Manitowoc 2250 MAX-ER 2000 Operator's Manual
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Manitowoc 2250 MAX-ER 2000 Operator's Manual

Manitowoc 2250 MAX-ER 2000 Operator's Manual

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Manitowoc
2250
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MAX-ER
2000
Operator Manual

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Summary of Contents for Manitowoc 2250 MAX-ER 2000

  • Page 1 Manitowoc 2250 ® MAX-ER 2000 Operator Manual...
  • Page 3 NOTICE The serial number of the crane and applicable attachments (i.e. luffing jib, MAX-ER) is the only method your Manitowoc dealer or Manitowoc Crane Care 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 5: Table Of Contents

    Manitowoc Dealer........
  • Page 6 TABLE OF CONTENTS 2250 MAX-ER 2000 OPERATOR’S MANUAL Pin Removal ..............2-22 Disassembly Precaution .
  • Page 7 2250 MAX-ER 2000 OPERATOR’S MANUAL TABLE OF CONTENTS Install Load Line............. . 4-26 Install Block-Up Limit Control.
  • Page 8 TABLE OF CONTENTS 2250 MAX-ER 2000 OPERATOR’S MANUAL Lower Boom and Jib............4-69 Lower Jib Strut .
  • Page 9 2250 MAX-ER 2000 OPERATOR’S MANUAL TABLE OF CONTENTS Removing Jib or Boom Point ........... . 6-12 Maintenance .
  • Page 10 TABLE OF CONTENTS 2250 MAX-ER 2000 OPERATOR’S MANUAL THIS PAGE INTENTIONALLY LEFT BLANK TOC-vi Published 01-08-13, Control # 049-05...
  • Page 11 Manitowoc Dealer ........
  • Page 12 2250 MAX-ER 2000 OPERATOR’S MANUAL THIS PAGE INTENTIONALL LEFT BLANK 1-ii Published 01-08-13, Control # 049-05...

  • Page 13: Crane Data

    2250 MAX-ER 2000 OPERATOR’S MANUAL INTRODUCTION SECTION 1 INTRODUCTION CRANE DATA CRANE ORIENTATION See the end of this section for crane data specific to your The terms RIGHT, LEFT, FRONT, REAR used in this manual crane: see operator’s right, left, front, and rear sides when seated in the operator’s cab looking forward.
  • Page 14 INTRODUCTION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 Upper Boom Point Boom Lower Straps Boom Point Boom Hoist Equalizer Hook and Weight Ball 25 ft (7,6 m) Transition Insert Load Lines Load Block Boom Hoist Wire Rope (from Drum 2) 130 ft (39,6 m)

  • Page 15: Outline Dimensions

    2250 MAX-ER 2000 OPERATOR’S MANUAL INTRODUCTION OUTLINE DIMENSIONS 140 ft 3-1/2 in 42,8 m) Mast Height 50 ft 40 ft 30 ft 15,2 m) 12,2 m) 9,14 m) Radius Radius Radius 12 ft 4 in 10 ft 2 in 3,7 m)

  • Page 16: Weights Of Components

    INTRODUCTION 2250 MAX-ER 2000 OPERATOR’S MANUAL WEIGHTS OF COMPONENTS NOTE: Weights may fluctuate ±3% due to manufacturing tolerances Weight Description Pounds Kilograms LIFTCRANE: Upperworks and lowerworks complete, 2 swing drives, counterweight, gantry, backhitch, MAX-ER equipped with 462,000 lb (209 560 kg) wheeled counterweight, 130 ft (39,6 m)
  • Page 17 2250 MAX-ER 2000 OPERATOR’S MANUAL INTRODUCTION Weight Description Pounds Kilograms 34 ft 5-3/4 in (10,5 m) counterweight strap (each) 26 ft 10-5/8 in (8,2 m) counterweight strap (each) 26 ft 6 in (8,1 m) counterweight strap (each) 1 ft 1 in (0,3 m) counterweight link set (each) with pins and collars 2 ft (0,6 m) counterweight link set (each) with pins and collars NO.
  • Page 18 INTRODUCTION 2250 MAX-ER 2000 OPERATOR’S MANUAL Weight Description Pounds Kilograms NO. 44 FIXED JIB: 40 ft (12,2 m) butt 8,605 3 903 30 ft (9,1 m) top with lower point and wire rope guide 12,040 5 461 10 ft (3,0 m) insert - No. 44 1,890 20 ft (6,1 m) insert - No.
  • Page 19 2250 MAX-ER 2000 OPERATOR’S MANUAL INTRODUCTION Weight Description Pounds Kilograms WIRE ROPE: Boom Hoist - 2,600 ft (792 m) of 1-1/8 in (28,6 mm) wire rope - 2.58 lb per ft (3,84 kg/m) 6,710 3 043 Load Lines 1-1/8 in (28,6 mm) wire rope - 2.58 lb per ft (3,84 kg/m)

  • Page 20: English And Metric Conversions

    INTRODUCTION 2250 MAX-ER 2000 OPERATOR’S 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 21: Change Of Ownership Registration

    907.1847 CHANGE OF OWNERSHIP REGISTRATION MANITOWOC DEALER A new owner of a Manitowoc crane should register the crane For questions about this manual, the MLC165 crane, or the with Manitowoc Crane Care so we can contact you if the MLC165 luffing jib, contact a Manitowoc dealer. Before need arises.
  • Page 22 INTRODUCTION 2250 MAX-ER 2000 OPERATOR’S MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-10 Published 01-08-13, Control # 049-05...
  • Page 23 Pedestal Mounted Crane ............2-26 Manitowoc...
  • Page 24 2250 MAX-ER 2000 OPERATOR’S MANUAL Definition ............. . . 2-26 Examples .

  • Page 25: Diesel Engine Exhaust

    2250 MAX-ER 2000 OPERATOR’S MANUAL SAFETY INFORMATION SECTION 2 SAFETY INFORMATION DIESEL ENGINE EXHAUST safety alert symbol and a signal word to identify the hazard’s degree of seriousness. Safety Alert Symbol WARNING California Proposition 65 Diesel engine exhaust and some of its constituents are This is the safety alert symbol.
  • Page 26 SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Crush Hazards Cut or Crush Hazards Electrocution Hazard Cut Hazard Explosion Hazard Fall Hazard FIGURE 2-1 Published 01-08-13, Control # 049-05...
  • Page 27 2250 MAX-ER 2000 OPERATOR’S MANUAL SAFETY INFORMATION Engine Diesel Coolant Fuel Engine Hydraulic Coolant Filter Vent Fall Hazards Engine Hydraulic Oil Level Pump Drive Oil Level Fluid Symbols Flying Object Hazards Falling Boom Hazards (Crush Hazard) Overhead Obstruction Hazard Falling Load Hazards...

