Page 1 Manitowoc 16000 Operator Manual...
Page 3 The serial number of the crane and applicable attachments (i.e. 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
Manitowoc Dealer........
Page 6 TABLE OF CONTENTS 16000 OPERATOR MANUAL Location ..............2-23 Pin Removal .
Page 7 16000 OPERATOR MANUAL TABLE OF CONTENTS Wireless Remote Controls ............3-42 Wired Remote Controls .
Page 8 TABLE OF CONTENTS 16000 OPERATOR MANUAL Pin and Connecting Hole Cleanliness ..........4-3 Hose and Cable Cleanliness .
Page 9 16000 OPERATOR MANUAL TABLE OF CONTENTS Connect Boom Wiring ............4-58 Perform Pre-Raising Checks .
Page 10 TABLE OF CONTENTS 16000 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK TOC-vi Published 05-09-17, Control # 011-29_v2...
Page 11 Manitowoc Dealer........
Page 12 16000 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 05-09-17, Control # 011-29...
Page 13: Section 1
EC Declaration (if applicable) MANITOWOC DEALER CRANE/ATTACHMENT IDENTIFICATION For questions about this manual or the 16000 crane, contact An identification plate is attached to the outside of the your Manitowoc dealer. If you do not know the contact operator’s cab (see...
Page 14: Identification And Location Of Components
INTRODUCTION 16000 OPERATOR MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS Item Description Upperworks Undercarriage Operator’s Cab Carbody Counterweight (both ends) Enclosures (both sides) Crawler Crane Counterweight Boom Hoist Sheaves Boom Hoist Wire Rope Mast Arms with Cylinders Mast (Live) Telescopic Boom Stop...
Page 15 16000 OPERATOR MANUAL INTRODUCTION A10740-4 FIGURE 1-2 continued Manitowoc Published 05-09-17, Control # 011-29...
Page 16: English And Metric Conversions
INTRODUCTION 16000 OPERATOR MANUAL ENGLISH AND METRIC CONVERSIONS Inverse Conversion DIVIDE (÷) known value by conversion factor to obtain Direct Conversion equivalent value in desired units. For example, 3,6576 m is MULTIPLY (x) known value by conversion factor to obtain converted to feet, as follows: equivalent value in desired units.
Page 17 16000 OPERATOR MANUAL INTRODUCTION To Convert Symbol Application Symbol Multiply By VOLUME (LIQUID) Ounce Milliliter 29.5735 Pint Liter 0.4732 Fluid Capacities Quart Liter 0.9464 Gallon Liter 3.7854 Gallon Per Minute Pump Flow Liters Per Minute L/min 3.7854 WEIGHT Pound Unit/Component Kilogram 0.4536...
Page 18 INTRODUCTION 16000 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-09-17, Control # 011-29...
Page 19: Section 2
Disassembly Precaution ............2-23 Manitowoc...
Page 20 16000 OPERATOR MANUAL Personnel Handling Policy ............2-24 Pedestal/barge Mounted Cranes.
Page 21: Continuous Innovation
Used with the safety alert symbol, indicates a hazardous manual is subject to change without notice. If you are in situation which, if not avoided, could result in minor or doubt about any procedure, contact your Manitowoc dealer moderate injury. or the Manitowoc Crane Care Lattice Team.
Page 22 SAFETY INFORMATION 16000 OPERATOR MANUAL Table 2-1 Common Safety Symbols Cut or Crush Hazards Cut Hazard M100090 M100091 M100066 M100065 M100069 M100067 Fire Crush Hazards Extinguisher M100070 M100071 M100072 M100073 M100074 M100082 Explosion Fall Hazards Falling Boom (Crush) Hazards Hazard...
Page 23: Safety And Information Signs
16000 OPERATOR MANUAL SAFETY INFORMATION Table 2-2 Miscellaneous Symbols Engine Coolant Diesel Fuel Engine Coolant Engine Oil Level Hydraulic Filter Hydraulic Oil Vent M100271 M100267 M100268 M100269 M100272 M100273 Pump Drive Oil Tire Pressure Level (if equipped) M100270 M100266 SAFETY AND INFORMATION SIGNS...
Page 24 SAFETY INFORMATION 16000 OPERATOR MANUAL Counterweight Boxes Have Non-Skid Surface Step (current production) Operator’s Platform M100274 Ladder Behind Enclosure Stairway (2 places) Stairway (2 places) Carbody and Carbody Grated Alternate Location Counterweights Have Platforms of Stairway (2 places) (Walkways) Non-Skid Surfaces...
Page 25: Crane Access Points
Falling from any height could result in serious injury or death. GETTING ON OR OFF CRANE Manitowoc has provided stairways, ladders, and platforms at Personnel getting on and off crane shall do so only at steps the locations shown in Figure 2-1.
Page 26: Operator Manual/Capacity Chart Storage
If the serial numbers of your manuals and capacity charts do not match the serial numbers of the crane or attachment, Crush Hazard! contact your Manitowoc dealer for the proper manual or To prevent personnel from being crushed by swinging capacity charts.
Page 27: Deploying Swing Radius Barrier
16000 OPERATOR MANUAL SAFETY INFORMATION A13372 View A Swing Radius Barriers WORKING View B Item Description Barrier Arm View D View C (2 places) (4 places) Spring-Loaded Pin Extension Arm Rope or Ribbon (user furnished) View C Swing Radius Barriers STORED...
Page 28: Safe Operating Practices
National Standard, or in any other applicable federal, state, planners, rigging personnel, and job site personnel in safe or local laws. operation. Manitowoc cannot foresee all hazards that will Operator training and qualification is crane owner’s arise in the field; therefore, safety remains responsibility responsibility.
Page 29 16000 OPERATOR MANUAL SAFETY INFORMATION operation, the crane shall not be operated until unsafe All attachments are properly assembled and conditions have been corrected. attached to the crane according to the rigging drawings called for in the Capacity Chart. If there is a warning sign at the start controls, the operator shall not start the engine until the warning sign b.
Page 30: Handling Load
NOTE: Capacity charts for Manitowoc cranes show the and the like. total weight of freely suspended loads for various boom and jib lengths and operating radii.
Page 31: Lifting/Moving Load
16000 OPERATOR MANUAL SAFETY INFORMATION Secure unused legs of a multi-leg sling before handling b. Avoid sudden starts and stops while swinging. Keep a load with one leg of sling. the swing speed under control to prevent the load from swinging out beyond the radius at which the...
Page 32: Multiple Load Line Operation
Engage the luffing hoist pawl when operating with Manitowoc authorizes multiple load line operation for those the luffing jib at a fixed radius. applications requiring it, provided the following steps are...
Page 33: Signals
16000 OPERATOR MANUAL SAFETY INFORMATION SIGNALS Manitowoc’s Capacity Charts are based on freely suspended loads. To prevent side load damage to the Continuous communication shall maintained boom, the jib, and the sheaves: between the operator and the signal person during all •...
