Page 1 Manitowoc 16000 Service/Maintenance 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
16000 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS See end of this manual for Alphabetical Index SECTION 1 ........Introduction Continuous Innovation .
Page 6 MAX-ER 16000 Description Of Operation ........1-54...
Page 7 16000 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Charge Pressure Test..........2-29 High Pressure Adjustment .
Page 8 TABLE OF CONTENTS 16000 SERVICE/MAINTENANCE MANUAL Bypass Limit Test ..........4-2 Adjustment .
Page 9 16000 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Battery Maintenance ........... . 7-1 Safety Information.
Page 10 TABLE OF CONTENTS 16000 SERVICE/MAINTENANCE MANUAL SECTION 10........Troubleshooting Introduction.
Page 11 Travel Brakes ........... . . 1-26 Manitowoc...
Page 12 MAX-ER 16000 Description Of Operation ........1-54...
Page 13 16000 SERVICE/MAINTENANCE MANUAL Jacking Cylinders ..........1-57 Jack Cylinder(s) Extend .
Page 14 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-iv Published 05-09-17, Control # 014-28...
Page 15: Section 1
Due to continuing product innovation, the information in this CAUTION manual is subject to change without notice. If you are in doubt about any procedure, contact your Manitowoc dealer Used with the safety alert symbol, indicates a hazardous or the Manitowoc Crane Care Lattice Team.
Page 16: Safe Maintenance Practices
Safety harness and tither line must be worn when working on top of enclosure. To ensure safe and proper operation of Manitowoc cranes, they must be maintained according to the instructions Lift tools and other equipment which cannot be carried in...
Page 17: Environmental Protection
16. Do not smoke or allow open flames in refueling area. 29. Unless authorized in writing by Manitowoc, do not alter crane in any way that affects crane’s performance (to 17. If a safety-type can is used to add fuel to the fuel tank, it...
Page 18: Identification And Location Of Components
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS Figure 1-1 through Figure 1-7 for graphic identification of crane 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...
Page 19 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION A10740-4 P2261 Boom Butt End FIGURE 1-1 continued Manitowoc Published 05-09-17, Control # 014-28...
Page 20: General Views
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL General Views Item Description Item Description Boom/Mast Drum Crawler Automatic Lubricator Sequence Valve (all drum motors) Left and Right Swing Gearboxes Boom/Mast Motor Turntable Automatic Lubricator Load Drum Motor Swing Gears Load Drum Turntable Bearing Drum Speed Sensor (all drums)
Page 21: Top
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description Boom Stop Limit Switch Swivel Accessory System Enable Pressure Sender Low-Pressure Reducing Valve Swing Brake Solenoid Swing Lock Solenoid (Past Production) Travel Brake Solenoid Travel Two-Speed Solenoid Mast Angle Sensor Mast Arm Raising Cylinder...
Page 22: Right Side
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Right Side Item Description Jacking Cylinder Pads Engine Oil Fill Hydraulic Oil Return Filters Hydraulic Tank Breather (past production) Tank Access Cover (16001141 and prior) Drum 2 Charge Filters (16001141 and prior) Fuel Filter P2249a P2282...
Page 23: Left Side
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Left Side Item Description Item Description Left Front Jacking Solenoid Drum 2 to Drum 1 Diverting Solenoid Right Front Jacking Solenoid Drum 1 to Drum 2 Diverting Solenoid Mast Raising Cylinders Solenoid Drum 4 Pawl Solenoid...
Page 24 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Left Side Item Description Accessory System Manifold (S/N 16001142 and newer) P2439a for MAX-ER, Engine Cooling Fan, Accessory High Pressure, and Accessory Low Pressure 500 - 5,000 psi (35 to 345 bar) Accessory System Proportional Relief Valve HS-68...
Page 25: Undercarriage/Crawler
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Undercarriage/Crawler Item Description Carbody Pedestal Intermediate Crawler Roller (14 each crawler) Crawler Roller (1 each crawler) Right Crawler Pin Handle Left Crawler Pin Handle Crawler Input Planetary (both crawlers) Crawler Brake (both crawlers) Drive Shaft (both crawlers)
Page 26: Crane Description Of Operation
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL CRANE DESCRIPTION OF OPERATION Solenoid Valve Identification Each hydraulic solenoid valve is assigned an HS number for General Abbreviations training identification only. HS-1 Swing Brake Release Amber Light HS-2 Swing Lock Engage (Past Production) Air Conditioning Relay...
Page 27: General Operation
A diesel engine provides power to operate system pumps This section describes the standard and optional equipment through a pump drive transmission. In a closed-loop available for Model 16000 crane. Disregard any equipment hydraulic system, high-pressure hydraulic fluid from the your crane does not have.
Page 28: Hydraulic Components
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Hydraulic Components pawls, and counterbalance pin cylinders returns to other return manifold, bypassing cooler before entering tank. High-pressure piston pumps driven by a multi-pump drive Hydraulic Fluid Cooler transmission provide independent closed-loop hydraulic power for crane functions. Each system has relief valves to If hydraulic fluid temperature is above 140°F (60°C), fluid...
Page 29: Pressure Monitoring
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION command direction. Hydraulic fluid displaced by motor exits motor and returns to inlet side of system pump through returns through hydraulic piping to inlet side of system pump. hydraulic piping. Swashplate tilt angle determines volume of fluid that can be Pressure Monitoring pumped to the motor.
Page 30 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL opposite direction of spool with linkage. This centers and The pressure limiting relief valve (1) serves as pilot valve to maintains spool in a neutral position until the 15 psi (1 bar) open system relief valve (5) when desired relief pressure chamber spring pressure is reached.
Page 31: Accessory/Max-Er Pump
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION 16-1003 Motor Pump M4 M3 350 psi (24 bar) Output Max. Disp. Input FIGURE 1-10 The load drums and boom/mast hoist motors also have a system for added cooling and purification. If system pressure PCOR (Pressure Compensating Over-Ride) valve (16) that is under 200 psi (14 bar) loop flush is disabled.
Page 32: Electrical Control System
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Crane systems speed depends on engine speed and system are either AC or DC variable voltages or currents. Digital control handle movement. Engine speed is controlled with input/output voltages are zero volts (no voltage) or 24 volts.
Page 33: Display Screens
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Display Screens clock. When key-operated engine switch is placed in RUN position, power is available to the following relays: Figure 1-11 for the following procedure. • Engine control module (ADM2) The display screens contain the RCL display and main •...
Page 34: Cab Power Electrical Schematic
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Cab Power Electrical Schematic 24 VDC BATTERY 16-1005 BATTERY DISCONNECT LEFT STARTER MOTOR ENGINE RIGHT STARTER MOTOR GROUND STRAP MACHINE 6C12 6C12A LEFT STARTER SOLENOID GROUND 6C12B RIGHT STARTER SOLENOID A/C CLUTCH HIGH 6C11A 6C11 CU/ES...
Page 35: Pressure Senders And Speed Sensors
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Pressure Senders and Speed Sensors Move control in the opposite direction away from limit to correct the problem. NOTE: The swing brake pressure sensor is only available The limit bypass switch allows crane to be operated beyond on cranes with the swing lock removed.
Page 36: Switches And Sensors Electrical Schematic
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Switches and Sensors Electrical Schematic 16-1006 – 24 Volts Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 Cab Power P11-21 Display 2 6C14 NODE 1...
Page 37: Swing System Operation
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION SWING SYSTEM OPERATION below 200 psi (14 bar), swing brake or swing lock could be partially applied and damage the swing system. If brake Figure 1-14, Figure 1-15, and Figure 1-17 for the pressure or electrical power is lost when operating, the swing following procedure.
Page 38: Swing Brake Pressure Sensor
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Swing Lock past production. Swing Lock removed current production. Brake Motor Swing Lock Pressure Sender Pump Pressure Sender HS-1 HS-3 HS-2 Accessory Pump (Low-Pressure) FIGURE 1-15 16-1008 HS-1 When swing control handle is moved to right, an input voltage of 2.6 volts or more is sent to Node-1 controller.
Page 39: Swing Electrical Schematic
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Swing Electrical Schematic Swing lock removed on current production cranes. 16-1009 – 24 Volts Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 P12-31 NODE 0 P12-32 50 Amp P11-21 Display 2...
Page 40: Travel System Operation
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL TRAVEL SYSTEM OPERATION When travel brake switch is in off - park position, an input signal is sent to Node-1 controller. Travel system circuit is Figure 1-18 Figure 1-19 for the following procedure enabled, waiting for a travel control handle command. When...
Page 41: Travel Electrical Schematic
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Travel Electrical Schematic 16-1011 – 24 Volts Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 P11-21 Cab Power Display 2 6C14 NODE 1 System Fault Alarm...
Page 42: Two-Speed Travel Operation
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Travel motors are variable displacement and shift internally maximum displacement (high torque, low speed) position. with an adjustable spring in each motor P/C (Pressure/ Travel motors remain in this position until travel speed switch Compensator) valve, preset at approximately 3,915 psi (270 is placed in high speed position and engine speed is more bar).
Page 43: Boom/Mast Hoist System Operation
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION BOOM/MAST HOIST SYSTEM OPERATION HS-11 (drum 4) or (drum 5) HS-31 is enabled to keep pawl applied to drum flange. Hoist pump does not stroke in Figure 1-20, Figure 1-21, and Figure 1-22 for the response to control handle movement.
Page 44: Lowering Boom
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL s y s t e m p r e s s u r e e x c e e d s t h e P C O R ( P r e s s u r e...
