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Manitowoc Grove Crane 16000 Operator’s Manual SN 16001Ref – PDF DOWNLOAD
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Description
Manitowoc Grove Crane 16000 Operator’s Manual SN 16001Ref – PDF DOWNLOAD
FILE DETAILS:
Manitowoc Grove Crane 16000 Operator’s Manual SN 16001Ref – PDF DOWNLOAD
Language : English
Pages : 240
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Manitowoc Grove Crane 16000 Operator’s Manual SN 16001Ref – PDF DOWNLOAD
INTRODUCTION:
CRANE DATA:
See end of this section for crane data specific to your crane:
• Basic Specifications.
• EC Declaration (if applicable).
CRANE/ATTACHMENT IDENTIFICATION:
An identification plate is attached to the outside of the operator’s cab (see Figure 1-1) and to
the attachments (for example, luffing jibs and MAX-ER’s).
The crane or attachment model and serial number are provided on the plate.
For the exact location of the identification labels on your crane and attachments, refer to the
Nameplates and Decals Drawing in Section 2 of this manual.
CHANGE OF OWNERSHIP REGISTRATION:
If you are the new owner of a Manitowoc crane, please register it with Manitowoc Crane Care so we
can contact you if the need arises.
Go to www. manitowoccranes.com/MCG_CARE/ Includes/EN/changeofownership.cfm and complete the form.
CRANE ORIENTATION:
The terms RIGHT, LEFT, FRONT, REAR used in this manual refer to operator’s right, left, front, and
rear sides when seated in the operator’s cab looking forward.
• The boom is on the front of the rotating bed.
• The carbody and crawler controls are on the front of the carbody.
TABLE OF CONTENTS:
Manitowoc Grove Crane 16000 Operator’s Manual SN 16001Ref – PDF DOWNLOAD
SECTION 1............................................................................ 9 Introduction..................................................................... 11 Crane Data................................................................... 11 Crane/Attachment Identification.............................................. 11 Change of Ownership Registration............................................. 11 Crane Orientation............................................................ 11 Identification and Location of Components.................................... 12 English and Metric Conversions............................................... 16 Direct Conversion........................................................ 16 Inverse Conversion....................................................... 16 Manitowoc Distributors....................................................... 17 SECTION 2............................................................................ 19 Safety Information............................................................... 21 Nameplates and Decals........................................................ 21 Safety Messages.............................................................. 21 General.................................................................. 21 Safety Alert Symbol...................................................... 21 Signal Words............................................................. 21 Safety Symbols........................................................... 21 Crane Access Points.......................................................... 27 General.................................................................. 27 Getting On or Off Crane...................................................... 27 Operator’s Manual/Capacity Chart Storage..................................... 28 General.................................................................. 28 Storing Manuals.......................................................... 28 Deploying Swing Radius Barrier........................................... 29 Storing Swing Radius Barrier............................................. 29 Safe Operating Practices..................................................... 30 General.................................................................. 30 Read Operator’s Manual................................................... 30 Operator Qualifications.................................................. 30 Operator Conduct......................................................... 30 Handling Load............................................................ 32 Size of Load......................................................... 32 Attaching Load....................................................... 32 Lifting/Moving Load.................................................. 32 Multiple Load Line Operation......................................... 34 Holding Load......................................................... 34 Signals.................................................................. 35 Operational Aids......................................................... 35 Operating Near Electric Power Lines and Transmission Lines................... 36 Electrocution Hazard..................................................... 36 Set-Up and Operation..................................................... 36 Electrocution Hazard Devices............................................. 37 Electrical Contact....................................................... 37 Refueling.................................................................... 38 Fire Extinguishers........................................................... 38 Accidents.................................................................... 38 Safe Maintenance Practices................................................... 38 Maintenance Instructions................................................. 38 Safe Maintenance Practices............................................... 38 Environmental ProtectioN..................................................... 41 Boom Disassembly Safety...................................................... 43 General.................................................................. 43 Location................................................................. 43 Pin Removal.............................................................. 43 Disassembly Precaution................................................... 43 Personnel Handling Policy.................................................... 44 Pedestal/barge Mounted Cranes................................................ 45 Pedestal Mounted Crane................................................... 45 Definition........................................................... 45 Examples............................................................. 45 Barge Mounted Crane...................................................... 46 Definition........................................................... 46 Examples............................................................. 46 Capacity Charts.......................................................... 47 Shock Loading............................................................ 47 Definition........................................................... 47 Operation On Barge....................................................... 48 General.............................................................. 48 Definitions.......................................................... 48 Crane Inspection......................................................... 