Page 34: Safety Devices
• Always tag-out any faulty safety device and place a Manitowoc provides the following operational aids on its warning tag in the cab stating that the crane is out of cranes, either as standard equipment or optional equipment.
Page 35: Category 2 Operational Aids
16000 OPERATOR MANUAL SAFETY INFORMATION d. Clearly mark the boom or luffing hoist cable (so it Refer to the pendulum boom angle indicator on the can easily be seen by a designated signal person) boom butt (viewable from operator’s cab).
Page 36: Assembling, Disassembling, Or Operating Crane Near Electric Power And Transmission Lines
WARNING dangerous. Electrocution Hazard! Set-Up and Operation Manitowoc cranes are not equipped with all features required to operate within OSHA 29CFR1926.1408, Table During crane use, assume that every line is energized A clearances when the power lines are energized. (“hot” or “live”) and take necessary precautions.
Page 37: Electrocution Hazard Devices
16000 OPERATOR MANUAL SAFETY INFORMATION source. This person should have no other duties while The insulating characteristics of these devices can be the crane is working. compromised if not kept clean, free of contamination, and undamaged. Taglines should always be made of non-conductive materials.
Page 38: Refueling
Safety information in this publication is intended only as a for any evidence of damage and all damaged parts are guide to assist qualified maintenance personnel in safe repaired or replaced as authorized by Manitowoc or your maintenance. Manitowoc cannot foresee all hazards that Manitowoc dealer.
Page 39 16000 OPERATOR MANUAL SAFETY INFORMATION Place a warning sign at the start controls alerting 12. Avoid battery explosion: do not smoke while performing other personnel that crane is being serviced and the battery maintenance or short across battery terminals to engine must not be started.
Page 40: Environmental Protection
33. Perform a function check to ensure proper operation at connecting bolts or pins are being removed. the completion of maintenance or repair. 28. Unless authorized in writing by Manitowoc, do not alter ENVIRONMENTAL PROTECTION the crane in any way that affects the crane’s...
Page 41 16000 OPERATOR MANUAL SAFETY INFORMATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 2-21 Published 05-09-17, Control # 011-29...
Page 42 SAFETY INFORMATION 16000 OPERATOR MANUAL A10415 View A WRONG – DANGEROUS! and there is No Blocking If Boom is Off Ground Under Boom Sections... and Supported by Straps... Boom will COLLAPSE when Lower Pins are Removed! View B WRONG – DANGEROUS! Handling Pendants are Slack...
Page 43: Boom Disassembly Safety
16000 OPERATOR MANUAL SAFETY INFORMATION BOOM DISASSEMBLY SAFETY blocking, individual pin connections may still be under load. Pins can be ejected forcefully if the boom has any pressure NOTE: The term “boom” used in the following instructions on it or if the boom is not supported properly.
Page 44: Personnel Handling Policy
50 percent of the rated capacity conditions. for the radius and configuration of the crane. Use of a Manitowoc crane to handle personnel is acceptable • The crane is uniformly level within one percent of level provided: grade and located on a firm footing.
Page 45 • Hoisting personnel within 20 ft (6 m) of a power line that signs must be in place and legible. We also urge Manitowoc is up to 350 kV or within 50 ft (15 m) of a power line that...
Page 46: Pedestal/Barge Mounted Cranes
NOTE: If bolting carbody to foundation, contact your Manitowoc does not permit use of a truck crane on a Manitowoc dealer for recommended bolt barge, ship or floating platform. pattern and for type and quantity of bolts to be used.
Page 47 Rear When Parked Carbody Foundation Curbing Foundation FIGURE 2-8 NOTE: Manitowoc does not permit traveling with load. FIGURE 2-9 Crawler-mounted crane working on a timbered area of the barge, ship, or floating platform with the crawlers ® RINGER (crawler mounted,...
Page 48: Capacity Charts
16000 OPERATOR MANUAL Capacity Charts must be taken into account for safe operation on a barge, ship, or floating platform. Manitowoc provides two types of Capacity Charts for a crane mounted on a barge or other supporting structure under static conditions. WARNING A Capacity Chart based on tipping when the crane is anchored only to prevent shifting.
Page 49: Crane Inspection
16000 OPERATOR MANUAL SAFETY INFORMATION • Backhitch • Rotating Bed • Wire Rope • Pendants and Straps • Hook and House Rollers Through Boom Hinge Pins When equipped with hook rollers, it is recommended that each hook roller assembly be inspected daily for any sign of...
Page 50 SAFETY INFORMATION 16000 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-30 Published 05-09-17, Control # 011-29...
Page 51: Section 3
D2. Main Display ............3-19 Manitowoc...
Page 52 16000 OPERATOR MANUAL D3. Limit Bypass Switch ........... 3-19 D4.
Page 53 16000 OPERATOR MANUAL 1–Power Switch ............3-45 1a–Power Light (Wireless Remotes Only) .
Page 54 16000 OPERATOR MANUAL Pins and Fan Accessory Diagnostic Screen ........3-57 Cab Tilt, Rigging Winch, and Mast Accessory Diagnostic Screen .
Page 55 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 05-09-17, Control # 011-29...
Page 56: Standard Hand Signals For Controlling Crane Operations
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5-2014. Table 3-1 Standard Hand Signals For Controlling Crane Operations M100118 M100119 M100120 M100121 M100122 M100123 M100124 M100125...
Page 57 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Item Description HOIST—With forearm vertical, forefinger pointing up, move hand in small horizontal circles. LOWER—With arm extended downward, forefinger pointing down, move hand in small horizontal circles. USE MAIN HOIST—Tap fist on head. Then use regular signals.
Page 58: Symbol Identification
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL SYMBOL IDENTIFICATION The following symbols are used on the control consoles to identify the operating controls and their operation. Air Circulation – Cab Cylinders – Live Mast Air Circulation – Outside Data, Enter...
Page 59 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Engine Temperature Energize (turn on) Engine Heater/Defroster Engine, Battery Voltage Engine, Fuel Horn Engine Pressure Engine Run Light, Panel Engine Start Engine Stop STOP Light, Dome Engine (Tier 4) DPF High Temperature Lighter...
Page 60 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL On/Start and Off/Stop Pins – Main Mast Off/Stop Pins – Rotating Bed Front Pins – Rotating Bed Rear On/Start Scroll (up, down, and side- Park Off ways) Setup Mode Park On Pins – Disengage Speed, Fast Pins –...
Page 61 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Travel Direction Reverse – Right Crawler Swing Swing Left Travel Speed Winch, Rigging Swing Right Winch, Rigging– Haul In Rope Travel Winch, Rigging – Pay Out Rope Travel Cruise Travel Direction Windshield Wiper Forward –...
Page 62 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Extend Cylinder Pin, Hinge (telescopic beam) Retract Energize (turn on) Cylinder, Counterweight Lifting Cylinder, Telescopic Beam Set-Up (remote) Fast Engine Speed: Slow Extend Jack: Stop, Emergency Retract Left Front Wheels, Right Left Rear...