  • Page 28: Safety And Information Signs

    SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Sound Power Level Personal Fall Protection Read Manual Pressure Cleaning Tire Pressure (if applicable) Pressure Release Hazard FIGURE 2-1 continued SAFETY AND INFORMATION SIGNS Maintaining Signs The crane owner/user shall make sure that all safety and information signs are legible and installed at the proper locations on the crane.

  • Page 29: Crane Access Points

    A s s e m b l y i n S e c t i o n 4 o f t h i s m a n u a l f o r instructions. Manitowoc has provided stairways, ladders, and platforms at the locations shown in Figure 2-2.
  • Page 30 SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL P824 Catwalks Boom Butt View E Catwalk P823 Gantry View D P821 Catwalk Tube View A Standard Cab Shown Steps (4 places) (2 places) A1048 Rear Load Drums View C Catwalk View B...
  • Page 31 2250 MAX-ER 2000 OPERATOR’S MANUAL SAFETY INFORMATION A03893 Elevated Cab Catwalk/ Back-Up Catwalk/ Shown Platform Power Plant Platform Operator’s Stairs Enter/ Exit Catwalk/Platform Between Drums Enter/ Exit Catwalk/ View E Platform Elevated Cab FIGURE 2-2 continued Manitowoc Published 01-08-13, Control # 049-05...

  • Page 32: Operator's 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, STORAGE contact your Manitowoc dealer for the proper manuals or Manitowoc provides the following manuals and other Capacity Charts.

  • Page 33: Safe Operating Practices

    (United States Federal Law), in ASME B30.5 American planners, rigging personnel, and job site personnel in safe National Standard, or in any other applicable federal, state, operation. Manitowoc cannot foresee all hazards that will or local laws. arise in the field; therefore, safety remains responsibility Operator training and qualification is crane owner’s...
  • Page 34 SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL necessary or if there are known defects that impair safe 11. The operator shall verify that: operation, the crane shall not be operated until unsafe All attachments are properly assembled and conditions have been corrected.

  • Page 35: 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 36: Lifting/Moving Load

    SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Secure unused legs of a multi-leg sling before handling Accelerate and decelerate the load smoothly to a load with one leg of sling. avoid excessive stress on the crane boom and machinery. Lifting/Moving Load b.
  • Page 37 2250 MAX-ER 2000 OPERATOR’S MANUAL SAFETY INFORMATION p r e ve n t s h ift in g , t o p p l in g , o r e xc e ss iv e If equipped, the automatic travel alarm will sound settlement under load.

  • Page 38: Signals

    The crane operator must be familiar with the operational Manitowoc authorizes multiple load line operation for those characteristic of the crane as it relates to multiple drum applications requiring it, provided the following steps are...

  • Page 39: Safety Devices

    2250 MAX-ER 2000 OPERATOR’S MANUAL SAFETY INFORMATION be agreed upon in advance by the operator and the Manitowoc provides the following safety devices on its signal person. The signals used shall not conflict with or cranes. have potential to be confused with the standard signals.

  • Page 40: Category 1 Operational Aids

    SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Category 1 Operational Aids NOTE: The temporary alternative measures for the anti- t wo - b lo ck d ev ise d o no t a p pl y wh e n li ft in g If a Category 1 operational aid is not working properly, it must p e r s o n n e l in l o a d l i n e s u p p o r t e d b a s k e ts .

  • Page 41: Assembling, Disassembling, Or Operating Crane Near Electric Power And Transmission Lines

    The qualified person directing the lift shall establish Electrocution Hazard! procedures to furnish equivalent protection (for Manitowoc cranes are not equipped with all features example, assign an additional signal person to observe required to operate within OSHA 29CFR1926.1408, Table the distance between the boom or load and job site A clearances when the power lines are energized.

  • Page 42: Set-Up And Operation

    SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL the load, load line, or crane boom if it comes too close to stops does not ensure that electrical contact will not an electrical power source. Low voltages can also be occur. Even if codes or regulations require the use of dangerous.

  • Page 43: Electrical Contact

    ; t h e r e f o r e , s a f e t y r e m a i n s If the dealer is not immediately available, contact responsibility of maintenance personnel and crane Manitowoc Crane Care at the factory. The crane must owner. not be returned to service until it is thoroughly inspected...

  • Page 44: Safe Maintenance Practices

    SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL crane’s operation and required maintenance as well as the hazards involved in performing these tasks. Training and qualification of maintenance and repair WARNING personnel are crane owner’s responsibility. Burn and Inhalation Hazards! Safe Maintenance Practices Temperature of exhaust and exhaust components for Tier 4 engines can be higher than other engines.

  • Page 45: Environmental Protection

    13. Read safety information battery 28. Unless authorized in writing by Manitowoc, do not alter manufacturer’s instructions before attempting to charge a battery. the crane in any way that affects the crane’s performance (to include welding, cutting, or burning of 14.

  • Page 46: Boom Disassembly Safety

    SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL BOOM DISASSEMBLY SAFETY WARNING Falling Boom Hazard! DANGER! Crane can tip or boom can collapse if excess boom is Collapsing Boom Hazard! cantilevered. Never cantilever more boom than specified Prevent death or serious injury when disassembling boom in Boom Assembly Drawing.
  • Page 47 2250 MAX-ER 2000 OPERATOR’S MANUAL SAFETY INFORMATION A1301 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 –...

  • Page 48: 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 49 Manitowoc recommends that cranes be properly maintained, regularly inspected, and repaired as necessary. All safety adverse weather conditions which could affect the signs must be in place and legible. We also urge Manitowoc safety of personnel . crane owners to upgrade their cranes with rated capacity •...

