exchanger problem. Dirty filter. System multifunction valves are not set correctly. Pump or motor problem. CHECKS Is hydraulic oil level in reservoir OK? Fill tank to full level or open shut-off valve.
  • Page 328 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 22 Gantry cylinders will not raise or lower. POSSIBLE CAUSES Switch failure. Solenoid failure. Mechanical problem. Wiring problem. Cylinder failure. CHECKS Does system pressurize to 241 bar (3,500 psi) when moving gantry switch from neutral to lower position at remote control?
  • Page 329 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 23 Frame connecting pin cylinders will not extend or retract. POSSIBLE CAUSES Faulty relief valve. Faulty auxiliary system disable valve. Faulty proportional flow control valve. Cylinder failure. Faulty control valve section. Mechanical problem. CHECKS Check for 12 volts at auxiliary disable valve when enabling cylinders.
  • Page 330 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 24 Jacking cylinder(s) will not extend or retract. POSSIBLE CAUSES Faulty relief valve. Faulty control valve section. Faulty enable valve. Bad pump. Faulty cylinder. CHECKS Check for 12 volts at auxiliary disable valve when enabling cylinders.
  • Page 331 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 25 Boom hinge pin or crawler pin cylinders will not operate. POSSIBLE CAUSES Faulty relief valve, auxiliary disable valve, proportional control valve, or control valve section. Cylinder failure. Bad pump. Mechanical problem. CHECKS Check for 12 volts at auxiliary disable valve when enabling cylinders.
  • Page 332 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 26 Boom handling cylinders will not extend or retract. POSSIBLE CAUSES Faulty relief valve, auxiliary disable valve, proportional control valve, or control valve section. Cylinder failure. Pump is bad. CHECKS Check for 12 volts at auxiliary disable valve when enabling cylinders.
  • Page 333 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 27 System pump will not return to neutral. POSSIBLE CAUSES System pump control handle is worn. System pump EDC is worn or out of adjustment. System pump is bad. CHECKS Does diagnostic display screen A1 display voltage for problem system handle in neutral position?
  • Page 334 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 28 Counterweight pins will not extend (engage). POSSIBLE CAUSES Setup controller switch or wiring failure. Solenoid valve failure. Cylinder failure. Mechanical problem. CHECKS Check for 12 volts at remote control switch (wire #56B for upper counterweight and wire #56C for lower counterweight) while toggling switch.
  • Page 335 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 29 Counterweight pins will not retract (disengage). POSSIBLE CAUSES Setup switch or wiring failure. Solenoid valve failure. Cylinder failure. Fuse is blown. CHECKS Check for 12 volts at remote control switch (wire #56B for upper counterweight and wire #56C for lower counterweight) while toggling switch.
  • Page 336 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL PROBLEM 30 A load drum pawl is not operating correctly. POSSIBLE CAUSES Mechanical hang-up. Air pressure problem. No voltage to front or rear drum motor. No voltage to auxiliary drum pawl solenoid. Cylinder failure. Motor failure.
  • Page 337 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 31 Upper and lower valve cylinders are not operating. POSSIBLE CAUSES Faulty relief valve, auxiliary system disable valve, switch, or wiring. Fan circuit component failure. Pump is bad. Wiring problem. CHECKS Check for 241 bar (3,500 psi) pressure at auxiliary system disable valve while enabling any upper valve assembly components.

  • Page 338: Testing Components

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL TESTING COMPONENTS Test 1—Testing the Battery (12 and 24 volts 12 Volts DC Item Description Positive Lead Negative Lead P1538 FIGURE 10-1 Test the 12-volt DC accessory system voltage with a digital A voltage reading of 12 volts or less before engine cranking multimeter.

  • Page 339: Test 2-Checking Resistance At The Engine Temperature Switch

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 2—Checking Resistance at the Engine Temperature Switch P860 Item Description Engine Temperature Switch FIGURE 10-3 Set the digital multimeter to test resistance. Make the crane and the positive lead to the engine temperature required connections to the test lead adapter at the meter.

  • Page 340: Test 3-Checking Resistance At The Engine Oil Pressure Switch

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 3—Checking Resistance at the Engine Oil Pressure Switch P933 Item Description Oil Pressure Switch FIGURE 10-4 Set the digital multimeter to test resistance. Make the crane and the positive lead to the oil pressure switch (1) wire required connections to the test lead adapter at the meter.