Page 63 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc Published 05-09-17, Control # 011-29...
Page 64: Front Window Operation
Read and thoroughly understand instructions in this section, in Section 2, and in Capacity Chart Manual. Knob • Contact your Manitowoc dealer for assistance if you do not clearly understand any operating procedure. P1752 View C (2 places at top of window)
Page 65: Cab Door Damper Adjustment
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CAB DOOR DAMPER ADJUSTMENT It may take several trial and error adjustments to obtain desired damping. Figure 3-4 for the following procedure. The cab door damper prevents the cab door from slamming open or closed. This is especially critical when the cab is P2289 tilted at an angle other than horizontal.
Page 66 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL A02019 A09260 A1297 Low Idle High Idle Shown in Connected (Closed) Disengaged Position Position P2290 To Disconnect Pull Out to Engaged Hydraulic Heater Electrical Cord (1 each side of crane) Right Side of Upperworks...
Page 67: Controls Identification And Function
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CONTROLS IDENTIFICATION AND Push handle FORWARD to DECREASE engine speed. FUNCTION NOTE: The selected engine speed is maintained when the handle is released. The speed of the crane functions depends on engine speed and on how far the control handles WARNING are moved in either direction from off.
Page 68: B - Accessory Controls
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL A1297 Electrical G and H Test Port (Cab Floor) Left Side of Hydraulic Tank P2233 Laptop Computer Connector Thermostat Knob (for loading software and Under Covers programming functions) FIGURE 3-6 P1708a B – Accessory Controls •...
Page 69: B4. Climate Control
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES NOTE: The windshield washer tank is mounted at rear of B6. Cab Tilt Switch cab support. Fill the tank with a quality brand PRESS and hold TOP of rocker to RAISE front of cab.
Page 70: B13. Tinted Visor And Shade
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL P2101 A17492 Left Side of Boom P2102 On Cab Support A00984 Inside Cab at Rear Behind Operator’s Seat Released Applied P2229 Left Side of Cab Floor Typical at Boom A09311 and Jib Points...
Page 71: C - Indicators
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES B15. Fire Extinguisher C2. RCL Alarm (optional) One fire extinguisher is in operator’s cab behind seat. The amber beacon rotates and the alarm sounds whenever Foreign code requires another fire extinguisher be mounted the crane’s capacity is near an overload condition (when...
Page 72 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL A1297 Under Seat FIGURE 3-10 3-18 Published 05-09-17, Control # 011-29...
Page 73: D - Special Controls
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Figure 3-10 for the following indicators. Remove key to prevent unauthorized operation. C6. Fuel Level D4. Luffing Jib Limit Bypass Switch This switch bypasses the limits identified in Table 3-2. This Indicates amount of fuel remaining in fuel tank.
Page 74 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Table 3-2 Bypassable Limit Identification This Table Applies Only to Cranes with Limit Bypass Switch (D3) and Luffing Jib Limit Bypass Switch (D4) Luffing Jib Limit Bypass Switch Limit Bypass Switch (D3) 1, 2...
Page 75 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-3 Bypassable Limit Identification This Table Applies Only to Cranes without Limit Bypass Switch (D4) Limit Bypass Switch (D3) External Limit Bypass Switch (D3) (momentary key switch) Override (momentary key switch) Limit...
Page 76 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-22 Published 05-09-17, Control # 011-29...
Page 77: Luffing Jib Setup Mode
Table 3-3 can be bypassed. NOTE: The software version of your crane is shown in the Manitowoc screen of the main display (see Figure 3-35). Access the Setup Enter the function mode screen in the main display Mode Screen...
Page 78 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL A02452 DRUM AND HANDLE IDENTIFICATION Description Drum No Rigging Winch (in boom butt) Boom Butt Load Drum (in boom butt) Load Drum Load/Luffing Drum (in boom butt) Mast Boom/Mast Hoist ® with MAX-ER ®...
Page 79: E - Boom/Mast Hoist Controls
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES F – Load Drum Controls Figure 3-14 for drum and handle identification. E – Boom/Mast Hoist Controls Each load drum has a spring-applied, hydraulically-released disc brake on motor at one end of drum.
Page 80: G - Swing Controls
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL A1297 FIGURE 3-14 G – Swing Controls Press BOTTOM of rocker to TURN OFF swing park switch. With park switch off, swing handle is operable, swing brake is Figure 3-14 for swing controls.
Page 81: H - Travel Controls
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES G3. Swing Holding Brake Switch In low speed, the travel motors operate at approximately 1/3 the speed of high speed. Use the swing holding brake switch (on side of handle) to NOTE: It is okay to change travel speed while traveling: hold the rotating bed in position for short periods of time during the operating cycle.
Page 82: Limit Devices
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL LIMIT DEVICES The test is complete: release the limit bypass key and the boom stop rod to the normal operating positions. Table 3-2 Table 3-3 to determine which limit bypass switch bypasses a given limit.
Page 83: Luffing Jib Down Limit
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES NOTE: For cranes meeting 2010 European Requirements The luffing jib can be raised after either limit is contacted. and with crane software version FCN 2.654 and NOTE: For cranes meeting 2010 European Requirements newer, the luffing jib cannot be lowered after JIB and with crane software version FCN 2.654 and...
Page 84: Seat Controls
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL SEAT CONTROLS BACKREST CAUTION • Move switch up to release backrest. Avoid Damage! Disconnect electric cord from rear of left • Use body weight to adjust backrest console before you remove seat from •...
Page 85: Preparing Crane For Operation
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES PREPARING CRANE FOR OPERATION Moving Machinery Hazard! To avoid injuring personnel or damaging crane and property: • Do not start engine if warning or out-of-order sign is WARNING present at start controls. Read Capacity Charts! •...
Page 86: Operation
Pull Ring Out NOTE: Manitowoc recommends the use of heaters to Unlock (engine, hydraulic tank, etc.) to aid startup when the ambient temperature will be 32°F (0°C) and Past Production below.
Page 87 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES NOTE: If the engine does not start, check to see if the Select crane configuration and capacity charts on RCL engine emergency stop switch or the remote display, Configuration screen. The load drums and hoist control stop switch is depressed.
Page 88: Boom/Mast Hoist Operation
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Select crane configuration and capacity charts on RCL display, Configuration screen. Drum 4 or 5 Drum 3 Standard Luffing Jib Turn off Drum 4 or Drum 5 park switch. Configuration Configuration Lower Drum 4 or 5...
Page 89: Luffing Hoist Operation
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Luffing Hoist Operation Figure 3-18 for Luffing hoist operation. CAUTION Avoid Boom or Luffing Jib Damage! When the crane is configured with a luffing jib (Drum 3), the multi-function handle on left console controls the luffing jib...
Page 90: Swing Operation
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Turn off swing park switch. Swing Left Swing Right CAUTION Avoid Boom/Swing Drive Damage! Do not apply swing holding brake or turn on swing park switch while swinging; brake will bring rotating bed to an abrupt stop.