  • Page 50: Pedestal/Barge Mounted Cranes

    Manitowoc does not permit use of a truck crane on a barge, ship or floating platform. Pedestal Mounted Crane Carbody Also see ASME publication B30.8-2004, Floating Cranes...

  • Page 51: Barge Mounted Crane

    Front and Required Crawler-mounted crane with carbody anchored with tie- Rear When Parked Carbody downs to the foundation (Figure 2-8). Curbing Foundation NOTE: Manitowoc does not permit traveling with load. FIGURE 2-9 ® RINGER (crawler mounted, carbody mounted) Tie-Downs Carbody...

  • Page 52: Capacity Charts

    Trim Pitch FIGURE 2-11 Capacity Charts Operation On Barge Manitowoc provides two types of Capacity Charts for a crane General mounted on a barge or other supporting structure under Machine list and/or dynamics will be experienced when a static conditions.

  • Page 53: Crane Inspection

    2250 MAX-ER 2000 OPERATOR’S MANUAL SAFETY INFORMATION angle between horizontal and a line drawn through overloading in the following load bearing components is centerline of the crane’s boom hinge pins. required. Correct each defect found before placing the crane into service.
  • Page 54 SAFETY INFORMATION 2250 MAX-ER 2000 OPERATOR’S MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-30 Published 01-08-13, Control # 049-05...
  • Page 55 Wind Conditions............3-18 Manitowoc...
  • Page 56 2250 MAX-ER 2000 OPERATOR’S MANUAL 3-ii Published 01-08-13, Control # 049-05...

  • Page 57: Standard Hand Signals For Controlling Crane Operations

    2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5 - 2007 USE WHIPLINE. (Auxiliary LOWER. With arm extended HOIST.
  • Page 58 OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL STOP. Arm extended, palm EME RG ENCY STO P. Both T R AV E L . A r m e x t e n d e d DOG EVERYTHING. Clasp down, move arm back and...

  • Page 59: General Instructions

    2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES GENERAL INSTRUCTIONS COUNTERWEIGHT The instructions in this section supplement the operating See Figure 3-3, View E in this section and the MAX-ER control instructions in your Crane Operator’s Manual. This Capacity Charts for counterweight identification and section also contains operating precautions.

  • Page 60: Drum Identification

    OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL DRUM IDENTIFICATION MAX-ER 2000 Drum in Boom Butt Drum 2250 and MAX-ER 2000 Number MAX-ER 225 or 400 Front Load Drum No Drum Available Rear or Right Rear 2250 Boom Hoist...
  • Page 61 2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES FIGURE 3-2 continued Right Console Left Console a1060_a a1060_c HANDLE-TO-DRUM IDENTIFICATION HANDLE A HANDLE B HANDLE C HANDLE D Mode/Drum Options Controls Controls Controls Controls Standard or Setup Mode Split Rear Drums (2-Drum Crane)
  • Page 62 OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL P1308a P1305 Receptacle for MAX-ER Remote Control (left side of trailer) P1311 Receptacle for Mast Strap Pins Remote Control (left side of crane) Cord from Mast Strap Pins Remote Control Left Side of Trailer...
  • Page 63 2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Remote Control Mast Strap Pins Extend Jack Raise Counterweight (Extend Cylinder) Raise Counterweight Carrier Retract Jack Lower Counterweight Lower Counterweight Carrier (Retract Cylinder) Lower Tongue Left Jack (Retract Cylinder) Raise Tongue...

  • Page 64: Max-Er Operating Controls

    OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL MAX-ER OPERATING CONTROLS Crane Mode Selector – Crane Software Version 5007 and Higher Crane Mode Selector – Crane Software The crane mode selector is located in the operator’s cab. Version 5005 and Lower See Section 3 in your Crane Operator’s Manual for operation...
  • Page 65 2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES To TURN OFF MAX-ER Mode proceed as follows: Trailer Controls Turn crane mode key clockwise repeatedly until MAX- CRANE MODE ER ON appears on display as shown in Figure 3-13. TRAILER CTL ON...

  • Page 66: Symbol Identification

    OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL Symbol Identification Toggle DOWN to RETRACT all jacking cylinders at same time. The symbols shown in Figure 3-4 are used to identify 6. Steering Pins Control controls on current production remote controls.

  • Page 67: Digital Display

    2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Connect cord from mast strap pins remote control to A LOAD PIN fault occurs due to faulty voltage output from receptacle on MAX-ER controller (Figure 3-3, View C). the pin (at or near 0 volts or at or near 10 volts).

  • Page 68: Tire Inflation

    OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL TIRE INFLATION assemblies have been rotated and pinned in proper position. Check tire inflation weekly. Inflate tires equally to: Make sure crawlers are blocked, if required per Capacity • Michelin 116 -120 psi (8,0 - 8,3 bar).

  • Page 69: Operating The Max-Er

    2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES 15. Warn all personnel to stand well clear of crane. Wheeled Select and confirm desired main mode — Standard, counterweight assembly rises and lowers automatically Drum 5 [Luff Jib], Drum 5 [Aux Hst] — and MAX-ER without warning —...
  • Page 70 OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL A1153 All Views from Top Looking Down Trailer Frame and other Details Removed for Clarity SWING Right Side Shown Left & Right View A Left Side Similar Pin 2 View B...

  • Page 71: Traveling And Swinging

    2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Traveling and Swinging Swing upperworks wheeled counterweight assembly in-line with crawlers (perform Swinging steps). The following travel and swing instructions apply only when Raise counterweight with jacking cylinders until bulge is the MAX-ER wheels are on the ground.

  • Page 72: Swinging

    OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL Set stop pins (see Table 3-2). Rotate wheels to until Pin 2 hits stop plate (crab position) (View E). DANGER Engage steering pins (Pin 3) in outer Holes A (View B).
  • Page 73 2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Table 3-3 Pinning Arrangements Tongue Rear Jack Struts Front Jacks Axle Function Hole 1 Hole 2 Hole 3 Hole 4 Hole 5 Hole 6 Wedges Trailer NOT ATTACHED to Crane Shipping (CRAB Position)

  • Page 74: Leaving Crane Unattended

    OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL LEAVING CRANE UNATTENDED When crane is left unattended, it shall be parked as instructed in Section 3 of the Crane Operator’s Manual. The WARNING following additional steps shall be taken if the boom cannot Tipping Crane Hazard! be lowered to ground.
  • Page 75 2250 MAX-ER 2000 OPERATOR’S MANUAL OPERATING CONTROLS AND PROCEDURES Forward stability is affected by wind o n t h e r e a r o f t h e b o o m . W i n d applies a force to the boom and load that adds to the crane’s overturning...
  • Page 76 OPERATING CONTROLS AND PROCEDURES 2250 MAX-ER 2000 OPERATOR’S MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-20 Published 01-08-13, Control # 049-05...