48 Transporting Crane on Barge.............................................. 49 Safety and Information Signs................................................. 49 Maintaining Signs........................................................ 49 Ordering Signs........................................................... 49 SECTION 3............................................................................ 51 Operating Controls And Procedures................................................ 55 Standard Hand Signals for Controlling Crane Operations....................... 55 Symbol Identification........................................................ 57 Front Window Operation....................................................... 62 Closing Window........................................................... 62 Opening Window For Ventilation........................................... 62 Opening Window For Emergency Exit........................................ 62 Operating Controls........................................................... 62 General.................................................................. 62 Cab Door Damper Adjustment................................................... 63 Closing Cab Door......................................................... 63 Damper Adjustment........................................................ 63 Controls Identification And Function......................................... 65 A – Engine Controls...................................................... 65 A1. Engine Ignition Switch........................................... 65 A2. Engine Emergency Stop Switch..................................... 65 A3. Engine Hand Throttle............................................. 65 A4. Engine Foot Throttle............................................. 65 A5. Engine Clutch Lever.............................................. 65 A6. Battery Disconnect Switch........................................ 65 B – Accessory Controls................................................... 66 B1. Crane Work or Drum Lights Switch................................. 66 B2. Overhead Windshield Wiper Switch................................. 66 B3. Front Windshield Wiper-Washer Switch............................. 66 B4. Climate Control.................................................. 67 B5. Radio/CD Player (optional)....................................... 67 B6. Cab Tilt Switch.................................................. 67 B7. Panel Lights Switch.............................................. 67 B8. Dome Light Switch................................................ 67 B9. Horn Switches.................................................... 67 B10. Cigarette Lighter............................................... 67 B11. 12 Volt Power Supply Receptacle................................. 67 B12. Machinery Heaters............................................... 67 B13. Tinted Visor and Shade.......................................... 68 B14. Air Ventilation Knob............................................ 68 B15. Fire Extinguisher............................................... 69 B16. Cab Door Brake.................................................. 69 C – Indicators........................................................... 69 C1. Boom Angle Indicator............................................. 69 C2. RCL Alarm (optional)............................................. 69 C3. Rear View Mirrors................................................ 69 C4. Bubble Level..................................................... 69 C5. Wind Speed Transmitter........................................... 69 C6. Fuel Level....................................................... 70 C7. Engine Coolant Temperature....................................... 70 C8. Engine Oil Pressure.............................................. 70 C9. Battery Voltage.................................................. 70 C10. Drum Rotation Indicators........................................ 70 D – Special Controls..................................................... 70 D1. RCL Display and Indicator Lights................................. 70 D2. Main Display..................................................... 70 D3. Limit Bypass Switch.............................................. 71 D4. Luffing Jib Limit Bypass Switch.................................. 71 E – Boom/Mast Hoist Controls............................................. 73 E1. Drum 4 (Boom/Mast Hoist) Park Switch............................. 73 F2. Drum 5 (Boom Hoist) Park Switch.................................. 73 E3. Drum 4 or 5 (Boom/Mast Hoist) Handle............................. 73 E4. Drum Indicator................................................... 73 F – Load Drum Controls................................................... 73 F1. Drum 1 Park Switch............................................... 73 F2. Drum 2 Park Switch............................................... 73 F3. Drum 3 Park Switch............................................... 73 F4. Drum 1 Handle.................................................... 73 F5. Drum 2 Handle.................................................... 73 F6. Drum 3 Handle.................................................... 73 F7. Drum Indicator................................................... 73 G – Swing Controls....................................................... 74 G1. Swing Park Switch................................................ 74 G2. Swing Handle..................................................... 74 G3. Swing Holding Brake Switch....................................... 74 H – Travel Controls...................................................... 75 H1. Travel Park Switch............................................... 75 H2. Travel Speed Selector............................................ 75 H3. Travel Cruise Selector........................................... 75 H4. Left Crawler Handle.............................................. 75 H5. Right Crawler Handle............................................. 75 J – Winch Controls....................................................... 75 Rigging Winch Mode................................................... 75 Limit Devices................................................................ 76 1. Boom Up Limit......................................................... 76 3. Block-Up Limit........................................................ 76 4. Luffing Jib Up Limit.................................................. 76 5. Luffing Jib Down Limit................................................ 76 7. Minimum Bail Limit.................................................... 77 Seat Controls................................................................ 79 Preparing Crane for Operation................................................ 80 Operation.................................................................... 80 Engine Startup........................................................... 80 Boom/Mast Hoist Operation................................................ 82 Luffing Hoist Operation.................................................. 83 Swing Operation.......................................................... 83 Load Drum Operation...................................................... 84 Travel Operation......................................................... 