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Manitowoc Wheeled MAX-ER 16000 Operator's Manual
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Manitowoc Wheeled MAX-ER 16000 Operator's Manual

Manitowoc Wheeled MAX-ER 16000 Operator's Manual

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Summary of Contents for Manitowoc Wheeled MAX-ER 16000

  • Page 1 Manitowoc 16000 Operator Manual ® Wheeled MAX-ER Attachment...
  • 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 Manitowoc Product Support has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator’s cab and each attachment.
  • Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH...

  • Page 5: Table Of Contents

    Manitowoc Dealer........
  • Page 6 TABLE OF CONTENTS 16000 WHEELED MAX-ER® OPERATOR MANUAL Maintenance Instructions ............2-17 Safe Maintenance Practices.
  • Page 7 Operating Rigging Winch............4-82 Manitowoc...
  • Page 8 TABLE OF CONTENTS 16000 WHEELED MAX-ER® OPERATOR MANUAL Reeving – Load Block ............4-84 Load Block Identification.
  • Page 9 Manitowoc Dealer........
  • Page 10 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-ii Published 07-29-22, Control # 013-19...

  • Page 11: Section 1

    CHANGE OF OWNERSHIP REGISTRATION • The boom is on the front of the rotating bed. If you are the new owner of a Manitowoc crane, please • The carbody and crawler controls are on the front of the register it with Manitowoc Product Support so we can contact carbody.

  • Page 12: Identification And Location Of Components

    INTRODUCTION 16000 WHEELED MAX-ER® OPERATOR MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS Item Description 16000 Crawler Crane Physical Boom Stop Boom #58 Load Block Hook and Weight Ball Upper Boom Point Lower Boom Point Boom Top Wire Rope Guide Boom Straps Load Lines Boom Hoist Equalizer Boom Hoist Wire Rope...
  • Page 13 Counterweight Box (5 each side) M1-2b Identification Drum No Rigging Winch (in boom butt) Load Drum (in boom butt) Load Drum Load/Luffing Drum (in boom butt) Mast Hoist Boom Hoist M1-2c FIGURE 1-2 continued Manitowoc Published 07-29-22, Control # 013-19...

  • Page 14: Max-Er Outline Dimensions

    INTRODUCTION 16000 WHEELED MAX-ER® OPERATOR MANUAL MAX-ER OUTLINE DIMENSIONS M1-3 Centerline of Rotation Dimension Item 36.1 ft (11 m Working Position) 42.7 ft (13 m Working Position) 49.2 ft (15 m Working Position) 43 ft 8 in (13,30 m) at 11 m Working Position 50 ft 0 in (15,24 m) at 13 m Working Position 56 ft 6 in (17,22 m) at 15 m Working Position 26 ft 8-3/4 in (8,14 m)

  • Page 15: English And Metric Conversions

    Meters Per Second 0.4470 Feet Per Minute Line Speed Meters Per Minute m/min 0.3048 VOLUME Cubic Yard Cubic Meter 0.7646 Bucket Capacity Cubic Foot Cubic Meter 0.0283 Cubic Inch Pump Displacement Cubic Centimeter 16.3871 Manitowoc Published 07-29-22, Control # 013-19...
  • Page 16 INTRODUCTION 16000 WHEELED MAX-ER® OPERATOR MANUAL To Convert Symbol Application Symbol Multiply By VOLUME (LIQUID) Ounce Milliliter 29.5735 Pint Liter 0.4732 Fluid Capacities Quart Liter 0.9464 Gallon Liter 3.7854 Gallon Per Minute Pump Flow Liters Per Minute L/min 3.7854 WEIGHT Pound Unit/Component Kilogram...

  • Page 17: Section 2

    Pin Removal ..............2-21 Manitowoc...
  • Page 18 16000 WHEELED MAX-ER® OPERATOR MANUAL Disassembly Precaution ............2-21 Special Application/Service .

  • Page 19: Continuous Innovation

    If you are in Used with the safety alert symbol, indicates a hazardous doubt about any procedure, contact your Manitowoc dealer situation which, if not avoided, could result in minor or or Manitowoc Product Support.
  • Page 20 SAFETY INFORMATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Table 2-1 Common Safety Symbols Cut or Crush Hazards Cut Hazard M100090 M100091 M100066 M100065 M100069 M100067 Fire Crush Hazards Extinguisher M100070 M100071 M100072 M100073 M100074 M100082 Explosion Fall Hazards Falling Boom (Crush) Hazards Hazard M100083 M100084...

  • Page 21: Safety And Information Signs

    Ordering Signs Order replacement safety and information signs from your Maintaining Signs Manitowoc dealer. The crane owner/user shall make sure that all safety and When ordering a sign, give the crane model number, the information signs are legible and installed at the proper crane serial number, and the name and part number of the locations on the crane.

  • Page 22: Crane Access Points

    Manitowoc has provided a ladder, steps, platforms, and d. if the performance of their duties requires them to do catwalks at the locations shown in...
  • Page 23 Stairway (2 places) Non-Skid Surfaces (Walkways) WARNING Trip Hazard! Use caution when walking on carbody counterweights so you do not trip on lifting lugs and fall. Grated Platform in Boom Butt Figure 2-1. Crane Access Points Manitowoc Published 07-29-22, Control # 013-19...

  • Page 24: Personal Fall-Protection

    Manitowoc dealer for the proper manual or capacity charts. Do not operate the crane if the proper Capacity Chart is not in the cab.

  • Page 25: Swing Radius Barrier

    16000 WHEELED MAX-ER® OPERATOR MANUAL SAFETY INFORMATION SWING RADIUS BARRIER Manitowoc’s optional swing radius barrier is shown in Figure 2-3. WARNING Crush Hazard! To prevent personnel from being crushed by swinging crane, deploy swing radius barrier before operating crane. A13372...

  • Page 26: Storing Swing Radius Barrier

    Remove pins (2, View B) from working position. Because of a program of continuing improvement in product Rotate barrier arms (1) inward and install pins (2, View design, Manitowoc reserves the right to change the C) in shipping position. information and specifications contained in the Operator Manual at any time without notice.

  • Page 27: Operator Conduct

    — is in place and of proper weight. All personnel are clear of the crane. Deploy a swing Maximum required counterweight must not be radius barrier. exceeded. Manitowoc Published 07-29-22, Control # 013-19...
  • Page 28 SAFETY INFORMATION 16000 WHEELED MAX-ER® OPERATOR MANUAL operation. The load and landing area must be illuminated. 15. The operator shall not operate the crane during periods WARNING of bad weather if his/her ability to see the load or the Moving Load/Tipping Crane Hazard! signal person is impaired by darkness, fog, rain, snow, and the like.