  • Page 77: Section 4

    General ............4-35 Manitowoc...
  • Page 78 2250 MAX-ER 2000 OPERATOR’S MANUAL Install Counterweight (current production)....... 4-37 Install Counterweight (past production) .
  • Page 79 2250 MAX-ER 2000 OPERATOR’S MANUAL Wire Rope Storage ..........4-72 Removing Wire Rope from Shipping Reel .
  • Page 80 2250 MAX-ER 2000 OPERATOR’S MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-iv Published 01-08-13, Control # 049-05...

  • Page 81: Max-Er 2000 Components

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION SECTION 4 SET-UP AND INSTALLATION Programmable Controller which operates the attachment’s electric and hydraulic systems to automatically raise and lower the wheeled counterweight assembly in response to signals from the load sensing pin and the boom hoist control WARNING handle.

  • Page 82: Assist Crane Requirements

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL prevent falling off the crane and attachment during assembly and disassembly. O w n e r / u s e r s h a l l p r o v i d e a p p r o v e d l a d d e r s o r...

  • Page 83: Blocked Crawlers

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION NOTE: See MAX-ER 2000 Capacity Charts for capacity limitations and counterweight requirements for Boom Removable operation with mast only (wheeled counterweight or Mast 7/8-9UNC x 2-1/2 in Diagonal removed). Insert Grade 5 Hex Bolt...
  • Page 84 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Disconnect boom butt from remainder of boom and 10. Lower gantry (see Gantry Raising and Lowering in travel crane to rear approximately 20 ft (6,1 m). Leave Crane Operator’s Manual). boom butt connected to crane.
  • Page 85 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc Published 01-08-13, Control # 049-05...
  • Page 86 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 Fixed Pin B Vertical Mast Butt with Hole C1 Adapter Frame Hole C2 Pin A with Keeper Plate Mast View C Sections View B 40 ft (12,2 m) 10 ft (3,0 m)

  • Page 87: Install Max-Er Attachment

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Install MAX-ER Attachment Lower mast butt onto blocking 12 in (305 mm) high (View A). Install Mast Install mast inserts: See Figure 4-3 for following procedure. Lift 10 ft (3,0 m) insert into position and engage top...
  • Page 88 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Line from A1152 Line from Assist Crane Tie-Down Clip Assist Crane Gantry Mast Strap (intermediate position) Bracket (working) P684 View B Gantry (stored) View D Mast Strap Bracket (stored) View C Mast...

  • Page 89: Install Straps

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Straps Slowly pay out 2250 mast hoist wire rope (Drum 4) and carefully lift equalizer clear of tie-down clips on gantry See Figure 4-4 for following procedure. (View B) (must guide equalizer forward slightly).
  • Page 90 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 1/2 in 9 in (229 mm) Rod End (12.7 mm) 4-9/16 in (116 mm) View C 18 20 View A View B View D To Mast To Boom Stop Stop (stored)

  • Page 91: Connect Mast Straps

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Connect Mast Straps d. Unpin equalizer from rails. Store stop pins (12) in lugs on rails. See Figure 4-5 for following procedure. Connect Counterweight Straps Mast straps and links are stored on the mast top and butt for shipping.

  • Page 92: Install Intermediate Suspension Links

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Install Intermediate Suspension Links Perform following steps only for #79-44 boom lengths that require intermediate suspension. Intermediate suspension is See Figure 4-5 for following procedure. required for boom lengths of 320 ft (98 m) – 400 ft (122 m).
  • Page 93 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-13 Published 01-08-13, Control # 049-05...
  • Page 94 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 A1247 Accumulator P1620 P1619a Gauge (behind fitting) Accumulator View C1 View C2 Gauge Hose H4 Must be From Coupled to Hose H5 Prior Mast Accessory to Starting Engine when Stop System...

  • Page 95: Raise Mast

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Dimension L Horizontal Vertical 36,6 13,450 10,940 45,7 13,450 9,230 61,0 13,450 7,320 76,2 13,450 6,070 Holdback forces are with equalizer attached NOTE: to holdback 3 ft (0,9 m) above ground. Boom Hoist...
  • Page 96 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Stop engine. Fully close (clockwise) valve knob (4, View C3). Make sure locking knob doesn’t prevent full closure of valve knob. WARNING Make sure valve (3, View C3) is fully open — line on valve stem in line with piping.
  • Page 97 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-17 Published 01-08-13, Control # 049-05...
  • Page 98 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Mast at A1152 A1193 75° Circled Numbers in Illustrations Correspond to Numbered Steps 40° – 75° in Raise Mast Procedure. MAST CAN BE USED AS A BOOM (See Mast Capacities for Self-Assembly and Disassembly.)

  • Page 99: Raise Mast

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Raise Mast Slowly mast up (hoist with Drum 4). Pay out boom hoist wire rope (boom down with Drum 2) as needed. See Figures 4-7 and 4-8 for following procedure. Stop raising mast when it is at 70 – 75° (View A).
  • Page 100 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 Circled Numbers in Illustrations Correspond to Numbered Steps in Raise Mast Procedure. View F (viewed from above) Strut Cylinder View A Equalizer Rod End Spreader P1299 Beam Mast 21 24 Remote...
  • Page 101 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION See Figure 4-8 for remainder of procedure. d. If saddle does not align properly with gantry pin after adjusting length of strut rod, adding, removing, or 15. As mast nears vertical, gradually tighten boom hoist wire...
  • Page 102 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Tongue Rear Jack Struts Front Jacks Axle Function Hole 1 Hole 2 Hole 3 Hole 4 Hole 5 Hole 6 Wedges Trailer NOT ATTACHED to Crane Shipping (CRAB Position) Pin A No Pin...

