Manitowoc 16001Ref Manuals

Manuals and User Guides for Manitowoc 16001Ref. We have 1 Manitowoc 16001Ref manual available for free PDF download: Operating/Service/Maintenance Manual

Manitowoc 16001Ref Operating/Service/Maintenance Manual

Manitowoc 16001Ref Operating/Service/Maintenance Manual (292 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 23.98 MB

Table of Contents

See End of this Manual for Alphabetical Index

5
- Table of Contents
  5
- Section 1
  15
  - Continuous Innovation
    15
  - Safety Messages
    15
    
    Safety Alert Symbol
    15
    
    Signal Words
    15
  - Safe Maintenance Practices
    16
    
    Maintenance Instructions
    16
  - Environmental Protection
    17
  - Identification and Location of Components
    18
    
    Assorted Views
    20
    
    Top
    21
    
    Right Side and Front
    22
    
    Left Side
    23
    
    Undercarriage/Crawler
    25
    
    Abbreviations Used in Section 1
    26
    
    Solenoid Valve Identification
    26
  - Description of Crane Operation
    27
    
    Accessory/Max-ER Pump
    28
    
    Charge Pressure
    28
    
    Hydraulic Components
    28
    
    Hydraulic Pumps
    28
    
    Hydraulic Tank
    28
    
    Oil Temperature Valve
    28
    
    Return Manifolds
    28
    
    Shut-Off Valve
    28
    
    Basic Operation
    29
    
    Hydraulic Motors
    29
    
    Pressure Monitoring
    29
    
    Accessory/Max-ER Pump
    31
    
    Engine Controls
    31
  - Electrical Control System
    31
    
    Display Screens
    33
    
    Electrical Power to Operator Cab
    33
    
    Cab Power Electrical Schematic
    34
    
    Brake and Drum Pawl Operation
    35
    
    Pressure Senders and Speed Sensors
    35
    
    System Faults
    35
  - Swing System Operation
    37
    
    Swing Brake
    37
    
    Swing Right or Left
    37
    
    Swing Holding Brake Switch
    38
    
    Swing Electrical Schematic
    39
  - Travel System Operation
    40
    
    Travel Brakes
    40
    
    Travel Forward and Reverse
    40
    
    Travel Electrical Schematic
    41
    
    Travel Cruise
    42
    
    Two-Speed Travel Operation
    42
  - Boom/Mast Hoist System Operation
    43
    
    Boom/Mast Hoist Brake and Pawl
    43
    
    Raising Boom
    43
    
    Lowering Boom
    44
  - Load Drum 1
    47
    
    Load Drum 1 Brake
    47
    
    Raising Load
    47
    
    System Components
    47
    
    Lowering Load
    48
    
    Drum 1 Electrical Schematic
    50
  - Load Drum 2
    51
    
    Load Drum 2 Brake
    51
    
    Raising Load
    51
    
    System Components
    51
    
    Lowering Load
    52
  - Load/Luffing Drum 3
    54
    
    Drum 2 Electrical Schematic
    54
    
    System Components
    54
    
    Load Drum 3 Brake and Pawl
    55
  - Raising
    55
  - Lowering
    56
    
    Drum 3 Electrical Schematic
    57
  - Accessory System Components
    58
    
    Accessory Systems
    58
    
    Jacking Cylinders
    58
    
    Rotating Bed Jacking - Raise
    58
    
    Counterweight Pins
    59
    
    Rotating Bed Jacking - Lower
    59
    
    Accessory System Electrical Schematic
    61
    
    Boom Hinge Pins
    62
    
    Front or Rear Rotating Bed Pins
    62
    
    Rigging Winch (Drum 0)
    63
    