Page 91: Load Drum Operation
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES WARNING Falling Load Hazard! Prevent load on unused drums from falling. Turn on drum Lower park switch for drums not in use. Load Select crane configuration and capacity charts on RCL display, Configuration screen.
Page 92: Travel Operation
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Travel Operation CAUTION Boom Damage! WARNING Avoid shock loading boom and rigging! Tipping Hazard! • Perform all travel functions — starting, turning, stopping — slowly and smoothly. Travel surface must be firm and uniformly supporting.
Page 93 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES To TRAVEL STRAIGHT (Figure 3-21), move both crawler handles same amount in desired direction from A823 off. A823 Forward Forward Left Right Crawler Crawler Left Handle Right Handle Crawler Crawler Handle Handle Reverse FIGURE 3-23 11.
Page 94: Stopping Engine/ Leaving Crane Unattended
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL STOPPING ENGINE/ LEAVING CRANE Turn on drum park switch for each load drum. UNATTENDED If possible, lower boom and luffing jib onto blocking at ground level and turn on boom park switch. If the boom and luffing jib cannot be lowered, as...
Page 95: Remote Controls
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES REMOTE CONTROLS • Manual carbody remote control shown in Figure 3-33 Remote Control Priority The following instructions apply only to Crane Serial Number WARNING 16001128 and newer. Read Instructions! The swing and travel alarm will sound continuously when a...
Page 96: Wireless Remote Controls
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Wireless Remote Controls P1976 Remote Control Stored on Shelf Behind Seat in Cab P2288a A12639 View A — with Upperworks Jacking View B — with Carbody Jacking Item numbers in this figure correspond to the component numbers under...
Page 97: Wired Remote Controls
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Wired Remote Controls Node-5 Right Side of Rotating Bed WN-OUT Receptacle Remote Control WNE14T Electric Cable WNE14T Electric Cable Stored In Cabinet on Cab Rear Item numbers in this figure correspond to the component numbers under the topic...
Page 98: Crane Setup Remote Control Activation
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Crane Setup Remote Control Activation Scroll up or down to turn on the remote control. Continue to hold down the power button on the Wireless Remote Control remote control until the remote control ON The wireless remote control can be operated in any mode.
Page 99: Crane Setup Remote Controls Operation
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Remote Control WARNING Moving Part Hazard! FIGURE 3-32 To avoid serious crushing injury: 14-COM-3-23 • Keep feet clear of moving jacks. Scroll up or down to turn on (I) remote control. • Warn all personnel to stay clear of jacks while they Remote control ON prompt remains in display until it is are being extended.
Page 100: 8-Boom Pins Switch
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL 8–Boom Pins Switch 11–Counterweight Pins Switch Move toggle DOWN and hold to DISENGAGE counterweight pins. Counterweight pins return to ENGAGED position when toggle is released. WARNING 12–Engine Speed Switch Falling Load Hazard! The engine speed switch allows the operator to select high To prevent boom or boom butt from falling off the crane: or low engine idle speed from a remote position.
Page 101: Carbody Remote Controls Operation
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Carbody Remote Controls Operation Push handle TOWARD carbody to LOWER carbody (retract jack). The speed at which the jacks and pins operate depends on Release handle to CENTER to stop jack. Valves on the jack control handle movement and engine speed.
Page 102: Displays
Use the green select touchpad buttons to select screen images, icons or data boxes, and values or icons within data 16000 FCN 2.039 and newer, try the following procedure to restore the display. Do not return a display to Manitowoc boxes.
Page 103: Main Gui Display Format
60 seconds at startup if there is a problem with the data logger (most likely caused by the real time clock). A graphic picture of the Manitowoc logo is displayed at crane startup (see Figure 3-35.) The Manitowoc screen displays...
Page 104: Information Screen
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Pressure Test and Calibration Screen icon charts, all crane operations must be performed with crane level to within one 1% of grade in all directions — 1 ft in 100 ft The Menu screen operates on one level only.
Page 105: Max-Er® (Optional)
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES • Fuel level in percent of fuel in main tank Table 3-4 lists all the faults that can appear in the fault screen. Some of the fault items shown in Table 3-4 •...
Page 106 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Table 3-4. Faults (*=optional) Item Description 50-Jib Maximum Down 1* — Program limit Item Description activates fault alarm. Operation does not stop. 0-No Fault. You can lower luffing jib an additional 3° to Luffing jib maximum down 2 limit (67).
Page 107: Diagnostic Screen
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Item Description Item Description 69-Hydraulic Reservoir Level— Hydraulic oil at 85-CAN Communication — One or more caution low level indicated on tank gauge. Fill computer nodes are not communicating tank. correctly. See CAN Bus screen to identify node(s).
Page 108 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Gear Pump Disc Brake Accessory pump or system charge pump. Displays disc brake status— ap plied or released (shown). Variable Closed-Loop Motor Swing Lock (Past Production) Displays motor command with 0% maximum displacement and 100% minimum displacement.
Page 109: Tier 4 Engine Diagnostic Information
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Remote Control: Wireless and Wired is on (see page 3-19 and Engine Manufacturer’s Manual for additional information): Displays remote control status by indicating • ON when DPF is starting to fill. Turn off regeneration which switches are closed.
Page 110: Swing Diagnostic Screen
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Drum Diagnostic Screens Swing Diagnostic Screen Select drum icon in screen level 1 as shown Figure 3-38. Select swing icon in screen level 1 as shown in Figure 3-40. Press Enter button to go to level 2...
Page 111: Jacking Accessory Diagnostic Screen
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Jacking Accessory Diagnostic Screen D16-09 Select crane carbody with jacking icon in screen level 1 as shown in Figure 3-44. Press Enter button to go to level 2 Diagnostic Screen Diagnostic Screen Travel Selected...
Page 112: Cab Tilt, Rigging Winch, And Mast Accessory Diagnostic Screen
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL FIGURE 3-46 FIGURE 3-48 D16-13 D16-15 For counterweight pins, boom hinge pins, front/rear rotating For cab tilt, rigging winch, and mast raising cylinders screen pins, and engine fan screen see Figure 3-47. In the Figure 3-49.
Page 113: Function Mode Screens
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Function Mode Screens Swing Functions Select swing functions from screen shown below. Figure 3-50 for the following procedure. The Function Mode screens are used to enable/disable modes and set operating parameter for the individual crane Swing functions.
Page 114: Swing Pressure Limit
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL In level 3, use the Select buttons to enable or disable the D16-19 motion limiter mode. When in level 3 with the motion limiter mode enabled, the controller monitors and stores the maximum right/left or up/down angles during operation. After exiting level 3, these angles are used to limit boom or swing motion.
Page 115 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 3-61 Published 05-09-17, Control # 011-29...
Page 116: Can Bus Screen
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL CAN Bus Screen Each individual input/output is assigned a number (identifier) in the binary system (powers of two). The identifiers of all Figure 3-60 for the following procedure. inputs/outputs that are ON (active) for each bank are added for a total of 0 –...