  • Page 103: Install Wheeled Counterweight Assembly

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Wheeled Counterweight Assembly b. For 40 ft (12,2 m) radius, pin one 10 ft (3,0 m) insert to adapter. Before attaching wheeled counterweight assembly to 2250, For 30 ft (9,1 m) radius, only the adapter is used.
  • Page 104 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Connect electric power cord from trailer to receptacle on Install pins to connect trailer arm adapter to crane. crane (Figure 4-11, View C). Move trailer pins to proper positions for Trailer NOTE: Remaining steps require use of trailer remote ATTACHED to Crane (Figure 4-9).
  • Page 105 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Strap Cylinder (working) Strap Cylinder (stored) Locking Counterweight See Counterweight Installation View A A1152 Front of Trailer Viewed from front View B of Trailer A1153 FIGURE 4-12 14. Raise each strap cylinder...

  • Page 106: Install Boom

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Install Boom All insert and strap connecting pins are installed and properly retained. See Boom Rigging in this section for boom installation Jib inserts and pendants are installed in proper instructions. sequence.

  • Page 107: Remove Max-Er Counterweight

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Remove MAX-ER Counterweight Disconnect Trailer from Crane WARNING DANGER Tipping Hazard! Trailer Tipping Hazard! Alternate removal of counterweight boxes from front to • Support trailer on a firm level uniformly supporting rear and from side to side to prevent unbalanced loading surface in either of following positions when it is of trailer.

  • Page 108: Lower Mast

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Remove pins attaching trailer arm adapter to lugs on crane (Figure 4-10, View C). Dimension L Horizontal Vertical (Figure 4-6, View D) Use jacks and tongue cylinder to raise or lower trailer arm as required to loosen pins.
  • Page 109 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-29 Published 01-08-13, Control # 049-05...
  • Page 110 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 A1193 Mast at 75° MAST CAN BE USED AS A BOOM (See Mast Capabilities for Self- Assembly and Disassembly.) CAUTION Continuing to boom up after equalizer is snug in forks will Mast at damage equalizer and/or mast.
  • Page 111 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION The SETUP mode must be selected in order to lower the Lower mast by slowly paying out mast hoist wire mast. The following controls are used: rope. Haul in boom hoist wire rope as needed to keep boom hoist equalizer off ground.

  • Page 112: Disconnect Hydraulic Hoses

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL 16. Disassemble boom. Using outside assist, swing forks up and insert Pin A (View C). If weight block and hook are installed, go to step If not, go to step 17. g. Using outside assist, swing weight box and hook up and pin to equalizer with Pin C (View C).
  • Page 113 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-33 Published 01-08-13, Control # 049-05...
  • Page 114 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Line from A1152 Line from Tie-Down Clip Assist Crane Assist Crane Gantry Mast Strap (intermediate position) Bracket (working) P684 View B Gantry (stored) View D Mast Strap Bracket (stored) View C Mast...

  • Page 115: Lower Gantry And Store Mast Hoist Equalizer

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Lower Gantry and Store Mast Hoist Repeat steps 2-5 for mast inserts to up to mast butt. Equalizer Remove mast butt and mast adapter frame as follows: See Figure 4-14 for following procedure.
  • Page 116 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1153 This illustration shows maximum counterweight arrangement. See Counterweight Arrangements chart in your MAX-ER Capacity Chart Manual for other counterweight arrangements. See MAX-ER Capacity Charts to determine proper counterweight arrangement for your lifting requirements.

  • Page 117: Install Counterweight (Current Production)

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Counterweight (current production) from breaking, do not lift more than one box at a time. See Figure 4-15 for following procedure. Connect slings from assist crane to lifting lugs (4 places)
  • Page 118 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1153 This illustration shows maximum counterweight arrangement. See Counterweight Arrangements chart in your MAX-ER Capacity Chart Manual for other counterweight arrangements. See MAX-ER Capacity Charts to determine proper counterweight arrangement for your lifting requirements.

  • Page 119: Install Counterweight (Past Production)

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Counterweight (past production) Connect slings from assist crane to lifting lugs (4 places) and install side counterweight boxes (1) alternating from See Figure 4-16 for following procedure. side to side until all side boxes are installed. To prevent...
  • Page 120 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 75° MAXIMUM WORKING ANGLE To Prevent Mast from Falling Over Backwards Operating Range 35° MINIMUM WORKING ANGLE Table 4-1 Load Handling Capacities MAX-ER Mast Mast Operating Mast Operating Mast Capacity Radius...

  • Page 121: Mast Capacities For Self-Assembly And Disassembly

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION MAST CAPACITIES FOR SELF-ASSEMBLY Crane must be operated in STANDARD mode (MAX-ER mode off) to enable automatic mast stop which is set at AND DISASSEMBLY 80°. Crane Requirements With STANDARD mode on, the following drums are used: •...

  • Page 122: Disconnecting & Connecting Wheeled Counterweight Trailer - With Boom Raised

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL DISCONNECTING & CONNECTING accommodate the crane with wheeled counterweight assembly and selected boom length. WHEELED COUNTERWEIGHT TRAILER — WITH BOOM RAISED General WARNING The topic contains instructions for disconnecting and TIPPING HAZARD! connecting the wheeled counterweight trailer from the crane Read instructions in this topic.
  • Page 123 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION A1152 130 ft (39,6 m) Mast #44 Mast Straps #79 or #79-44 Counterweight Boom Straps Trailer Arm Counterweight Carbody Counterweight Inserts Boxes (both ends) Wheeled Trailer 50 ft (15,2 m) Trailer Arm...
  • Page 124 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1153 Front of Trailer Axle Wedge Counterweight Strap Steering Bolted in Shipping Position Post Pin D (Remove for Operation) Strap Cylinder (working) Locking Pin Axle P1624 VIEW B 4 Places Tire VIEW A...

  • Page 125: Disconnecting Trailer From Crane - With Boom Raised

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION NOTE: To ensure proper operation of the crane’s drums, If desired, rotate wheels to 90° stand-alone position the MAX-ER mode must be on. All of the functions (wheels parallel to front of trailer).