    Cab Tilt
    64
    
    Crawler Pin Cylinders
    64
    
    Carbody Jacking Cylinders (Optional)
    65
    
    Live Mast
    66
    
    Mast Raising/Lowering with Mast Switch
    66
    
    Mast Raising from Transport Position
    67
    
    Mast Lowering to Transport Position
    68
    
    Live Mast Electrical Schematic
    69
    
    Cooling Fan Diagnostic Screen
    70
    
    Hydraulic Cooling Fan
    70
    
    Tier 4 Equipped Machines
    70
  - MAX-ER 16000 Description of Operation
    71
    
    Hydraulic Solenoid Valve Identification
    71
    
    MAX-ER Components
    71
    
    Accessory Pumps
    72
    
    MAX-ER System Pressure
    72
    
    Wheeled Counterweight Valves
    72
    
    Electrical System
    73
    
    EPIC® Programmable Controller
    73
    
    MAX-ER Wireless Remote Controls
    73
    
    Extend Jacking Cylinders
    74
    
    Jacking Cylinders
    74
    
    Retract Jacking Cylinders
    74
    
    Telescopic Beam Cylinder
    77
    
    Extend Telescopic Beam Cylinder
    78
    
    Retract Telescopic Beam Cylinder
    78
    
    Counterweight Lift Cylinder
    80
    
    Counterweight Lift Cylinder Switch
    80
    
    Extend Counterweight Lift Cylinder
    80
    
    Retract Counterweight Lift Cylinder
    82
    
    Wheel Assemblies
    84
    
    Wheel Steering Clockwise
    84
    
    Wheel Steering Counter-Clockwise
    84
    
    Telescopic Beam Hinge Pins
    87
Section 2 Hydraulic System

91
- Inspecting Hydraulic Hoses
  93
  - Every Month or 200 Hours
    93
  - Degradation Due to Extreme Environment
    93
- Hydraulic System Maintenance
  94
  - Safety
    94
  - Storing and Handling Oil
    94
  - Storing and Handling Parts
    94
  - Inspecting the System
    97
  - Replacing Desiccant Breather
    98
  - Replacing Filters
    98
  - Changing Oil
    99
  - Servicing Pumps
    100
  - Hydraulic Connections
    101
    
    Pipe Thread Connection
    101
    
    Precautions to Observe During Maintenance and Repair
    101
    
    SAE Straight Thread Connection
    102
    
    ORS Connection
    103
    
    Split Flange Connection
    104
    
    SAE Flare Connection
    105
- System Calibration and Tests
  107
  - Accessory System Checks
    107
    
    Carbody Jacking Cylinders (Optional)
    107
    
    Front and Rear Rotating Bed Pins
    107
    
    Live Mast Cylinders
    107
    
    Rotating Bed Jacking Cylinders
    107
    
    Boom Hinge Pins
    108
    
    Cab Tilt
    108
    
    Counterweight Pins
    108
    
    Crawler Pins
    108
    
    Low Pressure Accessory System
    108
    
    Rigging Winch (Optional)
    108
    
    Swing Brake
    108
    
    Travel Brakes
    108
  - Speed Checks
    109
    
    Swing and Drum Speeds
    109
    
    Travel Speed
    109
- Hydraulic System Specifications
  110
- Drum Identification
  111
- Pump Components
  112
- Pump Identification
  112
- Motor Components
  113
- Hydraulic System Test, Calibration, and Adjustment Procedures
  114
  - Pressure Test and Calibration Screen
    114
  - Pressure Sender Test
    114
  - Control Calibration
    115
  - High Pressure Test
    116
  - Charge Pressure Test
    117
  - High Pressure Adjustment
    117
  - Charge Pressure Adjustment
    119
  - Pump Neutral Adjustment
    119
    
