Manitowoc Published 05-03-17, Control # 228-03 2-5
16000 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM
Inspecting the System
The damaging effects of dirt, heat, air, and water in the
hydraulic system can only be prevented by regular, and
thorough inspection of the system. The frequency of
inspection depends on the operating conditions and
experience with the system. Inspecting the system and
correcting deficiencies more frequently will make the system
less likely to malfunction.
A good inspection program will include the following:
1. Keep accurate records for future maintenance needs.
NOTE: For detailed instructions on accessing the display
screens in the cab, see Section 3 of the Service
Manual.
2. Check the hydraulic oil level daily when the oil is cold by
looking at the hydraulic tank display on the information
screen in the cab (Figure 2-2
).
Full (Cold) Level
(approximately 16°C [60°F])
Screen should read 87 to 90%.
Full (Hot) Level
(approximately 82°C [180°F])
Screen should read 95%.
Do not fill the tank to 100%. Oil will flow out of the
breather.
If the oil level drops to 50%, a fault alarm will come on
and a fault symbol will appear on the active display. The
HYDRAULIC FLUID LOW icon will appear on the fault
display (). Fill the tank immediately.
Fill the tank manually through the plug opening (2a,
Figure 2-1
) or by pumping oil through the power-fill coupling
(2b) with a portable pump.
Do not fill the tank through the breather port.
The hydraulic system could be contaminated
with unfiltered oil.
3. Only use approved hydraulic oil in the system (see
Section 9 in this manual).
4. Replace the disposable cartridge in the desiccant
breather when all the desiccant beads have turned from
gold (when new) to dark green. See Replacing
Desiccant Breather topic for more information.
5. Clean the exterior of the system often. Do not let dirt
accumulate on or around any part of the system.
6. Check for external leaks. Leaks are unsafe, attract dirt,
and may allow air and water into the system. Do not
return leakage oil back to the hydraulic tank.
Do not use your hands to check for leaks.
Use the following to check for leaks:
• Look for oil leaking from fittings or between parts
that are bolted together. Tighten any loose fittings
and attaching bolts to the proper torque. Do not
over-tighten any loose fittings or attaching bolts.
• If leakage persists at these points, replace the seals
or gaskets.
• Look for oil leaking from the pump, motor shaft,
valve spool, and cylinder shaft ends. Replace the
seal if leakage is found at any of these points.
• Replace tubes that are cracked, kinked, or bent.
• Replace hoses that are cracked, split, or abraded.
• Listen to the pumps and motors for any unusual
noises. A high-pitched whine or scream can indicate
that air is being drawn into the system.
To pinpoint an air leak, flood the inlet fitting, hose, or
tube with oil. If there is an air leak, the oil will reduce the
noise noticeably. Correct the cause of any air leak, to
avoid permanent damage to the pump/motor.
NOTE: A high-pitched whine or scream from the pump can
also indicate cavitation (pump being starved of oil).
This condition is caused by the following problems:
• Collapsed or plugged suction line
• Wrong oil (the viscosity is too high)
7. Look for signs of overheating, including heat-peeled
parts, burned or scorched oil odor, or darkened thick oil.
The temperature of the oil in the tank must not exceed
82°C (180°F).
If the oil temperature in the tank goes
above 82°C (180°F), a fault alarm will
come on and a fault symbol will appear on
the active display. The hydraulic reservoir
temperature icon will appear on the fault
display.
Hydraulic Tank Level and
Temperature Display
FIGURE 2-2
HYDRAULIC FLUID LOW
Fault Icon
FIGURE 2-3
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