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TROUBLESHOOTING 2250 SERVICE/MAINTENANCE MANUAL

10-64

Published 11-06-15, Control # 040-13

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Table of Contents5
Section 117
Continuous Innovation17
Safety Messages17
General17
Safety Alert Symbol17
Signal Words17
Safe Maintenance Practices17
Maintenance Instructions18
Safe Maintenance Practices18
Environmental Protection19
Identification and Location of Components20
Past Production and Tier 3 Engine Components36
Tier 4 Engine Components38
Crane Description of Operation40
General Operation40
Hydraulic Components41
Hydraulic Tank41
Shutoff Valve41
Suction Manifold41
Return Manifolds41
Hydraulic Pumps41
Charge Pressure42
Hydraulic Motors42
Main Pressure Monitoring43
Basic Operation43
Accessory Systems45
Pressurized Air Supply47
Engine Controls48
Drum Identification48
EPIC® Programmable Controller (PC)49
Digital Display49
Rated Capacity Indicator/Limiter (RCL)49
Crane Modes49
Electrical Power to Operator's Cab50
Pressure Senders and Speed Sensors52
Limit Switches and Faults52
Hydraulic Brake Systems52
Load Drum Air Brakes53
Working (Service) Brakes54
Load Drum Clutch Release System54
Drum Pawls55
Swing System Operation56
General56
Swing Brake and Swing Holding Brake56
Swing Lock (Past Production)56
Swing Right or Left56
Travel System Operation58
General58
Travel Brakes58
Two-Speed Travel Operation58
Travel Detent Selector58
Travel Forward and Reverse58
Boom Hoist/Luffing Jib System Operation61
General61
Brake and Pawl61
Boom Hoist/Luffing Jib Raise61
Boom Hoist/Luffing Jib Lower62
Load Drum System - Full Power64
General64
Drum Brake64
Load Drum Hoisting64
Load Drum Lowering66
Dual Load Drum Motor Operation66
Load Drum System - Free Fall69
General69
Load Drum Hoisting - Free Fall69
Load Drum Lowering - Free Fall69
Upper Accessory System Components72
General72
Jacking Cylinders72
Adapter Frame Pin Cylinders76
Gantry Cylinders78
Lower Accessory System Components80
General80
Boom Hinge Pins80
Boom Butt Handling Cylinder82
Rigging Winch84
Crawler Frame Pins85
Air System Components87
Counterweight/Back Hitch Pins87
Hydraulic Quick Disconnect88
General88
MAX-ER™ 2000 Description of Operation91
MAX-ER Components91
MAX-ER Hydraulic Attachments91
Auxiliary Pump91
MAX-ER Accessory Valve92
MAX-ER Pressurized Air Supply92
EPIC® Programmable Controller94
MAX-ER Modes95
Electrical System95
MAX-ER Remote Switch Assembly95
Mast Back Hitch Pins Remote Switch95
Digital Display95
Pressure Senders and Speed Senders95
Limit Switches96
Back Hitch Pins97
Back Hitch Pins Extend/Retract97
Tongue Cylinder98
Tongue Cylinder Extend98
Tongue Cylinder Retract99
Counterweight Jack Cylinders100
Jack Cylinder(S) Extend100
Jack Cylinder(S) Retract101
Steering Pin Cylinders103
Steering Pin Cylinders Disengage103
Steering Pin Cylinders Engage103
Steering Arm Cylinders105
Steering Cylinders Extend (Swing/Crab)105
Steering Cylinders Retract (Straight)106
Counterweight Strap Cylinders108
Counterweight Switch110
Counterweight Strap Cylinders Lower110
Counterweight Strap Cylinders Raise110
Mast Stop Raising and Boom Stop111
Mast Stop Raising Cylinders111
Boom Stop Cushion Cylinders111
Mast Stop112
Mast Stop Cylinders112
Mast Stop System Operation112
Jib Stop Cylinders113
Jib Stop System Operation113
Drum 9 Operation114
Drum 9 Brake115
Drum 9 Hoisting (MAX-ER Mode)115
Drum 9 Lowering (MAX-ER Mode)117
Hydraulic Cooler Fan Drive - Tier 4 Only119
Description119
Maintenance119
Hydraulic Schematics125
Hydraulic System - General125
Checking and Replacing Hydraulic Hoses125
Hydraulic System Maintenance126
Safety126
Storing and Handling Oil126
Storing and Handling Parts126
Inspecting System126
Servicing Pumps127
Cleaning Fill Cap Assembly127
Replacing Suction Filter Element128
Changing Oil129
Tightening Hydraulic Connections131