  • Page 126: Connecting Trailer To Crane - With Boom Raised

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 Pin with Crane Right Cotter Pin Rear (two places) P1306 Insert Crane Counterweight Hydraulic Hoses from Trailer Adapter P1304 View A View B Electric Cord from Trailer FIGURE 4-21 Connecting Trailer to Crane — with Boom Connect hydraulic hoses from trailer to quick-connect couplings on crane (View B).
  • Page 127 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Fully retract jacks. counterweight straps strap cylinders (Figure 4-20, View B). 10. Using tongue switch on remote control, adjust tongue so top of trailer and extender arm are parallel. Remove taglines. 11. Connect counterweight straps to strap cylinders on g.
  • Page 128 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Boom Stop P1323 STORED POSITION Boom Stop OPERATING POSITION (operating) View B View C View A Blocking Front of Crane P1324 Blocking Mast Boom Butt View D View E Front of Crane...

  • Page 129: Boom Installation

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION BOOM INSTALLATION Raise boom stop to operating position, as follows: Attach a nylon sling from assist crane to boom stop in Boom Rigging Assembly Drawings stored position (View B). Boom components (top, inserts, straps) must be assembled Raise boom stop to operating position (View C).
  • Page 130 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 Insert with Insert with Transition Boom Equalizer Wire Rope Insert Rails Guides View A #79 Boom Blocking Blocking Blocking (operating) Hole 1 5 (stored) Hole 2 Lugs View B P1326 View C...

  • Page 131: Assemble Boom Inserts - #79 Boom

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Assemble Boom Inserts — #79 Boom Lift insert until bottom connecting holes line up. Insert both horizontal pins (3, View C) and safety pins See Figure 4-23 for following procedure. (4, View C).
  • Page 132 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL #79 Boom A1152 View B View C Equalizer Rail 4, 5, 6 Blocking Insert B3 See Figure 4-29 View D View A View E SHIPPING POSITION (from inside of boom) Item Description...

  • Page 133: Connect Boom Straps - #79 Boom

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Connect Boom Straps — #79 Boom d. Rotate links forward and pin to strap on adjacent insert. See Figure 4-24 for following procedure. Boom straps and links are shipped in the stored position on CAUTION the boom inserts as shown in View E.
  • Page 134 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL #79-44 Boom View E #79/#44 View B P1326 Transition Insert P524 P523 Insert Insert (79 boom inserts) (see View G) View D View A (44 Boom Inserts) (79 Boom Inserts) A1152 Blocking...

  • Page 135: Assemble Boom Inserts - #79-44 Boom

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Assemble Boom Inserts — #79-44 Boom Engage horizontal pins (1) into hooked connector at top end of butt or insert (View B). See Figure 4-25 for following procedure. Lower insert until bottom connecting holes line up.
  • Page 136 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 #79-44 Boom Insert with First Boom Additional Equalizer Insert Butt Inserts Rails View A Blocking Sling (from assist crane) (stored) View B (stored) View C Hole 1 Item Description Deflector Sheave...

  • Page 137: Position Wire Rope Guides - #79-44 Boom

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Connect Boom to Boom Butt — #79-44 Position Wire Rope Guides — #79-44 Boom Boom See Figure 4-26 for following procedure. See Figure 4-26 for following procedure. Two wire rope guide assemblies (1, View B) may be shipped in the stored position on first boom insert.
  • Page 138 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL #79-44 Boom A1152 Item Description Item Description Strap (typical) Boom Hoist Equalizer Strap Storage Pin Stop Pin View B Link (typical) Equalizer Strap Link Connecting Pin 15 ft (4,6 m) Transition Equalizer...

  • Page 139: Connect Boom Straps - #79- 44 Boom

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Connect Boom Straps — #79 44 Boom CAUTION See Figure 4-27 for following procedure. Equalizer rails are provided only to support equalizer Boom straps and links are shipped in the stored position on during assembly and disassembly.

  • Page 140: Install Intermediate Suspension - #79-44 Boom

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL 5 ft 6 in (1,7 m) Item Description Between Pins Strap, Insert Pin with Collar (Note 1) Strap 11 ft 10-3/4 in (3,6 m) A1193 Sheave Pendant Guard Pin (Note 2) View A...

  • Page 141: Finish Assembling Boom (All Booms)

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION • Install pins (2, Figure 4-24, View E) to secure the links and straps in stored position. CAUTION Avoid Pendant Damage! CAUTION Watch intermediate suspension pendants as boom is raised/lowered. Do not allow pendants to get caught on Pendant Damage! adjacent parts.
  • Page 142 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL #79 Boom A1149 Item Description Length Butt 30 ft (9,1 m) Insert 20 ft (6,1 m) Insert with Equalizer Rails 40 ft (12,2 m) 120 ft Transition Insert 25 ft (7,6 m)
  • Page 143 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION #79-44 Boom Item Description Length A1149 #79 Butt 30 ft (9,1 m) 200 ft #79 Insert with Sheaves 40 ft (1,2 m) (61,0 m) #79 Insert with Straps 20 ft (6,1 m)
  • Page 144 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1069 A1080 Item Description Fixed Vertical Pin Washer (Fixed Vertical Pin) Retaining Pin with Cotter Pins Butt Support Cable Assembly Removable Horizontal Pin – 10 -27/32 in (275 mm) – with Cotter Pins...

  • Page 145: Jib Installation - #132 Jib

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION JIB INSTALLATION — #132 JIB If necessary, separate boom sections to provide space for links. General b. Lift a backstay link into position on either side of required insert. The jib consists of a 20 ft (6,1 m) butt and a 20 ft (6,1 m) top, providing a basic length of 40 ft (12,2 m).
  • Page 146 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1076 View B P1 or P2 Jib Top Pin and Collar A1080 View C Boom A1080 View A Jib Butt Jib Top Jib Butt A1076 View D Heavy Lift Top Item Description...

  • Page 147: Install Jib Pendants

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Install Jib Pendants Pin basic backstay pendants (5) to spreader. Lay basic backstay pendants (5) on ground along boom NOTE: With the exception of the basic pendants, the jib top. pendants must be installed in the same sequence as the inserts as shown in Figure 4-34.
  • Page 148 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL 5° Offset Item Description Basic Backstay Pendant 65 ft 7 in (20 m) Backstay Pendant 7 ft 4 in (2,2 m) Link 3 ft 8 in (1,1 m) Link 12 in (0,3 m) 15°...

