Manitowoc 14001Ref Manuals

Manuals and User Guides for Manitowoc 14001Ref. We have 1 Manitowoc 14001Ref manual available for free PDF download: Service Maintenance Manual

Manitowoc 14001Ref Service Maintenance Manual

Manitowoc 14001Ref Service Maintenance Manual (278 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 23 MB

Table of Contents

See End of this Manual for Alphabetical Index

5
- Table of Contents
  5
- Section 1
  13
  - Continuous Innovation
    13
  - Safety Messages
    13
    
    Safety Alert Symbol
    13
    
    Signal Words
    13
  - Safe Maintenance Practices
    13
    
    Maintenance Instructions
    13
    
    Safe Maintenance Practices
    14
  - Environmental Protection
    15
  - Identification and Location of Components
    16
    
    Front of Crane/Cab Components
    18
    
    Left Side Components
    20
    
    Left Side Components Continued
    22
    
    Right Side Components
    23
    
    Rear/Top of Crane Components
    24
    
    Abbreviations
    26
    
    Solenoid Valve Identification
    26
  - Description of Crane Operation
    27
    
    Charge Pressure
    28
    
    Hydraulic Components
    28
    
    Hydraulic Pumps
    28
    
    Hydraulic Tank
    28
    
    Oil Temperature Valve
    28
    
    Return Manifold
    28
    
    Shut-Off Valve
    28
    
    Suction Manifold
    28
    
    Hydraulic Motors
    29
    
    Hydraulic System Operation
    29
    
    Pressure Monitoring
    29
    
    Brake and Drum Pawl Operation
    31
    
    Engine Controls
    31
    
    Gear Pumps (Optional)
    31
  - Electrical Control System
    33
    
    Display Screens
    33
    
    Electrical Power to Operator's Cab
    33
    
    Pressure Senders and Speed Sensors
    34
    
    System Faults
    34
  - Swing System
    36
    
    Swing Brake
    36
    
    Swing Holding Brake Switch
    36
    
    Swing Left
    36
    
    Swing Right
    36
  - Travel (Crawlers) System
    39
    
    Travel Brakes
    39
    
    Travel Forward
    39
    
    Travel in Reverse
    39
    
    Travel Motors
    39
    
    Travel Cruise
    41
    
    Two-Speed Travel Operation
    41
  - Drum 4 (Boom Hoist) System
    43
    
    Drum 4 Brake and Pawl
    43
    
    Raising Boom
    43
    
    Lowering Boom
    44
  - Drum 1 (Front Drum) System
    46
    
    Drum 1 Brake
    46
    
    Raising Load
    46
    
    Lowering Load
    48
  - Drum 2 (Rear Drum) System
    50
    
    Drum 2 Brake
    50
    
    Raising Load
    50
    
    Lowering Load
    52
  - Drum 1 and Drum 2 - Free Fall (Optional)
    54
    
    Free Fall - Hoisting
    55
    
    Free Fall - Lowering
    55
  - Drum 3 (Auxiliary/Luffing Jib) System
    58
    
    Drum 3 Brake and Pawl
    58
    
    Raising
    58
    
    Lowering
    60
  - Upper Accessory System
    62
    
    Gantry Cylinders Raise
    62
    
    Gantry System
    62
    
    Gantry Cylinders Lower
    64
    
    Mast Raising
    66
    
    Mast System
    66
    
    Mast Lowering
    68
    
    Boom Hinge Pins
    70
    
    Cab Tilt
    72
  - Lower Accessory System
    74
    
    Carbody Jacking Cylinder Raise
    74
    
    Carbody Jacking System
    74
    
    Carbody Jacking Cylinder Lower
    76
    
    Crawler Pin Cylinders
    78
    
    Crawler Pin Cylinders Extend
    78
    
    Crawler Pin Cylinders Retract
    80
    
    Back Hitch Pin Cylinders
    82
    
    Hydraulic Engine Cooling Fan
    84
Section 2 Hydraulic System

87
- Hydraulic Schematics
  89
- Inspecting Hydraulic Hoses
  89
  - Every Month or 200 Hours
    89
  - Degradation Due to Extreme Environment
    90
- Hydraulic System-Maintenance
  90
  - Safety
    90
  - Storing and Handling Oil
    90
  - Storing and Handling Parts
    91
  - Inspecting System
    92
  - Replacing Desiccant Breather Cartridge
    93
  - Replacing Filter
    93
    
    Return Filter
    93
  - Changing Oil
    95
  - Servicing Pumps
    96
  - Hydraulic Connections
    96
    
    Pipe Thread Connection
    96
    
    SAE Straight Thread Connection
    97
    
    ORS Connection
    98
    
    Split Flange Connection
    99
    
    SAE Flare Connection
    100
- Shop Procedures
  102
  - Initial Oil Fill
    102
  - Initial Start-Up
    102
  - High Pressure Accessory System Checks
    104
  - Low Pressure Accessory System Checks
    104
    