Page 45 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Node controllers continuously balance the system pressure that moves swashplate toward center position. This shifts the and motor displacement angle so the motor displacement motors back to maximum displacement for slower output goes to minimum when control handle is fully forward, if the speed to slow drum rotation.
Page 46: Drum 4 Electrical Schematic
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Drum 4 Electrical Schematic 16-1014 – 24 Volts Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 Cab Power P11-21 Display 2 NODE 1 6C14...
Page 47: Load Drum 1
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION LOAD DRUM 1 Raising Load Figure 1-23 Figure 1-25 for the following procedure. System Components When drum 1 control handle is moved back for raising, an Figure 1-23, Figure 1-24, and Figure 1-25 for the input voltage of 2.4 volts or less is sent to Node-1 controller.
Page 48: Lowering Load
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL When system pressure exceeds the PCOR (Pressure pressure is high enough, Node-6 controller sends a 24 volt Compensating Over-Ride) valve setting of 4,930 psi (340 output to enable drum 1 brake release solenoid HS-15. Drum bar), the valve shifts to direct flow from shuttle valve into brake solenoid shifts to block drain port and opens port to maximum displacement side of servo cylinder.
Page 49: Drum 1 Electrical Schematic
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION center position. This shifts the motors back to maximum pressure to brake and opens a line to tank. When brake displacement for slower output speed to slow drum rotation. applies, an input signal is sent to Node-1 controller. Node-3...
Page 50: Load Drum 2
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL LOAD DRUM 2 Raising Load Figure 1-26 Figure 1-28 for the following procedure. System Components When drum 2 control handle is moved back for raising, an Figure 1-26, Figure 1-27, and Figure 1-28 for the input voltage of 2.4 volts or less is sent to Node-1 controller.
Page 51: Lowering Load
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION When system pressure exceeds the PCOR (Pressure pressure is high enough, Node-6 controller sends a 24 volt Compensating Over-Ride) valve setting of 4,930 psi (340 output to enable drum 2 brake release solenoid HS-20. Drum bar), the valve shifts to direct flow from shuttle valve into brake solenoid shifts to block drain port and opens port to maximum displacement side of servo cylinder.
Page 52: Drum 2 Electrical Schematic
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL center position. This shifts the motors back to maximum pressure to brake and opens a line to tank. When brake displacement for slower output speed to slow drum rotation. applies, an input signal is sent to Node-1 controller. Node-3...
Page 53: System Components
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION LOAD/LUFFING DRUM 3 When drum 3 brake switch is placed in off - park position, brake release solenoid HS-25 remains applied. Brakes System Components remain applied until Node-6 controller sends a 24 volt output to release the brake. Node-6 controller sends a zero volt...
Page 54: Lowering
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL maximum displacement side of servo cylinder. The PCOR The pump EDC tilts swashplate in the lowering direction as valve over-rides the command from servo PC valve, hydraulic fluid flow is from pump port to motor port. Return increasing motor displacement and output torque and fluid is from motor outlet port to pump inlet port.
Page 55: Drum 3 Electrical Schematic
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Left travel to drum 3 diverting solenoid HS-28 remains enabled until left travel handle is moved. Drum 3 Electrical Schematic 16-1023 – 24 Volts Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01...
Page 56: Accessory System Components
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL ACCESSORY SYSTEM COMPONENTS When a jacking cylinder proportional control valve is not enabled, it shifts to neutral position where both valve section Accessory Systems cylinder ports are connected to tank. This prevents in-line pressure from opening counterbalance valve, holding Accessory system components includes rotating bed jacking rotating bed load in position by the counterbalance valve.
Page 57: Counterweight Pins
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION proportional control solenoid HS-62 and shifts valve spool to Restraining section of counterbalance valve opens, center position. Node-3 controller sends a variable zero to 24 controlling fluid out of jacking cylinder. Hydraulic fluid then volt output to disable accessory system proportional relief flows through free-flow check valve section of flow control solenoid HS-68.
Page 58: Accessory System Electrical Schematic
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Accessory System Electrical Schematic 16-1027 – 24 Volts Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 Cab Power P11-21 Display 2 NODE 1 6C14...
Page 59: Boom Hinge Pins
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Boom Hinge Pins Pressure Figure 1-35, Figure 1-36, and Figure 1-37 for the Sender following procedure. During normal operation the boom hinge pins solenoid valve HS-52 HS-53 is motor spooled where both cylinder ports and tank port of Boom valve spool section are connected in center position.
Page 60: Rigging Winch (Drum 0)
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION When front or rear rotating bed pins switch is placed in the spool section are connected in center position. When an engage position and held, an input voltage is sent to Node-1 accessory valve spool shifts, supply flow to the other controller.
Page 61: Cab Tilt
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION When an accessory valve spool shifts, supply flow to the 3 controller sends a 24 volt output to enable solenoid HS-57 other accessory valves is limited. The accessory system and shifts valve to the lower position. Node-3 controller pressure sender monitors accessory system pressure.
Page 62: Carbody Jacking Cylinders (Optional)
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL carbody. Hydraulic fluid from rod end of crawler pin cylinder counterbalance valves provide relief protection for the flows through lower accessory valve and returns to tank. cylinders and shields them from mechanical overloading. When crawler pin handle is moved back to center position,...
Page 63: Live Mast
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Live Mast Pressure Figure 1-46 through Figure 1-49 for the following Sender procedure. The live mast is the rectangular shaped structure that HS-50 HS-51 supports the boom. The mast is also used for crane Hand-Held Mast assembly and disassembly.
Page 64: Mast Lowering To Transport Position
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL volt output that is divided by a resistor and applied to boom/ Hydraulic fluid from side B sections of both counterbalance mast hoist pump EDC in down direction. valves combines, and the free-flow check valve section on side B of load equalizing valve blocks the flow.
Page 65 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION mast raising cylinders solenoid HS-51 in retract (mast Hydraulic fluid from side A sections of both counterbalance lowering) direction. The valve shifts to block tank port and valves combines, and the free-flow check valve section on open port to low-pressure side of pump.
Page 66: Live Mast Electrical Schematic
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Live Mast Electrical Schematic 16-1039 – 24 Volts Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 Cab Power P11-21 Display 2 NODE 1 6C14...
Page 67: Hydraulic Cooling Fan
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Hydraulic Cooling Fan to the feedback of various engine temperature sensors while the accessory system is disabled. When the accessory Past Production s/n 16001141 and older system is enabled, solenoid HS-59 shifts, allowing the lower accessory system pump to supply oil flow to the fan motor at Figure 1-50 for the following procedure.
Page 68: Max-Er 16000 Description Of Operation
HS-72 Counterweight Lift Cylinder Retract The MAX-ER 16000 wheeled counterweight assembly HS-73 Counterweight Lift Cylinder Retract consists of the following components (see...
Page 69: Accessory Pumps
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION M16-01 Item Description Telescopic Beam Hinge Pin Manifold Telescopic Beam (Front) Hydraulic Hoses (connect to crane) Jacking Cylinders/Wheels Manifold Wheel Assembly Brakes Manifold Electric Cables (connect to crane) Connecting Hinge Pins (2 places) Counterweight Lift Cylinder/...
Page 70: Epic® Programmable Controller
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL MAX-ER Wireless Remote Controls ® EPIC Programmable Controller To operate the MAX-ER wireless remote control see  The operating system is an EPIC (Electrical Processed Operating Controls and Procedure in Section 3 of MAX-ER Independent Control) with CAN-bus (Controller Area Operator Manual.
Page 71: Jacking Cylinders
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Jacking Cylinders forward enables all jacking cylinders down. Moving the left travel handle back enables all jacking cylinders up. The left Figure 1-53 Figure 1-54 in the flowing procedure. travel jacking cylinder extend/retract is similar to the hand- held wireless remote control operation described next.
Page 72 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL M16-03 Jacking Cylinders 24 Volts – Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 Hand-Held Cab Power P11-21 NODE 1 Display 2 NODE 1...
Page 73 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Hydraulic fluid from piston end of jack cylinder is blocked by valve supports the weight and gravity force of the wheeled free-flow check valve section of counterbalance valve and counterweight assembly. flow restraining section of relief valve preset for a relief When selected jack switch is released, an input signal is sent setting of approximately 2,000 psi (138 bar).
Page 74: Telescopic Beam Cylinder
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Telescopic Beam Cylinder Telescopic Beam Cylinder Extend When telescopic beam switch is moved and held in extend Figure 1-55 Figure 1-56 in the following procedure. position, an input signal from wireless transmitter is sent to a The telescopic beam cylinder connects the wheeled receiver on the crane.
Page 75: Telescopic Beam Cylinder Retract
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION M16-06 Telescopic Beam Cylinder 24 Volts – Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 Hand-Held Cab Power P11-21 Display 2 NODE 1 Wireless...
Page 76 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Node-3 sends a variable voltage output to accessory system proportional relief solenoid HS-68 to provide approximately 3,000 psi (207 bar) system pressure. M16-07 Suction Manifold Variable Accessory Pump 400 to 5,000 Telescopic Beam Extend (28 to 345 bar)
Page 77: Counterweight Lift Cylinder
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Counterweight Lift Cylinder The counterweight lift cylinder has a counterbalance valve at each cylinder port to provide smooth operation when Figure 1-57 Figure 1-58 in the following procedure. operating. Counterbalance valves lock cylinder in position. and also provide relief protection for the cylinder. The...
Page 78: Counterweight Lift Cylinder Retract
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL M16-12 Counterweight Lift Cylinder 24 Volts – Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 Hand-Held Cab Power P11-21 Display 2 NODE 1 Wireless...