  • Page 149: Jib Removal

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Raise Jib Strut Determine pendants and links required for jib offset (2, 3, 4, Figure 4-33, View B). WARNING Pin pendants and links to backstay links. Collapsing Jib Hazard! NOTE: Backstay links (3, Figure 4-33, View B), if used, To prevent death or serious injury, do not stand on, inside, must be adjacent to connecting links (4).

  • Page 150: Remove Backstay Pendants

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Disconnect backstay pendants and links (Figure 4-33, Disconnect jib pendants (P1 or P2) from links (1) on jib View B) from backstay links. Lay pendants on ground strut (3) and lugs on jib top.
  • Page 151 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION A1076 40 ft (12,2 m) 60 ft (18,3 m) 80 ft (24,4 m) 100 ft (30,5 m) 120 ft (36,6 m) Section Type Length Pendant Type Length Jib Butt 20 ft (6,1 m)

  • Page 152: Wire Rope Installation

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S 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 153: Anchoring Wire Rope To Drum

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Seizings Wire Rope Type WARNING! Required Preformed Falling Load Hazard! Non-preformed Wire rope can be pulled out of drum if following steps are 7/8 in (22 mm) Diameter or Smaller not taken.

  • Page 154: Anchoring Wire Rope To Wedge Socket

    SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL Apply tension to wire rope as it is wound slowly onto Anchoring Wire Rope to Wedge Socket drum. First wrap must be tight against drum flange for approximately three-fourths of drum diameter (see WARNING Figure 4-39).

  • Page 155: Breaking In Wire Rope

    2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION practice allows the wire rope to form its natural lay and the strands to seat properly. WARNING NOTE: Wire rope will stretch during the break-in period, reducing the wire rope’s diameter as the strands Falling Load Hazard! compact around the core.

  • Page 156: Anchoring Wire Rope To Button Socket

    Anchoring Wire Rope to Button Socket General See Figure 4-41 for following procedure. Some rotation-resistant wire rope supplied by Manitowoc is equipped with a No. 1.5 pad eye welded to the leading end of Remove pin from socket. the wire rope.
  • Page 157 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION A1189 Sucker Line Rope Pull Sucker Line with Clips Winch or Fork-Lift Truck Sucker Line Wire Rope from Drum P1519 Boom Point Sheaves Wire Rope Load Block Sheaves (EXAMPLE) No. 1.5 Pad Eye...
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  • Page 159: Load Block Reeving

    Load block or shackle can fail if overloaded, allowing load to fall. Load Block The following load blocks are available from Manitowoc: A802 • 500 USt (454 t) – 16,500 lb (7 484 kg) Duplex Hook •...
  • Page 160 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL A1152 A1193 Wire Rope Routing Upper Boom Point #79 Boom Dead-End Options O = Route OVER Sheave U = Route UNDER Sheave 3 = Drum 3 3 - O Required Routing 5 = Drum 5...
  • Page 161 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION A616 #79-44 Boom Bolt Clamp BOOM TOP GUIDE SHEAVES Lockwasher Nuts Tighten each side equally to provide an equal gap. See NOTE 1 for torque value. LOWER POINT SHEAVES Location of Guide Sheaves with Lead Line NOTE 1: Hand position clamps tight against bearing.
  • Page 162 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL #79-44 Boom CAUTION! Wire Rope Damage! Prevent wire rope from disengaging sheaves. Install all guide sheave rope guards and rollers after wire rope is reeved. 3 - O NOTE 1 5 - O...
  • Page 163 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION Wire Rope Routing #132 Jib on #79-44 Boom O = Route OVER Sheave 9 - O U = Route UNDER Sheave 3 = Drum 3 5 = Drum 9 = Drum 9...
  • Page 164 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL #132 Jib on #79-44 Boom Point 2 PART Load Block 4 PART 3 PART Load Sensing Sheaves Fixed WARNING Jib Point Avoid Death or Serious Injury! If you are using a load block that can be stood up vertically for Dead End Here reeving, exercise care, as the potential for tipping exists.
  • Page 165 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION #79-44 Boom FIGURE 4-50 Manitowoc 4-85 Published 01-08-13, Control # 049-05...
  • Page 166 SET-UP AND INSTALLATION 2250 MAX-ER 2000 OPERATOR’S MANUAL FIGURE 4-50 continued 4-86 Published 01-08-13, Control # 049-05...
  • Page 167 2250 MAX-ER 2000 OPERATOR’S MANUAL SET-UP AND INSTALLATION A769 VIEW A Without Luffing Hoist Item Description Tieback Lug (1-3/4 in Diameter) Tieback Lug (1-5/16 in Diameter) Shackle (1-1/2 in) Shackle (1-1/8 in) Tieback Sling VIEW B Load Block With Luffing Hoist...

  • Page 168: Load Block Tieback

    See Figure 4-51 for identification of tieback hole diameter General and shackle size. Manitowoc provides a lug on the front of the rotating bed (Figure 4-51, View A) and on the luffing hoist frame (View B) for tieing back the load block when not in use.

  • Page 169: Section 5

    Lubrication ............5-1 Manitowoc...
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  • Page 171: Section 6

    2250 MAX-ER 2000 OPERATOR’S MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION See F2105 at the end of this section. Manitowoc Published 01-08-13, Control # 049-05...
  • Page 172 LUBRICATION 2250 MAX-ER 2000 OPERATOR’S MANUAL THIS PAGE INTENIONALLY LEFT BLANK Published 01-08-13, Control # 049-05...
  • Page 173 Actuator Installation and Adjustment ........6-17 Manitowoc...
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  • Page 175: General Maintenance

    2250 MAX-ER 2000 OPERATOR’S MANUAL MAINTENANCE SECTION 6 MAINTENANCE GENERAL MAINTENANCE A1174 This section contains maintenance and adjustment Boom and Jib Angle Identification instructions for devices used with the MAX-ER 2000 attachment. Luffing Jib F o r m a i n t e n a n c e a n d i n s p e c t i o n o f t h e f o l l o w i n g...