85 Stopping Engine/ Leaving Crane Unattended.................................... 87 Remote Controls.............................................................. 88 General.................................................................. 88 Crane Setup Remote Controls.............................................. 88 1–Power Switch....................................................... 89 2–Stop Switch........................................................ 89 3–Left Front Jacking Toggle Switch................................... 89 4–Right Front Jacking Toggle Switch.................................. 89 5–Left Rear Jacking Toggle Switch.................................... 89 6–Right Rear Jacking Toggle Switch................................... 89 7–All Jacking Toggle Switch.......................................... 89 8–Boom Pins Switch................................................... 90 9–Front Rotating Bed Pins Switch..................................... 90 10–Rear Rotating Bed Pins Switch..................................... 90 11–Counterweight Pins Switch......................................... 90 12–Engine Speed Switch............................................... 90 13–Mast Switch....................................................... 90 Carbody Manual Remote Controls........................................... 90 14–Right Crawler Pin Handle.......................................... 90 15–Left Crawler Pin Handle........................................... 90 16–Right Front Carbody Jack Handle................................... 91 17–Right Rear Carbody Jack Handle.................................... 91 18–Left Rear Carbody Jack Handle..................................... 91 19–Left Front Carbody Jack Handle.................................... 91 20–Carbody Level..................................................... 91 Replacing Wireless Remote Batteries...................................... 91 Displays..................................................................... 92 Display Controls......................................................... 92 1 – RCL Display...................................................... 92 2 – Main Display..................................................... 92 3 – Display Touchpad Controls........................................ 92 4 – Display Select Buttons........................................... 92 5 – Select Buttons................................................... 92 6 – Enter/Exit Buttons............................................... 92 7 – Confirm Button................................................... 92 Display Brightness and Color Contrast.................................... 92 Factory Default Display Settings......................................... 92 Blank Display............................................................ 92 Main GUI Display Format.................................................. 92 Screen Prompts........................................................... 93 Menu Screen.............................................................. 93 Information Screen....................................................... 94 Crane Level.......................................................... 94 Boom to Luffing Jib Working Angle.................................... 94 Wind Speed Indicator................................................. 94 Mast Angle........................................................... 94 Hydraulic Tank....................................................... 94 Battery.............................................................. 94 Pump Drive........................................................... 94 Engine............................................................... 94 MAX-ER (Optional).................................................... 95 Faults............................................................... 95 Diagnostic Screen........................................................ 97 Diagnostic Screen Component Icons.................................... 97 Control Handle................................................... 97 System Pressure Sender........................................... 98 DIN Electrical Connector......................................... 98 Swing Lock....................................................... 98 Swing Diagnostic Screen..............................................100 Travel Diagnostic Screen.............................................100 Jacking Accessory Diagnostic Screen..................................101 Pins and Fan Accessory Diagnostic Screen.............................101 Cab Tilt, Rigging Winch, and Mast Accessory Diagnostic Screen........102 MAX-ER Diagnostic Screen.............................................102 Function Mode Screens....................................................102 Drum Functions.......................................................102 Swing Functions......................................................103 Travel Functions.....................................................103 Setup Remote Functions...............................................103 MAX-ER Functions.....................................................103 Drum, Swing or Track Speed Limits....................................103 Swing Pressure Limit.................................................103 Rigging Winch Mode...................................................103 Boom or Swing Motion Limiter Mode....................................104 Setup Remote Control Mode............................................104 CAN Bus Screen...........................................................104 Packet Information...................................................104 Digital Output Disable Fault.........................................105 Engine Node Status...................................................105 Crane Status.........................................................105 Load Link Status.....................................................105 Wireless Receiver Status.............................................105 Boom Node Status.....................................................105 Digital Output Reference Chart...........................................108 Digital Input Reference Chart............................................109 Camera Screen (Optional).................................................112 Pressure Test and Calibration Screen.....................................112 Engine Low Idle......................................................112 Pressure Sender Test.................................................112 Control Calibration..................................................113 High Pressure Test...................................................114 Charge Pressure Test.................................................115 Wind Conditions..............................................................116 Preparation for Cold Weather.................................................118 Crane Limitations........................................................118 Wire Rope................................................................118 Cold Weather Starting Aid................................................118 Coolant and Oil Pan Heaters..........................................118 Cooling System...........................................................118 