Page 79 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION valve. Fluid pressure on rod end of lift cylinder retracts the When retraction is reached, release switch to lock cylinder in cylinder to the desired length. position. Hydraulic fluid at piston end of lift cylinder counterbalance valve holds lift cylinder in selected position.
Page 80 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL When switch is released, an input signal is sent to Node-1 Node-3 sends a variable voltage output to accessory system controller. Node-7 controller sends a zero volt output to proportional relief solenoid HS-68 to provide approximately hydraulic solenoids HS-72 and 73 to return valve to center 3,000 psi (207 bar) system pressure.
Page 81: Wheel Assemblies
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Wheel Assemblies Hydraulic pressure from accessory pump flows through pressure control pilot valve, six bank manifold valve, and Figure 1-59 Figure 1-60 in the following procedure. enters free-flow check valve section of counterbalance valve. Fluid pressure turns motor output shaft so wheels Wheel assembly swing motors allow positioning of MAX-ER rotate in a clockwise direction.
Page 82 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL M16-09 Wheel Assemblies 24 Volts – Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 Hand-Held Cab Power P11-21 Display 2 NODE 1 Wireless 6C14...
Page 83 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION M16-10 Left Wheel Assembly with Brake - Clockwise To Right Wheel Assembly Brake HS-87 HS-86 Suction Manifold Variable Accessory Pump 400 to 5,000 Pressure (28 to 345 bar) Reducing 500 psi (35 bar) HS-68 To Telescopic...
Page 84: Telescopic Beam Hinge Pins
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Telescopic Beam Hinge Pins 24 volt output to enable telescopic beam hinge pins solenoid HS-91 and shifts valve to disengage position. Figure 1-61 Figure 1-62 in the following procedure. Node-3 controller sends a variable zero to 24 volt output to...
Page 85 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION M16-15 Telescopic Beam Hinge Pins 24 Volts – Engine Stop 6C5A Run 3 Start 10 Amp P12-24 CAN Power P11-01 Display 1 NODE 0 P12-31 50 Amp P12-32 Hand-Held Cab Power P11-21 Display 2 NODE 1...
Page 86 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL When telescopic beam hinge pin switch is moved and held in pin cylinder, extending cylinder rod to engage beam hinge engage (in) position, an input signal from wireless pins. Hydraulic fluid from rod end of beam pin cylinder leaves transmitter is sent to a receiver on the crane.
Page 87 Motor Leakage Test ..........2-33 Manitowoc...
Page 88 16000 SERVICE/MAINTENANCE MANUAL Loop Flushing Valve Adjustment ........2-33 Manual Override Tests .
Page 89: Hydraulic Schematics
Leaking ports Crane Operator Manual. b. Leaking valve sections or manifolds and valves Contact the Manitowoc Crane Care Lattice Team for an installed into cylinders or onto motors explanation of any procedure not fully understood. Damaged or missing hose clamps, guard or shields Adjustments in this section were made to the crane before it d.
Page 90: Hydraulic System - Maintenance
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Storing And Handling Oil mechanical properties and long term exposure to these cold temperatures will negatively impact service life. It is • Store oil drums in clean, cool, dry location. Avoid recommended for these hoses to be inspected to step 1 outdoor storage.
Page 91 16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc Published 05-09-17, Control # 014-28...
Page 92 HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Item Description Item Description Filter 2 (in tank return)(2 or 3 each) Shut-Off Valve Handle Fill Plug (manual fill port) Locking Pin Power-Fill Coupling Hydraulic Tank Drain Valve Breather Vent Cap (2 in charge pressure manifold) past production only...
Page 93 16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Current Production S/N 16001142 and newer Top of Hydraulic Reservoir Bleed Port for Initial Fill Valve Shown in Located on Suction Manifold the CLOSED Position. Rotate 90° Clockwise to Lock Open P2243a View G Past Production...
Page 94: Inspecting System
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Inspecting System Only use approved hydraulic oil in system (see Section The damaging effects of dirt, heat, air, and water in the If equipped with a desiccant breather (Figure 2-5), hydraulic system can only be prevented by regular, thorough inspection of the system.
Page 95: Replacing Desiccant Breather
The following instructions apply only to current production cranes. Original Equipment Manufacturers’ filter elements – available from the Manitowoc Crane Care Lattice Team – Figure 2-5 for the following procedure. must be used on this crane. Substituting with any other Unscrew breather from tank.
Page 96: Filter 2 (Return)
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL b. Using handle provided, lift filter element out of body Filter 2 (Return) and discard element. Figure 2-1 Figure 2-8 for the following procedure. Do not attempt to clean or reuse element. Replace return filter elements when FILTER 2 fault comes on Do not operate crane without charge filter elements and at each oil change interval.
Page 97: Changing Oil
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Past production filter assemblies: Soak in clean, nonflammable solvent. Brush off outer surface, and flush from inside out. Discard if Remove cover. Use care not to damage O-rings. damaged. b. Cover has a hexagon stud for easy removal with a d.
Page 98: Servicing Pumps
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Tightening Hydraulic Connections 17. Fill hydraulic tank to FULL COLD LEVEL – 87-90% – while watching hydraulic tank display on information • Make sure fittings and O-rings being used are proper screen (see Figure 2-2). Use proper hydraulic oil (see size and style.
Page 99: Sae Straight Thread Connection
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SAE Straight Thread Connection Tighten jam nut. When fitting is properly installed, O-ring will completely fill seal cavity and washer will be tight This type of connection leaks most often because the jam against spot face as shown in Figure 2-12, View B.
Page 100: Split Flange Connection
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Table 2-5 ORS Leakage Table 2-6 Split Flange Assembly Torque Causes Cures "A" Flange Torque Dimension Size Nut Loose. Tighten to proper torque. in-lb inch (mm) O-ring cut. Replace. O-ring wrong size. Replace with proper size.
Page 101: Sae Flare Connection
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SAE Flare Connection Misalignment of marks will show how much nut has been tightened, and best of all that it has been tightened. Tighten nut finger tight until sealing surfaces touch. Table 2-8 SAE 37° Flare Tightening...
Page 102 HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-14 Published 05-09-17, Control # 014-28...
Page 103 16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM P2252 P2298 P2300 P2297 P2270a P2299 Item Case Drain Ports Item Brakes Swing Motor (2 places) Swing (2 places) Load Drum Motor (1 or 2 places each drum) Travel (2 places) Boom Hoist Motor (2 places)
Page 104: Shop Procedures
(11) as soon as clear oil appears at each vent Initial Oil Fill opening. If required, apply 3 to 5 psi (0.20 to 0.34 bar) owner The following procedure is used at Manitowoc to fill the supplied air pressure to air valve (4a, Figure 2-1) or hydraulic system on new cranes.
Page 105: System Calibration And Tests
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Make sure hydraulic tank shutoff valve (7a, Figure 2-1) Stop engine. is fully open. Pumps can be damaged from cavitation Remove bleed lines from gauge couplers at each if this step is not performed. pressure sender.
Page 106 HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL 16-1013 Handle Command Drum Speed Pump Command System Typical Diagnostic Screen Pressure (Screen for Drum 4 Shown) FIGURE 2-18 2-18 Published 05-09-17, Control # 014-28...
Page 107: Accessory System Checks
(206 bar) is present when cylinders are fully extended and retracted (stalled). When controls are off, cylinders must not retract. If they do, contact the Manitowoc Crane Care Lattice Team. When controls are off, cylinders must not retract. If they do, contact the Manitowoc Crane Care Lattice Team.
Page 108: Low Pressure Accessory System
When control is off, cylinders must not retract. If they do, swing lock is engaged. contact the Manitowoc Crane Care Lattice Team. Travel Brakes When lowering cab, it must lower slowly and smoothly. If...
Page 109: Speed Checks
Table 2-10. If marks make — must be within range given in Table 2-10. proper speeds are not indicated, contact the Manitowoc Crane Care Lattice Team. If speed is not within specified range, contact the Manitowoc Crane Care Lattice Team.
Page 110: Hydraulic System Specifications
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SPECIFICATIONS Table 2-10 Hydraulic System Specifications System System Charge Speed Function Direction Pump-Port Pressure Pressure 1 Pressure 2 psi (bar) psi (bar) psi (bar) Hoist Pump 4 - B 50 - 55 Drum 1...
Page 111: Drum Identification
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM DRUM IDENTIFICATION Boom Butt Drum No. Description Main Load Drum Whip Load Drum MAX-ER Luffing/Auxiliary Load Drum Mast Boom Hoist - Standard Butt Mast Hoist - with MAX-ER (in mast butt) Rigging Winch Crane FIGURE 2-20...
Page 112: Pump Identification
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL PUMP IDENTIFICATION Past and Tier 3 Production Tier 4 Production A10584-2 A13469 81013192 – – Bottom – Bottom – Item Description Item Description Item Description Right Crawler and Drum 4 Pump Swing Pump Acc. Sys. Fixed Gear Pump (Past, T3 Prod.)
Page 113: Motor Components
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM MOTOR COMPONENTS A1188 Boom Hoist, Load Drums, and Travel Motors Item Port Description Main System Pressure Main System Pressure Case Pressure Case Pressure Gauge Port A Gauge Port B Servo Pressure Gauge Port or Servo Pressure Supply...
Page 114: Hydraulic System Test, Calibration, And Adjustment Procedures
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM TEST, CALIBRATION, The pressure sender test calculates the zero-pressure output level for each pressure sender. Pressure sender null AND ADJUSTMENT PROCEDURES (0) must be with in 0.65 to 1.35 volts. It is only necessary to perform the following procedures at...