Page 117: Load Link Status
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES The number displayed in the crane status top bank 128 — indicates a RF (radio frequency) communication corresponds to the numbered communication errors listed error. below: Drum load link and wireless remote battery status displays: 0 —...
Page 118 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Table 3-6 Digital Output Disable 38-1-128 Load Hoist (Drum 1) LS Motor Control (N6) 38-2-1 Load Hoist (Drum 1) RS Motor Control (N6) CAN Packet 38-2-2 Load Hoist (Drum 1) Min. Bail Limit Sw. (N6)
Page 119: Digital Output Reference Chart
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Digital Output Reference Chart Table 3-7 Digital Outputs CAN Packet Item Description CAN Packet Item Description Number (Node Number) Number (Node Number) CAN24-1-1 Cab Base RCL Beacon (N2) CAN26-2-32 Boom Hoist (Drum 5) Pawl – In (N6)
Page 120: Digital Input Reference Chart
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL CAN Packet Item Description CAN Packet Item Description Number (Node Number) Number (Node Number) ® CAN-28-2-64 Right Front Jacking Cylinder Extend (N7) MAX-ER CAN-28-1-1 Counterweight Lift Cylinder Extend (N7) CAN-28-2-128 Right Front Jacking Cylinder Retract (N7)
Page 121 16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-9 Bank Identifier Numbers Dark shaded boxes indicate ON; white boxes OFF. Manitowoc 3-67 Published 05-09-17, Control # 011-29...
Page 122 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Table 3-9 Bank Identifier Numbers (continued) Dark shaded boxes indicate ON; white boxes OFF. 3-68 Published 05-09-17, Control # 011-29...
Page 123: Camera Screen (Optional)
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Camera Screen (Optional) The pressure sender test calculates the zero-pressure output level for each pressure sender. Pressure sender null The camera screen (not shown) displays camera options (0) must be within 0.65 to 1.35 volts.
Page 124: Control Calibration
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL NOTE: The cause of a failed pressure sender test or faulty Inability to smooth start motion. display pressure reading may not be the pressure Calibrate controls as follows: sender. The cause of the fault could be trapped air Apply all park brakes and start engine.
Page 125: High Pressure Test
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES High Pressure Test Press Enter button to go to level 2. Use Select buttons to show HIGH PRESSURE Figure 3-63 for the following procedure. icon in data box. The high pressure test checks the ability of all primary crane Press Confirm button to start test.
Page 126: Charge Pressure Test
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Charge Pressure Test pressure within a specified range is highlighted yellow. Troubleshoot failed circuit to determine cause of fault. Figure 3-64 for the following procedure. The charge pressure test checks the ability of all primary cane functions to build proper charge pressure.
Page 127: Wind Conditions
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES WIND CONDITIONS Wind speed (to include wind gusts) must be monitored by job planners and supervisors. Wind adversely affects lifting capacity and stability as shown The wind speed at boom or jib point can be greater than wind Figure 3-65.
Page 128 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL Forward stability is affected by wind on A910 the rear of the boom. Wind applies a force to the boom and load that adds to the crane’s overturning moment. This action has the same effect as adding load to the hook.
Page 129: Preparation For Cold Weather
Each heater has an extension cord for connecting to an Manitowoc cranes is not affected by cold weather. owner furnished electric power supply. The coolant heater Manitowoc’s capacity charts are acceptable for use in cold must be capable of maintaining the engine’s coolant and oil weather.
Page 130: Hydraulic Oil
Turn on external power supply. Heater package described in this section may not provide Turn on main circuit breaker. adequate protection when operating below -30°F (-34°C). Contact Manitowoc dealer for recommendations. Turn on each heater circuit breaker. Hydraulic Pump Damage! Turning Heaters Off To prevent damage to pumps, warm hydraulic oil to 60°F...
Page 131: Circuit Breakers
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CIRCUIT BREAKERS Perform the remaining steps only if power supply cord will be disconnected or electrical system is being See Section 3 in the Service Manual for identification and serviced: location of circuit breakers used to protect crane’s electric Turn off external power supply.
Page 132: Past Production Cold Weather Package
OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL PAST PRODUCTION COLD WEATHER PACKAGE Item Description 240 Volt Receptacle Main Circuit Breaker Engine Coolant Heater Engine Oil Heater Hydraulic Reservoir Heaters Left Side (2) or Top (1) Hydraulic Reservoir Heaters Right Side (2)
Page 133: Current Production Cold Weather Package
16000 OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES CURRENT PRODUCTION COLD WEATHER PACKAGE Item Description 240 Volt Receptacle Main Circuit Breaker Engine Coolant Heater Engine Oil Heater Hydraulic Reservoir Heater Not Used Mounted on Rear of Cab Cab Front Console Heater...
Page 134 OPERATING CONTROLS AND PROCEDURES 16000 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-80 Published 05-09-17, Control # 011-29...
Page 135 Remove Boom Butt ............4-38 Manitowoc...
Page 136 16000 OPERATOR MANUAL Disassemble Boom............4-39 Remove Counterweight .
Page 137 16000 OPERATOR MANUAL Duplex Hook ..............4-72 Guide Sheaves and Drums .
Page 138 16000 OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-iv Published 05-09-17, Control # 011-29_v2...
Page 139: Rigging Drawings
Do not exceed swing limits and mast lifting capacities given in Table 4-2. The 16000 is equipped with the following self-erect • Keep the crane level when operating carbody jacks. components for assembly and disassembly: Carbody jacks with pads for lifting the crane onto and off WARNING the trailer.
Page 140: Assist Crane Requirements
Optional boom ladders (stored in boom first 40 ft [12 m] insert) are available from Manitowoc. If your crane has Read and become thoroughly familiar with the instructions in ladders, see the Boom Ladder Assembly instructions.
Page 141: Handling Components
16000 OPERATOR MANUAL SET-UP AND INSTALLATION HANDLING COMPONENTS RETAINING CONNECTING PINS The major components are equipped with lifting lugs which Connecting pins are retained in various ways: are identified in the assembly and disassembly steps. • Snap pins • Quick-release pins CAUTION •...
Page 142 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Component Identification Item Description Live Mast Handling Pendant (Mast and Boom Butt) Load Block — 45 USt (41 t) 4-Leg Chain Sling Operator’s Cab Crawler Assembly Rotating Bed Adapter Frame Carbody Carbody Jacks Carbody Counterweight (both ends)
Page 143 16000 OPERATOR MANUAL SET-UP AND INSTALLATION Table 4-2 Operating Limitations See Liftcrane Mast Capacities Chart at the end of this section for detailed lifting capacities. Crane Configuration Swing Max Capacity Max Radius • Crane on carbody jacks (rotating bed, adapter frame, and carbody) •...
Page 144: Shipping Crane Components
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL SHIPPING CRANE COMPONENTS Rated Capacity Indicator/Limiter (RCL/RCI) Configuration screen. See the RCI/RCL manual for instructions. To ensure the crane’s self-erecting system can load and The boom hinge pins, upper counterweight cylinder pins, cab unload the carbody and upperworks assembly, the trailer...