  • Page 29: Handling Load

    When cranes are used for service person directing the lift shall make the following checks: other than lifting service and/or special lifting operations, Manitowoc or a qualified person shall establish the Crane has a firm, uniformly supporting foundation ratings, operating limitations, maintenance, testing, and under all crawlers.

  • Page 30: Holding Load

    SAFETY INFORMATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Accelerate and decelerate the load smoothly to Of sufficient thickness, width, and length to avoid excessive stress on the boom and machinery. completely support the jack pad or float, transmit the load to the supporting surface, and b.

  • Page 31: Signals

    4. For operations not covered in the standard signals, or for special situations or emergencies, additional signals Manitowoc provides the following safety devices on its may be required. In those cases, the signals used must cranes.

  • Page 32: Operational Aids

    Clearly mark the hoist cable (so it can easily be seen by the operator) at a point that will give the Manitowoc provides the following operational aids on its operator sufficient time to stop the load a safe cranes, either as standard equipment or optional equipment.

  • Page 33: Assembling, Disassembling, Or Operating Crane Near Electric Power And Transmission Lines

    Electrocution Hazard! sector specified in the Capacity Chart). Manitowoc cranes are not equipped with all features required to operate within OSHA 29CFR1926.1408, 6. OPTIONAL Drum Spooling Limiter Table A clearances when the power lines are energized.

  • Page 34: Set-Up And Operation

    If the dealer is not immediately available, contact 5. Appoint a reliable and qualified signal person, equipped Manitowoc Product Support. The crane must not be with a loud signal whistle or horn and voice returned to service until it is thoroughly inspected for any...

  • Page 35: Refueling

    REFUELING Maintenance Instructions 1. When using a portable container to refuel the crane, the To ensure safe and proper operation of Manitowoc cranes, container must be a safety-type can equipped with an they must be maintained according to the instructions automatic closing cap and a flame arrester.
  • Page 36 14. Avoid battery acid contact with skin and eyes. If contact 28. Unless authorized in writing by Manitowoc, do not alter occurs, flush the area with water and immediately the crane in any way that affects the crane’s consult a doctor.

  • Page 37: Environmental Protection

    SAFETY INFORMATION 30. Store tools, oil cans, spare parts, and other necessary Potentially harmful waste used in Manitowoc cranes includes equipment in tool boxes. Do not allow these items to lie — but is not limited to — oil, fuel, grease, coolant, air...
  • Page 38 SAFETY INFORMATION 16000 WHEELED MAX-ER® OPERATOR MANUAL View A WRONG – DANGEROUS! If boom is off ground and supported by boom rigging, and there is no blocking under boom sections, boom will collapse when lower pins are removed. View B WRONG –...

  • Page 39: Boom Disassembly Safety

    Pin Removal cantilevered. Never cantilever more boom than allowed in rigging drawing or capacity chart. When removing pins from boom sections, stand clear of pins being removed. Even though the boom is resting on Manitowoc 2-21 Published 07-29-22, Control # 013-19...

  • Page 40: Special Application/Service

    As identified in ASME B30.5, cranes are sometimes used for Use of a Manitowoc crane to handle personnel is acceptable service other than lifting service and/or special lifting provided: operations. In such cases Manitowoc or a qualified person •...

  • Page 41: Pedestal/Barge Mounted Cranes

    All safety Cranes with outriggers or stabilizers must have them all signs must be in place and legible. We also urge Manitowoc extended and locked. All outriggers or stabilizers must crane owners to upgrade their cranes with rated capacity be extended equally in accordance with the Capacity indicator/limiter systems for all lifting operations.

  • Page 42: Pedestal Mounted Crane

    Manitowoc does not permit use of a lattice boom truck crane on a barge, a ship, or a floating platform. Pedestal Mounted Crane Figure 2-7.

  • Page 43: Capacity Charts For Barge Mounted Crane

    Capacity Charts for Barge Mounted Crane NOTE RINGERS must be equipped with hook rollers on Manitowoc provides two types of Capacity Charts for a crane the boom carrier and the counterweight carrier. mounted on a barge or other supporting structure under static conditions.

  • Page 44: Shock Loading Caused By Barge Dynamics

    1. A Capacity Chart based on tipping when the crane is anchored only to prevent shifting. 1. Machine List, as defined by Manitowoc, is the crane’s 2. A Capacity Chart based on structural competence when out-of-level condition — from side-to-side — as...

  • Page 45: Transporting Crane On Barge

    Manitowoc crawler showing inspections were performed on the crane crane. These notes are in addition to any guidelines during the time it was used for pile driving or extraction.

  • Page 46: Electrocution Hazard Devices

    6. Manitowoc recommends that each load line be equipped instructions, limitations and restrictions related to the with an anti two-block device.

  • Page 47: Multiple Crane Lifts

    These controls must be in accordance with the qualified person’s Manitowoc 2-29 Published 07-29-22, Control # 013-19...
  • Page 48 SAFETY INFORMATION 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-30 Published 07-29-22, Control # 013-19...

  • Page 49: Section 3

    Wind Conditions ..............3-20 Manitowoc...
  • Page 50 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-ii Published 07-29-22, Control # 013-19...
  • Page 51 16000 WHEELED MAX-ER® OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES SECTION 3 OPERATING CONTROLS AND PROCEDURES THIS SECTION STARTS ON THE NEXT PAGE Manitowoc Published 07-29-22, Control # 013-19...

  • Page 52: Standard Hand Signals For Controlling Crane Operations

    OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS The following standard hand signals comply with ASME B30.5-2014. Table 3-1 Standard Hand Signals For Controlling Crane Operations M100118 M100119 M100120 M100121 M100122 M100123 M100124 M100125 M100126...
  • Page 53 EXTEND BOOM (Telescoping Boom)—One Hand Signal. One fist in front of chest with thumb tapping chest. RETRACT BOOM (Telescoping Boom)—One hand signal. One fist in front of chest, thumb pointing outward and heel of fist tapping chest. Manitowoc Published 07-29-22, Control # 013-19...