Page 115: Control Calibration
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM NOTE: The cause of a failed pressure sender test or faulty Calibrate controls as follows: display pressure reading may not be the pressure Apply all park brakes with switches on control console. sender. The cause of the fault could be trapped air or hydraulic pressure in the system during the Start and run engine at high idle.
Page 116: High Pressure Test
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL High Pressure Test Press Confirm button to start test. Test starts and percent of completion is displayed in data Figure 2-26 for the following procedure. box. The high pressure test checks the ability of all primary crane When test is complete, high pressure icon reappears in functions to reach and hold high pressure.
Page 117: Charge Pressure Test
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Charge Pressure Test High Pressure Adjustment Figure 2-27 for the following procedure. The following adjustment is only required when a system fails the High Pressure Test described in this section. The charge pressure test checks the ability of all primary cane functions to build proper charge pressure.
Page 118 HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL A1161 Typical Pump Installation 3 (5 under) Multi-Function Valve Wrench Size P1537a Lock Nut Internal Pump Size Hex Size Hex Size Item Description Series 042 -100 Units 19 mm 5 mm Port A Multi-Function Valve...
Page 119: Charge Pressure Adjustment
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Charge Pressure Adjustment P1600a The following adjustment is only required when a system fails the Charge Pressure Test described in this section. Scroll to diagnostic screen for corresponding function (see Figure 2-29). Start and run engine at high idle. With function in neutral, system pressure on diagnostic screen should read 320 to 370 psi (22 to 26 bar).
Page 120 HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL If you think that a low pressure accessory system is not Stop engine, remove gauge, and reconnect hydraulic operating properly, proceed as follows: lines. Install an accurate 0 to 1,000 psi (0 to 69 bar) hydraulic...
Page 121: Motor Leakage Test
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Motor Leakage Test Typical Motor Installation Perform the following test if troubleshooting indicates the need: • Low Charge Pressure • Sluggish Operation • Excessive Heat Figure 2-33 for the following procedure. Stop engine. Install an accurate flow meter in highest case drain port...
Page 122: Pump Or Motor Override
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Pump or Motor Override Solenoid Valve Override Figure 2-34 for the following procedure. Figure 2-34 for the following procedure. Start and run engine at low idle. Start and run engine at low idle. Rotate manual override (2) in either direction to stroke Insert a rigid steel rod through hole in end of valve cap.
Page 123: Pressure Sender Replacement
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pressure Sender Replacement Slowly loosen pressure senders only enough to allow any remaining pressure to exhaust. Remove pressure senders. Install new pressure senders and connect electric cords. WARNING Pressure senders have pipe threads. Be sure to install High Pressure Oil Hazard! thread sealant.
Page 124: Disc Brake Operational Test
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Disc Brake Operational Test Reconnect electric connector to all brake solenoid valves at completion of operational test. There is no physical way to check the disc brakes for travel, If disc brakes were repaired or replaced, retest brakes boom hoist, lo ad dru ms, and swing.
Page 125 Diagnostic Screen..........3-40 Manitowoc...
Page 126 16000 SERVICE/MAINTENANCE MANUAL Diagnostic Screen Component Icons ....... 3-40 Engine Diagnostics Screen ........3-41 Swing Diagnostic Screen .
Page 127: Electrical Drawings And Schematics
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM ELECTRICAL DRAWINGS AND b. Damaged or missing electrical clamps or tie straps SCHEMATICS Excessive corrosion or dirt on the junction boxes Applicable electrical system drawings and schematics are d. Loose junction box mounting hardware attached at the end of this section.
Page 128: Circuit Breaker And Fuse Id
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL CIRCUIT BREAKER AND FUSE ID Circuit breakers are mounted in the following locations: Circuit breakers CB-1 through CB-8 are mounted in the This section identifies the fuses and circuit breakers. engine node-0 controller box in left side enclosure. There are Fuses are mounted in the fuse junction box located in the no in-line fuses used on this crane model.
Page 129 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Circuit Amps Description of Items Protected Breaker Cold Weather Package Circuit Breakers (Past Production) Cold Weather Package Main Load Center Circuit Breaker Engine Coolant Heater, Engine Oil Heater Hydraulic Reservoir Heaters – Left or Right Hydraulic Reservoir –...
Page 130 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Circuit Amps Description of Items Protected Breaker Cold Weather Package Circuit Breakers (Current Production) Cold Weather Package Main Load Center Circuit Breaker Engine Coolant Heater, Engine Oil Heater Hydraulic Reservoir, Cab Console and Battery Pad Heaters...
Page 131 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Circuit Amps Wire No. Description of Items Protected Breaker Air Conditioner & Heater Assembly Fuses ECM/Power Interface Module, Cab Temp A0A8CB2 8 HP Sensor, Blower Motor, Evaporator Thermostat, Electric Water Valve A0A8CB3 Front Wiper, Overhead Wiper...
Page 132: Test Voltages
TEST VOLTAGES Node Heading Descriptions The CAN ID. NO. indicates the CAN BUS system node ® The Model 16000 operating system is an EPIC with CAN number, cable, receptacle number, and pin number code ® technology. The CAN Bus system uses multiple nodes (34-R) is as follows: that contain controllers.
Page 133: Alphabetical Index Of Components
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Alphabetical Index of Components Abbreviations Find the desired component item in this index. Check the The following abbreviations are used in test voltage tables: component item node location, then refer to indicated node Alternating Current to find the test voltage for that item.
Page 134: Node 1 - Master (Front Console)
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Table 3-2. Pump and Motor Control Test Voltages All Hoist Pumps Boom and Mast Hoist Motors Load and Luffing Hoist Motors 0 to 25.4 Volts (at Node) 0 to 18.8 Volts (at Node) 0 to 16 Volts (at Node) 0 to 2.0 Volts (at Pump)
Page 135 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Receptacle – Front Console (Unused Terminals are Omitted) P12-1 24 Volts Power from Node-3 to Node-1 24 Volts Nominal P12-13 DI-3 Load Hoist (Drum 1) Park Switch 0 Volts Off; 24 Volts On CAN129-3-4 P12-14...
Page 136: Node 2 - Handles And Cab Controls
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Node 2 — Handles and Cab Controls Reference Electrical Schematic A10871, Sheet 1, 4, 5, 6, and 15. Function Packet Wire No. Description Test Voltage Type Code No. Receptacle – Controls (Unused Terminals are Omitted)
Page 137 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM P52-5 DO-5 Overhead Wiper Switch 0 Volts Off, 24 Volts On CAN24-1-16 P52-6 DO-13 Limit Bypass and Jib Up Limit Switches 24 Volts Nominal CAN24-2-16 P52-7 DO-16 Park Switches 24 Volts Nominal CAN24-2-128 P52-8 DO-9...
Page 138: Node 3 - Drum Pumps, Alarms, Sensors, And Accessories
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Node 3 — Drum Pumps, Alarms, Sensors, and Accessories Reference Electrical Schematic A10871, Sheet 1, 7, and 16. Function Packet CAN ID. No. Description Test Voltage Type Code No. Input/output cable routing to remote nodes vary - see Electrical Schematic specific to your crane.
Page 139 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM 34-R DO-15 Pump 3 Control (Drum 4/Drum 5) Table 3-2 page 3-8 CAN25-2-64 34-S DO-18 Pump 6 Control (Drum 2/Drum 1) Table 3-2 page 3-8 CAN25-3-2 34-T Ground Pump 2 Control (Left Travel/Drum 3) Ground...
Page 140: Node 4 - Pressure Senders, Drum 4, And Accessories
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Node 4 — Pressure Senders, Drum 4, and Accessories Reference Electrical Schematic A10871, Sheet 1, 8, and 16. Function Packet CAN ID. No. Description Test Voltage Type Code No. Input/output cable routing to remote nodes vary - see Electrical Schematic specific to your crane.
Page 141 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM 44-P DO-16 Left Rear Jack Solenoid - Retract 0 Volts Off; 24 Volts On CAN27-2-128 44-R DO-15 Left Rear Jack Solenoid - Extend 0 Volts Off; 24 Volts On CAN27-2-64 44-S DO-18 Right Rear Jack Solenoid - Retract 0 Volts Off;...
Page 142: Node 5 - Drum 2, Sensors, And Auto Lubrication
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Node 5 — Drum 2, Sensors, and Auto Lubrication Reference Electrical Schematic A10871, Sheet 1, 9, and 16. Function Packet Can ID. No. Description Test Voltages Type Code No. Input/output cable routing to remote nodes vary - see Electrical Schematic specific to your crane.
Page 143 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM 54-U DO-19 Travel 2-Speed Solenoid 0 Volts Off; 24 Volts On CAN29-3-4 54-V Ground Travel Brake Release Solenoid Ground 54-W DO-20 Swing Brake Release Solenoid 0 Volts Off; 24 Volts On CAN29-3-8 54-X Ground Swing Lock Solenoid - In *3...
Page 144 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL 1.2 or 3.2 Volts Not Moving; 56-n EC1A Load Hoist (Drum 2) Motor Speed Sensor CAN52-2 *2 2.2 Volts Moving 1.2 or 3.2 Volts Not Moving; 56-p EC1B Load Hoist (Drum 2) Motor Speed Sensor CAN52-2 *2 2.2 Volts Moving...
Page 145: Node 6 - Drum Brakes, Pawls, And Motor Sensors
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Node 6 — Drum Brakes, Pawls, and Motor Sensors Reference Electrical Schematic A10871, Sheet 1, 10, and 16. Function Can ID. No. Description Test Voltages Packet No. Type Input/output cable routing to remote nodes vary - see Electrical Schematic specific to your crane.