General131
Pipe Thread Connection131
SAE Straight Thread Connection131
ORS Connection132
Split Flange Connection132
SAE Flare Connection133
Programmable Controller Calibration Procedures - Past134
General134
Controls Calibration134
Pressure Sender Calibration134
Programmable Controller Calibration Procedures - Current134
Pressure Sender Calibration135
Controls Calibration135
Pressure Sender Replacement136
General136
Disc Brake Operational Test138
General138
Operational Test138
Shop Procedure140
General140
Pump Identification140
Pump Port Identification140
Pump Components140
Initial Oil Fill141
Pressure Sender Calibration141
Initial Start-Up142
Controls Calibration143
Fan and Pilot Pressure Adjustment143
Charge Pressure Checks143
Operating Pressure Checks144
Boom Hoist down144
Boom Hoist up144
Swing144
Auxiliary System Pressure Checks145
Travel145
Load Drums145
Auxiliary System Relief Valve145
Rotating Bed Jacking Cylinders146
Connecting Pin Cylinders (Crawler, Boom Hinge, and Adapter Frame)147
Boom Butt Handling Cylinder147
Gantry Cylinders147
System Speed Checks148
Travel Straightness148
Unloader Pilot Valve Maintenance149
General149
Adjustment149
Maintenance149
Moisture Ejector Valve Maintenance150
General150
Control Handle Positions150
Operational Checks150
Maintenance150
Automatic Operation150
Shut-Off150
Air System Filter Maintenance151
General151
Daily Maintenance151
Monthly Maintenance151
Automatic Drain Valve Operation152
Air System De-Icer Maintenance152
Operation152
Adjusting152
Maintenance153
Filling153
Air Dryer Maintenance (Current Production)155
Description155
Operation and Leak Test155
Disassembly155
Cleaning and Inspection156
Assembly156
Preventive Maintenance157
Every 500 Operating Hours or Every Three Months157
Air Dryer Maintenance (Past Production)158
Description158
Operation158
Every 6,000 Hours or 36 Months158
Compressor Cut-In158
Compressor Cut-Out158
Maintenance159
Breather Vent Maintenance161
Solenoid Valve Maintenance162
Operation162
Air Line Connection162
Electrical Connection162
Maintenance162
Normally Closed162
Troubleshooting162
Disassembly162
Reassembly162
Quick Release Valve Maintenance164
General164
Adjustment164
Maintenance166
Air Pressure Safety Switches Maintenance166
General166
Operation166
Adjustment Requirements166
Adjustment167
Shuttle Valve Maintenance168
General168
Operation168
Maintenance168
Type a Air Regulator Maintenance169
Installation169
Adjustment169
Maintenance169
Maintenance170
Pressure Reducing Valve Maintenance170
Operation170
Adjustments170
Type S Relay Valve Maintenance172
General172
Operation172
Increasing Pressure172
Balanced Position172
Maintenance173
Decreasing Pressure173
Electrical Drawings and Schematics177
Checking or Replacing Electrical Components177
Circuit Breaker and Fuse ID178
General178
Test Voltages for Crane Controller187
General187
Controller Board Layout187
Abbreviations187
Crane Controller Pin Identification188
Crane Controller Wire Identification194
Crane Controller Description Identification199
Master Node Pin Identification204
Aux Power Plant Controller Pin Identification206
Model 2250 MAX-ER 2000™ Test Voltages207
General207
Controller Board Layout207
Abbreviations207
MAX-ER Controller Pin Identification208
MAX-ER Controller Wire Identification210
MAX-ER Controller Description ID212
Digital Display Readings214
General214
Operating Conditions214
Operating Limits214
System Faults214
Selecting Display Language215
Drum Identification222
Diagnostic Display223
General223
Drums 1, 2, and 3 (Crane Load Drums)223
Drum 4 (Boom Hoist)223
Drum 5 (Luffing or Auxiliary Hoist)223
Drum 9 (MAX-ER 2000 Load Drum)223
Swing (Crane)224
Track (Crane Crawlers)224
Mast Accumulator224
Mxr (Max-Er 2000)224
A1 (Handles)225
A2 (Programmer's Screen)225
D1 and D2 (Digital Outputs and Inputs)226