  • Page 54: Control Symbols Identification

    OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL CONTROL SYMBOLS IDENTIFICATION The following symbols are used on the remote control. Extend Cylinder Pin, Hinge (telescopic beam) Retract Energize (turn on) Cylinder, Counterweight Lifting Cylinder, Telescopic Beam Set-Up (remote) Fast Engine Speed: Slow...
  • Page 55 16000 WHEELED MAX-ER® OPERATOR MANUAL OPERATING CONTROLS AND PROCEDURES Left Side Right Side M3-3 View from Rear Looking Forward FIGURE 3-2 Manitowoc Published 07-29-22, Control # 013-19...
  • Page 56 OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL M1-2a A1277 Item Description 16000 Crawler Crane Physical Boom Stop Boom #58 #59A Fixed Mast Mast Straps Counterweight Straps Load Sensing Pin (left side) Live Mast Boom Hoist Physical Mast Stop Wheeled Counterweight Assembly Telescopic Beam Counterweight Lifting Cylinder...

  • Page 57: Max-Er Operation - General

    Luffing Jib Operator Manual for identification and operation Manitowoc assumes that a qualified crane operator will be o f t h e l u ffi n g j i b c o n t r o l s a n d a d d i t io n a l o pe r a ti n g used to operate the 16000 with MAX-ER attachment.

  • Page 58: Max-Er Remote Control

    OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL To turn on the MAX-ER remote control, proceed as follows: DM16-RCL-01 MAX-ER Set-Up Capacity Chart: In function mode screen, enter MAX-ER remote control • 9999A for U.S. units data box (Figure 3-5).

  • Page 59: Operating Remote Control

    3-7) will appear in the fault counterweight straps to be slackened during MAX-ER screen. installation and removal. The operator shall then level the base with the Toggle held UP to EXTEND counterweight lifting cylinder. individual jack switches. Manitowoc Published 07-29-22, Control # 013-19...

  • Page 60: Max-Er Operating Mode

    OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL When properly configured, the proper MAX-ER Capacity DM16-03 Chart and icon will appear on the RCL working screen as shown in Figure 3-8. See MAX-ER Operator Information MAX-ER System Fault Manual in the crane cab for a complete list of MAX-ER capacity charts for your crane.

  • Page 61: Main Display

    Telescopic beam length sensor out of range. Perform Telescopic Beam Sensor Calibration steps Mast Stop Position in Section 6. (feet or meters). Not Available on Crane Software Version M002066 or newer. FIGURE 3-9 Manitowoc 3-11 Published 07-29-22, Control # 013-19...

  • Page 62: Diagnostic Screen

    OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL MAX-ER Fault Screens MAX-ER Diagnostic Screen 1 Fault #9 Swing Park Fault #27 Mast Stop Retracted (Crane Software Version M002066 or newer) Fault #47 Wheel Alignment DM16-08 MAX-ER Diagnostic Screen 2 Fault #48 System FIGURE 3-10...

  • Page 63: Mast Stop Limit Switch

    If proper reading is not indicated at either gauge, determine cause of faulty pressure and take corrective action. Telescopic Beam Hinge Pins Displays command state of a telescopic beam hinge pins (engaged/disengaged). Pins shown disengaged in graphic. Manitowoc 3-13 Published 07-29-22, Control # 013-19...

  • Page 64: Tire Inflation

    OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL OPERATING PRECAUTIONS WARNING DANGER Explosion Hazard! Observe the following operating precautions to prevent Mast stop cylinders are equipped with nitrogen pre- tipping or structural failure of attachment. charged accumulators. Read instructions in this section and in MAX-ER Do not tamper with accumulators unless authorized and Capacity Charts before operating crane.
  • Page 65 20 in (508 mm). Disconnected from Crane Connected to Crane 19. Before disconnecting wheeled counterweight assembly from rear of crane (operating from 0 counterweight FIGURE 3-14 column of capacity chart), fully retract telescopic Manitowoc 3-15 Published 07-29-22, Control # 013-19...
  • Page 66 OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 3-16 Published 07-29-22, Control # 013-19...

  • Page 67: Max-Er Operation

    Access desired MAX-ER screen on main display to If the operator tries to travel when the wheels are in monitor MAX-ER operating conditions. the swing position, the crawler handles will be inoperable and the fault alert will come on. Manitowoc 3-17 Published 07-29-22, Control # 013-19...

  • Page 68: Traveling

    OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL Swing upperworks wheeled counterweight assembly in-line with crawlers (perform Swinging steps). CAUTION Raise wheeled counterweight assembly with jacks until bulge is out of tires. Use left crawler handle in cab or Wire Rope Damage! switch on remote control.

  • Page 69: Swinging

    Turn off travel park and swing park with switches on front console. Proceed to swing right or left. For additional swing and travel information, see Swing and Travel Specifications in MAX-ER Capacity Chart Manual. Manitowoc 3-19 Published 07-29-22, Control # 013-19...

  • Page 70: Leaving Crane Unattended

    OPERATING CONTROLS AND PROCEDURES 16000 WHEELED MAX-ER® OPERATOR MANUAL LEAVING CRANE UNATTENDED Wind adversely affects lifting capacity and stability. The result could be loss of control over the load and crane, even When crane is left unattended, it must be parked as if the load is within the crane’s capacity.
  • Page 71 Prepare Crane ........... . 4-60 Disconnect Wheeled Counterweight Assembly ......4-60 Manitowoc Published 07-29-22, Control # 013-19...
  • Page 72 16000 WHEELED MAX-ER® OPERATOR MANUAL Removing MAX-ER Attachment for Shipping ....... . 4-60 Prepare Crane .

  • Page 73: General Set-Up And Installation

    Contac t Manitowoc Product Support for a deta iled explanation of any procedure you do not fully understand. See MAX-ER Capacity Charts to determine how...

  • Page 74: Max-Er Weights

    SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL • If an assist crane is used, it must provide the forces It is the owner/user’s responsibility to ensure the following: given in Figure 4-1. • All trailer loads comply with local, state, and federal transportation requirements Vertical Force = 25,000 lb (111 kN)

  • Page 75: Blocked Crawlers

    Use nylon lifting slings. If wire rope or chain slings are • Keeper plates with cap screws and lock washers used, install protective covering (such as sections of rubber tire) between slings and chords. Manitowoc Published 07-29-22, Control # 013-19...
  • Page 76 60,000 lb (27 216 kg) — each End C2 = Crane Counterweight 332,000 lb (150 593 kg) — Total (8 Boxes each Side) C3 = Wheeled Counterweight (Manitowoc Furnished Boxes) 4 Arrangements, Depending on Load Handling Requirements — • 0 lb (0 kg) — Wheeled Counterweight Assembly Removed •...