Page 146 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Function Can ID. No. Description Test Voltages Packet No. Type Load/Luffing (Drum 3) Motor Speed Sensor/ 64-r Ground Ground Jumper to Node Select 2 1.2 or 3.2 Volts Not Moving; 64-s EC3B Load/Luffing (Drum 3) Motor Speed Sensor CAN47-6 *2 2.2 Volts Moving...
Page 147: Node 7 - Max-Er
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Node 7 — MAX-ER Reference Electrical Schematic A15592, Sheet 1, 2, 3 and 4. Function Packet CAN ID. No. Description Test Voltage Type Code No. Input/output cable routing to remote nodes vary - see Electrical Schematic specific to your crane.
Page 148 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL 74-P DO-16 Right Front Jacking Cylinder Retract 0 Volts Off; 24 Volts On CAN28-2-128 74-R DO-15 Right Front Jacking Cylinder Extend 0 Volts Off; 24 Volts On CAN28-2-64 74-S DO-18 Right Rear Jacking Cylinder Retract 0 Volts Off;...
Page 149 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM 1.2 or 3.2 Volts Not Moving; 76-n EC-1A Left Wheel Steering Encoder CAN50-2 *2 2.2 Volts Moving 1.2 or 3.2 Volts Not Moving; 76-p EC-1B Left Wheel Steering Encoder CAN50-2 *2 2.2 Volts Moving 1.2 or 3.2 Volts Not Moving;...
Page 150: Boom Node 20 - Block-Up, Load Sensor, Angle Indicator, And Wind Speed
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Boom Node 20 — Block-Up, Load Sensor, Angle Indicator, and Wind Speed Reference Electrical Schematic A10871, Sheet 1, 11 and 20. Function Packet CAN ID. No. Description Test Voltage Type Code No. Receptacle – CAN In (From RCL Receiver)
Page 151: Jib Node 21 - Block-Up, Load Pin, And Wind Speed
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Jib Node 21 — Block-Up, Load Pin, And Wind Speed Reference Electrical Schematic A10871, Sheet 1, 11 and 21. Function Packet CAN ID. No. Description Test Voltage Type Code No. Receptacle – CAN In (From Jib Butt)
Page 152: Node 0 - Engine
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Node 0 — Engine Reference Electrical Schematic A10871, Sheet 1 and 12. Receptacle/ Function Wire No. Description Test Voltage Pin No. Type Connector – 40 Pin P1-1 24 Volts Ignition Signal 24 Volts Nominal P1-2...
Page 153: Digital Output Disable Chart
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Digital Output Disable Chart CAN38-1-64 Load Hoist (Drum 1) Brake Solenoid (N6) CAN38-1-128 Load Hoist (Drum 1) LS Motor Control (N6) Table 3-3 Digital Output Disable CAN38-2-1 Load Hoist (Drum 1) RS Motor Control (N6) CAN38-2-2 Load Hoist (Drum 1) Min.
Page 154: Digital Output Reference Chart
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Digital Output Reference Chart Table 3-4 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 155: Digital Input Reference Chart
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM CAN Packet Item Description CAN Packet Item Description Number (Node Number) Number (Node Number) MAX-ER CAN-28-2-64 Right Front Jacking Cylinder Extend (N7) CAN-28-1-1 Counterweight Lift Cylinder Extend (N7) CAN-28-2-128 Right Front Jacking Cylinder Retract (N7)
Page 156: Max-Er Faults (Software, M002047.0 & Up)
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL MAX-ER Faults (Software, m002047.0 & up) Table 3-6 Digital Inputs CAN Packet Item Description Number (Node Number) Wheeled MAX-ER CAN147-1-1 Lift Cylinder Length Sensor Out of Range CAN147-1-2 Lift Cylinder Retract Pressure Sensor Out of Range...
Page 157: Wired Remote
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Wired Remote Table 3-7 Digital Inputs CAN Packet Item Description Number CAN168-1-1 Engine Low Speed Switch CAN168-1-2 Engine High Speed Switch CAN168-1-64 Boom Pins In Switch CAN168-1-128 Boom Pins Out Switch CAN168-2-1 Front Adapter Pins In Switch...
Page 158: Checking Electrical Inputs/Outputs
3 volts can indicate that a circuit is turned off and is universal nodes. The in-line test boards can be ordered from an open circuit. the Manitowoc Crane Care Lattice Team. To test for amperes: The node number and pin numbers for each component to Open knife switch across test terminal.
Page 159 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM A00323 In Boom Butt CONTROLLER UNIVERSAL NODE A00323 MCC A01411 A10740-23 P2071 P2065 P2067 P2066 Item Description Item Description Universal Node Controller (3, 4, & 5) J1 Connector - Communication In Node In-line Test Board (3 Separate Boards)
Page 160: Displays
5 – Select Buttons If a display goes blank on cranes with program number 16000 FCN 2.039 and newer, try the following procedure to Use the green select touch pad buttons to select screen images, icons or data boxes, and values or icons within data restore the display.
Page 161: Main Gui Display Format
(most likely caused by the real time clock). A graphic picture of Manitowoc is displayed at crane startup Figure 3-8. The Manitowoc screen displays the following program items:...
Page 162: Information Screen
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL The Menu screen shows six screen icons: The crane information items currently available (if equipped) for the two smaller data boxes on the left side of the screen Information Screen icon are as follows: Diagnostic Screen icon...
Page 163: Engine
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Engine fault. When the fault data box is selected, the screen scrolls through the current faults one icon at a time. The fault history Engine data box displays the following goes back in time to review past faults.
Page 164 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Table 3-8. Faults Item Description 49-Jib Maximum Up 1* — Program limit stops Item Description luffing jib when jib is raised to maximum working 0-No Fault. angle. Lower luffing jib. Can bypass this limit to raise jib to Maximum Up 2 limit.
Page 165 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Item Description Item Description 67-Jib Maximum Down 2* — Limit switch stops 84-Digital Output Disabled — Digital output luffing jib when jib is lowered to minimum angle. signal has a short circuit between computer Raise luffing jib.
Page 166: Diagnostic Screen
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Diagnostic Screen NOTE: Variable outputs may show a yellow icon all the time. Diagnostic screen shows a graphic of hydraulic circuit and Drum Speed status of all pumps, motors, valves, and switches that apply to crane function selected.
Page 167: Engine Diagnostics Screen
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Rigging Winch Status Description Description Rear Adapter Pins - In 22 All Jacks - Extend Displays command state of rigging winch — Rear Adapter Pins - Out 24 Counterweight Pins - Out haul in or pay out (shown) line.
Page 168 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Drum Diagnostic Screens For load drums 1 or 2, drum 2 pump is dedicated to the drum 1 motor through diverting valve when drum 1 is selected. The Select drum icon in screen level 1 as shown Figure 3-11.
Page 169: Swing Diagnostic Screen
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Swing Diagnostic Screen Travel Diagnostic Screen Select swing icon in screen level 1 as shown in Figure 3-13. Select travel icon in screen level 1 as shown in Figure 3-15. Press Enter button to go to level 2.
Page 170: Jacking Accessory Diagnostic Screen
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Jacking Accessory Diagnostic Screen Select crane carbody with jacking icon in screen level 1 as shown in Figure 3-27. Press Enter button to go to level 2. Diagnostic Screen D16-13 FIGURE 3-19 Accessory Jacking Selected...
Page 171: Function Mode Screens
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Cab Tilt, Rigging Winch, and Mast Accessory The Function Mode screen is to enable/disable modes and to set operating parameter for the individual crane functions. Diagnostic Screen This screen operates on four levels. Select cab tilt, rigging winch, and mast icon in screen level 1 Level 1—...
Page 172: Swing Pressure Limit
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Swing Functions Drum, Swing or Track Speed Limits Select swing functions from screen shown below. Figure 3-28 in the following procedure. Drum, swing, and crawler speeds can be selected. In level 3, the value shown in these data boxes can be adjusted with...
Page 173: Can Bus Screen
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM CAN Bus Screen Boom or Swing Motion Limiter Mode Figure 3-30 in the following procedure. Figure 3-34 for the following procedure. NOTE: Motion limiter mode data boxes do not appear The CAN (Controller Area Network) bus diagnostic screen is unless crane has this option.
Page 174: Digital Output Disable Fault
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Each individual input/output is assigned a number (identifier) Load Link Status (900 MHz System) in the binary system (powers of two). The identifiers of all CON0 depicted in Figure 3-8, page 3-35. inputs/outputs that are ON (active) for each bank are added for a total of 0 –...
Page 175: Boom Node Status
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Boom Node Status The number displayed in the crane status top bank corresponds to the numbered communication errors listed Figure 3-34, item 9. below: The boom node status displays boom top node and jib node 0 = Crane status normal.
Page 176 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Table 3-10 Bank Identifier Numbers Dark shaded boxes indicate ON; white boxes OFF. 3-50 Published 05-09-17, Control # 014-28...
Page 177 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-10 Bank Identifier Numbers (continued) Dark shaded boxes indicate ON; white boxes OFF. Manitowoc 3-51 Published 05-09-17, Control # 014-28...
Page 178: Camera Screen (Optional)
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Camera Screen (Optional) The camera screen (not shown) displays camera options and items for selecting and operating. The camera option includes up to three different cameras to monitor drum spooling and the area behind the crane.
Page 179: Section 4
Lattice Section Inspection and Lacing Replacement ......4-15 Manitowoc Published 05-09-17, Control # 014-28...