Page 145: Pre-Start Checks
16000 OPERATOR MANUAL SET-UP AND INSTALLATION PRE-START CHECKS Cable Terminator Make the following checks before starting the engine upon Plug arrival at the assembly site. See Section 3 for starting instructions. Engine Check for leaks. Check fuel, oil, and coolant levels.
Page 146: Crane Assembly
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL CRANE ASSEMBLY Store rain caps (3) in enclosure frame (View A). Remove both exhaust pipes (2) from shipping position Install Exhaust Pipes (Past Production) (View A). IMPORTANT Perform following steps before starting Install both exhaust pipes (2) in working position (View...
Page 147 16000 OPERATOR MANUAL SET-UP AND INSTALLATION View A Top of Rotating Bed Over Engine with Rear Enclosure Panels Removed Item Description Rear Enclosure Panel Exhaust Pipe Rain Cap Connecting Springs Spring Anchor WORKING Position SHIPPING Position SHIPPING Position WORKING (point down)
Page 148: Remove Crane From Trailer
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL CIRCLED NUMBERS CORRESPOND TO REMOVE CRANE FROM TRAILER PROCEDURE Jack Pads Stored (both ends of carbody) View A View B 10 1 Connecting Pin (working hole) Connecting Pin (storage hole) Carbody Jack (stored) Jack Rod...
Page 149 16000 OPERATOR MANUAL SET-UP AND INSTALLATION Remove connecting pin from storage hole (View C). Using controls on front of carbody, extend carbody jacks fully to raise the crane off trailer. Swinging is Rotate jack out from storage position to working position prohibited.
Page 150 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Item Description Live Mast Mast Assist Arm and Cylinder 103° Minimum Operating Boom Hoist Angle with Load Boom Hoist Wire Rope 115° Mast Assist Arm Contact Operating Range 142° Maximum Operating Angle with Load 156°...
Page 151: Raise Live Mast To Operating Position
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Raise Live Mast To Operating Position • Hazard warning symbol and MAST BELOW 2 DEGREES icon will appear on fault screen. Figure 4-9 for the following procedure. The following controls are used to raise the mast. See...
Page 152 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL 4-9C 4-9D A10740-18a A10740-21 14,000 lb (6 350 kg) Stored View B From Whip View A Drum View C Component Identification Item Description Live Mast Handling Pendant Owner-Furnished Nylon Slings Assist Crane Load Block...
Page 153: Install Assembly Block
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Install Assembly Block Figure 4-10 for the following procedure. WARNING Crush Hazard! Do not stand or work under mast unless it is supported by WARNING assist crane. Falling Mast Hazard! Prevent mast from falling: •...
Page 154 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL A10740-11bb Component Identification Item Description Assembly Block 4-Leg Chain Sling Grab Hook Crawler Item not used P1972 View A View B FIGURE 4-11 4-16 Published 05-09-17, Control # 011-29_v2...
Page 155: Handling Crawlers
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Handling Crawlers Using grab hooks, shorten both outboard legs eleven chain links so crawler tips inward when lifted. Figure 4-11 for the following procedure. Position chains between crawler pads (View A). Attach hooks from chain sling (7, View A and B) to four shackles (9) on crawler lifting lugs —...
Page 156 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL 4-10aa See Liftcrane Mast Capacities 4-10cc P2230a Chart at end of this section for detailed lifting capacities. View G 1 - Entire Underside P1985 View F View A View E P1984 1 - Entire Underside...
Page 157: Install Crawlers
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Install Crawlers crane while traveling. Though not harmful, operators may find the sounds disturbing. The crane must be in the following configuration to install Once the crawlers are installed, the drive shafts will be at...
Page 158 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL 4-11A 4-11EE View B P1932 View C P1941b (stored) View A View F (4 places each crawler) P2283 View D P1941a Tip of Hook Must Pass Through Holes in Pad as Shown View E...
Page 159: Install First Crawler (Continued)
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Legend for Figure 4-14 Item Description Item Description Chain with Hook Flange Screw (8 each) Crawler Pad Drive Shaft Guard Crawler Lug Safety Pin Crawler Drive Shaft 11-14 See Figure 4-12 Storage Bracket Crawler Assembly (First Installed)
Page 160 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Carbody Counterweight Identification 4-13A A10786 Required Each End Weight Each Total Weight Item Description of Carbody lbs (kg) lbs (kg) No Carbody Series 1 Counterweight 30,000 60,000 Series 2 Center Box (13 608) (27 216)
Page 161: Install Counterweight
Attach crawler handling shackles to lifting lugs (3) Identification and installation of additional counterweight for on center box (1). the 16000 Series 4 and 5 are located in separate 16000 Wind Attachment manuals. b. Attach legs of chain sling to shackles.
Page 162 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL View C A11446-1 Alternate Location Alternate Location Legend Item Description Platform Platform Extension Support Safety Pin Hitch Pin View A Stairway (2 provided) Sleeve Safety Pin Stored Working Position View B FIGURE 4-16 4-24...
Page 163: Install Crawler Platforms
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Install Crawler Platforms Install Crawler Stairways Figure 4-16 for the following procedure. Figure 4-16 for the following procedure. The crawlers are equipped with platforms (1) as shown in If the crawler stairways are not already installed, proceed as View A.
Page 164 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL A10787-2 45,000 lb (20 412 kg) Legend Item Description Handling Pendant Hydraulic Couplers Hooks 24 ft (7,3 m) To Ground Counterweight Pin Hitch Pin Adapter Plate Lifting Sling (Owner Furnished) Stored Installed View B...
Page 165: Install Crane Counterweight
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Install Crane Counterweight Hoist, travel, boom, and swing as required with assist crane to guide counterweight tray into position under The crane counterweight must be installed with an assist rear of rotating bed (View C).
Page 166 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL 4-15D A10882 M4-11c Legend Item Description Boom Butt Wire Rope Guide Lifting Lug Pin with Cotter Pins Hoses Couplers in Boom Butt Shipping Couplers on Rotating Bed Position Hinge Pin Locking Pin Shims View A...
Page 167: Assemble Boom
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Assemble Boom Shim tabs must face inward and rest on rotating bed lugs. The boom can now be assembled using live mast. b. Install next thickest shim possible between inboard See Boom Assembly later in this section for detailed side of butt and first shim on both sides of crane.
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Page 169 16000 OPERATOR MANUAL SET-UP AND INSTALLATION P2021 Legend Item Description Coupling Assist Tool Retaining Bar Safety Pin Motor Pilot Anti-Cavitation High Pressure Case Drain View A Views B and C are from Crane Looking Forward P2263a P2264a View C View B...
Page 170 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL 4-17B 4-17C Legend 4-17F Item Description Trailer Boom Butt Mast Stored Chain Sling 14,000 lb Assembly Block (6 350 kg) Handling Pendant View A Assist Crane Load Block Nylon Sling Mast Strap Hooked Connector...