  • Page 77: Installing Max-Er Attachment

    0 lb (0 kg) of swung. wheeled counterweight installed (see MAX-ER If 16000 is used to assemble wheeled counterweight Capacity Charts) assembly, completely assemble the 16000, to include the Manitowoc Published 07-29-22, Control # 013-19...
  • Page 78 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL M4-3b Lift View A M4-3a View B M4-3c On Current Production Units, Item (11) and Cable Shipping (WNE16T) are on Inboard Position Side of Rotating Bed WNE16T View C Working Position M4-3e M4-3g Node 6 View E...

  • Page 79: Assemble Fixed Mast

    If possible, install the thinnest shim between both NOTE: Refer to Figure 4-5 for electrical connections on sides of mast butt and previous shim. current productions cranes with software version M002066 or newer. Manitowoc Published 07-29-22, Control # 013-19...
  • Page 80 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL NODE 6 Electrical Connections for Current Productions Cranes with Software Version M002066 or Newer 6a (behind) 6b (behind) View A View B Item Component Description Node 6 Front of Rotating Bed Receptacle W66 W66 Terminating Plug w/ Dust Cap Drum 1 in Boom Butt Cable W66...
  • Page 81 If equipped with a luffing hoist, connect electric cable Connect electric cable (4b, View C) from the mast butt to (3b, View B) to receptacle (3a). receptacle (4a). Connect electric cable (2d, View C) to electric cable (4c). Manitowoc Published 07-29-22, Control # 013-19...
  • Page 82 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL P1957 P1958 Stored P1241a View C View B Lift View D M4-4a View A View E P1241 M4-4b View F 70 ft (21 m) See View C Lift M4-4c View G See View B FIGURE 4-6 4-10 Published 07-29-22, Control # 013-19...

  • Page 83: Remove Top From Shipping Position

    Attach lifting slings from assist crane to lifting lugs (4, View G) on insert (9). Lift insert into position at end of mast butt (View G) so fixed pins (7, View C) in insert engage hooked connectors (8) in mast butt. Manitowoc 4-11 Published 07-29-22, Control # 013-19...
  • Page 84 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL View A Lift M4-5a View B Lift M4-5b View C P1958 3 and 4 See View C View D Lift M4-5c View E Lift M4-5d View F See View D FIGURE 4-7 4-12 Published 07-29-22, Control # 013-19...

  • Page 85: Install 40 Ft (12 M) Insert)

    Block mast so equalizer (8, View F) is clear of foundation. Disconnect lifting slings. Using assist crane, lift wire rope from Drum 5 onto top of mast and spool slack wire rope onto drum. Manitowoc 4-13 Published 07-29-22, Control # 013-19...
  • Page 86 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Working Position Lift Shipping Position M4-6a View A Shipping Lift Position M4-6b Item Description Mast Stop M4-6b Pin with Cotter Pins (2 places) Bracket Strut Wire Rope Guide Pin with Snap Pin Link View B Working...

  • Page 87: Raise Mast Stops

    Lower wire rope guide (5) to working position. Raise mast stop to working position. Pin links to wire rope guide. Raise strut (4) to working position and pin to mast stop with pin (2). Manitowoc 4-15 Published 07-29-22, Control # 013-19...
  • Page 88 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL M4-7a View A2 Working Position An assist crane must be used to lower mast to angles greater than 156°. View A1 Shipping 156° Position Maximum LOCATION A Typical 6 Places M4-7b LOCATION C Typical 2 Places LOCATION B View B1...

  • Page 89: Connect Mast And Counterweight Straps

    Store pin (3) and links (4) at butt end of links (11) — strap (1, View B2). same as shown in View B. d. Rotate links (11) rearward and lay them on top of mast butt. Manitowoc 4-17 Published 07-29-22, Control # 013-19...
  • Page 90 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-18 Published 07-29-22, Control # 013-19...

  • Page 91: Raise Fixed Mast

     Wind within allowable limits for operation. NOTE: Best results are obtained when the yoke on the mast stop is below horizontal. Manitowoc 4-19 Published 07-29-22, Control # 013-19...
  • Page 92 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL P1241 View A M4-8a Edge of Crawler View B P1241a Center of Block Circled numbers match steps in raising procedure. View C P1959 View D M4-8b View E Indicator Approximately Arrow 0.958 ft (0,292 m) M4-8d Green Line...
  • Page 93 18. Install boom (View H). See Install Boom topic in this Verify that all mast strap and counterweight strap section for instructions. shipping pins are removed and stored. Manitowoc 4-21 Published 07-29-22, Control # 013-19...
  • Page 94 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL P1241 View A M4-8a View B Circled numbers match P1241a steps in raising procedure. View C 65° Maximum View D P1959 M4-9a View E Approximately Indicator 0.958 ft (0,292 m) Arrow M4-8d Green Line Indicator...
  • Page 95 The MAX-ER mast stop position information Avoid mast or equalizer damage. Do not raise mast until screen will not be available with crane software all straps are unpinned from mast strap supports. version M002066 or newer. Manitowoc 4-23 Published 07-29-22, Control # 013-19...

  • Page 96: Check Mast Stop Pressure

    SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL 21. While watching indicator rod on mast stops (View F) or the mast stop position information screen on the main display (View G), mast up slowly until: WARNING • Indicator rods are flush with ends of indicator tubes Explosion Hazard! •...
  • Page 97 16000 WHEELED MAX-ER® OPERATOR MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-25 Published 07-29-22, Control # 013-19...
  • Page 98 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL DO NOT RAISE WIRE ROPE GUIDE. It will hit mast when boom is raised. A10740-18c M4-11a View A Blocking Blocking Item Description Boom butt View B Insert — 40 ft (12 m) with Sheaves in Top End Fixed Pin Hooked Connector P2259...

  • Page 99: Install Boom

    Coupler-assist tool (View C) can be used to (7b) in boom butt. Thoroughly clean couplers. connect the large couplers. Connect hydraulic hoses (7a, View D) to couplers (7c) on left side of rotating bed. Continued on page 4-31. Manitowoc 4-27 Published 07-29-22, Control # 013-19...
  • Page 100 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL WNE16T WN20 P2281 On Current Production Units, Item (10), Cable (WN20), and Cable (WNE16T) are on Inboard Side of Rotating Bed View A Right Side of Rotating Bed Node 6 M4-3f View B Front of Rotating Bed Item Description...
  • Page 101 Safety Pin Motor Pilot Anti-Cavitation High Pressure Case Drain View C Views D and E are from Crane Looking Forward P2263a View D P2264a View E View F P2262a From Front FIGURE 4-15 continued Manitowoc 4-29 Published 07-29-22, Control # 013-19...
  • Page 102 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL View A A10740-18c M4-13a View B View C If Equipped Item Description Insert — 40 ft (12 m) with Sheaves in Top End Insert — 40 ft (12 m) with Equalizer Rail Insert —...

