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 Manitowoc Crane Care has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator’s cab and each attachment.
Page 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........1-57...
Page 7 16000 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Low Pressure Accessory Adjustment ........2-28 Motor Leakage Test .
Page 8 TABLE OF CONTENTS 16000 SERVICE/MAINTENANCE MANUAL Adjustment............4-6 Boom and Luffing Jib Angle Indicator.
Page 9 16000 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Engine Throttle ............7-6 Hand Throttle Control .
Page 10 TABLE OF CONTENTS 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK TOC-vi Published 05-03-17, Control # 228-03...
Page 11 Boom/Mast Hoist Brake and Pawl ........1-29 Manitowoc...
Page 12 MAX-ER 16000 Description of Operation........1-57...
Page 13 16000 SERVICE/MAINTENANCE MANUAL Counterweight Lift Cylinder Switch ....... . . 1-66 Extend Counterweight Lift Cylinder .
Page 14 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-iv Published 05-03-17, Control # 228-03...
Page 15: Section 1
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 the Manitowoc Crane Care Lattice Team.
Page 16: Safe Maintenance Practices
Maintenance Instructions with operator permission. Use both hands and the handrails, steps and ladders To ensure safe and proper operation of Manitowoc cranes, provided to climb onto and off of the crane. they must be maintained according to the instructions contained in this manual, provided with the crane.
Page 17: Environmental Protection
15. Stop the engine before refueling the crane. 29. Unless authorized in writing by Manitowoc, do not alter 16. Do not smoke or allow open flames in the refueling area. the crane in any way that affects the crane’s performance (including welding, cutting, or burning of 17.
Page 18: Identification And Location Of Components
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL IDENTIFICATION AND LOCATION OF COMPONENTS Figure 1-1 through Figure 1-6 for component identification. Item Description Upperworks Undercarriage Operator 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 05-03-17, Control # 228-03...
Page 20: Assorted Views
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Assorted Views Item Description Item Description Boom/Mast Drum Crawler Auto Lube Pump Sequence Valve (all drum motors) Left and Right Swing Gearboxes Boom/Mast Motor Turntable Auto Lube Pump Load Drum Motor Swing Gears Load Drum Turntable Bearing...
Page 21: Top
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Item Description Boom Stop Limit Switch Accumulator, Travel System Hydraulic Swivel Manifold Exhaust After Treatment Assembly Charging Circuit Breaker Mast Angle Sensor Mast Arm Raising Cylinder Mast Arm Raising Cylinder Counterbalance Valve (1 each side) Batteries...
Page 22: Right Side And Front
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL P2282 Right Side and Front Item Description Jacking Cylinder Pads Primary Fuel Filter/Water Separator Coolant Filter Ether Starting Aid Canister Node 5 Controller Air Cleaner Service Indicator Engine Air Cleaner Engine Node 0 Clutch Handle Battery Disconnect Switch...
Page 23: Left Side
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Left Side Item Description Item Description Left Front Jacking Solenoid Drum 4 Pawl Solenoid Right Front Jacking Solenoid R Travel to Drum 4 Diverting Solenoid Mast Raising Cylinders Solenoid L Travel to Drum 3 Diverting Solenoid...
Page 24 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Left Side Item Description Accessory System Manifold for MAX-ER, Engine Cooling Fan, Accessory High Pressure, and Accessory Low Pressure 35 to 345 bar (500 to 5,000 psi) Accessory System Proportional Relief P2439a Valve HS-68 214 bar (3,100 psi) Relief Valve Fixed 24 volt, 3-way, 2 Position Hydro Fan Solenoid Valve Logic Relief Element Set at 0.8 bar (12 psi)
Page 25: Undercarriage/Crawler
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Undercarriage/Crawler Item Description Carbody Pedestal Intermediate Crawler Roller (14 per crawler) Crawler Roller (1 per crawler) Right Crawler Pin Handle Left Crawler Pin Handle Crawler Input Planetary (both crawlers) Crawler Brake (both crawlers) Drive Shaft (both crawlers)
Page 26: Abbreviations Used In Section 1
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Abbreviations Used in Section 1 Solenoid Valve Identification Each hydraulic solenoid valve is assigned an HS number for training identification only. Air Conditioning Analog Input HS-1 Swing Brake Release Alternator HS-5 Travel Brake Release Analog Output...
Page 27: Description Of Crane Operation
In a closed-loop hydraulic system, high-pressure hydraulic This section describes the standard and optional equipment fluid from the system pump drives a hydraulic motor or available for the Model 16000 crane. Disregard any cylinder. Pressure develops within the closed-loop system equipment your crane does not have.
Page 28: Hydraulic Components
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Hydraulic Components Hydraulic Pumps See the hydraulic pump manufacturer’s service manual for a High-pressure piston pumps driven by a multi-pump drive description of a hydraulic piston pump. transmission provide independent closed-loop hydraulic power for crane functions. Each system has relief valves to T h e d r u m , s w i n g , a n d t r a v e l p u m p s a r e v a r i a b l e protect for overload or shock.
Page 29: Pressure Monitoring
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION operation. If the charge pressure is set too high, the block one of the orifice ports, depending on the command hydraulic system could be damaged. When a system control direction. handle is in the neutral position the main display indicates the system charge pressure.
Page 30 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL de-stroke the pump to limit system pressure. When rapid the low-pressure side of the system through the make-up loading produces pressure spikes, the system relief valve (5) check valve (8). shifts. This allows high-pressure fluid to return to the tank Pump displacement depends on the swashplate tilt angle.
Page 31: Accessory/Max-Er Pump
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION back to minimum displacement when in motion if the load is In an emergency, the emergency stop button stops the below a preset pressure of 270 bar (3,916 psi). Depending engine, applies all brakes, and stops all functions abruptly.
Page 32 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL 16-1004 Pressure Brake Command Voltages In Sender Valve Limit Node 1 Switches Controller Processing Switches Motor Gear Brake Drum Reducer Memory Selectors Pump Voltages Drum Control Speed Counts Handles Voltages Monitoring Voltages Out Node 2 Node 3...
Page 33: Display Screens
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Display Screens • Cab power relay (CAB PWR). When the cab power relay is enabled, power is available to operate crane controls. Figure 1-10. • Air conditioning system relay (A/C CLUTCH) 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 6C12A LEFT STARTER SOLENOID 6C12 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 apply the brake. Move the control in the opposite direction from the limit to correct the problem. Pressure senders monitor drum system pressures, right/left The limit bypass switch allows the crane to be operated travel system pressure, swing right/left system pressure, beyond the limits for crane setup or maintenance only.
Page 36 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 After startup, place the swing brake switch in the off-park position. An input voltage is sent to the Node-1 controller. Figure 1-13 Figure 1-14. The Node-5 controller sends a 24 volt output to enable the swing brake solenoid HS-1.
Page 38: Swing Holding Brake Switch
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Swing Holding Brake Switch The swing holding brake switch on the side of the swing control handle, holds the rotating bed in position (applies swing park brake) for short periods when operating. To prevent damage to the swing system, the swing holding brake switch must only be applied when crane is at a standstill.
Page 39: Swing Electrical Schematic
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Swing Electrical Schematic 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 Cab Power NODE 1 6C14 (Master)
Page 40: Travel System Operation
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL TRAVEL SYSTEM OPERATION When the travel brake switch is in the OFF-park position, an input signal is sent to the Node-1 controller. The travel Figure 1-15 Figure 1-16. Each travel hydraulic system circuit is enabled, waiting for a travel control handle pump drives a crawler system motor and gearbox.
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 The travel motors are variable displacement and shift Place the travel two-speed switch in high speed when internally with an adjustable spring in each motor P/C maximum available travel speed is required (normal (Pressure/Compensator) valve, preset at approximately 270 operation).
Page 43: Boom/Mast Hoist System Operation
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION BOOM/MAST HOIST SYSTEM OPERATION When the boom/mast hoist brake switch is in the ON-park position, the hoist brake release solenoid HS-10 (drum 4) or Figure 1-17, Figure 1-18, and Figure 1-19. HS-30 (drum 5) is disabled to apply the brake to drum. The...