Battery..................................................................118 Engine Oil...............................................................118 Fuel Oil.................................................................118 Gear Oil.................................................................118 Hydraulic Cranes.....................................................118 Hydraulic Oil............................................................119 General..............................................................119 Cold Weather Heater Package..................................................119 General..................................................................119 Heaters..................................................................119 Turning Heaters On.......................................................119 Turning Heaters Off......................................................119 Circuit Breakers.............................................................119 SECTION 4............................................................................121 Set-Up and Installation..........................................................125 Rigging Drawings.............................................................125 Liftcrane Mast Capacities....................................................125 Optional Attachments.........................................................125 General Safety...............................................................125 Crane Orientation............................................................125 Self-Erecting Equipment......................................................125 Assist Crane Requirements....................................................126 Assembly and Disassembly Notes...............................................126 Assembly And Disassembly Area................................................126 Accessing Parts..............................................................126 Crane Weights................................................................126 Handling Components..........................................................126 Retaining Connecting Pins....................................................126 Cold Weather Mast Operation..................................................127 Shipping Crane Components....................................................129 Operating Controls...........................................................129 Pre-Start Checks.............................................................131 Engine...................................................................131 Gear Boxes...............................................................131 Hydraulic System.........................................................131 Crane Assembly...............................................................131 Install Exhaust Pipes....................................................131 Remove Rotating Bed from Trailer.........................................133 Remove Carbody and Adapter Frame from Trailer............................137 Lower Crane onto Carbody Pedestals.......................................140 Connect Hydraulic Hoses and Electric Cables..............................140 Raise Live Mast To Operating Position....................................143 Install Assembly Block...................................................145 Install Crawlers.........................................................145 Handling Crawlers........................................................147 Install First Crawler................................................149 Install First Crawler (continued)....................................151 Install Second Crawler...............................................151 Install Crawler Platforms................................................153 Past Production......................................................153 Past Production......................................................153 Install Crawler Stairways................................................153 Install Counterweight....................................................155 Install Carbody Counterweight........................................155 General..........................................................155 Installation.....................................................155 Install Crane Counterweight..........................................157 Assemble Boom............................................................159 Install Boom Butt........................................................159 Remove Assembly Block....................................................163 Connect Boom Butt to Boom................................................163 Crane Disassembly............................................................165 Lower Boom...............................................................165 Disconnect Boom Butt from Boom...........................................165 Install Assembly Block...................................................166 Remove Boom Butt.........................................................166 Disassemble Boom.........................................................167 Remove Counterweight.....................................................167 Remove Crane Counterweight...........................................167 Remove Carbody Counterweight.........................................168 General..........................................................168 Removal..........................................................168 Remove Crawler Stairways.................................................168 Store Crawler Platforms..................................................168 Past Production......................................................168 Past Production......................................................168 Remove Crawlers..........................................................168 Remove First Crawler.................................................169 Remove Second Crawler................................................169 Remove Assembly Block....................................................169 Lower Live Mast To Shipping Position.....................................170 Disconnect Hydraulic Lines and Electric Cables...........................170 Raise Crane Off Carbody Pedestals........................................170 Place Carbody and Adapter Frame on Trailer...............................170 Remove Rotating Bed from Trailer.........................................171 Remove Exhaust Pipes.....................................................171 Boom Ladder Assembly.........................................................173 General..................................................................173 Removing Ladders from Boom Butt..........................................173 Installing Ladders on Boom Inserts.......................................173 Storing Ladders in Boom Butt.............................................173 Boom Rigging.................................................................174 Assist Crane Requirements................................................174 Blocked Crawler..........................................................174 Handling Components......................................................174 Boom Assembly Drawing....................................................174 