  • Page 103: Assemble Remaining Boom Sections

    Lift insert (2, View C) — insert with equalizer rails — into d. Install both bottom connecting pins (8, View B). position in front of insert (1). Disconnect slings. Lift with slings from assist crane attached to four lifting lugs on insert. Manitowoc 4-31 Published 07-29-22, Control # 013-19...
  • Page 104 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL #58, 12 m (39.4 FT) MAX-ER Insert with Storable Equalizer Rails CONFIGURED FOR USE WITH 16000 WIND ATTACHMENT Boom Straps and Links Stored in Inboard Position (2 places) Removable Strap Bracket in Working Position (6 places) Boom Straps and Links Stored in Inboard Position Equalizer Rail in Stored...
  • Page 105 Boom Straps and Links Stored in Outboard Position Equalizer Rail in Working Position (2 places) Equalizer Rail in Working Position (2 places) FIGURE 4-18 Manitowoc 4-33 Published 07-29-22, Control # 013-19...
  • Page 106 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL A11388 Lift Here A11543 Lift Here Operating Position Shipping Position Shipping Position View A View B Operating Position Stored Operating Position View C M4-14 Holes A Holes B M4-9b View D View E 11a in Hole A Stored Installed...
  • Page 107 Attach strap links from boom to equalizer. See procedure in this section. b. Hoist just enough to support wire rope guide and remove pin (7) from shipping position. Remove and store pins (14) securing equalizer to rails. Manitowoc 4-35 Published 07-29-22, Control # 013-19...
  • Page 108 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL A11543-1 Luffing Jib Straps, Links, and all Hardware Must be Collars Toward Inside A11543-2 Removed if Luffing Jib is Not Used of Boom Sections View B View A Shipping Position Working Position M4-14 Item Description...

  • Page 109: Connect Boom Straps

    W h e n th e b o om i s r a i s e d , th e b o om s t r a p s l i f t t h e required. intermediate suspension into position to support the inserts. Perform the following steps on both sides of the boom. Manitowoc 4-37 Published 07-29-22, Control # 013-19...
  • Page 110 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-38 Published 07-29-22, Control # 013-19...
  • Page 111 374.0 ft (114 m) Boom 295.3 ft (90 m) Boom Figure 4-20 for List of Item Numbers Stored Holes 324.8 ft (96 m) 334.6 ft (102 m) 354.3 ft (108 m) Boom FIGURE 4-21 Manitowoc 4-39 Published 07-29-22, Control # 013-19...
  • Page 112 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL A11388-4,5,6 View B 2 Places View A Item Description Boom Top Lower Boom Point Lifting Holes Pin with Cotter Pins Pin with Cotter Pins Pin (long) with End Plates and Hex Screws Pin (short) with End Plate and Hex Screws (used only with Extended Upper Boom Point) Keeper Plate...

  • Page 113: Install Standard Upper Boom Point

    Do not rest weight of entire boom on standard upper boom point. Structural damage will occur. If installed, remove pins (6 or 6a, View C) with end plates and keeper plates (7) from boom top (1). Manitowoc 4-41 Published 07-29-22, Control # 013-19...
  • Page 114 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Stored P2320 View D View A View E View F P2321 Item Description Boom Top Pin (long) with End Plates and Hex Screws Pin (short) with End Plate and Hex Screws Keeper Plate Pin with Cotter Pins Link Lifting Lug...

  • Page 115: Perform Pre-Raising Checks

     Wind within allowable limits for operation. Install Block-Up Limit Control Install block-up limit components and connect electric cables from block-up limit switches and wind speed transmitters to proper receptacles on boom and jib node controllers. Manitowoc 4-43 Published 07-29-22, Control # 013-19...
  • Page 116 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL A1284 Item Description Item Description Wire Rope Guide Lower Boom Point Weight Extended Upper Boom Point (lower sheaves) Lift Plate Standard Upper Boom Point Load Block Extended Upper Boom Point (upper sheave) Weight Block-Up Limit Switch Lift Block...
  • Page 117 16000 WHEELED MAX-ER® OPERATOR MANUAL SET-UP AND INSTALLATION Single Part Reeving Multiple Part Reeving Dead Ended at Upper Boom Point A11993 FIGURE 4-24 continued Manitowoc 4-45 Published 07-29-22, Control # 013-19...
  • Page 118 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Lift Working Position M4-20aa Shipping Position M4-20c VIEW B Wheels in USA Shipping Position Wheels in EUROPEAN Shipping Position Item Description VIEW A Carrier Base Shipping Support (4 places) with Cap Screws and Lock washers Wheel Chock Lifting Lug (4 places) M4-20d...

  • Page 119: Assemble And Attach Wheeled Counterweight Carrier

    Attach shackles to lifting lugs (4, View A) on carrier base Remove Carrier Base from Trailer (1). The carrier base is shipped in the following configuration Attach slings from assist crane to shackles and hoist just from Manitowoc: enough to support carrier base. • Counterweight boxes removed •...
  • Page 120 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL M100304 Lift VIEW B VIEW A NOTE: On current production units, jack pads (5a) are stored on jacks (5). M4-20b Item Description Carrier Base Lifting Lug (2 places each end) Handrail (2 places each end) Shipping Support (4 places) with Cap Screws and Lock washers Jack...
  • Page 121 Install U-shaped pin (5c). 10. Make sure carrier base is level in all directions. To maintain stability of carrier base, block under jack pads as shown in View A. 11. Raise handrails (3). Manitowoc 4-49 Published 07-29-22, Control # 013-19...
  • Page 122 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Lift Item Description Lifting Frame Telescopic Beam Lifting Lugs (4 places) Connecting Lugs (4 places) Front Carrier Base Solenoid Valves Pin with Retaining Pin and Snap Pin (4 places) Ladder Snap Pin (2 places) Strut Pin with Cotter Pin (2 places) M4-21a VIEW A...