EPROM Replacement230
Dielectric Grease232
Section 4233
Automatic Boom Stop Adjustment235
General235
Operation235
Maintenance235
Operating Angle235
Setup Angle235
Limit Bypass Test236
Adjustment238
Maximum (MAX) Boom Stop238
Minimum (MIN) Boom Stop238
Setup Boom Angle239
Physical Boom Stop239
General239
Operation239
Maintenance241
Lowering Boom Stop to Shipping Position241
Raising Boom Stop to Working Position241
Adjustments241
Boom Stop Rod Ends241
Angle Indicator Adjustment241
General241
Boom Stop Engagement241
Boom Stop Compression241
Disconnecting Luffing Jib Angle Indicator243
Sending Unit Assembly243
Pendulum-Type Potentiometer243
Adjusting Angle Indicator244
Solid State Sensor244
Boom Hoist Ratchet and Pawl Adjustment246
General246
Limit Switch Adjustment246
Return Spring246
Strap Inspection and Maintenance248
Inspection248
Identifying Straps248
Frequent Inspection248
Periodic Inspection248
Cranes Not in Regular Use248
Replacement Specifications249
Corrosion or Abrasion249
Straightness250
Flatness250
Elongated Hole251
Length251
Storing Straps252
Removing Straps from Service252
Inspection Checklist252
Lattice Section Inspection and Lacing Replacement252
Minimum Bail Limit Adjustment259
General259
Weekly Maintenance259
Wire Rope Removal261
Electric Wiring261
Minimum Bail Limit Adjustment261
Block-Up Limit Control Adjustment262
General262
Block-Up Limit Control Operation263
Load Block Level Transmitter263
Installation263
Storing Electric Cord263
Disconnecting Block-Up Limit Control264
Removing Jib or Boom Point264
Maintenance264
Adjustment266
Drum Brake Inspection and Adjustment267
Description267
Brake Inspection and Adjustment269
Treadle Valve Checks270
Treadle Valve Adjustments270
Brake Actuator Overhaul271
Removal271
Repair271
Rework - Current Production Actuators271
Brake Release Adjustment272
Rework - Past Production Actuators272
Installation272
Drum Clutch Inspection and Adjustment - Standard274
Description274
Inspection and Adjustment274
Band Disassembly and Assembly Notes276
Clutch Cylinder Overhaul277
Cylinder Removal277
Cylinder Disassembly277
Cylinder Assembly277
Cylinder Installation277
Drum Clutch Inspection and Adjustment - Right Rear Drum Clutch (421339)279
General279
Inspection and Adjustment280
Band Disassembly and Assembly Notes281
Cylinder Rod Marking281
Gearbox Cooling Blower281
Slack Line Sensor Adjustment282
General282
Light Sensor Adjustment282
Slack Line Indicator Calibration282
Drum Pawl Adjustment283
General283
Limit Switch Adjustment283
Return Spring283
Wire Rope Lubrication284
Wire Rope Inspection and Replacement284
General284
Keeping Records284
Inspecting Wire Rope284
Frequent Inspection284
Inspecting Rope Not in Regular Use285
Replacing Wire Rope285
Periodic Inspection285
Wire Rope Diameter285
Broken Wires285
Wear and Other Damage286
Distributing Wire Rope Wear287
Sheave, Roller, and Drum Inspection288
Load Block and Hook-And-Weight Ball Inspection291
Manual Release of Swing Brake and Lock297
Manual Release Procedure297
Section 7297
Battery Maintenance301
Safety Information301
Causes of Battery Failure301
Multiple Battery System301
Overcharging301
Undercharging301
Lack of Water301
Hold-Downs301
Overloads301
Maintenance302
Weekly - Check Electrolyte Level302
Every 2 Months - Test Batteries302
Charging303
Storage303
Battery Disconnect Switch303
Quarterly303
Engine Diagnostics (Celect Plus Engine)304
General304
Controls304
Engine Running Diagnostics304
Engine off Diagnostics304
Engine Stop Light304
Engine Warning Light304
Engine Maintain Light304
Engine Diagnostics (QSX 15 Engine)306
General306
Diagnostic Lights306
Engine off Diagnostics306
Engine Stop Light306
Engine Warning Light306
High Exhaust System Temperature - Tier 4 Only306
DPF on - Tier 4 Only306
DPF Regeneration Inhibit - Tier 4 Only306
Engine Air Cleaner Maintenance - Tier 3 Engine308