Page 44: Lowering Boom
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL The pump EDC continues to tilt the swashplate in the up The pump EDC tilts the swashplate in the up direction to direction as the hydraulic fluid flows from the pump ports to satisfy the pressure memory. The Node-1 controller the motor ports.
Page 45 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION position restricts the returning fluid flow. The pressure builds When the control handle is moved to the neutral position, on the fluid return side of the closed-loop, acting as a The Node-1 controller stores the load holding pressure in the hydraulic brake to control the lowering speed.
Page 46 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL 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 (Master) System Fault Alarm...
Page 47: Load Drum 1
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION LOAD DRUM 1 Raising Load Figure 1-20 Figure 1-22. When the drum 1 control System Components handle is moved back for raising, an input voltage of 2.4 volts Figure 1-20, Figure 1-21 Figure 1-22. or less is sent to the Node-1 controller. The Node-3 controller sends a variable zero to 24 volt output that is divided by a Load drum 1 is located in the boom butt.
Page 48: Lowering Load
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL When the system pressure exceeds the PCOR (Pressure The Node-1 controller checks that the drum block-up limit Compensating Over-Ride) valve setting of 340 bar (4,930 switches are closed and no system faults are present. psi), the valve shifts to direct the flow from the shuttle valve The pump EDC tilts the swashplate in the raising direction to into the maximum displacement side of the servo cylinder.
Page 49 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION too high. The Node-1 controller monitors the motor pressure memory. After the control handle center switch displacement and controls the motor speed by regulating the opens, the Node-4 controller sends a zero output to disable hydraulic fluid flow through the pumps.
Page 50: Drum 1 Electrical Schematic
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Drum 1 Electrical Schematic 16-1017 – 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 51: Load Drum 2
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION LOAD DRUM 2 Raising Load Figure 1-23 Figure 1-24. System Components When the drum 2 control handle is moved back for raising, Figure 1-23, Figure 1-24 Figure 1-25. an input voltage of 2.4 volts or less is sent to the Node-1 Load drum 2 is located at the front top of the rotating bed.
Page 52: Lowering Load
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL When the system pressure exceeds the PCOR (Pressure block-up limit switches are closed and no system faults are Compensating Over-Ride) valve setting of 340 bar (4,930 present. psi), the valve shifts to direct the flow from the shuttle valve The pump EDC tilts the swashplate in the raising direction to into the maximum displacement side of the servo cylinder.
Page 53 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION handle is fully forward, if the motor torque requirements is When the control handle is moved to the neutral position, the not too high. The Node-1 controller monitors the motor Node-1 controller stores the load holding pressure in the displacement and controls the motor speed by regulating the pressure memory.
Page 54: Load/Luffing Drum 3
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Drum 2 Electrical Schematic 16-1020 – 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 55: Load Drum 3 Brake And Pawl
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION The control handle is inoperable when the drum 3 park brake the raising direction. The Node-6 controller sends a variable is applied. 0 to 24 volt output that is divided by a resistor and applied to the motor PCP.
Page 56: Lowering
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL When the drum control handle is moved to the neutral position, the Node-1 controller compensates for the 16-1022 HS-25 hydraulic system leakage or changing engine speed. The Diverting Node-3 controller sends a zero output voltage to the pump Valve EDC that moves the swashplate to the center position.
Page 57: Drum 3 Electrical Schematic
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Drum 3 Electrical Schematic 16-1023 – 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 58: Accessory System Components
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL ACCESSORY SYSTEM COMPONENTS the counterbalance valves provide relief protection for the cylinders and shields them from mechanical overloading. Accessory Systems When a jacking cylinder proportional control valve is not enabled, it shifts to the neutral position where both the valve Accessory system components include the rotating bed section cylinder ports are connected to the tank.
Page 59: Counterweight Pins
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION flow control valve before entering the lower accessory valve. restraining section that has a relief setting of 172 bar (2,495 Hydraulic fluid leaving the accessory valve is returned to the psi). The counterbalance valve acts as a deceleration control tank.
Page 60 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION When the counterweight pins are extended, fluid flows When the counterweight pins switch is released, the pins through the counterweight pins solenoid HS-58 to the rod return to the extend position. The Node-3 controller sends a end of the pin cylinders.
Page 61: Accessory System Electrical Schematic
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION 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 62: Boom Hinge Pins
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Boom Hinge Pins Pressure Figure 1-33 Figure 1-34. Sender During normal operation the boom hinge pins solenoid valve is motor spooled where both cylinder ports and the tank port of the valve spool section are connected in the center...
Page 63: Rigging Winch (Drum 0)
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Rigging Winch (Drum 0) When the front or rear rotating bed pins switch is placed in the engage position and held, an input voltage is sent to the Figure 1-37 Figure 1-38. Node-1 controller. The Node-4 controller sends a 24 volt output to enable the rotating bed pins solenoid HS-40 (front The rigging winch (Drum 0) is located in the boom butt.
Page 64: Cab Tilt
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL When the selected rigging winch control handle is moved Hydraulic fluid from the rod end of cylinder enters the free- back to the haul in position, the Node-4 controller sends a flow check valve before entering the accessory valve and 24 volt output to enable the rigging winch pay out solenoid returns to the tank.
Page 65: Carbody Jacking Cylinders (Optional)
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION selected crawler pin handle. The Node-1 controller monitors the system pressure. WARNING Lower Accessory 500 to 3,000 psi Enable Pressure (35 to 204 bar) Collapsing Hazard! Sender Keep the rotating bed as level as possible while jacking.
Page 66: Live Mast
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL sends a zero volt output to disable the accessory system equalizing valves. The load equalizing valves ensure the proportional relief solenoid HS-68. mast-raising cylinders operate in unison, protecting the mast from structural damage caused by twisting. The load...
Page 67: Mast Raising From Transport Position
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Mast Raising from Transport Position drum pays out the wire rope between the drum and the mast sheaves. A speed sensor at motor rotor monitors the drum Figure 1-44 Figure 1-45. rotational speed. Use the RCL Screen to select the Liftcrane Mast Handling Fluid pressure from the accessory valve enters the free-flow Capacity Chart.
Page 68: Mast Lowering To Transport Position
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Mast Lowering to Transport Position Figure 1-45. Pressure Sender Use the RCL Screen to select the Liftcrane Mast Handling Capacity Chart. The mast controls will not operate and the mast operating limits remain off until the Liftcrane Mast...
Page 69: Live Mast Electrical Schematic
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION 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 70: Hydraulic Cooling Fan
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Hydraulic Cooling Fan manufacturer. It should not be changed by either the operator or a service person. Figure 1-47. NOTE: Fan speed should never be 100%. If the actual fan The hydraulic cooling fan is supplied fluid from either the uni-...
Page 71: Max-Er 16000 Description Of Operation
Table 1-1Hydraulic Solenoid Valve Identification The MAX-ER 16000 wheeled counterweight assembly consists of the following components: HS-68 Accessory System Proportional Relief •...
Page 72: Accessory Pumps
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL 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/Telescopic...
Page 73: Epic® Programmable Controller
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION ® ER Operator Manual. Also, the MAX-ER Function mode EPIC Programmable Controller screen must be selected on the main display.  The operating system is an EPIC (Electrical Processed Power is available to the hand-held wireless remote control...
Page 74: Jacking Cylinders
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Jacking Cylinders When operating, the left travel handle can control the operation of the jacking cylinders when travel is parked and a Figure 1-49 Figure 1-50. MAX-ER chart is selected. Moving the left travel handle forward enables all the jacking cylinders down. Moving the There is one jacking cylinder on each corner of the left travel handle back enables all the jacking cylinders up.
Page 75 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION sends a 24 volt output to enable the selected jack cylinder The Node-3 controller also sends a variable 0 to 24 voltage solenoid (HS-75 in this example) and shifts the valve to the to enable the proportional relief solenoid HS-68 to provide retract position.
Page 76 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Hydraulic pressure from the accessory pump flows through When the desired jack cylinder retraction is reached, release the pressure control pilot valve, the six bank manifold valve, the selected jack switch to lock the jack cylinder(s) in and enters the free-flow check valve section of the position.