  • Page 123: Install Lifting Frame On Base

    Hook top end of ladder into slots in bottom of platform. b. Unpin struts (6b) from ladder. Pins struts to lugs under carrier base. Connect Hydraulic Hoses from Carrier Base to Lifting Frame Figure 4-28 for the following procedure. FIGURE 4-28 Manitowoc 4-51 Published 07-29-22, Control # 013-19...
  • Page 124 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Item Description Telescopic Beam Hydraulic Hoses from Lifting Frame Couplers on Rotating Bed Rotating Bed Bracket WN22 Electric Cable on Rotating Bed WNE56 Electric Cable from Telescopic Beam WNE20 Electric Cable on Rotating Bed WNE56 WNE56 Electric Cable from Telescopic Beam...

  • Page 125: Connect Telescopic Beam To Crane

    ( 5 ) . Thoroughly clean connectors. M4-24 Connect cables to corresponding receptacles on rotating bed bracket. View B Continued on page 4-55. FIGURE 4-30 Manitowoc 4-53 Published 07-29-22, Control # 013-19...
  • Page 126 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Item Description Locking Pin with Cotter Pin Hinge Pin Guide Bar Telescopic Beam Rotating Bed Lug Lifting Frame Pin with Collar, Retaining Pin, and Cotter Pins Counterweight Links Spreader Link Blocking Counterweight Carrier Jack M4-26d View A M4-21cc...
  • Page 127 If you fail to perform this step, struts and jacks can Extend all of the jacks about 1 in (25,4 mm). be damaged. b. At any one corner of counterweight carrier, remove blocking (10, View B) from under jack (11). Manitowoc 4-55 Published 07-29-22, Control # 013-19...
  • Page 128 Ladder (2 each box) Centering Lugs Centering Lugs Carrier Base M4-25a Wheeled Counterweight with MANITOWOC FURNISHED BOXES 4 Arrangements, Depending on Load Handling Requirements — • 0 lb (0 kg) — Wheeled Counterweight Assembly Removed • 159,400 lb (72 303 kg) — 1 Small Box each Side •...

  • Page 129: Install Counterweight Boxes

    335,400 lb (152 135 kg) — 1 Small Box, 2 Large Boxes each Side Lift • 511,400 lb (231 967 kg) — 1 Small Box, 4 Large Boxes each Side * Also Used for Luffing Jib with MAX-ER Attachment. M4-25b FIGURE 4-32 continued Manitowoc 4-57 Published 07-29-22, Control # 013-19...

  • Page 130: Ready Crane For Operation

    SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL READY CRANE FOR OPERATION CALIBRATION AND ADJUSTMENT MAX-ER attachment is now ready for operation. Perform the calibration and adjustment procedures given in Section 6. Damage can occur if components are not If required, lower boom onto blocking at ground level properly calibrated or adjusted.
  • Page 131 16000 WHEELED MAX-ER® OPERATOR MANUAL SET-UP AND INSTALLATION THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 4-59 Published 07-29-22, Control # 013-19...

  • Page 132: Disconnecting Wheeled Counterweight Assembly For Job Site Storage

    SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL DISCONNECTING WHEELED Extend jacks so wheeled counterweight assembly is level in all directions. COUNTERWEIGHT ASSEMBLY FOR JOB SITE STORAGE d. Disconnect hydraulic hoses and electric cables between telescopic beam and rear of crane To perform the following procedure: (Figure 4-29,...

  • Page 133: Remove Counterweight Boxes

    Disconnect hydraulic hoses and electric cables between telescopic beam and rear of crane Lower carrier base with assist crane so shipping (Figure 4-29, page 4-52). Clean all connectors supports are resting firmly on foundation. and install protective caps. Manitowoc 4-61 Published 07-29-22, Control # 013-19...

  • Page 134: Remove Boom

    SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL DANGER WARNING Tipping Hazard! Crushing Injury Hazard! For EUROPEAN shipment, do not disconnect lifting slings Boom inserts can collapse when connecting pins are until shipping supports are installed (so that carrier base is removed.
  • Page 135 12. Store boom top wire rope guide (2, Figure 4-19, View B, 17. Disconnect boom butt from crane. Reverse assembly page 4-34): steps. Attach a sling from assist crane to hole in wire rope guide (5). Manitowoc 4-63 Published 07-29-22, Control # 013-19...
  • Page 136 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-64 Published 07-29-22, Control # 013-19...

  • Page 137: Lower Fixed Mast

    Assist crane and equalizer must be traveled to dimension A once mast is out of way. The following controls are used to lower the mast: • Drum 4 (mast hoist) on left console Manitowoc 4-65 Published 07-29-22, Control # 013-19...
  • Page 138 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Circled numbers match steps in raising procedure. M4-8c View A P1959 View C View E P1241a M4-8b View B P1241 Edge of Crawler Center of Block M4-8a View F P1241 View D FIGURE 4-33 4-66 Published 07-29-22, Control # 013-19...

  • Page 139: Lower Fixed Mast Using Assist Crane As Hold-Back

    15. Raise live mast arms using crane set-up remote control. be centered with relation to mast to prevent side loading mast. Assist crane must provide specified hold-back forces (B and C, View B and Table 4-2). Manitowoc 4-67 Published 07-29-22, Control # 013-19...
  • Page 140 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL M4-8c Circled numbers match steps in raising procedure. View A 65° Minimum M4-8b View B P1959 View E P1241a View C View F P1241 FIGURE 4-34 View D 4-68 Published 07-29-22, Control # 013-19...

  • Page 141: Lower Fixed Mast Using Boom As Hold-Back

    18. Disconnect assist crane from equalizer. 11. Remove boom. See procedure in this section. 19. Raise live mast arms using crane set-up remote control. 12. Attach assist crane to boom hoist equalizer (View C): Manitowoc 4-69 Published 07-29-22, Control # 013-19...
  • Page 142 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-70 Published 07-29-22, Control # 013-19...

  • Page 143: Remove Fixed Mast

    4-15 to lower mast On right side of live mast, disconnect electric cable stops (1, Figure 4-8, View A) to shipping position. (W37, View B3), from load pin and from cable on Manitowoc 4-71 Published 07-29-22, Control # 013-19...
  • Page 144 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Lift M4-30a View A P1958 View B View C Lift 4 and 5 See View A M4-30b View D See View C 4 and 5 See View A Lift Lift M4-30c M4-30d View E View F Figure 4-4...

  • Page 145: Remove Mast Inserts

    Lift mast butt and top clear of crane and store on job pins (3, View C) between insert (7) and butt (9). site or place on transport trailer. g. Store pins in end of mast butt. Manitowoc 4-73 Published 07-29-22, Control # 013-19...
  • Page 146 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 4-74 Published 07-29-22, Control # 013-19...