    Boom Hinge Pin Cylinder
    104
    
    Cab Tilt Cylinder
    104
    
    Carbody Jacking Cylinders
    104
    
    Crawler Pin Cylinders
    104
    
    Drum Pawls
    104
    
    Gantry Cylinders
    104
    
    Live Mast Cylinders
    104
  - Speed Checks
    105
    
    Back Hitch Pins
    105
    
    Swing and Drum Speeds
    105
    
    Swing Brake
    105
    
    Travel Brakes
    105
    
    Travel Speed
    105
  - Hydraulic System Specifications
    105
- Hydraulic System Specifications
  106
- Drum Identification
  107
- Pump Components
  108
- Pump Identification
  108
- Motor Components
  109
- Hydraulic System Test, Calibration, and Adjustment Procedures
  110
  - Pressure Test and Calibration Screen
    110
  - Pressure Sender Test
    110
  - Control Calibration
    111
  - High Pressure Test
    112
  - Charge Pressure Test
    113
  - High Pressure Adjustment
    114
  - Charge Pressure Adjustment
    115
  - Pump Neutral Adjustment
    116
  - Motor Leakage Test
    117
  - Low Pressure Accessory Adjustment
    118
  - Loop Flushing Valve Adjustment
    118
  - Manual Override Tests
    119
    
    Pump or Motor Override
    119
    
    Solenoid Valve Override
    119
  - Pressure Sender Replacement
    120
  - Disc Brake Operational Test
    120
Section 3 Electric System

121
- Electrical Drawings and Schematics
  123
- Inspect Electrical Components
  123
  - Every Month or 200 Hours
    123
  - Degradation Due to Severe Environment
    123
- Circuit Breakers
  124
  - Engine Node
    124
  - Operator's Cab
    124
  - Intake Air Heater
    124
  - Aftertreatment Load Center
    124
- Test Voltages
  125
  - Component-Node Cross-Reference
    125
  - Node Table Heading Descriptions
    126
  - Abbreviations
    127
  - Checking Electrical Inputs/Outputs Using the Test Box
    128
  - Checking Electrical Inputs/Outputs Using the Test Board
    129
  - Test Voltages Tables
    130
    
    Node 1-Master (Front Console)
    130
    
    Node 2-Handles and Cab Controls
    131
    
    Node 3-Drum 1, 2 & 3, Alarms, Sensors, and Accessories
    133
    
    Node 4-Drum 4, Pumps, and Accessories
    136
    
    Node 5-Swing Limits (Optional)
    139
    
    Boom Remote Input Node
    140
    
    Luffing Jib Remote Input Node
    141
    
    Node 0-Engine
    142
- Displays
  146
  - Navigation and Settings
    146
    
    Confirm Button
    146
    
    Display Brightness and Color Contrast
    146
    
    Display Select Buttons
    146
    
    Display Touch Pad Controls
    146
    
    Enter/Exit Buttons
    146
    
    Main Display
    146
    
    Rated Capacity Indicator/Limiter Display
    146
    
    Select Buttons
    146
  - Main Display
    147
  - Manitowoc" Screen
    147
    
    Menu Screen
    147
    
    Screen Prompts
    147
  - Information Screen
    148
    
    Crane Faults
    148
  - Diagnostic Screens
    150
    
    Component Information Icons
    150
    
    Drum Diagnostic Screens
    151
    
    Engine Diagnostics
    151
    
    Swing Diagnostic Screen
    152
    
    Travel Diagnostic Screen
    152
    
    Accessory Diagnostic Screen
    153
  - Function Mode Screens
    154
    
    Drum Functions
    154
  - Swing Functions
    154
  - Travel Functions
    154
  - Multiple Points or Load Pin Disable Functions
    155
  - Swing or Track Speed Limits
    155
  - Drum Functions
    156
  - Swing Torque
    156
  - Boom or Swing Motion Limiter Mode
    156
  - Remote Control
    157
  - Multiple Points or Load Pin Disable Functions
    157
  - Fan Function
    157
  - CAN Bus Diagnostic Screen
    158
  - Packet Information Boxes
    158
  - Engine Node Status Box
    158
  - Crane Status Box
    158
  - Using the CAN Bus Screen to Troubleshoot a Digital Output Fault
    159
  - Camera Screen (Optional)
    159
  - Pressure Test and Calibration Screen
    159
  - Boom Node Status Box
    159
- Dielectric Grease
  163
Section 4 Boom

165
- Section 4
  165
  - Automatic Boom Stop (Limit Switch)
    167
    
    Maintenance
    167
    
    Actuator Rod Replacement
    169
    
    Adjustment
    169
  - Physical Boom Stop
    171
    
    Adjustment
    171
    
    Operation
    171
  - Boom and Luffing Jib Angle Indicator
    172
  - Mast Angle
    172
    