Page 77: Telescopic Beam Cylinder
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Telescopic Beam Cylinder The top and bottom telescopic beam position encoders detect telescopic beam position and direction of the beam Figure 1-51 Figure 1-52. movement. The Node-1 controller receives this input information as two out-of-phase square wave voltages that The telescopic beam cylinder connects the wheeled are converted to counts.
Page 78: Extend Telescopic Beam Cylinder
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Extend Telescopic Beam Cylinder Retract Telescopic Beam Cylinder When the telescopic beam switch is moved and held in the When the telescopic beam switch is moved and held in the extend position, an input signal from the wireless transmitter retract position, an input signal from the wireless transmitter is sent to a receiver on the crane.
Page 79 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION M16-07 Suction Manifold Variable Accessory Pump 400 to 5,000 Telescopic Beam Extend (28 to 345 bar) HS-68 To Other MAX-ER Systems Proportional Pressure Control 4,500 psi HS-70 HS-72 HS-88 HS-89 HS-71 HS-73 Relief Valve Pilot (310 bar)
Page 80: Counterweight Lift Cylinder
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Counterweight Lift Cylinder Counterweight Lift Cylinder Switch The counterweight lift cylinder switch allows the lift cylinder Figure 1-53 Figure 1-54. to be disconnected from the mast straps during assembly/ When a MAX-ER chart is selected, a load sensing pin in one disassembly.
Page 81 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION When the desired extension is reached, release the switch to output to the hydraulic solenoids HS-70 and 71 to the return lock the cylinder in position. Hydraulic fluid at the piston end valve to the center position.
Page 82: Retract Counterweight Lift Cylinder
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Retract Counterweight Lift Cylinder Hydraulic fluid from piston end of the lift cylinder is blocked by the free-flow check valve section of the counterbalance When the counterweight lift cylinder switch is moved and valve and the flow restraining section of the relief valve held in the retract position, an input signal from the wireless preset for a relief setting of 152 bar (2,205 psi).
Page 83 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION M16-13 Counterweight Lift Cylinder Extend Suction Manifold Variable Accessory Pump 400 to 5,000 (28 to 345 bar) To Other MAX-ER Systems 4,500 psi Proportional Pressure Control (310 bar) HS-70 HS-72 HS-88 HS-89 HS-71 HS-73 Relief Valve...
Page 84: Wheel Assemblies
INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL Wheel Assemblies Hydraulic pressure from the accessory pump flows through the pressure control pilot valve, the six bank manifold valve, Figure 1-55 Figure 1-56. and enters the free-flow check valve section of the counterbalance valve. Fluid pressure turns the motor output The wheel assembly swing motors allow the positioning of shaft so the wheels rotate in a clockwise direction.
Page 85 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION 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 86 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL 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 87: Telescopic Beam Hinge Pins
16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION Telescopic Beam Hinge Pins beam hinge pin solenoid HS-91 and shifts the valve to the disengage position. Figure 1-57 Figure 1-58. The Node-3 controller sends a variable 0 to 24 volt output to The telescopic beam hinge pin cylinders have a three...
Page 88 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL 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 89 16000 SERVICE/MAINTENANCE MANUAL INTRODUCTION When the telescopic beam hinge pin switch is moved and beam pin cylinder, extending the cylinder rod to engage the held in the engage (in) position, an input signal from the beam hinge pins. Hydraulic fluid from the rod end of the wireless transmitter is sent to a receiver on the crane.
Page 90 INTRODUCTION 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-76 Published 05-03-17, Control # 228-03...
Page 91 Low Pressure Accessory Adjustment ........2-28 Manitowoc...
Page 92 16000 SERVICE/MAINTENANCE MANUAL Motor Leakage Test..........2-30 Loop Flushing Valve Adjustment .
Page 93: Inspecting Hydraulic Hoses
Other signs of significant deterioration procedures for the hydraulic system and related components If any of these conditions exist, evaluate the hose on the Model 16000 crane. See the end of this section for assemblies for correction or replacement. applicable hydraulic schematics.
Page 94: Hydraulic System Maintenance
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Storing and Handling Oil High Duty Circuits High duty circuits can include, but are not limited to hoists, Use the following guidelines when storing or handling oil: boom lift, swing, travel, pump suction and discharge to •...
Page 95 16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Item Description Item Description Filters, Return Shut-Off Valve Handle Fill Plug (manual fill port) Locking Pin Power-Fill Coupling Hydraulic Tank Drain Valve Breather Vacuum Switch Shrader Air Valve Suction Manifold Coupler Tube Nut Fitting DEF System Hoses (Ref.)
Page 96 HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL P2243a Rear Side of Hydraulic Tank Valve Shown in the CLOSED Position. Rotate 90 Degrees Top of Clockwise to Lock Open Hydraulic Reservoir Rear Side of Hydraulic Tank FIGURE 2-1 continued Published 05-03-17, Control # 228-03...
Page 97: Inspecting The System
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Inspecting the System Only use approved hydraulic oil in the system (see Section 9 in this manual). The damaging effects of dirt, heat, air, and water in the Replace the disposable cartridge in the desiccant...
Page 98: Replacing Desiccant Breather
The original equipment manufacturers’ filter elements, Remove the protective caps from the top and bottom of available from Manitowoc Crane Care, must be used on the new cartridge. this crane. Substituting any other brand or type of filter element is not allowed.
Page 99: Changing Oil
Do not operate the crane without the return filter In the Event of a Catastrophic Failure of a elements installed. Hydraulic Component Contact your Manitowoc dealer or the Crane Care Lattice A00651 Cover Team if the crane’s hydraulic system has experienced a...
Page 100: Servicing Pumps
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL 11. Replace the desiccant breather when necessary (see 18. Apply 0.2 to 0.3 bar (3 to 4.4 psi) air pressure to the air Replacing Desiccant Breather topic). valve (4a) or to the coupler (4b) on the hydraulic tank.
Page 101: Hydraulic Connections
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Hydraulic Connections Pipe Thread Connection Apply sealant (Loctite 92 or equivalent) to the male Precautions to Observe During Maintenance and threads, never to the female threads. Do not apply Repair sealant to the first two male threads.
Page 102: Sae Straight Thread Connection
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL SAE Straight Thread Connection Be sure to lubricate the o-ring with clean oil. Thread fitting into the port until the washer bottoms This type of connection leaks most often because the jam against the spot face as shown in Figure 2-8, View B.
Page 103: Ors Connection
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM ORS Connection Table 2-4 ORS Assembly Torque NOTE: ORS is the registered trade mark for a face-type seal manufactured by Aeroquip Corporation. Nut Size Torque Fitting inch To maintain an ORS fitting, use the following procedure:...
Page 104: Split Flange Connection
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Split Flange Connection Table 2-7 Split Flange Assembly Torque To maintain a split flange fitting, use the following procedure: "A" Torque Lubricate and install the o-ring in the shoulder groove Dimension (see Figure 2-10). Align the shoulder with the port and inch (mm) assemble the flanges over the shoulder.
Page 105: Sae Flare Connection
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SAE Flare Connection Table 2-8 SAE 37°Flare Tightening To maintain an SAE flare connection, use the following procedure: Connector Nut Size Adapter Flats Tighten the nut finger tight until the sealing surfaces Fitting Size in (mm) across to Rotate touch.
Page 106 HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL P2252 P2298 P2300 P2297 P2270a P2299 Item Description Item Description Swing Motor Drain Case Port Load Drum Brake Solenoid (typical Load Drum Motor Case Drain (1 or 2 places per drum) Boom Hoist Brake Solenoid...
Page 107: System Calibration And Tests
(stalled). CAUTION When the controls are off, the cylinders must not retract. If they do, contact Manitowoc Crane Care Lattice Team. Damage to Mast! When raising the mast for the first time, or after When retracting the jacks, the rotating bed must lower maintenance of mast cylinder, raise the mast slowly and slowly and smoothly.
Page 108: Crawler Pins
16000 SERVICE/MAINTENANCE MANUAL When the controls are off, the cylinders must not retract. Rigging Winch (Optional) If they do, contact the Manitowoc Crane Care Lattice To verify wench operation, use the following procedure: Team. Enable the rigging winch (see instructions in Section 3 of When retracting the jacks, the carbody must lower 16000 Operator Manual).