  • Page 147: Wire Rope Installation

    Number of seizings to be applied to the ends of wire rope and to both sides of the point where a cut will be made A925 FIGURE 4-37 • Proper application method: each seizing should be one rope diameter long Manitowoc 4-75 Published 07-29-22, Control # 013-19...

  • Page 148: Anchoring Wire Rope To Drum

    SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Straight Wedge Seizing Outside Drum WARNING! Wire Falling Load Hazard! Rope Wire rope can be pulled out of drum if the following steps are not taken. • Install straight wedge so corrugated side is against Don’t Allow End of Wire Hole in Drum Flange...

  • Page 149: Winding Wire Rope Onto Drum

    Button Screw Line Socket A1263 (behind) Winding Wire Rope onto Drum Button Socket Assembly See Drum and Lagging Chart in Capacity Chart Manual for correct size of drum laggings, if used. FIGURE 4-41 Manitowoc 4-77 Published 07-29-22, Control # 013-19...
  • Page 150 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL TL (Tail Length) T (Rope Clip Nut Torque) Standard 6 to 8 Strand Wire Wire Rope/Clip Size Rope inch 1-1/8 1-1/4 Minimum of 6 rope diameters, (mm) (22,23) (25,4) (28,58) (31,75) but not less than 6 in (152 mm). Torque Rotation Resistant Wire Rope * ft/lbs...

  • Page 151: Anchoring Wire Rope To Wedge Socket

    When slackness is noted, tightly wind the dead wraps of wire deep into socket as possible. rope onto the drum. If left uncorrected, a wedging action with subsequent layers will occur, and the resultant abrasion may cause broken wires in the dead wraps. Manitowoc 4-79 Published 07-29-22, Control # 013-19...
  • Page 152 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL A1189 A09310 Rope Pull Rigging Line Clips with Winch or Fork-Lift Truck Rigging Line Wire Rope from Drum Wire Rope P1519 Boom Point Sheaves Load Block Sheaves Wire Rope EXAMPLE without Button No.

  • Page 153: Drum Kicker Adjustment

    Drum Flange General Kicker Cap Screw Some rotation-resistant wire rope supplied by Manitowoc is Washers equipped with a pad eye welded to the leading end of the Lock Nut wire rope or to the button on the end of the wire rope.

  • Page 154: Rigging Winch Operation

    SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL RIGGING WINCH OPERATION Operating Rigging Winch If your crane is equipped with the optional rigging winch Free-Wheel Operation (Drum 0) see the Rigging Winch Assembly drawing at the The winch has a free-wheel clutch which allows the drum end of this section for wire rope routing.
  • Page 155 Pay out rigging line with Drum 0 control handle while g. Turn OFF rigging winch mode. hauling in load line with load drum control handle • Keep rigging line slacker than load line with engine throttle Manitowoc 4-83 Published 07-29-22, Control # 013-19...

  • Page 156: Reeving - Load Block

    SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL REEVING – LOAD BLOCK A802 Duplex Load Block Identification Hook See the Boom Assembly Drawing at the end of this section for a complete list of load blocks and weight balls available for this crane.
  • Page 157 (depending on load and layer). Wire Rope Guide (on boom top) To Lower Boom Point To Extended Upper Boom Point (lower sheaves) To Standard Upper Boom Point To Extended Upper Boom Point (upper sheave) FIGURE 4-48 Manitowoc 4-85 Published 07-29-22, Control # 013-19...
  • Page 158 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL A08493 This Link Not Used Battery Side of Wireless Load Cells Anchored to Boom Point Must Face Away from Crane Item Description Extended Upper Boom Point Standard Upper Boom Point Link with Pin with Cotter Pin Pin with Cotter Pin A08833 Load Cell –...
  • Page 159 Pin with Cotter Pin Load Cell – 35,000 lb (13 063 kg) Links Pin with Collar, Retaining Pin, and Cotter Pins Swivel Button Socket – 1-1/8 in (28 mm) with Pin and Cotter Pin FIGURE 4-50 Manitowoc 4-87 Published 07-29-22, Control # 013-19...
  • Page 160 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Reeving_1 LOWER BOOM POINT REEVING 6 Part 3 Sheave Block with Item Description Upper Boom Point Boom Top Guide Sheaves (Standard) Lower Boom Point Load Block Standard Upper Boom Point Dead-End Socket Two-Block Weight 8 Part 4 Sheave Block with...
  • Page 161 16 Part 18 Part 9 Sheave Block 9 Sheave Block 22 Part 20 Part 13 Sheave Block 13 Sheave Block 24 Part 26 Part 13 Sheave Block 13 Sheave Block FIGURE 4-51 continued Manitowoc 4-89 Published 07-29-22, Control # 013-19...
  • Page 162 SET-UP AND INSTALLATION 16000 WHEELED MAX-ER® OPERATOR MANUAL Item Description Boom Top Guide Sheaves Extended Upper Boom Point (lower sheaves) Load Block Dead-End Socket Two-Block Weight EXTENDED BOOM POINT REEVING (Lower Sheaves) Reeving_3 2 Part 4 Part 6 Part FIGURE 4-52 4-90 Published 07-29-22, Control # 013-19...

  • Page 163: Section 5

    Lube and Coolant Product Guide ........... . . 5-1 Manitowoc...
  • Page 164 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-ii Published 07-29-22, Control # 013-19...

  • Page 165: Lube And Coolant Product Guide

    16000 WHEELED MAX-ER® OPERATOR MANUAL LUBRICATION SECTION 5 LUBRICATION LUBRICATION LUBE AND COOLANT PRODUCT GUIDE See F2109 at the end of this section. See the publication at the end of this section. Manitowoc Published 07-29-22, Control # 013-19...
  • Page 166 LUBRICATION 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 07-29-22, Control # 013-19...

  • Page 167: Section 6

    Mast Stop Limit Switch Component Overview ........6-19 Manitowoc...
  • Page 168 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6-ii Published 07-29-22, Control # 013-19...

  • Page 169: General

    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 components, see the Service Manual supplied with your crane: • Straps • Wire Rope • Load Block and Weight Ball • Boom and Jib Continued on Next Page Manitowoc Published 07-29-22, Control # 013-19...
  • Page 170 MAINTENANCE 16000 WHEELED MAX-ER® OPERATOR MANUAL A14479a Outer Ring Access Cover in Top of (Top View) Carrier Base (4 places) Access Holes in Both Ends of Both Wheel Supports P2346 Inner Ring Bolts 36 each, 7/8 in - 9 UNRC x 5-1/2 in Long with Hardened Flat Washers Numbers Indicate Tightening Sequence...