Page 171: Remove Assembly Block
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Remove Assembly Block Raise mast to at least 150° with assist crane. As mast is raised haul in wire rope on boom hoist. Figure 4-20 for the following procedure. 10. Once mast is at or above 150°, support mast with boom hoist wire rope and disconnect handling pendants (6) from assist crane block.
Page 172 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Legend Item Description Mast Strap Insert Strap Links Pin (shipping) Link (shipping) Pin, with Collar, Retaining Pin, and Cotter Pins Terminator Plug with Sealing Cap Electric Cable on Crane Electric Cable From Boom Electric Cable from Drum 1 on Boom...
Page 173 16000 OPERATOR MANUAL SET-UP AND INSTALLATION Figure 4-21 for the remaining steps. Remove pins (5, View C) from storage. Connect electric cable from crane to controller on boom d. Rotate links (2, View A) up and pin to mast straps butt: (1a) with pins (5, View B).
Page 174: Node-6 Configuration With Mast Stop Limit Switch
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Node-6 Electrical Connections For MAX-ER With Mast Stop Limit Switch 6a (behind) 6b (behind) View B View A Legend Item Component Description Node 6 Front of Rotating Bed Receptacle W66 W66 Shorting Plug w/ Dust Cap...
Page 175: Working Configuration With Boom (View B)
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Working Configuration with Boom (View B) Connect sealing caps to electric cables (9 and 10) and store the cables in the boom butt. Disconnect terminating plug (2b, View A) from Disconnect electric cable from cable reel in butt at receptacle (2a).
Page 176: Install Assembly Block
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL d. Slowly boom down to lower boom onto blocking at Reeve wire rope from whip drum through sheaves in least 6 in (152 mm) (View C). mast point and sheaves in assembly block (see Figure 4-10, View B).
Page 177: Disassemble Boom
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Remove Counterweight Disconnect hydraulic hoses (5a, View B) from couplers (5b) in boom butt. Thoroughly clean couplers to prevent dirt from entering hydraulic system. WARNING Connect hydraulic hoses (5a, View C) to couplers (5c) Tipping Hazard! on left side of rotating bed.
Page 178: Remove Crawler Stairways
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Repeat steps 1 and 2 at other end of carbody. Attach shackles to crawlers for storage. WARNING Remove Crawler Stairways Tipping Hazard! Figure 4-16, View C for the following procedure. To prevent the crane from tipping — remove crane If necessary, remove each crawler stairway as follows: counterweight before removing carbody counterweight.
Page 179: Remove Assembly Block
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Using controls on front of carbody, extend carbody jacks until crawler treads are just clear of ground. CAUTION A 2-way level is provided near controls on front of Parts Damage! carbody to aid in jacking.
Page 180: Lower Live Mast To Shipping Position
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Lower Live Mast To Shipping Position Figure 4-9 for the following procedure. CAUTION Equipment Damage! Use extreme care not to hit jacks with trailer when backing trailer into position: WARNING Provide a signal person to give instructions to truck driver.
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Page 182 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL A13170 View A Stored View B (4 places) Hooked Over Top Chord View C (4 places) Legend Item Description 40 ft (12 m) Insert Ladder Hook Keeper Rubber Latch View D Installed Firm Against...
Page 183: Boom Ladder Assembly
• Avoid improper use. Ladder is intended for use only pad (6) is firm against lower chord (View D). on Manitowoc #58 boom inserts. Any other use is prohibited. Ladder must hang vertically against boom insert when in use.
Page 184: Boom Rigging
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL BOOM RIGGING Assist Crane Requirements WARNING Either the live mast or an assist crane can be used to handle Falling Load Hazard! and assemble the boom section. See Crane Weights in Section 1 for the weights of boom sections.
Page 185: Identifying Boom And Jib Components
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Identifying Boom and Jib Components Boom straps and links are marked for proper identification as shown in View D, Figure 4-24. Boom and jib sections are marked for proper identification as NOTE: The markings shown in...
Page 186 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL A11388 A11543 Lift Here A10740-24 A10740-25 Lift Here Operating Position Shipping Shipping Position Position View A Operating Position View B Operating Position Stored View C Working Position Shipping Holes A Position Holes B 16 in Hole A...
Page 187: Assemble Boom Sections
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Attach a sling to rope guide pin. b. Support wire rope guide with hoist and remove pin (3) from shipping position. WARNING Raise wire rope guide to operating position and Crushing Injury Hazard! install pin (3).
Page 188 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL A11543-1 Luffing Jib Straps, Links, and all Hardware Must be Collars Toward Inside A11543-2 Removed if Luffing Jib is Not Used of Boom Sections View B View A Shipping Position Working Position Legend 7a or 7b...
Page 189: Connect Boom Straps
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Connect Boom Straps NOTE: Intermediate suspension is required at locations specified in Boom Assembly Drawing. Figure 4-26 for the following procedure. If not already done, replace links (2a, View A) with links The boom straps and links are shipped on the boom sections (2b, View C).
Page 190 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL A11388-4,5,6 View B 2 Places View A Legend Item Description Boom Top Lower Boom Point Lifting Holes Lower Pin with Cotter Pins Upper Pin with Cotter Pins Pin (long) with End Plates and Hex Screws...
Page 191: Install Standard Upper Boom Point
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Install Standard Upper Boom Point Install Extended Upper Boom Point Figure 4-25, View F for the following procedure. Figure 4-28 for the following procedure. Do not install standard upper boom point if an extended Remove lower boom point, as follows: upper boom point or luffing jib will be installed.
Page 192 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Stored P2320 View A View A View B View C P2321 View D View E FIGURE 4-29 4-54 Published 05-09-17, Control # 011-29_v2...
Page 193 16000 OPERATOR MANUAL SET-UP AND INSTALLATION For past production units, proceed as follows: h. If equipped with long top pins (6) in upper holes, store them with end plates (Figure 4-28, View C). Figure 4-29 for the following procedure. Install short top pins (6a, View D) and outboard end Remove pins (8, View A) to disconnect links (9) from plates.
Page 194 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Lift Stored View B View A P2321 View C View D View E P2320 View G View F View H FIGURE 4-30 4-56 Published 05-09-17, Control # 011-29_v2...
Page 195 16000 OPERATOR MANUAL SET-UP AND INSTALLATION For current production units, proceed as follows: Install short top pins (6a, View D) and outboard end plates. Figure 4-30 for the following procedure. m. Securely tighten end plate screws for pins (6 and Remove pins (8, View B) to disconnect links (9a) 6a).
Page 196: Install Load Line
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Install Load Line Perform Pre-Raising Checks Load Block Reeving instructions for proper routing and Perform following pre-raising checks and correct any defects reeving of load lines. before raising boom.  Crane on firm, level surface.
Page 197 16000 OPERATOR MANUAL SET-UP AND INSTALLATION Store insert straps and links. NOTE: It is not necessary to remove the boom straps. The straps can be left on the inserts for shipping. WARNING Rotate links at front end of butt and inserts forward...