    Low Pressure Accessory Adjustment
    120
    
    Loop Flushing Valve Adjustment
    122
    
    Manual Override Tests
    122
    
    Motor Leakage Test
    122
    
    Pump or Motor Override
    123
    
    Solenoid Valve Override
    123
    
    Pressure Sender Replacement
    124
    
    Cab Tilt Adjustment
    125
    
    Disc Brake Operational Test
    125
Section 3 Electric System

127
- Electrical Drawings and Schematics
  129
- Inspect Electrical Components
  129
  - Every Month or 200 Hours
    129
  - Degradation Due to Extreme Environment
    129
- Circuit Breaker and Fuse ID
  130
- Test Voltages
  132
- Checking Electrical Inputs/Outputs
  158
- Displays
  160
  - Navigation and Settings
    160
    
    Display Brightness and Color Contrast
    160
    
    Display Navigation
    160
    
    Restore Factory Default Display Settings
    160
  - Main Display
    161
    
    Blank Display
    161
    
    Manitowoc" Screen
    161
    
    Screen Prompts
    161
  - Information Screen
    162
    
    Crane Faults
    162
    
    Engine and Crane Information
    162
    
    Menu Screen
    162
  - Diagnostic Screen
    165
    
    Component Information Icons
    165
    
    Swing Diagnostic Screen
    168
    
    Travel Diagnostic Screen
    168
    
    Jacking Accessory Diagnostic Screen
    169
    
    Pins and Fan Accessory Diagnostic Screen
    169
  - Function Mode Screens
    170
    
    Cab Tilt, Rigging Winch, and Mast Accessory Diagnostic Screen
    170
    
    Drum Functions
    170
    
    MAX-ER Diagnostic Screen
    170
  - Swing Pressure Limit
    171
  - Rigging Winch Mode
    171
  - CAN Bus Screen
    172
  - Boom or Swing Motion Limiter Mode
    172
  - Crane Setup Remote Mode
    172
  - Digital Output Disable (DOD) Fault
    173
  - Engine Node Status
    173
  - Load Link Status (900 Mhz System)
    173
  - Load Link Status (2.4 Ghz System)
    173
  - Remote Control Status
    173
  - Boom Node Status
    174
  - Wireless Receiver Status
    174
  - Crane Status
    174
  - Camera Screen (Optional)
    177
  - Pressure Test and Calibration Screen
    177
- Dielectric Grease
  177
Section 4 Boom

179
- Section 4
  179
  - Automatic Boom Stop
    181
    
    Maintenance
    181
    
    Maximum Boom Angle
    181
    
    Operation
    181
    
    Bypass Limit Test
    182
    
    Adjustment
    184
  - Actuator Rod Replacement
    184
  - Physical Boom Stop
    186
    
    Adjustment
    186
    
    Operation
    186
    
    Stop Angles
    186
  - Boom and Luffing Jib Angle Indicator
    187
  - Mast Angle
    187
    
    Adjusting Mast Angle
    187
    
    Mast Angle Sensor
    187
  - Drum Pressure Roller
    188
    
    Adjustment
    188
  - Strap Inspection and Maintenance
    189
    
    Cranes Not in Regular Use
    189
    
    Frequent Inspection
    189
    
    Identifying Straps
    189
    
    Inspection
    189
    
    Periodic Inspection
    189
    
    Corrosion or Abrasion
    190
    
    Replacement Specifications
    190
    
    Straightness
    191
    
    Flatness
    192
    
    Inspection Checklist
    193
    
    Removing Straps from Service
    193
    
    Storing Straps
    193
  - Lattice Inspection and Lacing Replacement
    193
Section 5 Hoists

195
- Section 5
  
  195
  - Boom/Mast Hoist Pawl
    197
    
    Maintenance
    197
  - Speed Sensor
    198
    
    Adjustment
    198
    
    Replacement
    198
  - Minimum Bail Limit
    198
    
    Adjustment
    199
    
    Weekly Maintenance
    199
  - Block-Up Limit
    200
    
    Operation
    200
    
    Adjustment
    203
    
    Maintenance
    203
  - Wire Rope Lubrication
    205
  - Wire Rope Inspection and Replacement
    205
    