  • Page 171: Wheel Support Bearing Bolt Torque

    519 ft-lb (704 Nm), replace all of the Torque Values bolts in the corresponding ring. Torque the bolts in two steps: Replace all of the bolts each time a new bearing is installed. • First to 200 ft-lb (270 Nm) Manitowoc Published 07-29-22, Control # 013-19...
  • Page 172 MAINTENANCE 16000 WHEELED MAX-ER® OPERATOR MANUAL Legend Item Description Wheeled Counterweight Assembly Left Wheels Right Wheels Wheel Support Alignment Bar Center Bolt Hole Inner Edge VIEW A 16-5/16 ± 1/16 in 2 Places Inner (414,3 ± 1,6 mm) Edge Legend continued Item Description Angle Sensing Gear Encoder...

  • Page 173: Wheel Position Encoder Calibration

    Turn on the MAX-ER remote control. Using the MAX-ER remote control, extend the jacks as necessary until the bulge is out of the tires and rotate left wheels (2, View B) to the straight position. Manitowoc Published 07-29-22, Control # 013-19...
  • Page 174 MAINTENANCE 16000 WHEELED MAX-ER® OPERATOR MANUAL VIEW C 2 Places VIEW A VIEW B WORKING POSITION GND - 3 SIG - 2 VIEW E VIEW D Cover Removed ADJUSTING POSITION Legend Item Description Item Description Outer Telescopic Beam Top Cable Reel Bracket Intermediate Telescopic Beam Top Cable Inner Telescopic Beam...

  • Page 175: Cable Reel Length Potentiometer Calibration

    View D. cable reel (4a). If necessary, perform the following steps to tension top 10. Install cover (2, View A) on the rear of outer telescopic cable (3c). beam (1a). Manitowoc Published 07-29-22, Control # 013-19...
  • Page 176 MAINTENANCE 16000 WHEELED MAX-ER® OPERATOR MANUAL Legend Item Description Ratchet Pawl Hydraulic Cylinder Eye Bolt Spring A10767 1-7/16 in (36 mm) Initial Adjustment with Pawl Against Ratchet FIGURE 6-4 A14558 Legend Item Description Drum Pressure Roller 11-3/8 in (289 mm) Roller Frame Initial Adjustment with Pivot Pin...

  • Page 177: Boom Angle Indicator Calibration

    Continue to back out until the sensor orientation notch is 180 + 15 to the motor shaft centerline. Hold sensor from moving and tighten lock nut. Torque to 10 ft/lbs. Manitowoc Published 07-29-22, Control # 013-19...

  • Page 178: Automatic Boom Stop Adjustment

    MAINTENANCE 16000 WHEELED MAX-ER® OPERATOR MANUAL 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, Figure 6-7) automatically stops the replace any worn or damaged parts and/or adjust the boom boom and applies the boom hoist brake when the boom is...

  • Page 179: Bypass Limit Test

    Table 6-1 Horizontal Right Side of Crane Table 6-2 — Adjusting Rods Adjusting Rod and Length Boom Only With Luffing Jib 145471 A18794 7 in (178 mm) 6-1/8 in (156 mm) FIGURE 6-6 Manitowoc 6-11 Published 07-29-22, Control # 013-19...
  • Page 180 MAINTENANCE 16000 WHEELED MAX-ER® OPERATOR MANUAL Roller Limit Switch Wiring Over-Travel Switch Receptacle Function Terminals 1 (green) Max Angle 2 (black) 3 (white) 12 VDC Supply VIEW A SWITCH OPENED 2a or 2b 2a or 2b VIEW B STORED SWITCH CLOSED Legend Item...

  • Page 181: Adjustment

    Install dowel pin (10). b. If the boom reaches the specified angle before it stops, go to step 7. Install proper adjusting rod (2a or 2b). Figure 6-7 for the remaining steps. Adjust the boom stop. Manitowoc 6-13 Published 07-29-22, Control # 013-19...
  • Page 182 MAINTENANCE 16000 WHEELED MAX-ER® OPERATOR MANUAL Legend Item Description Item Description 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) Weight Block-Up Limit Switch (right hand) Lift Block...
  • Page 183 16000 WHEELED MAX-ER® OPERATOR MANUAL MAINTENANCE Single Part Reeving Multiple Part Reeving Dead Ended at Upper Boom Point A11993 FIGURE 6-9 continued Manitowoc 6-15 Published 07-29-22, Control # 013-19...

  • Page 184: Block-Up Limit Control

    MAINTENANCE 16000 WHEELED MAX-ER® OPERATOR MANUAL BLOCK-UP LIMIT CONTROL Block-Up Limit Control Activated When the weight is lifted by the lift block or the lift plates, General spring force rotates the actuating lever against the limit switch lever. This action causes the corresponding limit A block-up limit (also called anti-two-block device) is a two- switch to open the load drum UP and boom DOWN electric blocking prevention device which automatically stops the...

  • Page 185: Adjustment

    Elbow with Cord Gripper Setscrew Spring Enclosure Adjusting Screw Dimension A (Spring Tension) 1.04 in (26 mm) Grease Fitting Actuating Lever Roller Limit Switch Lever Shaft Cover Right Hand Shown Left Hand Opposite FIGURE 6-10 Manitowoc 6-17 Published 07-29-22, Control # 013-19...

  • Page 186: Mast Stop Limit Switch

    It should only be necessary to perform this procedure when Software Confirmation parts are replaced or the limit switch does not operate properly. NOTE: Contact Manitowoc Product Support for questions regarding the software verification procedure. NOTE: Mast stop limit switch to switch when the cylinder is 80% retracted.

  • Page 187: Mast Stop Limit Switch Component Overview

    Limit Switch Mounting Dust Cap Limit Switch Fixed Arm Node Node 6 on Front of Rotating Bed W66P8 Shorting Terminator Limit Switch Shorting Bypass W66 Shorting Terminator Node 6 Shorting Bypass FIGURE 6-12 Manitowoc 6-19 Published 07-29-22, Control # 013-19...
  • Page 188 MAINTENANCE 16000 WHEELED MAX-ER® OPERATOR MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 6-20 Published 07-29-22, Control # 013-19...
  • Page 189 Manitowoc Dealer........
  • Page 190 16000 WHEELED MAX-ER® OPERATOR MANUAL MAX-ER Outline Dimensions ............1-4 MAX-ER Remote Control .