Page 198 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL d. Lower wire rope guide (7) to shipping position. Attach a sling to rope guide pin. Using pin (9) pin lug (8) to upper boom point. b. Support wire rope guide (2) with hoist and remove pin (3) from operating position.
Page 199 16000 OPERATOR MANUAL SET-UP AND INSTALLATION Item Description Item Description Wire Rope Guide Lower Boom Point Weight Extended Upper Boom Point (lower sheaves) Lift Plate Standard Upper Boom Point Load Block Extended Upper Boom Point (upper sheave) Weight Block-Up Limit Switch...
Page 200: Wire Rope Installation
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL WIRE ROPE INSTALLATION NOTE: Wire rope manufacturer’s recommendations take precedence over information in this section. Reel Wire Rope Storage Drum Store wire rope in coils or on reels off the ground or floor in a Brake clean and dry indoor location.
Page 201: Anchoring Wire Rope To Drum
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Seizings WARNING Wire Rope Type Required Moving Machinery Hazard! Preformed Guards must be secured to drums during crane operation. Non-preformed When guards are removed for wire rope installation, use extreme care to prevent injury from a moving dead-end Place free end of seizing wire in valley between two stands.
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Page 203: Winding Wire Rope Onto Drum
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Winding Wire Rope onto Drum Tap adjacent wraps against each other with a soft metal or wooden mallet. See Drum and Lagging Chart in Capacity Chart Manual for Use extreme care not to put twists or turns in wire rope;...
Page 204 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL T (Rope Clip Nut Torque) Wire Rope/Clip Size TL (Tail Length) inch 1-1/8 1-1/4 Standard 6 to 8 Strand Wire Rope (mm) (22,23) (25,4) (28,58) (31,75) Minimum of 6 rope diameters, Torque but not less than 6 in (152 mm).
Page 205: Anchoring Wire Rope To Wedge Socket
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Anchoring Wire Rope to Wedge Socket Anchoring Wire Rope to Button Socket WARNING WARNING Falling Load Hazard! Falling Load Hazard! Wire rope can break if the following precaution is not observed: • Inspect all parts prior to use. Do not use parts that are cracked or otherwise defective.
Page 206: Drum Kicker Adjustment
General Some rotation-resistant wire rope supplied by Manitowoc is equipped with a pad eye welded to the leading end of the wire rope or to the button on the end of the wire rope.
Page 207 16000 OPERATOR MANUAL SET-UP AND INSTALLATION A1189 A09310 Rope Pull Rigging Line Clips with Winch or Fork-Lift Truck Rigging Line Wire Rope from Drum Wire Rope P1519 Boom Point Sheaves Wire Rope Load Block Sheaves EXAMPLE without Button Wire Rope No.
Page 208: Rigging Winch Operation
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL RIGGING WINCH OPERATION Operating Rigging Winch If your crane is equipped with the optional rigging winch Free-Spool Operation (Drum 0) see the Rigging Winch Assembly drawing at the The winch has a free-spool clutch which allows the drum end of this section for wire rope routing.
Page 209: Power Operation
16000 OPERATOR MANUAL SET-UP AND INSTALLATION Current Production Rigging Winch Gear Mode Free-Spool Engaged Gear Mode Disengaged Item Description Gear Shifting Lever FIGURE 4-44 Power Operation CAUTION! Turn free spool off and engage gear mode. Avoid Rigging Winch or Wire Rope Damage! Turn on rigging winch mode.
Page 210: Reeving - Load Block
SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Secure end of rigging line to boom for storage. Connect load line to dead-end socket. See instructions in this section. WARNING Falling Load Hazard! g. Turn OFF rigging winch mode. Limit load to be handled with shackle to capacity of load REEVING –...
Page 211 16000 OPERATOR MANUAL SET-UP AND INSTALLATION Standard Upper Boom Point Extended Upper Boom Point NOTE: See Wire Rope Specifications Chart for line pull of Item Description drums. Drums 2 and 3 do not have same line pull Main Hoist (Drum 1 in boom butt) as Drum 1.
Page 212 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL A08493 This Link Not Used (if equipped) Battery Side of Wireless Load Cells Anchored to Boom Point Must Face Away from Crane Item Description Extended Upper Boom Point Standard Upper Boom Point Link with Pin with Cotter Pin Pin with Cotter Pin Load Cell –...
Page 213 16000 OPERATOR MANUAL SET-UP AND INSTALLATION A11388 Item Description Lower Boom Point Battery Side of Wireless Load Cell Anchored to Boom Point Wire Rope Guide (on boom top) Must Face Away from Crane Luffing Hoist Guide Sheave Whip Hoist Guide Sheave...
Page 214 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Reeving_1 LOWER BOOM POINT REEVING 6 Part 3 Sheave Block with Item Description Upper Boom Point Boom Top Guide Sheaves (Standard) Lower Boom Point Load Block Standard Upper Boom Point Dead-End Socket Two-Block Weight...
Page 215 16000 OPERATOR MANUAL SET-UP AND INSTALLATION Reeving_2 LOWER BOOM POINT REEVING 14 Part 12 Part 9 Sheave Block 9 Sheave Block 16 Part 18 Part 9 Sheave Block 9 Sheave Block 22 Part 20 Part 13 Sheave Block 13 Sheave Block...
Page 216 SET-UP AND INSTALLATION 16000 OPERATOR MANUAL Item Description Boom Top Guide Sheaves Extended Upper Boom Point (lower sheaves) Load Block Dead-End Socket Reeving_3 Two-Block Weight EXTENDED BOOM POINT REEVING (Lower Sheaves) 2 Part 4 Part 6 Part FIGURE 4-50 4-78...
Page 217: Reeving - Live Mast
16000 OPERATOR MANUAL SET-UP AND INSTALLATION REEVING – LIVE MAST Wire Rope Specification Manitowoc recommends the following wire rope for the live General mast: The live mast wire rope must be reeved between Drum 4 and Manitowoc #A05680 — the mast hoist sheaves as shown in Figure 4-51.
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Page 219: Section 5
Lubrication ..............5-1 Manitowoc...
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Page 221 16000 OPERATOR MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION See F2109 at the end of this section. Manitowoc Published 05-09-17, Control # 011-29...
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Page 223 Fiberglass Maintenance ............6-1 Manitowoc...
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Page 225: Inspection And Maintenance Checklist
16000 OPERATOR MANUAL MAINTENANCE CHECKLIST SECTION 6 MAINTENANCE CHECKLIST INSPECTION AND MAINTENANCE FIBERGLASS MAINTENANCE CHECKLIST See Bulletin W04-009 at the end of this section. See F2097 at the end of this section. Manitowoc Published 05-09-17, Control # 011-29...
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Page 227 Manitowoc Dealer........
Page 228 16000 OPERATOR’S MANUAL Operator Manual/Capacity Chart Storage ..........2-6 Optional Attachments .

Manitowoc 16000 Operator's Manual

Section 1

Section 2

Section 3

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