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Page 181: Automatic Boom Stop Adjustment
16000 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM AUTOMATIC BOOM STOP ADJUSTMENT Maintenance At least once weekly, check that the automatic boom stop Maximum Boom Angle stops the boom at the specified maximum angle. If not, Boom stop limit switch (5,...
Page 182: Bypass Limit Test
BOOM 16000 SERVICE/MAINTENANCE MANUAL Table 4-1 — Boom Stop Limits Angle A (see Figure 4-1) 83° — #58 Boom without Luffing Jib For Cranes with a Boom Up Limit that Can be Bypassed * 87° — #58 Boom with #59 Luffing Jib 84°...
Page 183 16000 SERVICE/MAINTENANCE MANUAL BOOM A10867-1 Centerline of Boom 2a or 2b Table 4-2 Table 4-1 Horizontal Right Side of Crane Item Description Boom Butt Switch Assembly FIGURE 4-1 Table 4-2 — Adjusting Rod Adjusting Rod and Length (see Figure 4-1)
Page 184 BOOM 16000 SERVICE/MAINTENANCE MANUAL A10867 Roller Over-Travel VIEW A SWITCH OPENED 2a or 2b 2a or 2b VIEW B STORED SWITCH CLOSED Item Description Limit Switch Wiring Boom Butt Switch Adjusting Rod – Boom only Receptacle Function Terminals Adjusting Rod – Boom with Luffing Jib...
Page 185: Adjustment
16000 SERVICE/MAINTENANCE MANUAL BOOM Loosen jam nut (3, View B). Digital Level Angle A b. Turn adjusting rod (2a or 2b) all the way into Angle coupling (4). 83° 75.3° Boom up slowly until the boom reaches the 84° 76.3°...
Page 186 BOOM 16000 SERVICE/MAINTENANCE MANUAL • 76.1° - Initial Contact • 77.9° - Start of Spring Cushioning • 88.9° - Physical Stop (springs solid) View B View A 1-1/2 in (38 mm) View C Item Description Boom Butt Physical Boom Stop Strut Boom at 76.1º...
Page 187: Physical Boom Stop
16000 SERVICE/MAINTENANCE MANUAL BOOM PHYSICAL BOOM STOP Operation Figure 4-4 for the following procedure. When the boom is raised to 77.9°, springs in the boom stop tubes begin to compress. Physical Boom Stop Angles As the boom is raised higher, spring compression The physical boom stops serve the following purposes: increases to exert greater force against the boom.
Page 188: Boom And Luffing Jib Angle Indicator Calibration
BOOM 16000 SERVICE/MAINTENANCE MANUAL BOOM AND LUFFING JIB ANGLE • Automatically control the position of the mast raising cylinder and levers during crane setup. INDICATOR CALIBRATION • Allow the operator to monitor the mast angle on the Angle indicator sensors are located inside the node display during crane setup.
Page 189: Drum Pressure-Roller Adjustment
16000 SERVICE/MAINTENANCE MANUAL BOOM A11126 WARNING Crush Hazard! The roller is spring loaded. Stop drum and turn off engine before adjusting. Adjustment Figure 4-9 for the following procedure. The operator shall monitor drum spooling during operation. Scribe If the wire rope jumps layers or does not wind smoothly onto...
Page 190: Strap Inspection And Maintenance
Service Manual, contact your safe. dealer or the Manitowoc Crane Care Lattice Team. Before beginning inspection, thoroughly clean strap of all dirt, grease, oil, etc. so a thorough inspection can be made.
Page 191: Replacement Specifications
16000 SERVICE/MAINTENANCE MANUAL BOOM Replacement Specifications Dent Any strap not within specifications listed in Table 4-3 must be replaced. WARNING I f d a m a g e t o s t r a p e x c e e d s t h a t a l l o w e d w i t h i n...
Page 192: Straightness
BOOM 16000 SERVICE/MAINTENANCE MANUAL Strap Length Maximum Deviation Corrosion or Abrasion Allowed P325 20 to <30 ft (6,1 to <9,1 m) 0.250 in (6,4 mm) 30 to <40 ft (9,1 to <12,2 m) 0.375 in (9,5 mm) 40 to <50 ft (12,2 to <15,2 m) 0.50 in (12,7 mm)
Page 193: Storing Straps
16000 SERVICE/MAINTENANCE MANUAL BOOM Push pin tight against edge of hole along vertical center Length line. Measure dimension between pin and hole (View B). Link Strap If dimensions A and B are not identical, hole is elongated. Remove strap from service.
Page 194 BOOM 16000 SERVICE/MAINTENANCE MANUAL Table 4-4 Lacing and Chord Wall Thickness This table applies only to past production cranes. Lacing and chord wall thicknesses for current production cranes are located in the Lacing Drawings in the Attachment Section of the Parts Manual supplied with the crane.
Page 195: Lattice Section Inspection And Lacing Replacement
16000 SERVICE/MAINTENANCE MANUAL BOOM LATTICE SECTION INSPECTION AND LACING REPLACEMENT Refer to Folio 1316 at the end of this section for lattice section inspection and lacing replacement instructions. Manitowoc 4-15 Published 05-09-17, Control # 014-28...
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Page 197: Section 5
Load Block And Hook-and-Weight Ball Inspection ......5-15 Manitowoc Published 05-09-17, Control # 014-28...
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Page 199: Boom/Mast Hoist Pawl Adjustment
16000 SERVICE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS BOOM/MAST HOIST PAWL ADJUSTMENT A10767 View from Right Side General of Crane The boom/mast hoist (Drum 4) has a drum pawl which is a positive locking device. When engaged, the pawl prevents the boom/mast hoist drum from turning in the down direction.
Page 200: Speed Sensor Adjustment
HOISTS 16000 SERVICE/MAINTENANCE MANUAL SPEED SENSOR ADJUSTMENT Item Description General Speed Sensor The hydraulic motors for the hoists (boom, mast, load) and Notch swing have a speed sensor. For those functions having more Lock Nut than one motor, only one of the motors has a speed sensor.
Page 201: Weekly Maintenance
16000 SERVICE/MAINTENANCE MANUAL HOISTS Weekly Maintenance Adjustment Check minimum bail limit switch for proper operation. Pay out wire rope until rollers are against bare drum with 3 to 4 wraps of wire rope remaining on first layer. LED (light emitting diode, Past Production only) should be on for normal operation.
Page 202: Block-Up Limit Control
HOISTS 16000 SERVICE/MAINTENANCE MANUAL BLOCK-UP LIMIT CONTROL The block-up limit system consists of the following components (see Figure 5-4): General Normally closed limit switch assembly fastened at the following locations: A block-up limit (also called anti two-block device) is a two-...
Page 203 16000 SERVICE/MAINTENANCE MANUAL HOISTS Item Description Item Description A1284 Wire Rope Guide Shackle Lower Boom Point Extended Upper Boom Point (lower sheaves) Weight Standard Upper Boom Point Lift Plate Extended Upper Boom Point (upper sheave) Load Block Block-Up Limit Switch (left hand)
Page 204 HOISTS 16000 SERVICE/MAINTENANCE MANUAL Single Part Reeving Multiple Part Reeving Dead Ended at Upper Boom Point A11993 FIGURE 5-4 continued Published 05-09-17, Control # 014-28...
Page 205: Maintenance
16000 SERVICE/MAINTENANCE MANUAL HOISTS Maintenance b. BOOM RAISED: Slowly hoist each load block and weight ball — one at a time — against weight. Inspect and test the block-up limits weekly or every 40 When chain goes slack, corresponding load drum...
Page 206 HOISTS 16000 SERVICE/MAINTENANCE MANUAL A1050 A1007 A1131 From Boom or Jib Node Controller Limit Switch for Lower Boom Point and Jib Point Item Description Elbow with Cord Gripper Dimension A 1.04 in (26 mm) Setscrew Spring Enclosure Adjusting Screw (Spring Tension)
Page 207: Wire Rope Lubrication
16000 SERVICE/MAINTENANCE MANUAL HOISTS WIRE ROPE LUBRICATION • Broken or cut strands • Broken wires (see Periodic Inspection for additional R e f e r t o t h e L u b r i c a t i o n G u i d e i n S e c t i o n 9 f o r information) recommendations.
Page 208: Broken Wires
HOISTS 16000 SERVICE/MAINTENANCE MANUAL Measure the rope’s diameter across the crowns of the The wire rope must be taken out of service when it has strands so the true diameter is measured as shown in the following number of broken wires.
Page 209: Distributing Wire Rope Wear
16000 SERVICE/MAINTENANCE MANUAL HOISTS Wear and Other Damage M100655a-f Figure 5-9 for examples of wire rope damage. It is normal for the outer wires of the rope to wear first because of friction. The wire rope must be taken out of service if: •...
Page 210: Drum Kicker Adjustment
HOISTS 16000 SERVICE/MAINTENANCE MANUAL DRUM KICKER ADJUSTMENT Repeat steps 1-3 only enough to improve spooling. Moving drum kickers in too far can cause premature General wire rope wear. Securely tighten set screws (5) and lock nuts (4). A drum kicker is provided on both flanges of the main load drum (in boom butt) to improve wire rope spooling for long Reinstall drum guards.
Page 211 16000 SERVICE/MAINTENANCE MANUAL HOISTS PLASTIC SHEAVE DATA Sheave Outside Width Rope Diameter Tread Diameter Diameter Part No. inch inch inch inch 912738 631054 13.19 335,0 11.42 290,1 1.77 45,0 631056 631065 16.00 406,4 13.37 339,6 2.17 55,1 9/16 631071 16.00 406,4 13.88...