Page 109: Speed Checks
Control handles moved fully forward and back • No load • No rope on drums Speeds must be within the ranges specified in Table 2-10. If proper speeds are not indicated, contact the Manitowoc Crane Care Lattice Team. Manitowoc 2-17 Published 05-03-17, Control # 228-03...
Page 110: Hydraulic System Specifications
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SPECIFICATIONS Table 2-10 System System Charge Speed Function Direction Pump-Port Pressure 1 Pressure 2 Pressure bar (psi) bar (psi) Hoist Pump 4 - B 50 to 55 Drum 1 Lower Pump 4 - A...
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 2-15...
Page 112: Pump Identification
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL PUMP IDENTIFICATION A10584-2 A13469 – Top 81013192 – Bottom Item Description Item Description Item Description Right Travel or Boom Drum Drum 1 or Drum 2 Accessory System Left Travel or Luff Drum Swing Gear Pump for Fan (Front of Engine)
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
To understand the operation of the main display and touch pad controls, read the instructions in A new controller node that monitors pressure Section 3 or the 16000 Operator Manual. senders is installed The Pressure Test and Calibration Screen (see...
Page 115: Control Calibration
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM NOTE: The cause of a failed pressure sender test or faulty Calibrate controls using the following procedure: display pressure reading may not be the pressure Apply all park brakes with the switches on the control sender.
Page 116: High Pressure Test
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL High Pressure Test Press the Confirm button to start the test. The test starts and the percent of completion is Figure 2-21 for the following procedure. displayed in the data box. The high pressure test checks the ability of all primary crane When the test is complete, the high pressure icon 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 2-22 for the following procedure. The following adjustment is only required when a system fails the High Pressure Test. The charge pressure test checks the ability of all primary crane 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 13 mm (1/2 in) Port A Multi-Function Valve 4 mm (5/32 in)
Page 119: Charge Pressure Adjustment
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Charge Pressure Adjustment Install an accurate 0 to 69 bar (0 to 1,001 psi) hydraulic pressure gauge in each servo gauge port (1). The following adjustment is only required when a system Start and run the engine at high idle.
Page 120: Low Pressure Accessory Adjustment
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Low Pressure Accessory Adjustment Hold the adjusting screw in position and securely tighten the locknut. Figure 2-26 for the following procedure. Stop the engine, remove the gauge, and reconnect the The pressure reducing valve (1) controls pressure in the low hydraulic lines.
Page 121 16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Inside Adapter Frame P2300 P2308 Left Side of Rotating Bed Item Description Item Description Pressure Reducing Valve Drum 2 to Drum 1 Diverting Solenoid Lock Nut – 0.562 inch Hex Drum 1 to Drum 2 Diverting Solenoid Adjusting Screw –...
Page 122: Motor Leakage Test
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Motor Leakage Test Typical Motor Installation Perform the following test if troubleshooting indicates the need: • Low Charge Pressure • Sluggish Operation • Excessive Heat Figure 2-28 for the following procedure: Stop the engine. Install an accurate flow meter in the highest case drain...
Page 123: Pump Or Motor Override
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pump or Motor Override Solenoid Valve Override Figure 2-29 for the following procedure: Figure 2-29 for the following procedure: Start the engine and run at low idle. Start the engine and run at low idle.
Page 124: Pressure Sender Replacement
HYDRAULIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Pressure Sender Replacement Remove the pressure senders. Install the new pressure senders and connect electrical cords. Pressure senders have pipe threads. Be sure to install WARNING thread sealant. High Pressure Oil Hazard! Bleed the pressure senders:...
Page 125: Disc Brake Operational Test
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Disc Brake Operational Test Reconnect the electrical connector to all the brake solenoid valves at the completion of the operational test. There is no physical way to check the disc brakes for travel, If disc brakes were repaired or replaced, retest the boo m hoist, lo ad dru ms, and swing.
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Page 127 “Manitowoc” Screen ........
Page 128 16000 SERVICE/MAINTENANCE MANUAL MAX-ER Functions ..........3-43 Drum, Swing, or Track Speed Limits .
Page 129: Electrical Drawings And Schematics
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM ELECTRICAL DRAWINGS AND Degradation Due to Extreme Environment SCHEMATICS Table 3-1 for climate zone definition. Applicable electrical system drawings and schematics are Zones A and B: attached at the end of this section.
Page 130: Circuit Breaker And Fuse Id
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL CIRCUIT BREAKER AND FUSE ID Circuit breakers CB-1 to CB-8 are mounted in the engine node-0 controller box in the left side enclosure. There are no Fuses are mounted in the fuse junction box located in the in-line fuses used on this crane model.
Page 131 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Circuit Amps Items Protected Breaker Cold Weather Package Circuit Breakers Cold Weather Package Main Circuit Breaker Engine Coolant Heater, Engine Oil Heater Hydraulic Reservoir, Cab Console and Battery Pad Heaters Circuit Breaker Load Center 81004228...
Page 132: Test Voltages
TEST VOLTAGES Node Table Heading Descriptions The CAN tables on the following pages provide information ® The Model 16000 operating system uses the EPIC system found on the crane’s electrical schematics at the end of this ® with CAN Bus technology.
Page 133: Component-Node Cross-Reverence
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Component–Node Cross-Reverence Abbreviations Used in Test Voltage Tables Find the desired component item in this index. Check the The test voltage tables use the following abbreviations: component item node location, then refer to the indicated Accessory node 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. CAN Packet Function Connector # Description Test Voltage Number Type 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. CAN Packet Function Connector # Description Test Voltage Number Type Receptacle — Pressure Senders and Accessories W33-A...
Page 139 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM W34-S DO-18 Pump 6 Control (Drum 2/Drum 1) Table 3-2 page 3-6 CAN25-3-2 W34-T Ground Pump 2 Control (Left Travel/Drum 3) Ground Table 3-2 page 3-6 W34-U DO-19 Pump 2 Control (Left Travel/Drum 3) CAN25-3-4...
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. CAN Packet Function Connector # Description Test Voltage Type Number Input/output cable routing to remote nodes vary - see Electrical Schematic specific to your crane.
Page 141 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM W44-P DO-16 Left Rear Jack Solenoid - Retract 0 Volts Off, 24 Volts On CAN27-2-128 W44-R DO-15 Left Rear Jack Solenoid - Extend 0 Volts Off, 24 Volts On CAN27-2-64 W44-S DO-18 Right Rear Jack Solenoid - Retract...
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. CAN Packet Function Connector # Description Test Voltages Type Number Input/output cable routing to remote nodes vary - see wiring diagram specific to your crane.
Page 143 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM W54-U DO-19 Travel 2-Speed Solenoid 0 Volts Off, 24 Volts On CAN29-3-4 W54-V Ground Travel Brake Release Solenoid Ground W54-W DO-20 Swing Brake Release Solenoid 0 Volts Off, 24 Volts On CAN29-3-8 W54-c Ground Swing Bearing Auto Lubrication...
Page 144 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL 1.2 or 3.2 Volts Not Moving, W56-p EC1B Load Hoist (Drum 2) Motor Speed Sensor CAN52-2 2.2 Volts Moving Lower four bits can be multiplied by 5 or 10 depending on the sender, then divided by 16 for an estimation of the sender voltage.
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. CAN Packet Function Connector # Description Test Voltages Number Type Input/output cable routing to remote nodes vary - see Electrical Schematic specific to your crane.
Page 146 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL CAN Packet Function Connector # Description Test Voltages Number Type W66-C Ground Load Hoist (Drum 1) Left Side Motor Control Ground W66-D DO-8 Load Hoist (Drum 1) Left Side Motor Control Table 3-2 page 3-6...
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. CAN Packet Function Connector # Description Test Voltage Number Type Input/output cable routing to remote nodes vary - see Electrical Schematic specific to your crane.
Page 148 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL W74-N Ground Right Front Jacking Cylinder Retract Ground W74-P DO-16 Right Front Jacking Cylinder Retract 0 Volts Off, 24 Volts On CAN28-2-128 W74-R DO-15 Right Front Jacking Cylinder Extend 0 Volts Off, 24 Volts On...