  • Page 341: Test 4-Testing The Pump Edc And Motor Pcp

    (PCP) (5) requires a standard Connect the PC input cable to the PC end of the test test plug adapter (4) (can be ordered from Manitowoc plug adapter. Cranes) and a digital multimeter. To test a pump function, proceed as follows.

  • Page 342: Test 5-Cleaning And Adjusting The Engine Rpm Transducer

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 5—Cleaning and Adjusting the Engine RPM Transducer P933 Item Description Flywheel Housing RPM Transducer Lock Nut FIGURE 10-6 To clean and adjust the engine RPM transducer (2), perform Reinstall the transducer so the magnetic pickup makes the following procedure.

  • Page 343: Test 6-Location Of Motor Ports

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 6—Location of Motor Ports A1188 Swing Motor Boom Hoist, Load Drums, and Travel Motor Item Port Description Item Port Description Main System Pressure Control Pressure Main System Pressure Control Pressure Case Pressure Servo Pressure Supply...

  • Page 344: Test 7-Testing For Pump And Motor Leakage

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 7—Testing for Pump and Motor Leakage P894 P1532 Pumps Motors Item Description Case Drain Hose In-Line Flow Meter Hose to Highest Case Drain Port FIGURE 10-8 Testing for pump and motor leakage requires a 207 bar Record all measurements at neutral.

  • Page 345: Test 8-Location Of Pump Ports

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 8—Location of Pump Ports A1188 Item Description Port A—Main System Pressure Port B—Main System Pressure Case Drain (highest port as outlet) System Pressure Gauge Port A System Pressure Gauge Port B (other side) Charge Pressure Gauge Port (between multifunction valves)

  • Page 346: Test 9-Checking Voltage At The Hydraulic Brake Valve

    FIGURE 10-10 Testing for voltage at any hydraulic brake valve (1) requires a Check for 12 volts DC while releasing the brake for the standard test plug adapter (can be ordered from Manitowoc system being tested. Cranes) and a digital multimeter.

  • Page 347: Test 10-Manually Stroking The Pump

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 10—Manually Stroking the Pump P966 Item Description Manual Stroke Override Pump Electric Displacement Control (EDC) FIGURE 10-11 Test 8—Location of Pump Ports for the location of the Rotate the pump manual stroke override in the pump ports.

  • Page 348: Test 11-Testing For Voltage At The Fuse Box

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 11—Testing for Voltage at the Fuse Box A1188 F2 - HEATER & A/C 2 (8H) F3 - FRONT WIPER (8W1) F4 - OVERHEAD WIPER (8W2) F5 - DEFOGGER (8F) F6 - CONTAINER HANDLING (8X) F7 - MOISTURE EJECTOR (8M)

  • Page 349: Test 12-Checking Voltage At The Control Handle

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 12—Checking Voltage at the Control Handle P1524 Item Description Item Description Load Drum Handle Test Terminal Boom/Swing Handle Ground Terminal R Crawler Handle FIGURE 10-13 Perform the following procedure to determine the correct Place the positive lead on the test terminal (4) and the voltages at the control handle.

  • Page 350: Test 13-Adjusting The Control Handle Potentiometer

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 13—Adjusting the Control Handle Potentiometer Single Axis Controller Item Description Neutral (snap) Switch Jumper Connection (N/O) Ground Terminal R P1525 Slotted Setscrew Center Terminal C Potentiometer Socket Setscrew (qty 2) Double Axis Controller P1526 FIGURE 10-14...

  • Page 351: Test 14-Checking System Voltage At The Air Solenoid Panel

    12 volts DC while enabling the requires a standard test plug adapter (which can be ordered air solenoid being tested. from Manitowoc Cranes) and a digital multimeter. Perform Measure load current (amps) by making the current the following procedure to test for correct voltage and connections (red and white) to the digital multimeter.

  • Page 352: Test 15-Checking System Voltage At The Hydraulic Valve Assemblies

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 15—Checking System Voltage at the Hydraulic Valve Assemblies P923 Left Side Item Description DIN Plug Proportional Flow Control Valve Upper Valve Assembly (top to bottom): Spare Spare Right Front Jack Extend/Retract Solenoid Valve Right Rear Jack Extend/Retract Solenoid Valve...
  • Page 353 Measure the system voltage at various locations on the and the DIN plug (1). hydraulic valve assemblies with a standard test plug adapter (can be ordered from Manitowoc Cranes) and a digital Enable the valve being tested. multimeter. Check for 12 volts DC at the upper valve assembly (3) Figure 10-17 for identification of the valves.