Inspection308
Service308
Daily308
Engine Air Cleaner Maintenance - Tier 4 Engine309
Inspection309
Daily309
Weekly309
Service310
Air Cleaner - Tier 4 Only311
Engine Cooling System - Past Production312
General312
Cooling System Operation312
Auxiliary Tank Mounting312
Maintenance313
Daily Maintenance (Start of each Shift)313
Semiannual Checks313
Engine Cooling System with Cummins QSX-15 Engine - Current Tier 3314
General314
Cooling System Operation314
Maintenance315
Daily Maintenance (Start of each Shift)315
Draining Radiator316
Filling Radiator316
Semiannual Checks316
Engine Cooling System Fill - Current Production Tier 4317
General317
Cooling System Operation317
Maintenance317
Draining Radiator317
Daily Maintenance (Start of each Shift)317
Semiannual Checks317
Filling Radiator318
Engine Throttle Adjustment318
Cummins N14 - C450 Engine318
General318
Foot Throttle Linkage Adjustment319
Electronic Fuel Control Adjustment319
Cummins N14 - C525 Engine321
General321
Foot Throttle Linkage Adjustment321
Engine Speed Calibration321
Cummins N14 - C525E Engine322
Cummins QSC8.3, QSM11, or QSX15 Engine322
General322
Foot Throttle Linkage Adjustment322
Engine Speed Calibration322
Caterpillar 3406C Engine323
General323
Foot Throttle Linkage Adjustment323
Electronic Fuel Control Adjustment323
Test Voltages324
Diesel Particulate Filter Regeneration - Tier 4 ONLY325
General325
Regeneration325
Passive Regeneration325
Active Regeneration325
Stationary Regeneration325
Pump Drive Disconnect326
General326
Adjustment326
Turntable Bearing Bolt Torque331
Bearing Installation331
Torque Requirements331
Bolt Replacement331
Lubrication331
Torque Values331
Torque Sequence331
Torque Intervals331
Crawler Adjustment332
Maintenance332
Tread Slack Adjustment333
Adjustment Guideline333
Adjustment Procedure333
Hydraulic Hand Pump334
Assembly334
Maintenance334
Air Removal334
Pump Operation334
Rotating Bed Level Sensor336
To Reset (Re-Zero) the Level Sensor336
To Re-Calibrate the Rotating Bed Level Sensor336
Lubrication Guide339
Lube and Coolant Product Guide339
Section 10339
Basic Troubleshooting343
Safety Summary343
General Guidelines344
Test Equipment344
Troubleshooting Charts345
Testing Components377
Test 1 - Battery Test (12 and 24 Volts DC)377
Test 2 - Checking Resistance at Engine Temperature Switch378
Test 3 - Checking Resistance at Engine Oil Pressure Switch379
Test 4 - Electric Fuel Control (EFC) Box Test Points380
Test 5 - Testing the Pump EDC and Motor PCP381
Test 6 - Cleaning and Adjusting the Engine RPM Transducer382
Test 7 - Location of Motor Ports383
Test 8 - Testing for Pump and Motor Leakage384
Test 9 - Location of Pump Ports385
Test 10 - Checking Voltage at the Hydraulic Brake Valve386
Test 11 - Manually Stroking the Pump387
Test 12 - Testing for Voltage at the Fuse Box388
Test 13 - Checking Voltage at the Control Handle389
Test 14 - Adjusting the Control Handle Potentiometer390
Test 15 - Checking System Voltage at the Air Solenoid Panel391
Test 16 - Checking System Voltage at the Hydraulic Valve Assemblies392
Test 17 - Checking Pump Charge Pressure and Electrical Test394
Previous Production394
Current Production -SN 2251179, 2251183, 225185 & up394
Test 19 - Adjusting Pump Charge Pressure Relief394
Test 18 - Setting the Pump Pressure395
Test 19 - Adjusting Pump Charge Pressure Relief396
Test 20 - Setting Pump Neutral397
Test 21 - Checking Voltage at the Speed Encoders398
Test 22 - Adjusting the Counterbalance Valves399
Test 23 - Servicing the Motor Loop Flushing (Purge) Valves400
Test 24 - Checking Hydraulic Brake Pressure401
Test 25 - Checking and Adjusting Auxiliary System Working Pressure402
Test 26 - Checking Pin Cylinder Seals404
Test 27 - Actuating the Solenoid Valve Manual Overrides405

Manitowoc 2250 - Page 406

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