Page 149 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM W76-m 24 Volts Right Wheel Steering Encoder 24 Volts Nominal 1.2 or 3.2 Volts Not Moving, W76-n EC-1A Left Wheel Steering Encoder CAN50-2 2.2 Volts Moving 1.2 or 3.2 Volts Not Moving, W76-p EC-1B Left Wheel Steering Encoder CAN50-2 2.2 Volts 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. CAN Packet Function Connector # Description Test Voltage Type Number 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. CAN Packet Function Connector # Description Test Voltage Type Number 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. Function Connector # Wire No. Description Test Voltage Type Connector – 40 Pin P1-1 24 Volts Ignition Signal 24 Volts Nominal P1-2 0102...
Page 153: Digital Output Disable Chart
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Digital Output Disable Chart CAN38-1-16 Load/Luffing (Drum 3) Pawl Out (N6) CAN38-1-64 Load Hoist (Drum 1) Brake Solenoid (N6) Table 3-3 Digital Output Disable CAN38-1-128 Load Hoist (Drum 1) LS Motor Control (N6) CAN38-2-1 Load Hoist (Drum 1) RS Motor Control (N6)
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
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL MAX-ER Faults 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 CAN147-1-4 Lift Cylinder Extend 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
The in-line test boards can be ordered Open the knife switch across the test terminal. from the Manitowoc Crane Care Lattice Team. b. Select amperes on the meter. The node number and pin numbers for each component to be checked are contained in the node Test Volt tables.
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
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL DISPLAYS 4a. Select Screen 1 (RCI) 4b. Select Screen 2 (Main Display) Navigation and Settings Select Buttons Display Navigation Use the green select touch pad buttons to select screen Figure 3-5 for the following procedure.
Page 161: Main Display
If a display goes blank, try the following procedure to restore To select the Display, press and hold the the display. Do not return a display to Manitowoc Crane Care Confirm key, and then press key 1. Then before attempting this procedure: release the Confirm key.
Page 162: Information Screen
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Menu Screen The Menu screen shows six screen icons and operates on one level only: Figure 3-7 for the following procedure. • Use the Select buttons to select an icon. Press the Enter The Menu screen is the base screen for the crane system.
Page 163 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-8. Faults Item Description 49-Jib Maximum Up 1*—Program limit stops the Item Description luffing jib when the jib is raised to the maximum 0-No Fault. working angle. Lower the luffing jib. Can bypass this limit to raise the jib to Maximum Up 2 limit.
Page 164 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Item Description Item Description 67-Jib Maximum Down 2*—Limit switch stops 84-Digital Output Disabled—Digital output signal the luffing jib when the jib is lowered to the has a short circuit between the computer node minimum angle. Raise the luffing jib.
Page 165: Diagnostic Screen
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Diagnostic Screen ground icon or open circuit icon indicates a circuit fault that must be serviced immediately. The diagnostic screen shows a graphic of the hydraulic NOTE: Variable outputs may show a yellow icon all the circuit and the status of all pumps, motors, valves, and time.
Page 166 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Counterweight Pin Status Remote Control: Wireless and Wired Command state of the counterweight pin Remote control status, indicating which switches cylinders, extended (shown) or retracted. are closed. Boom Hinge Pin Status Each control switch corresponds with a number...
Page 167 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Drum Diagnostic Screens For load drums 1 or 2, the drum 2 pump is dedicated to the drum 1 motor through a diverting valve when drum 1 is Select the drum icon on screen level 1 as shown Figure 3-8.
Page 168: Swing Diagnostic Screen
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Swing Diagnostic Screen Travel Diagnostic Screen Select the swing icon on screen level 1 as shown in Select the travel icon on screen level 1 as shown in Figure 3-10. Press the Enter button to go to level 2.
Page 169: Jacking Accessory Diagnostic Screen
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Jacking Accessory Diagnostic Screen Pins and Fan Accessory Diagnostic Screen Select the crane carbody with the jacking icon on screen Select the crane, pins, and engine fan icon on screen level 1 level 1 as shown in Figure 3-14.
Page 170: Function Mode Screens
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Function Mode Screens Cab Tilt, Rigging Winch, and Mast Accessory Diagnostic Screen Figure 3-20 for the following: Select the cab tilt, rigging winch, and mast icon on screen Use the Function Mode screen to enable/disable modes and...
Page 171: Swing Pressure Limit
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Swing Functions Drum, Swing, or Track Speed Limits Highlight and select the swing functions as shown here. Figure 3-24 for the following procedure. The drum, swing, and crawler speeds can be selected and adjusted. On level 3, use the select buttons to highlight the...
Page 172: Can Bus Screen
The packet contents and format depend on the packet type. Many packets are not easily interpreted by non- CAN Bus Screen Manitowoc technical personnel and are not discussed in this Figure 3-30 publication. The CAN (Controller Area Network) bus diagnostic screen is Each individual input/output is assigned a number (identifier) for technicians.
Page 173: Digital Output Disable (Dod) Fault
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM is the sum of all identifiers that are ON in that bank. Each normally if the blue antenna icon is displayed. If the sensor is possible ON/OFF combination per bank has a unique total. not operating normally, the following numbers indicate the...
Page 174: Boom Node Status
ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Boom Node Status Crane Status Figure 3-30, Item 9 for the following procedure. Figure 3-30, Item 11 for the following procedure. The boom node status displays the boom top node and jib Two crane status banks display crane errors, and both banks node communication.
Page 175 16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-10 Bank Identifier Numbers Dark shaded boxes indicate ON, white boxes OFF. Manitowoc 3-47 Published 05-03-17, Control # 228-03...
Page 176 ELECTRIC SYSTEM 16000 SERVICE/MAINTENANCE MANUAL Table 3-10 Bank Identifier Numbers (continued) Dark shaded boxes indicate ON, white boxes OFF. 3-48 Published 05-03-17, Control # 228-03...
Page 177: Camera Screen (Optional)
16000 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Camera Screen (Optional) The camera screen sets the desired camera operation. The camera option includes up to three different cameras to monitor drum spooling and the area behind the crane. Use the select buttons to select the camera screen from the menu screen.
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Page 179: Section 4
Lattice Inspection and Lacing Replacement ....... . . 4-13 Manitowoc...
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Page 181: Automatic Boom Stop
16000 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM AUTOMATIC BOOM STOP Maintenance At least once per week, make sure the boom stop stops the Maximum Boom Angle boom at the specified maximum angle. If not, replace any The boom stop limit switch (5,...
Page 182: Bypass Limit Test
BOOM 16000 SERVICE/MAINTENANCE MANUAL Bypass Limit Test Lower the boom onto the blocking at ground level. Have an assistant push in the adjusting rod (Figure 4-2) Perform the following test to determine if the boom up limit in to open the boom stop limit switch.
Page 183 16000 SERVICE/MAINTENANCE MANUAL BOOM A10867 Roller Over-Travel VIEW A Switch Opened 2a or 2b 2a or 2b VIEW B Stored Switch Closed Item Description Boom Butt Limit Switch Wiring Adjusting Rod – Boom only Switch Receptacle Function Adjusting Rod – Boom with Luffing Jib...
Page 184: Adjustment
BOOM 16000 SERVICE/MAINTENANCE MANUAL b. Turn the adjusting rod (2a or 2b) all the way into the A10415 Digital Level coupling (4). Angle A Angle Boom up slowly until the boom reaches the 84° 76.3° specified angle. 88° 80.3° d. Turn the adjusting rod (2a or 2b) out against the boom butt (1) until the limit switch (5) clicks in the open position (View A).
Page 185 16000 SERVICE/MAINTENANCE MANUAL BOOM • 76.1° - Initial Contact • 77.9° - Start of Spring Cushioning • 88.9° - Physical Stop (springs solid) View B View A 38 mm (1-1/2 in) View C Item Description Boom at 76.1º Boom at 77.9º...