    Adjusting Mast Angle
    172
    
    Mast Angle Sensor
    172
  - Gantry Limit Switch
    173
    
    Adjustment
    173
    
    Operation
    173
  - Strap Inspection and Maintenance
    174
    
    Cranes Not in Regular Use
    174
    
    Frequent Inspection
    174
    
    Identifying Straps
    174
    
    Inspection
    174
    
    Periodic Inspection
    174
    
    Replacement Specifications
    175
    
    Corrosion or Abrasion
    176
    
    Straightness
    176
    
    Elongated Hole
    177
    
    Flatness
    177
    
    Inspection Checklist
    178
    
    Removing Straps from Service
    178
    
    Storing Straps
    178
  - Lattice Section Inspection and Lacing Replacement
    178
Section 5 Hoists

179
- Section 5
  
  179
  - Free Fall Clutch/Brake
    181
    
    Inspection
    181
    
    Overhaul
    182
  - Drum 4 Pawl
    183
    
    Maintenance
    183
  - Drum 3 Pawl
    184
    
    Adjustment
    184
    
    Maintenance
    184
  - Speed Sensor
    185
    
    Adjustment
    185
    
    Replacement
    185
  - Minimum Bail Limit
    187
    
    Adjustment
    187
    
    Limit Switch Head Position
    187
    
    Weekly Maintenance
    187
  - Block-Up Limit
    188
    
    Maintenance
    188
    
    Operation
    188
    
    Spring Tension Checking and Adjustment
    190
    
    Trip Setting Adjustment or Switch Replacement
    190
  - Wire Rope Inspection and Replacement
    192
    
    Maintain a Wire Rope Condition Report
    192
    
    Required Inspection Intervals
    192
    
    Wire Rope Care and Replacement Guidelines
    192
    
    Wire Rope Lubrication
    192
    
    Daily Inspection
    193
    
    Determining Frequency of Inspection
    194
    
    Periodic Comprehensive Inspection
    194
    
    Reduction in Rope Diameter
    194
    
    Replacement Criteria
    194
    
    Broken Rope Wires
    195
    
    Distributing Wire Rope Wear
    196
    
    Rope that Has Been Idle a Month or more
    196
  - Sheave, Roller, and Drum Inspection
    197
  - Load Block and Hook-And-Weight Ball Inspection
    200
- Section 6
  
  203
  - Manual Release of Swing Brake
    205
  - Swing Limiter (Optional)
    207
    
    Adjustment
    207
Section 7 Power Train

211
- Section 7
  211
  - Batteries
    213
    
    Causes of Battery Failure
    213
    
    Jump-Starting a Battery
    213
    
    Lack of Water
    213
    
    Loose Hold-Downs
    213
    
    Overcharging
    213
    
    Safety
    213
    
    Undercharging or Discharged
    213
    
    Checking Battery State-Of-Charge
    214
    
    Maintenance
    214
    
    Multiple Battery System
    214
    
    Overloads
    214
  - Battery Disconnect Switch
    215
    
    Quarterly Battery Maintenance
    215
    
    Troubleshooting-Slow Cranking
    215
  - Air Cleaner
    217
    
    Changing the Filters
    217
    
    Daily
    217
    
    Inspection
    217
    
    Monthly
    217
  - Engine Clutch
    218
    
    Adjustment
    218
    
    Lubrication and Inspection
    218
  - Engine Belt Routing
    220
  - Engine Enclosure
    220
  - Cooler Assembly
    221
    
    Check the Coolant Level
    221
    
    Fill and Deaerate a Drained Cooling System
    222
  - Exhaust Aftertreatment System
    224
    
    Aftertreatment Protection System
    224
    
    DOC Module
    224
    
    DRT Module
    224
    
    Excessive Nox Warning System
    224
    
    SCR Module
    224
    
    DEF Delivery Heating/Cooling System
    226
    
    DEF Dosing System
    226
    
    DEF Supply Module
    226
    
    Diesel Exhaust Fluid (DEF)
    226
    
    DEF Tank
    227
  - Engine Throttle
    229
    
    Foot Throttle Control
    229
    
    Foot Throttle Control Assembly and Calibration
    229
    
    Hand Throttle Control
    229
Section 8 under Carriage

231
- Turntable Bearing Bolt Torque
  235
  - Bolt Replacement
    235
  - Lubrication
    235
  - Torque Intervals
    235
  - Torque Requirements
    235
  - Torque Sequence
    235
  - Torque Values
    235
- Turntable Bearing Installation
  235
- Crawler Adjustment
  237
  - Adjustment Guideline
    237
  - Adjustment Procedure
    237
  - Maintenance
    237
  - Tread Slack Adjustment
    237
- Hydraulic Hand Pump
  239
  - Air Removal
    239
  - Assembly
    239
  - Maintenance
    239
  - Operation
    239
- Section 9
  
  241
  - Lubrication
    241
  - Lube and Coolant Product Guide
    243
- Section 10
  
  243
  - Introduction
    247
  - Safety Summary
    247
  - General Troubleshooting
    247
  - Troubleshooting Charts
    248

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