Identifying Boom Sections and Straps.....................................174 Assemble Boom Sections...................................................177 Connect Boom Straps......................................................179 Install Intermediate Suspension..........................................179 Install Standard Upper Boom Point........................................181 Install Extended Upper Boom Point........................................181 Install Load Line........................................................186 Connect Boom Wiring......................................................186 Perform Pre-Raising Checks...............................................186 Boom Removal.............................................................186 Wire Rope Installation.......................................................190 Wire Rope Storage........................................................190 Removing Wire Rope from Shipping Reel....................................190 Seizing and Cutting Wire Rope............................................190 Anchoring Wire Rope to Drum..............................................191 Drum Guards..............................................................191 Winding Wire Rope onto Drum..............................................193 Anchoring Wire Rope to Wedge Socket......................................195 Anchoring Wire Rope to Button Socket.....................................195 Breaking in Wire Rope....................................................195 Drum Kicker Adjustment.......................................................196 General..................................................................196 Adjustment...............................................................196 Pad Eye Usage for Wire Rope Reeving..........................................196 General..................................................................196 Safety...................................................................196 Rigging Winch Operation......................................................198 Selecting Rigging Winch Mode.............................................198 Operating Rigging Winch..................................................198 Free-Wheel Operation.................................................198 Power Operation......................................................198 Reeving – Load Block.........................................................200 Load Block Identification................................................200 Wire Rope Specifications.................................................200 Wire Rope Installation...................................................200 Duplex Hook..............................................................200 Guide Sheaves and Drums..................................................200 Load Block Reeving.......................................................200 Reeving – Live Mast..........................................................206 General..................................................................206 Wire Rope Specification..................................................206 SECTION 5............................................................................207 Lubrication......................................................................209 Symbol Identification........................................................209 General Lubrication..........................................................209 Lubrication Intervals........................................................209 Over-Lubrication.............................................................209 Lubrication Tips.............................................................209 Oil Can Points...............................................................210 Wire Rope Lubrication........................................................210 Cylinder Rod Lubrication.....................................................210 General..................................................................210 Protecting Cylinder Rods.................................................210 Environmental Protection.....................................................210 Reference Instructions.......................................................210 CraneLUBE....................................................................210 Approved Lubricants For Normal Operation.....................................212 Grease...................................................................212 Open Gear Oil............................................................212 Gear Oil.................................................................212 Hydraulic Oil............................................................212 Field Make-Up........................................................212 Hydraulic Filter Replacement.................................................213 Lubrication Points...........................................................213 Fluid Capacities.............................................................214 Approved Lubricants For Arctic Operation.....................................215 Upper and Lower Lubrication Points — Location................................216 Upper and Lower Lubrication Points — Identification..........................220 Prior to Use When Crane is Assembled.....................................220 Every 8 Hours of Operation or Daily (whichever comes first)..............220 Every 8 Hours of Operation or Daily Continued............................221 Every 40 Hours of Operation or Weekly (whichever comes first)............222 After First 200 Hours of Operation.......................................222 Every 200 Hours of Operation or Monthly (whichever comes first)..........223 Every 500 Hours of Operation or Quarterly (whichever comes first)........223 Every 1000 Hours of Operation or Semiannually (whichever comes first)....224 Boom Rigging Lubrication.....................................................226 Prior to Operation.......................................................227 Every 8 Hours of Operation or Daily (whichever comes first)..............227 Every 40 Hours of Operation or Weekly (whichever comes first)............227 Every 200 Hours of Operation or Monthly (whichever comes first)..........227 Every 2000 Hours of Operation or Annually (whichever comes first)........227 Automatic Lubrication System.................................................228 Operation................................................................228 Daily Inspection.........................................................228 Automatic Lubrication System Troubleshooting.............................230 SECTION 6............................................................................231 Preventive Maintenance Checklist.................................................233 Inspection and Maintenance Checks............................................233 Maintenance Intervals........................................................233 Maintenance Instructions.....................................................233 Initial Run-In Services......................................................234 Maintenance Checklist........................................................234
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