Page 186: Physical Boom Stop
BOOM 16000 SERVICE/MAINTENANCE MANUAL PHYSICAL BOOM STOP Operation Figure 4-4 The physical boom stops operate in the following order: When the boom is raised to 77.9°, springs in the boom Stop Angles stop tubes begin to compress. The physical boom stops multiple purposes, including the...
Page 187: Boom And Luffing Jib Angle Indicator
16000 SERVICE/MAINTENANCE MANUAL BOOM BOOM AND LUFFING JIB ANGLE of the mast raising cylinder and levers during crane setup, as well as to allow the operator to monitor the mast angle on the INDICATOR display during crane setup. Angle indicator sensors are located inside the node...
Page 188: Drum Pressure Roller
BOOM 16000 SERVICE/MAINTENANCE MANUAL DRUM PRESSURE ROLLER A11126 An optional pressure roller assembly is available for the boom hoist drum. The roller is spring-loaded to assist in maintaining proper wire rope spooling by firmly holding the wire rope against the drum and subsequent layers.
Page 189: Strap Inspection And Maintenance
A qualified inspector may modify the interval for periodic if there is damage to other major structural components, inspection depending on the following factors: Manitowoc recommends that a thorough inspection be • The severity of the environment in which the crane is made by a qualified person.
Page 190: Replacement Specifications
BOOM 16000 SERVICE/MAINTENANCE MANUAL Replacement Specifications Allowable Condition Reference Tolerance or Corrective Action Any strap not within the specifications listed in Table 4-5 Deviation must be replaced. Remove the strap Figure 4-18 Length None from service. < = less than ≥...
Page 191: Straightness
16000 SERVICE/MAINTENANCE MANUAL BOOM Corrosion or Abrasion Straightness Figure 4-14 for the following procedure. Figure 4-15 for the following procedure: For quick identification by repair workers, clearly mark the Stretch a line (string or wire) from the pin storage hole at damaged areas with brightly colored tape.
Page 192: Flatness
If the two dimensions are identical, but greater than 0,8 ≥3,7 (≥12) in any 3,7 m (12 ft) length of strap mm (0.030 in), contact the Manitowoc Crane Care Lattice Team. < = less than ≥ = equal to or greater than...
Page 193: Storing Straps
16000 SERVICE/MAINTENANCE MANUAL BOOM Removing Straps from Service Length Link Straps removed from service should be clearly marked to Strap prevent accidental future use. Rendering the strap useless in some way, such as cutting off an end, is recommended. Inspection Checklist...
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Page 195: Section 5
16000 SERVICE/MAINTENANCE MANUAL SECTION 5 HOISTS TABLE OF CONTENTS Boom/Mast Hoist Pawl........... 5-1 Maintenance .
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Page 197: Boom/Mast Hoist Pawl
16000 SERVICE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS BOOM/MAST HOIST PAWL A10767 View from Right Side Figure 5-1 for the following procedure. 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 198: Speed Sensor
HOISTS 16000 SERVICE/MAINTENANCE MANUAL SPEED SENSOR Hold the sensor in position and securely tighten the lock nut. Figure 5-2 for the following procedure. The hydraulic motors for the hoists (boom, mast, load) and Item Description swing have a speed sensor. For those functions with more Speed Sensor than one motor, only one of the motors has a speed sensor.
Page 199: Weekly Maintenance
16000 SERVICE/MAINTENANCE MANUAL HOISTS Weekly Maintenance Adjustment Perform the following during weekly maintenance: Use the following steps during adjustment: Check the minimum bail limit switch for proper Pay out wire rope until the rollers are against the bare operation: drum with 3 to 4 wraps of wire rope remaining on the first layer.
Page 200: Block-Up Limit
HOISTS 16000 SERVICE/MAINTENANCE MANUAL BLOCK-UP LIMIT Operation A block-up limit (also called an anti two-block device) is a Figure 5-4 Figure 5-5 for component identification. two-blocking prevention device that automatically stops the For a complete wiring diagram of the system, see the Boom load drum from hoisting and the boom from lowering when a Wiring and Limits Drawing in Section 3.
Page 201 16000 SERVICE/MAINTENANCE MANUAL HOISTS A1284 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)
Page 202 HOISTS 16000 SERVICE/MAINTENANCE MANUAL Single Part Reeving Multiple Part Reeving Dead Ended at Upper Boom Point A11993 FIGURE 5-4 continued Published 05-03-17, Control # 228-03...
Page 203: Maintenance
16000 SERVICE/MAINTENANCE MANUAL HOISTS Maintenance Inspect and test the block-up limits weekly or every 40 hours CAUTION of operation, whichever comes first, using the following Avoid Sheave Damage! procedure: Use extreme care when testing block-up limits when the boom is raised. If a block-up limit fails to stop the load,...
Page 204 HOISTS 16000 SERVICE/MAINTENANCE MANUAL From Boom or Jib Node Controller Limit Switch for Lower Boom Point and Jib Point A1007 A1131 Item Description Elbow with Cord Gripper Set screw Spring Enclosure Adjusting Screw (spring tension) Grease Fitting Actuating Lever Roller...
Page 205: Wire Rope Lubrication
Crane Care Lattice Team. fittings, use only pre-assembled lengths of wire rope as Wire Rope Lubrication supplied by Manitowoc Crane Care Lattice Team. Do not build lengths from individual components. Refer to the Lubrication Guide for recommendations. 2. Replace an entire wire rope assembly. Do not attempt to Maintain a Wire Rope Condition Report rework damaged wire rope or wire rope ends.
Page 206: Daily Inspection
HOISTS 16000 SERVICE/MAINTENANCE MANUAL Daily Inspection Broken wires—Record the number, distribution and type of broken wires (see the Broken Rope Wires Wire rope should be inspected in accordance with ANSI/ Topic) ASME B30.5 and OSHA 29 CFR 1926.1413. A running...
Page 207: Periodic Comprehensive Inspection
16000 SERVICE/MAINTENANCE MANUAL HOISTS • Comprehensive examination for broken wires (see the Broken Rope Wires topic) M100655a-f • End connections including broken wires or severely corroded, cracked, bent, worn, or improperly applied end connections • Areas subjected to rapid deterioration such as the...
Page 208: Replacement Criteria
HOISTS 16000 SERVICE/MAINTENANCE MANUAL • Exposure to abuse and shock loads, such as the following conditions: High-velocity movement, such as hoisting or swinging of a load followed by abrupt stops Load suspension while traveling over irregular surfaces such as railroad tracks, potholes, and...
Page 209: Distributing Wire Rope Wear
Da ily and Per iod ic Com preh en sive Inspections. NOTE: Wire rope may be purchased through Manitowoc Crane Care Lattice Team. DANGER Falling Load Hazard...
Page 210: Sheave, Roller, And Drum Inspection
HOISTS 16000 SERVICE/MAINTENANCE MANUAL SHEAVE, ROLLER, AND DRUM INSPECTION Observe groove to see if contour of gauge Perform the following inspections weekly: matches contour at bottom of sheave groove. 1. Check the drum clutches and brakes for proper adjustment. 2. Check all sheaves, rollers, and drums for the following...
Page 211 16000 SERVICE/MAINTENANCE MANUAL HOISTS 8. Inspect nylon sheaves to verify they have not separated and “walked off” steel inserts or bearings as shown in Figure 5-12. Maximum sideways displacement is 3 mm (1/8 in). Replace worn or damaged sheaves. NOTE:...
Page 212: Drum Kicker
HOISTS 16000 SERVICE/MAINTENANCE MANUAL DRUM KICKER Securely tighten the set screws (6) and lock nuts (5). Reinstall the drum guards. A drum kicker is provided on both flanges of the main load drum (in the boom butt) to improve wire rope spooling for long boom lengths with small fleet angles where the wire rope might stack up along either drum flange.
Page 213 16000 SERVICE/MAINTENANCE MANUAL HOISTS PLASTIC SHEAVE DATA Outside Sheave Tread Diameter Width Rope Diameter Part No. Diameter E = Replacement dimension inch inch inch inch E = B – 5 mm (3/16 in) (maximum) 912738 335,0 13.19 290,1 11.42 45,0 1.77...