    Maintain a Wire Rope Condition Report
    205
    
    Required Inspection Intervals
    205
    
    Wire Rope Care and Replacement Guidelines
    205
    
    Daily Inspection
    206
    
    Determining Frequency of Inspection
    207
    
    Periodic Comprehensive Inspection
    207
    
    Broken Rope Wires
    208
    
    Reduction in Rope Diameter
    208
    
    Replacement Criteria
    208
    
    Distributing Wire Rope Wear
    209
    
    Rope that Has Been Idle a Month or more
    209
  - Sheave, Roller, and Drum Inspection
    210
  - Drum Kicker
    212
    
    Adjustment
    212
  - Load Block and Hook-And-Weight Ball Inspection
    214
- Section 6
  
  217
  - Manual Release of Swing Brake and Lock
    219
Section 7 Power Train

221
- Section 7
  221
  - Batteries
    223
    
    Causes of Battery Failure
    223
    
    Hold-Downs
    223
    
    Lack of Water
    223
    
    Multiple Battery System
    223
    
    Overcharging
    223
    
    Overloads
    223
    
    Safety
    223
    
    Undercharging
    223
    
    Every 2 Months - Test Batteries
    224
    
    Maintenance
    224
    
    Weekly - Check Electrolyte Level
    224
    
    Charging
    225
    
    Disconnect Switch
    225
    
    Quarterly - Clean and Inspect Batteries
    225
    
    Storage
    225
  - Air Cleaner
    226
    
    Daily
    226
    
    Filter Replacement
    226
    
    Inspection
    226
    
    Monthly
    226
  - Engine Throttle
    228
    
    Foot Throttle Control
    228
    
    Foot Throttle Control Assembly and Calibration
    228
    
    Hand Throttle Control
    228
  - Engine Clutch
    230
    
    Adjustment
    230
    
    Monthly Maintenance
    230
  - Engine Belt Routing
    231
  - Cooling System
    232
    
    Draining Cooling System
    232
    
    Maintenance
    232
    
    Semiannual Checks
    232
    
    Filling Cooling System
    234
  - Exhaust Assembly
    236
    
    Raising the Exhaust Assembly
    236
    
    Removing the Exhaust Assembly
    236
  - Exhaust after Treatment System
    238
    
    After Treatment Protection System
    238
    
    DPF/DOC Module
    238
    
    DRT Module
    238
    
    Excessive Nox Warning System
    238
    
    SCR Module
    238
    
    DEF Delivery Heating/Cooling System
    240
    
    DEF Dosing System
    240
    
    DEF Supply Module
    240
    
    Diesel Exhaust Fluid (DEF)
    240
    
    DEF Tank
    241
  - DPF/DOC Module Operation and Service
    242
    
    Active Regeneration
    242
    
    Maintenance
    242
    
    Passive Regeneration
    242
    
    Regeneration
    242
    
    Regeneration Inhibit
    242
    
    DPF/DOC Module Replacement
    244
    
    Installation
    244
    
    Removal
    244
    
    DPF/DOC Module Inlet Re-Orientation
    245
Section 8 under Carriage

247
- Turntable Bearing
  249
  - Bearing Bolt Torque
    249
  - Bolt Replacement
    249
  - Installation
    249
  - Lubrication
    249
  - Torque Intervals
    249
  - Torque Sequence
    249
  - Torque Values
    249
- Crawler
  252
  - Maintenance
    252
  - Measuring Tread Slack
    252
  - Tread Slack
    252
  - Adjusting Tread Slack
    253
- Hydraulic Hand Pump
  254
  - Assembly
    254
  - Maintenance
    254
  - Operation
    254
  - Air Removal
    255
- Section 9
  
  257
  - Lubrication
    257
  - Lube and Coolant Product Guide
    259
- Section 10
  
  259
  - Introduction
    263
  - Safety Summary
    263
  - Guidelines
    263
  - Troubleshooting Charts
    264

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