Page 212: Sheave, Roller, And Drum Inspection
HOISTS 16000 SERVICE/MAINTENANCE MANUAL Observe groove to see if contour of gauge matches contour at bottom of sheave groove. Groove Too Small Groove Too Large Proper fitting sheave groove should support wire rope or 135–150° of rope circumference. Item Description...
Page 213: Load Block And Hook-And-Weight Ball Inspection
Block Weight (lb and kg) Block Serial Number Make sure sheaves, drums, and rollers are properly Block Part Number (OEM and Manitowoc) lubricated according to the instructions in the lubrication Design Factor guide provided with the crane (see Section 9).
Page 214 HOISTS 16000 SERVICE/MAINTENANCE MANUAL Daily inspection and maintenance will include the following Clean the load block or the hook-and-weight ball. points (see Figure 5-16 Figure 5-17): Lubricate the sheaves (if fittings provided), the hook trunnion, the hook swivel, and any other part equipped with a grease fitting at the intervals specified in the “Lubrication Guide.”...
Page 215 Hook latch is not intended as anti-fouling device, and load bearing component unless proper welding methods caution must be taken to prevent hook latch from are used (contact the Manitowoc Crane Care Lattice supporting any part of load. Team for material and welding specifications).
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Page 217: Section 6
Manual Release of Swing Brake and Lock ........6-1 Manitowoc...
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Page 219: Manual Release Of Swing Brake And Lock
16000 SERVICE/MAINTENANCE MANUAL SWING SECTION 6 SWING MANUAL RELEASE OF SWING BRAKE AND Hydraulic hand pumps with pressure gauges are needed to manually release the swing brake and swing lock. LOCK Disconnect hoses from fitting at brake release port and,...
Page 220 SWING 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-09-17, Control # 014-28...
Page 221: Section 7
General ............7-17 Manitowoc...
Page 222 16000 SERVICE/MAINTENANCE MANUAL Passive Regeneration ......... . 7-17 Active Regeneration .
Page 223: Battery Maintenance
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERY MAINTENANCE Undercharging Undercharging can cause a type of sulfate to develop on the Safety Information plates. The sulfate causes strains in the positive plates which causes plate buckling. Buckled plates can pinch the separators and cause a short circuit.
Page 224: Maintenance
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL Maintenance Readings must be temperature corrected. Subtract 0.004 from the reading for each 6° below 27°C (81°F). Weekly – Check Electrolyte Level Add 0.004 for each 6° above 27°C (81°F). Clean the top of the battery before removing the vent...
Page 225: Charging
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN Table 7-3 Open Circuit Cell Voltage If a battery was discharged rapidly (cranking until dead), it Approximate can be recharged on a fast charger with an output of up to 40 % Charge Specific Gravity Open Circuit amperes for a maximum of 2 hours.
Page 226 POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL A02258 A10577 P2237a Right Side of Upperworks Item Description Air Cleaner Assembly ™ Evacuator Valve Service Cover Latch O-Ring Primary Filter Safety Filter Housing Inlet Cap Clamp (11 each) Rubber Reducer Rubber Elbow (4 each)
Page 227: Engine Air Cleaner Maintenance - Past Production And Tier 3
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE AIR CLEANER MAINTENANCE – Check that Evacuator valve (1a) is open. PAST PRODUCTION AND TIER 3 CAUTION Figure 7-3 for the following procedures. Engine Damage! The air cleaner is mounted horizontally and fastened to engine air intake (6) with rubber elbows (5) and reducer (4).
Page 228: Engine Air Cleaner Maintenance - Tier 4 Engine
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL Install filters by hand: • A yellow flag in the indicator window (8a) extends as the filters become plugged. Replace filters when the Insert new safety filter (1e) carefully and seal it by hand, yellow indicator reaches the red zone at the end of making certain filter is completely seated in housing the indicator.
Page 229: Service
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN Service Service the air cleaner and its primary and secondary filter CAUTION elements per the intervals specified by the engine Engine Damage! m a n u f a c t u r e r a n d p e r t h e e n g i n e m a n u f a c t u r e r ’s instructions.
Page 230: Air Cleaner - Tier 4 Only
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL AIR CLEANER — TIER 4 ONLY IMG6048 IMG7658 IMG7607 Item1 Description Air Cleaner Assembly Service Cover Latch (6) Primary Filter (2) Secondary Filter (2) Housing Steel Tube (2) Clamp (6) Straight Adapter Fitting Rubber Elbow Reducer (2)
Page 231: Engine Clutch Adjustment
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE CLUTCH ADJUSTMENT will clean the disc surfaces and prevent the discs from seizing. Figure 7-5 for the following procedure. When disengaging clutch, check free travel. Readjust A disc-type manually operated clutch is mounted between clutch when free travel decreases to less than 1-3/8 in the engine and the pump drive on this crane.
Page 232: Engine Throttle Adjustment
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL ENGINE THROTTLE ADJUSTMENT Install setscrew (16). Do not insert deep enough to contact head on shaft (3). The engine throttle assembly consists of an electronic hand Rotate pedal approximately 40° to position B (low idle).
Page 233 16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN A02019 Supply Idle 22VDC Signal 5 WATT High Ground Idle Ground Signal Supply ELECTRICAL SCHEMATIC Section B–B Surface X Flat on Head of Shaft 70° RTV-162 These two holes should be aligned when initially inserting Section A–A...
Page 234: Engine Enclosure
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL ENGINE ENCLOSURE ENGINE BELT ROUTING — TIER 4 ENGINE ONLY The enclosure has panels (see Figure 7-7) that can be removed to allow access for engine service. Engine belt routing for the Tier 4 engine is shown in...
Page 235: Engine Cooling System Fill - Current Production Tier 4
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE COOLING SYSTEM FILL — The cooling system is of the deaeration type, which continually removes air from the system, as follows: CURRENT PRODUCTION TIER 4 • A small percentage of total coolant flow is circulated General through a vent line to the radiator.
Page 236: Maintenance
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL Maintenance Deaeration Tank Cooler Sight Glass (Full) WARNING Cooler Sight Burn Hazard! Glass (Low) Avoid personal injury from heated coolant spray or steam — do not remove radiator cap from hot engine. Stop engine and wait until coolant temperature is below 120° F IMG7667 (50°...
Page 237 16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN Bleed Screw Cooler Drain 81013188 Valve FIGURE 7-12 Bleed Screw Cooling Fins Deaeration Tank Bleed Valve Fill Cap Bleed Screw Bleed Screw FIGURE 7-13 Manitowoc 7-15 Published 05-09-17, Control # 014-28...
Page 238: Filling The Cooling System
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL Open drain valve (Figure 7-14) and drain coolant into a Install fill cap and run engine until at normal operating suitable container. temperature. 81013188_c CAUTION! Engine Damage! The required coolant level must be maintained to prevent engine damage.
Page 239: Diesel Particulate Filter Regeneration - Tier 4 Only
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN DIESEL PARTICULATE FILTER Regeneration REGENERATION — TIER 4 ONLY General General Regeneration is the process of converting the soot collected in the DPF into carbon dioxide. Regeneration requires heat The Diesel Particulate Filter (DPF) — located at the rear of to occur.
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Page 241: Diesel Particulate Filter (Dpf) Maintenance
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN DIESEL PARTICULATE FILTER (DPF) MAINTENANCE WARNING Accumulated ash must be periodically cleaned from the DPF. A build-up of ash can result in cold spots and compact the Burn and Inhalation Hazards! ash within the DPF. This reduces the life of the filter, can...
Page 242: Diesel Particulate Filter Component Overview
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL Diesel Particulate Filter Component Overview Item Description Item Description Engine Tube Support Brackets (2) Diesel Particulate Filter Hex-head Cap screws (4) Exhaust Filter Mounts (2) Locknuts (6) Mounting Straps (2) Wiring Harness V-Band Clamp U-bolt Guillotine Clamp...
Page 243: Installing The Dpf
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN Figure 7-16. If not correct, the DPF sections will need to be reoriented (see Side Inlet Re-orientation). Position top half of mounting straps (4), then loosely WARNING! tighten straps with hex-head cap screws (14) and Personal Injury Hazard! locknuts (15).
Page 244: Side Inlet Re-Orientation
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL NOTE: Engine Fault Codes: Rotate the inlet section to the orientation shown in Figure 7-16. If DPF was replaced or cleaned as a result of engine Fault Code 1922, the stored soot load in the Tighten V-band clamp (19) to a torque value of 14.8 ±...
Page 245 Operation ............8-6 Manitowoc...
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Page 247: Turntable Bearing Installation
16000 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE SECTION 8 UNDER CARRIAGE TURNTABLE BEARING INSTALLATION • Threads of each bolt • Underside of head of each bolt When installing a turntable bearing, align the dowel pin holes in the inner ring with the dowel pins in the underside of the •...
Page 248 UNDER CARRIAGE 16000 SERVICE/MAINTENANCE MANUAL See View A A10521 Numbers Indicate Tightening Sequence S Stamped Here on Outer Race Access to inner ring FRONT of bolts is through hole Rotating Bed in center of rotating and Carbody bed and carbody.
Page 249: Crawler Adjustment
16000 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE CRAWLER ADJUSTMENT Tread Slack Adjustment Adjustment Guideline Maintenance Check tread slack at the tumbler end of each crawler. Crawler wear cannot be eliminated, but the rate of wear can Maintain equal tread slack at both crawlers.
Page 250: Adjustment Procedure
UNDER CARRIAGE 16000 SERVICE/MAINTENANCE MANUAL Adjustment Procedure Adjust tread slack at roller end of each crawler (Figure 8-3). CAUTION Thoroughly clean crawler to be adjusted. Part Wear! Crawler roller and tumbler must be square with crawler Loosen bolt (8) on each side of crawler roller.