Page 214: Load Block And Hook-And-Weight Ball Inspection
Trunnion Block Weight (lb and kg) Thrust Bearing Block Serial Number Latch Block Part Number (OEM and Manitowoc) Hook Design Factor FIGURE 5-15 The operating condition of the load block and the hook-and- weight ball can change daily with use. Therefore, they must...
Page 215 The latch must not be wired open or shackles by welding. Furthermore, do not weld on any removed. load bearing component unless proper welding methods are used. Contact the Manitowoc Crane Care Lattice Team for material and welding specifications. Manitowoc 5-19...
Page 216 HOISTS 16000 SERVICE/MAINTENANCE MANUAL Item Description Shackle Check for Wear and Deformation Check for Wear and Straightness Check that Pin is Always Seated Hook Check that Hook is Not Twisted Check for Cracks and Twisting Check for Wear and Cracks...
Page 217: Section 6
16000 SERVICE/MAINTENANCE MANUAL SECTION 6 SWING TABLE OF CONTENTS Manual Release of Swing Brake and Lock ........6-1...
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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: LOCK Disconnect the hoses from the fitting at the brake Figure 6-1 for the following procedure.
Page 220 SWING 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-03-17, Control # 228-03...
Page 221: Section 7
Passive Regeneration ......... . . 7-20 Manitowoc...
Page 222 16000 SERVICE/MAINTENANCE MANUAL Active Regeneration ..........7-20 Regeneration Inhibit .
Page 223: Batteries
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN SECTION 7 POWER TRAIN BATTERIES Undercharging Undercharging can cause a type of sulfate to develop on the Safety plates. The sulfate causes strains in the positive plates which causes plate buckling. Buckled plates can pinch the separa- tors 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 each 6° C (10º F) below 27°C Weekly – Check Electrolyte Level (80º F). Add 0.004 each 6° C (10º F) above 27°C (80º F).
Page 225: Charging
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN Table 7-3 Open Circuit Cell Voltage up to 40 amperes for a maximum of 2 hours. If the electrolyte Approximate temperature reaches 52°C (126ºF) or gases violently, reduce % Charge Specific Gravity Open Circuit the charging current or stop charging to avoid battery Cell Voltage damage.
Page 226: Air Cleaner
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL AIR CLEANER Figure 7-3 for the following procedures. CAUTION Engine Damage! The air cleaner is mounted using lugs (7) to the engine. Rubber elbow reducers (5), clamps (3), steel tube (2) and a Stop the engine before servicing the air cleaner or straight adapter fitting (4) are part of the mounting assembly.
Page 227 16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN Item1 Description Air Cleaner Assembly Service Cover Latch (8) Primary Filter (2) Secondary Filter (2) Housing Steel Tube Clamp (4) Straight Adapter Fitting Rubber Elbow Reducer Engine Intake Mounting Lugs (4) Service Indicator Service Window...
Page 228: Engine Throttle
If there is a problem with the foot throttle, replace it or send potentiometer (7) into the cavity in the bottom of the the unit to the Manitowoc Crane Care Lattice Team for repair. housing (1) as shown in View B-B. Insert the...
Page 229 16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN A02019 Supply Idle 22VDC Ground 5 WATT High Signal Idle Signal Ground Supply B–B Surface X Flat on Head of Shaft 70° RTV-162 These two holes should be aligned when initially inserting A–A shaft and spring into housing.
Page 230: Engine Clutch
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL ENGINE CLUTCH To check free-travel, pull on the handle when the clutch is engaged until meeting resistance. This is the free- Figure 7-5 for the following procedure. travel. A disc-type manually-operated clutch is mounted between Readjust the clutch when free-travel decreases to less the engine and the pump drive.
Page 231: Engine Belt Routing
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE BELT ROUTING Service personnel may reference Figure 7-6 for engine belt routing when installing a drive belt on a QSX15 Tier 4F Tensioner Cummins engine. Looking at Engine from Fan End Alternator Belt #2...
Page 232: Cooling System
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL COOLING SYSTEM Look for coolant leaks while the engine is running. Fix any leaks. The cooling system consists of a horizontal radiator mounted above the engine and a variable-speed, hydraulically-driven Deaeration blower-type fan. Tank The cooling system flow is illustrated in Figure 7-9.
Page 233 16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN Bleed Screw System Pressure Cap Deaeration Tank Bleed Screw Bleed Screw Bleed Valve Coolant Drain Valve FIGURE 7-8 A678a MAIN FLOW MAKE-UP FLOW Item Description Item Description DEAERATION FLOW Engine Vent Line Water Pump Housing...
Page 234: Filling Cooling System
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL Filling Cooling System Continue adding coolant until the level is at the upper sight glass. Make sure all bleed valves are closed. Figure 7-8 for the following procedure. NOTE: Maximum fill rate is 11 liters/min (3 gpm).
Page 235 16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN THIS PAGE INTENTIONALLY LEFT BLANK Manitowoc 7-13 Published 05-03-17, Control # 228-03...
Page 236: Exhaust Assembly
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL EXHAUST ASSEMBLY After service, use a crane to lower the assembly back into the crane. Place the support rod back into the Figure 7-11 for the following procedure. Covers can be storage location. unlatched with a screwdriver and removed to allow access to the exhaust system and hydraulic tank for service.
Page 237 16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN Item Description Exhaust After Treatment Assembly Exhaust System Access Cover (3) Hydraulic Tank Access Cover Hitch Pin with Safety Clip 2-Hole Pin (2) Frame Support Rod Lifting Points FIGURE 7-11 Manitowoc 7-15 Published 05-03-17, Control # 228-03...
Page 238: Exhaust After Treatment System
For more infor- • Selective Catalytic Reduction (SCR) module mation, refer to Section 3 of the 16000 Operator Manual. Also, a Diesel Exhaust Fluid (DEF) dosing system supplies If an excessive NO warning is issued, check anything that DEF to the DRT module.
Page 239 16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN BLACK = DEF hose BLUE = coolant hose Item Description Coolant Manifold Block Air Bleed Valves Heating Flow for Coolant Flow Control Solenoid Valve DEF Tank DEF Tank DEF Supply Module Selective Catalytic Reduction (SCR)
Page 240: Def Dosing System
These conditions can lead to engine power being reduced (de-rated) by the ECM. If the condition persists, engine shutdown may occur. For more information, refer to the Fault Level Indicators topic in Section 3 of the 16000 Operator Manual. 7-18 Published 05-03-17, Control # 228-03...
Page 241: Def Tank
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN DEF Tank There is a 40-micron filter in the DEF supply (suction) pipe. For filter maintenance intervals, refer to the Cummins engine The DEF quality, level, and temperature are monitored by the manual. engine control module via sensors in the tank.
Page 242: Dpf/Doc Module Operation And Service
(nitrogen oxide) sensor, a dual pressure (dP) sensor, and Do not use the Inhibit switch unless specifically instructed to two temperature sensors. do so by the Manitowoc Crane Care Lattice Team. The Diesel Oxidation Catalyst (DOC) portion of the module is NOTE The Inhibit switch is only for special circumstances the inlet end of the module.
Page 243 16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN M101344 Item Description Handle, Hydraulic Tank Suction Valve Thermistor Junction Pressure Sensor Junction Hydraulic Tank Plug on Engine Oil Fill Tube Lifting Tab (2) Bracket Clamp Clamp, Inlet Pipe DOC half of Module DPF half of Module...
Page 244: Dpf/Doc Module Replacement
POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL DPF/DOC Module Replacement Removal Figure 7-14 for the following procedure: Raise the exhaust assembly according to Raising the WARNING Exhaust Assembly on page 7-14. Loosen, but do not remove, the pipe clamp with the Hot Exhaust Surfaces and Inhalation Hazards...
Page 245: Dpf/Doc Module Inlet Re-Orientation
16000 SERVICE/MAINTENANCE MANUAL POWER TRAIN DPF/DOC Module Inlet Re-orientation Rotate the inlet section to the orientation shown. d. Tighten the V-band clamp to 20 Nm (15 ft-lb). Figure 7-15 for the following procedure. Gently tap the circumference of the V-band clamp...
Page 246 POWER TRAIN 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 7-24 Published 05-03-17, Control # 228-03...