  • Page 354: Test 16-Checking The Pump Charge Pressure And Electrical Test

    (can be ordered The PC null or zero routine permits the pressure transducer from Manitowoc Cranes) and a digital multimeter. to operate outside the above voltage range. If the reading is less than 0.50 volts or more than 2.00 volts, the pressure To test the incoming power at the desired pressure transducer must be replaced.

  • Page 355: Test 17-Setting The Pump Pressure

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 17—Setting the Pump Pressure P1537 P1533 Item Description Multifunction Valve Adjusting Screw for Port A Multifunction Valve Adjusting Screw for Port B Lock Nut (qty 2) Bypass Hex Nut (qty 2) FIGURE 10-19 Figure 10-19 Table 10-1 for the following.

  • Page 356: Test 18-Adjusting The Pump Charge Pressure Relief

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 18—Adjusting the Pump Charge Pressure Relief P1534 Item Description Adjusting Screw Adjusting Lock Nut Port M3 Port M1 Port M2 FIGURE 10-21 The pump charge pressure must be measured to accurately Start the engine with all brakes and locks engaged.

  • Page 357: Test 19-Setting Pump Neutral

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 19—Setting Pump Neutral P1535 Item Description Neutral Adjusting Screw (with lock nut) Servo Gauge Port (qty 2) FIGURE 10-22 To set pump neutral, perform the following procedure. Note the handle position of the hex wrench and without...

  • Page 358: Test 20-Checking Voltage At The Speed Encoders

    (2) If this reading is not obtained, check the 5 amp F11 fuse (can be ordered from Manitowoc Cranes) and a digital at the fuse panel (see Test 11—Testing for Voltage at the multimeter.

  • Page 359: Test 21-Adjusting The Counterbalance Valves

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 21—Adjusting the Counterbalance Valves P893 Right side cylinder shown, for left side P901 P1527 Example item 2 is inboard and item 3 is outboard P904 P905 Item Description Item Description Gantry Cylinder (right side) Boom Butt-Handling Counterbalance (rod end) Gantry Lifting Counterbalance (rod end—outboard)

  • Page 360: Test 22-Servicing The Motor Loop Flushing (Purge) Valves

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 22—Servicing the Motor Loop Flushing (Purge) Valves P890 Item Description Motor Loop Flushing (purge) Valve Valve Flow Control FIGURE 10-25 Problems with a bad loop flushing valve are best corrected After draining, replace the hydraulic hose.

  • Page 361: Test 23-Checking The Hydraulic Brake Pressure

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 23—Checking the Hydraulic Brake Pressure P970 P924 Swing and Travel Systems Boom/Luffing Jib System Item Description Item Description ° Pilot/Brake Pressure Relief Valve Elbow Test Port (adjusting screw on opposite side) Flexible Hose Boom Hoist Brake Control Valve...

  • Page 362: Test 24-Checking And Adjusting The Auxiliary System Working Pressure

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 24—Checking and Adjusting the Auxiliary System Working Pressure P922 P923 P923 Item Description Proportional Flow Control Valve Upper Accessory Valve Assembly Auxiliary System Disable Valve Auxiliary System Disable Valve Adjusting Screw Disable Valve Gauge Port...
  • Page 363 2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Continue to stroke the valve section after the cylinders remains below 229 bar (3,325 psi), turn the auxiliary are fully retracted during the entire test. system disable valve adjusting screw all the way in. Verify the pressure is 229 to 241 bar (3,325 to 11.

  • Page 364: Test 25-Checking Pin Cylinder Seals

    TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL Test 25—Checking Pin Cylinder Seals P1536 Item Description Cylinder Extend Hose Hydraulic Hard Line Fitting (qty 2) Cylinder Retract Hose Pin Cylinder FIGURE 10-28 Worn cylinder seals can cause problems associated with Immediately plug the hard line fitting and place the hydraulic cylinder piston movement.

  • Page 365: Test 26-Actuating The Solenoid Valve Manual Overrides

    2250 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 26—Actuating the Solenoid Valve Manual Overrides P924 P974 Item Description Hydraulic Brake Valve (qty varies) Valve Override Auxiliary System Disable Valve (qty varies) FIGURE 10-29 To check that a solenoid valve or system valve is operating •...
  • Page 366 TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 10-62 Published 07-19-16, Control # 249-01...
  • Page 367 Inspecting Sheaves, Rollers, And Drums ........5-31 Inspecting the Load Block and Hook-And-Weight Ball ......5-34 Manitowoc Index-i...
  • Page 368 Model 2250 MAX-ER 2000® Test Voltages ....... . . 3-16...

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