Page 251 16000 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc Published 05-09-17, Control # 014-28...
Page 252: Hydraulic Hand Pump
Securely reinstall vent/fill cap. Prevent Possible Death or Serious Injury to Maintenance Personnel For Enerpac pump: Manitowoc has provided hand pump and cylinder for Place pump in vertical position with hose end crawler adjustment only. Any other use is neither intended down.
Page 253 16000 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE S135 S137 S138 Cylinder Vent/Fill Cap (Simplex Pump) Hose Close Valve Extend Cylinder Pump Notch in Dipstick (Enerpac Pump) Open Retract Valve Cylinder FIGURE 8-4 Manitowoc Published 05-09-17, Control # 014-28...
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Page 255: Section 9
Lube and Coolant Product Guide ......... . 9-1 Manitowoc...
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Page 257: Lube And Coolant Product Guide
16000 SERVICE/MAINTENANCE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION LUBE AND COOLANT PRODUCT GUIDE See Folio 2109 at the end of this section. See the publication at the end of this section. Manitowoc Published 05-09-17, Control # 014-28...
Page 258 LUBRICATION 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-09-17, Control # 014-28...
Page 259 PROBLEM 25 Crawler pin cylinder(s) will not extend or retract... . . 10-26 PROBLEM 26 Jacking cylinder(s) will not extend or retract....10-27 Manitowoc 10-i...
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Page 261 The following warnings apply to all troubleshooting • Use the display and main display for checking operations. Manitowoc cannot foresee all hazards that may pump, motor, handle, brake, etc. components. occur. • Use the in-line test boards (available from the...
Page 262 If directed, consult your Manitowoc dealer or the operation. These charts contain instructions to assist in Manitowoc Crane Care Lattice Team before proceeding.
Page 263 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 2 Engine rotates, but will not start. POSSIBLE No fuel to or from injector pump; Water or algae in fuel; Air intake restricted or blocked; Engine load is too high; Low battery amperage to gain starting RPM; Fuel shut-off is not working correctly.
Page 264 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 3 Engine runs, but no hydraulic operation. POSSIBLE CAUSES Clutch not engaged; No hydraulic fluid in tank; Blocked charge inlet to pumps; Clogged tank vent; Drive train damaged from flywheel to pump mount. CHECKS Check hydraulic filter service shut-off valve.
Page 265 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 4 Engine runs, but battery is not charging. POSSIBLE CAUSES Belt loose or broken; No input to alternator terminals; Damaged alternator; Corroded or loose battery connection; Battery damaged. CHECKS Check drive belt for correct tension.
Page 266 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 5 Engine faults enabled during engine operation. POSSIBLE CAUSES High engine coolant temperature or low engine oil pressure. High Engine Temperature Low Oil Pressure Check coolant level and quality. Check engine oil level at dipstick.
Page 267 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 6 Crawler travels only at slow speed. POSSIBLE CAUSES Partial control voltage from handle to PC; Partial control voltage from PC to pump EDC; Worn pump or motor. CHECKS Check travel speed switch for high-speed selection. Check for 100% travel speed on travel Diagnostic screen.
Page 268 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 7 Crawler track(s) will not travel in either direction. POSSIBLE CAUSES Damaged brake valve; Worn control handle; Damaged EDC; No voltage from handle to controller; No voltage to pump EDC; Node controller fault; Low brake pressure; Wiring or switch is damaged; Pump, motor, or gearbox is worn.
Page 269 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 8 A load drum does not operate. POSSIBLE CAUSES Load drum brake not releasing; No voltage through control handle to controller; No voltage out of controller to pump EDC; Node controller fault; Wiring or switch is damaged.
Page 270 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 9 Load drum will not raise load, but will lower load. POSSIBLE CAUSES Block up limit is opened; Pump is damaged; Control handle is worn; Maximum bail limit is opened; Speed sender is damaged. CHECKS When applicable switch or handle is enabled is the following displayed: Boom block-up limit fault.
Page 271 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 10 Load drum will not lower load, but will raise load. POSSIBLE CAUSES Pawl in; Control handle is worn; Minimum bail limit opened; Pump is damaged; Speed sender is damaged. CHECKS When applicable switch or handle is enabled is the following displayed: Drum 1 minimum bail limit fault.
Page 272 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 11 Load drum will not reach load drum maximum speed. POSSIBLE CAUSES Partial control from handle to controller; Partial control voltage from controller to pump EDC or motor PCP; Damaged pump or motor. CHECKS Check selected load drum speed screen for 100% speed selected.
Page 273 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 12 No boom/mast hoist operation. POSSIBLE CAUSES Boom/mast hoist brake not releasing; Boom/mast hoist pawl not released or hung up; No voltage through control handle to controller; No voltage out of controller to pump EDC; Wiring or switch is damaged.
Page 274 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 13 Boom/mast hoist will not reach maximum speed. POSSIBLE CAUSES Partial control voltage from handle to controller; Partial control voltage from controller to pump EDC; Motor controller in low; Pump or motor damaged. CHECKS Check boom/mast hoist drum speed screen for 100% reading.
Page 275 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 14 Boom will not boom up, but will boom down. POSSIBLE CAUSES Boom maximum up limit opened; Pump is damaged; Equalizer/boom stop limit opened; Control handle is worn. CHECKS When applicable switch or handle is enabled is the following displayed: Maximum boom up limit fault.
Page 276 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 15 Boom will not boom down, but will boom up. POSSIBLE CAUSES Boom maximum down limit opened; Pawl engaged; Pump is damaged; Block-up limit open; Control handle is worn; Speed encoder is damaged. CHECKS When applicable switch or handle is enabled is the following displayed: Boom down limit fault.
Page 277 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING NOTE: The swing lock is installed PROBLEM 16 on past production cranes only. On No swing operation, but engine loads. current production cranes the swing lock has been removed and the rocker switch has been removed from the console.
Page 278 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 17 No swing operation, engine does not load. POSSIBLE CAUSES No voltage through control handle to controller; No voltage out of controller to pump EDC; Wiring or switch is damaged; Node Damaged; Damaged pump or motor; Swing holding brake switch actuated.
Page 279 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 18 Travel system response is sluggish. POSSIBLE CAUSES Pump or motor is damaged; Travel speed out of adjustment. CHECKS Use a gauge to check charge pressure at travel pressure senders. 300 psi (21 bar) or less 300 psi (21 bar) or more Manually stroke travel pump with brakes applied.
Page 280 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 19 Closed-loop hydraulic system response is sluggish. POSSIBLE CAUSES Low hydraulic oil level in reservoir; Low hydraulic oil temperature; Reservoir shut-off is partially closed; Dirty charge filter; System multifunction valves are not set correctly; Pump or motor problem.
Page 281 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 20 Hydraulic system is operating hot. POSSIBLE CAUSES Low hydraulic oil level in reservoir; Heat exchanger problem; Dirty filter; System multifunction valves are not set correctly; Pump or motor problem. CHECKS Is hydraulic oil level in reservoir OK and shut-off valve fully open? Is heat exchanger radiator clean? Fill tank to full level or open shut-off valve.
Page 282 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 21 System pump will not return to neutral. POSSIBLE CAUSES System pump control handle is worn; System pump EDC is damaged; System pump is damaged; Pump is not centered. CHECKS Does Diagnostic screen show a percent for problem handle in neutral position?
Page 283 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 22 Drum pawl is not operating correctly. POSSIBLE CAUSES Mechanical hang-up; No hydraulic pressure; No voltage to pawl solenoid; Bad wiring; Actuator/cylinder failure. CHECKS Check for damage to pawl linkage. Check for pawl or pawl actuator/cylinder for freedom of movement.
Page 284 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 23 Mast cylinders will not raise or lower. POSSIBLE CAUSES Faulty control valve section; Low pump pressure; Bad pump; Switch failure; Faulty counterbalance valve. CHECKS Does system pressurize to 3,000 psi (207 bar) when moving mast switch to raise position?
Page 285 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 24 Accessory pin cylinder(s) will not extend or retract. POSSIBLE CAUSES Faulty control valve section; Low pump pressure; Bad pump; Switch failure; Mechanical problem. CHECKS Does system pressurize to 3,000 psi (207 bar) when moving problem switch to extend or...
Page 286 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 25 Crawler pin cylinder(s) will not extend or retract. POSSIBLE CAUSES Faulty control valve section; Low pump pressure; Bad pump; Pressure transducer bad; Faulty counterbalance valve. CHECKS Check for 3,500 psi (241 bar) at valve test port while manually enabling a crawler pin cylinder.
Page 287 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 26 Jacking cylinder(s) will not extend or retract. POSSIBLE CAUSES Faulty control valve section; Low pump pressure; Bad pump; Pressure transducer bad; Faulty counterbalance valve. CHECKS Check for 3,500 psi (241 bar) at valve test port while enabling jacking cylinder.
Page 288 Troubleshooting 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 10-28 Published 05-09-17, Control # 014-28...
Page 289 Lattice Section Inspection and Lacing Replacement ......4-15 Load Block And Hook-and-Weight Ball Inspection ......5-15 Manitowoc Index-i...
Page 290 MAX-ER 16000 Description Of Operation ........1-54...

Manitowoc 16000 Service And Maintenance Manual

See End of this Manual for Alphabetical Index

Section 2 Hydraulic System

Section 3 Electric System

Section 4 Boom

Section 5 Hoists

Section 5

Section 6

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