Page 247 16000 SERVICE/MAINTENANCE MANUAL SECTION 8 UNDER CARRIAGE TABLE OF CONTENTS Turntable Bearing ............8-1 Installation.
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Page 249: Turntable Bearing
16000 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE SECTION 8 UNDER CARRIAGE TURNTABLE BEARING Lubrication Before installing the turntable bearing bolts, lubricate the Installation following with “Never-Seez” or an equivalent anti-seize compound: When installing a turntable bearing, align the dowel pin holes in the inner ring with the dowel pins in the underside of the •...
Page 250 UNDER CARRIAGE 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-03-17, Control # 228-03...
Page 251 16000 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE 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 252: Crawler
UNDER CARRIAGE 16000 SERVICE/MAINTENANCE MANUAL CRAWLER Tread Slack Measuring Tread Slack 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. Use the...
Page 253: Adjusting Tread Slack
16000 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE Adjusting Tread Slack Adjust the tread slack at the roller end of each crawler CAUTION (Figure 8-3): Part Wear! Thoroughly clean the crawler to be adjusted. The crawler roller and tumbler must be square with the crawler frame within 3 mm (1/8 in) or the parts will wear Loosen the bolt on each side of the crawler roller.
Page 254: Hydraulic Hand Pump
Then, to Maintenance Personnel! pump the handle up and down. Manitowoc has provided a hand pump and cylinder for Pressure will be maintained until the valve is opened. crawler adjustment only. Any other use is neither intended nor approved.
Page 255: Air Removal
16000 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE Air Removal Operate the pump to fully extend the cylinder rod. Open the valve and retract the cylinder rod to force oil To remove air, use the following procedure: and trapped air back into the pump.
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Page 257: Section 9
Lube and Coolant Product Guide ......... . 9-1 Manitowoc...
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Page 259: 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 05-03-17, Control # 228-03...
Page 260 LUBRICATION 16000 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-03-17, Control # 228-03...
Page 261 PROBLEM 24 The accessory pin cylinder(s) will not extend or retract..10-25 PROBLEM 25 The crawler pin cylinder(s) will not extend or retract..10-26 Manitowoc 10-i...
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Page 263: Introduction
The following warnings apply to all troubleshooting • Use the display and main display for checking the operations. Manitowoc cannot foresee all hazards that may pump, motor, handle, brake, and other components. occur. • Use the in-line test boards (available from Manitowoc...
Page 264: Troubleshooting Charts
This topic provides a series of flow charts that identify complete troubleshooting procedure. If directed, consult your potential problems during normal operation. These charts Manitowoc dealer or Manitowoc Crane Care before contain instructions to assist in identifying and correcting proceeding.
Page 265 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 2 The engine rotates, but will not start. POSSIBLE No fuel to or from the injector pump, water or algae in the 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 266 (See Section 2 - Manual Override Tests.) Does the engine load when manual override is applied? Pump does not Load Pump Loads Consult your Manitowoc dealer or the Crane Check the electrical input from controller to Care Lattice Team. pump. (See Section 3 - Checking Electrical Inputs/Outputs.)
Page 267 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 4 The engine runs, but the 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 268 TROUBLESHOOTING 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 5 Engine faults POSSIBLE CAUSES High Engine Temperature Low Oil Pressure Check the engine oil level at the dipstick. Check the coolant level and quality. Not Ok Not Ok Add or replace the coolant. Check for leaks before adding oil.
Page 269 Diagnostic screen show 100% pump control in each direction? Are 28 volts present (full speed) at both sides of the EDC coil? Consult your Manitowoc dealer or Check the coil for a resistance of 17 to 19 ohms at pump.
Page 270 100% pump control in each direction? Replace the solenoid. Is pressure at the brake more than 21 bar (305 psi)? Consult your Manitowoc dealer or the Consult your Manitowoc dealer or Crane Care Lattice Team. the Crane Care Lattice Team.
Page 271 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 272 Repair or replace the control handle/wiring. Does the drum Diagnostic screen show 100% pump control with the handle moved back? Consult your Manitowoc dealer or the Crane Care Lattice Team. Are 28 volts present (full speed) at the pump EDC with the handle moved fully back? (See Section 3 - Checking Electrical Inputs/Outputs.)
Page 273 Replace the control handle or repair wiring. Does the drum Diagnostic screen show 100% pump control with the handle moved forward? Consult your Manitowoc dealer or the Crane Care Lattice Team. Are 28 volts present (full speed) at the pump EDC with the handle moved back? (See Section 3 - Checking Electrical Inputs/Outputs.)
Page 274 100% pump or motor control in each direction? Are 28 volts present (full speed) and coil resistance of 17 to Consult your Manitowoc dealer or the Crane 19 ohms at the pump EDC or to 26 ohms at the Motor PCP? Care Lattice Team.
Page 275 Does the engine load when moving the problem handle in either Is the control handle center switch at zero? direction? Consult your Manitowoc dealer or the Are 28 volts present at the brake solenoid when the Crane Care Lattice Team.
Page 276 When moving the boom/mast hoist control handle fully in both directions, does the Diagnostic screen show 100% pump control in each direction? Consult your Manitowoc dealer or the Crane Care Lattice Team. Check for control voltage and coil resistance of 17 to 19 ohms at the pump EDC or to 26 ohms at Motor PCP.
Page 277 Replace the control handle. Does the Diagnostic screen read 100% pump control with the handle moved back? Consult your Manitowoc dealer or the Crane Care Lattice Team. Are 28 volts present (full speed) at the pump EDC when the control handle is moved back? (See Section 3 - Checking Electrical Inputs/Outputs.)
Page 278 Are 28 volts present (full speed) at the pump EDC Consult your Manitowoc dealer or when the control handle is moved forward? (See the Crane Care Lattice Team. Section 3 - Checking Electrical Inputs/Outputs.) Repair or replace the wiring.
Page 279 When the applicable switch or handle is enabled is the following displayed: Swing lockout disengaged Swing brake disengaged Consult your Manitowoc dealer or Check for 28 volts DC to the swing lock or brake solenoid valve. the Crane Care Lattice Team.
Page 280 Is there voltage to the handle percent change? Repair or replace wiring, swing handle? node, or contact service. Consult your Manitowoc dealer or Replace the switch. the Crane Care Lattice Team. Replace the control handle or When moving the applicable handle fully in both repair the wiring.
Page 281 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 18 Travel system response is sluggish. POSSIBLE CAUSES The pump or motor is damaged, the travel speed out of adjustment. CHECKS Use a gauge to check charge pressure at travel pressure senders. 21 bar (305 psi) or Less More than 21 bar (305 psi) Manually stroke the travel pump with brakes applied.
Page 282 M8. (See Section 2 - Location of Pump Ports and Motor Ports.) Pressure Ok Pressure Not Ok Consult your Manitowoc dealer or the Repair or replace pump EDC Crane Care Lattice Team. or motor PCP, as required.
Page 283 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 20 The 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 the hydraulic oil level in reservoir OK and the shut-off valve fully open? Is the heat exchanger radiator clean? Fill the tank to full level or open shut-off valve.
Page 284 With the system handle in neutral does the Diagnostic control handle or wiring. screen show command activity for the pump? Consult your Manitowoc dealer or the Does the system pump EDC manually Crane Care Lattice Team. return to neutral? (See Section 3 - Checking Electrical Inputs/Outputs.)
Page 285 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 22 The 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 the pawl linkage, check for pawl or pawl actuator/cylinder for freedom of movement.
Page 286 TROUBLESHOOTING 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 23 The 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 the system pressurize to 207 bar (3,002 psi) when moving the mast switch to the raise position?
Page 287 16000 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING PROBLEM 24 The 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 the system pressurize to 207 bar (3,002 psi) when moving the problem switch to the...
Page 288 TROUBLESHOOTING 16000 SERVICE/MAINTENANCE MANUAL PROBLEM 25 The 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 241 bar (3,495 psi) at the valve test port while manually enabling a crawler pin cylinder.
Page 289 Mast Angle............4-7 Manitowoc...
Page 290 MAX-ER 16000 Description of Operation........1-57...

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Section 2 Hydraulic System

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Section 5 Hoists

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Section 6

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