  • Page 176: Adjusting Angle Indicator

    MAINTENANCE 2250 MAX-ER 2000 OPERATOR’S MANUAL Scribed Line on Protractor-Level Centerline of Boom Butt To locate center of boom or jib butt, punch mark two points equally spaced between edges of plate work about 1 ft (0,3 m) apart. Then scribe a line through punch marks.
  • Page 177 2250 MAX-ER 2000 OPERATOR’S MANUAL MAINTENANCE A1049 0 - Black 52 50° 3-Pole Receptacle With Protective Cap Boom Angle Sending Unit 82BA - Green 120° Pendulum-Type Potentiometer M.E.C. #575885 VIEW A 87FA - White Vendor #CP17-0693-1 Position Sensor A1294 Like This...
  • Page 178 MAINTENANCE 2250 MAX-ER 2000 OPERATOR’S MANUAL A487 Actuator A1162 Boom Angle Position All #79 or #79-44 Boom Lengths with 83° Luffing Jib Removed Less than 200 ft (61 m) of #79 Boom with Centerline #44 Luffing Jib Installed 85° Boom Butt...

  • Page 179: Automatic Boom Stop Adjustment

    2250 MAX-ER 2000 OPERATOR’S MANUAL MAINTENANCE AUTOMATIC BOOM STOP ADJUSTMENT Loosen capscrews retaining MAX actuator to actuator bracket. Unless otherwise specified, see Figure 6-5 for following Rotate MAX actuator CLOCKWISE in its slots so it does instructions. not contact limit switch roller when step 5 is performed.
  • Page 180 MAINTENANCE 2250 MAX-ER 2000 OPERATOR’S MANUAL A1162 Equal Distance Mast Butt Protractor- Level Mast Butt Bracket Capscrews 80° MAX Angle Actuator Bracket View A Hinge Pin At Left Side Bolt Mast Hinge Pin Limit Switch Electric Cord to Junction Box...

  • Page 181: Automatic Mast Stop Adjustment

    2250 MAX-ER 2000 OPERATOR’S MANUAL MAINTENANCE AUTOMATIC MAST STOP ADJUSTMENT Adjustment See Figure 6-7 for following instructions. The automatic mast stop must be installed, adjusted and sealed at initial installation. Readjustment is required only General when parts are replaced and when changing attachments.
  • Page 182 MAINTENANCE 2250 MAX-ER 2000 OPERATOR’S MANUAL Left Strap Cylinder LOWER Counterweight Viewed from Right Side of Trailer (Cylinder Extends) RAISE Counterweight Limit Switch (Cylinder Retracts) Mounting Holes Lever (typical all views) Used View D Limit Switch Mounting Bracket Roller (typical all views)

  • Page 183: Max-Er Load Sensing Pin Calibration

    2250 MAX-ER 2000 OPERATOR’S MANUAL MAINTENANCE MAX-ER LOAD SENSING PIN CALIBRATION See Figure 6-9 for following procedure. CAUTION Hydraulic Cylinder Damage! When replacing the load sensing pin, check its calibration prior to installation, as follows: Cylinders will remain pressurized (stalled out) after...

  • Page 184: Block-Up Limit Control

    MAINTENANCE 2250 MAX-ER 2000 OPERATOR’S MANUAL BLOCK-UP LIMIT CONTROL Block-Up Limit Control Deactivated During normal operation, the weight overcomes the spring General force and rotates the actuating lever away from the limit switch lever. This action allows the limit switch to close the The block-up limit control (also called anti two-block device) load drum UP and boom DOWN electric circuits.
  • Page 185 2250 MAX-ER 2000 OPERATOR’S MANUAL MAINTENANCE A1179 Lower Boom Upper Boom Limit Switch Point Point Assembly Electric Cords Chain Junction Single-Part Line Multiple-Part Line Chain Weight Lift Weight Limit Switch Block Assembly Chain Weight Weight Ball Lift Plates #79 Boom Shown...

  • Page 186: Disconnecting Block-Up Limit Control

    MAINTENANCE 2250 MAX-ER 2000 OPERATOR’S MANUAL Disconnecting Block-Up Limit Control Be sure to reconnect electric cord to proper block-up limit switch w hen corresponding attachment is A shorting plug (Figure 6-11) is provided on the left front reinstalled. corner of the upperworks adapter so the block-up limit...

  • Page 187: Adjustment

    2250 MAX-ER 2000 OPERATOR’S MANUAL MAINTENANCE Test block-up limit control for proper operation using Adjustment either of following methods: See Figure 6-13 for following procedure. BOOM LOWERED: Manually lift each weight — Lower boom onto blocking at ground level and adjust each one at a time —...

  • Page 188: Steering Post Bearing Bolt Torque

    MAINTENANCE 2250 MAX-ER 2000 OPERATOR’S MANUAL STEERING POST BEARING BOLT TORQUE bolt should be torqued. It does not matter which pair of bolts is torqued first, but bolt torquing must allow for access to See Figure 6-14 for following procedure.

  • Page 189: Boom Hoist Ratchet And Pawl Adjustment

    2250 MAX-ER 2000 OPERATOR’S MANUAL MAINTENANCE BOOM HOIST RATCHET AND PAWL Rotate lever and hold it so roller is against pawl. ADJUSTMENT A1066 A1148 See Figure 6-15 for following procedure. Pawl Roller General Screw Lever This topic applies only to the ratchet and pawl provided on...
  • Page 190 MAINTENANCE 2250 MAX-ER 2000 OPERATOR’S MANUAL Measure Dimension A Here View A Dimension A Dimension B 1-9/16 in 40 mm 21/32 in 17 mm Measure Dimension B Item Description Here View B Boom Butt Main Load Drum Ratchet Tooth Pawl...

  • Page 191: Main Load Drum Ratchet And Pawl Adjustment

    2250 MAX-ER 2000 OPERATOR’S MANUAL MAINTENANCE MAIN LOAD DRUM RATCHET AND PAWL Toggle DRUM 9 PARK switch to OFF to disengage pawl (4). ADJUSTMENT See Figure 6-16 for following procedure. WARNING General Pinch Point Hazard! The main load drum (Drum 9) is equipped with a drum pawl Actuator rod will retract when step 3 is performed, To as shown in Figure 6-16.
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  • Page 193 Manitowoc Dealer........
  • Page 194 2250 MAX-ER 2000 OPERATOR’S MANUAL INDEX MAX-ER Disassembly Procedures ..........4-26 MAX-ER Load Sensing Pin Calibration .

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