Manitowoc 2250 - Inspection and Maintenance Checklist; Fiberglass Maintenance

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Manitowoc Published 06-24-16, Control # 241-01 6-1

2250 OPERATOR MANUAL MAINTENANCE CHECKLIST

SECTION 6

MAINTENANCE CHECKLIST

INSPECTION AND MAINTENANCE

CHECKLIST

See F2097 at the end of this section.

FIBERGLASS MAINTENANCE

See Bulletin W04-009 at the end of this section.

Main Page

Table of Contents5
Section 115
Crane Data15
Crane/Attachment Identification15
Tier 4F Engine15
Change of Ownership Registration15
Crane Orientation15
Identification and Location of Components16
Crane Components16
Engine Components18
Hydraulic Tank Components20
Outline Dimensions21
Standard Crane (Series 3 Counterweight Arrangement Shown)21
35-Foot Elevated Cab22
Crane Weights23
English and Metric Conversions26
Direct Conversion26
Inverse Conversion26
Manitowoc Cranes Dealer27
Section 229
Continuous Innovation31
Nameplates and Decals31
Safety Messages31
General31
Safety Alert Symbol31
Signal Words31
Symbol Identification31
Safety and Information Signs33
Maintaining Signs33
Ordering Signs33
Crane Access Points34
General34
Getting on or off Crane35
Operator Manual/Capacity Chart Storage37
Storing Manuals37
Safe Operating Practices38
General38
Read the Operator Manual38
Operator Qualifications38
Operator Conduct38
Pre-Start Checks39
Leaving the Operator's Cab39
Handling the Load40
Power Failure40
Operating at Night or in Bad Weather40
Size of Load40
Attaching the Load41
Lifting/Moving the Load41
Multiple-Load-Line Operation42
Holding the Load43
Signals44
Safety Devices44
Operational Aids45
Category 1 Operational Aids45
Category 2 Operational Aids45
Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines47
Electrocution Hazard47
Setup and Operation47
Electrocution Hazard Devices48
Electrical Contact48
Refueling49
Fire Extinguishers49
Accidents49
Safe Maintenance49
Maintenance Instructions49
Safe Maintenance Practices49
Environmental Protection51
Boom Disassembly Safety52
General52
Location52
Pin Removal54
Disassembly Precaution54
Personnel Handling Policy55
Pedestal/Barge-Mounted Cranes57
Pedestal-Mounted Crane57
Definition57
Examples57
Barge-Mounted Crane58
Definition58
Examples58
Capacity Charts59
Shock Loading59
Operation on Barge59
Definition59
General59
Definitions59
Crane Inspection60
Transporting Crane on Barge60
Standard Hand Signals for Controlling Crane Operations68
Symbol Identification70
Front Window Operation76
Closing Window76
Opening Window for Ventilation76
Opening Window for Emergency Exit76
Controls Identification and Function76
General76
A-Engine Controls80
A1-Engine Run/Stop/Run Key Switch80
A2-Engine Start Switch80
A3-Engine Lights80
A4-Exhaust System Lights80
A5-Diesel Particulate Filter (DPF) Switch81
A6-Diesel Exhaust Fluid (DEF) Gauge and Light81
B-Accessory Controls82
A7-Emergency Stop Switch82
A8-Engine Foot Throttle82
A9-Engine Hand Throttle82
A10-Pump Drive Disconnect Handle82
A11-Battery Disconnect Switch82
B1-Tinted Visor82
B2-Defroster Fan82
B3-Horn Switch82
C-Indicators83
B4-Dome Light Switch83
B5-Air Conditioner Temperature Selector83
B6-Air Conditioner/Heater Switch83
B7-Air Conditioner/Heater Fan Switch83
B8-Panel Lights Switch83
B9-Windshield Washer Switch83
B10-Front Windshield Wiper Switch83
B11-Overhead Windshield Wiper Switch83
B12-Engine Block Heater83
C4-Digital Display84
C5-Digital Display Selector Switch84
C6-Operating Limit Alert84
C7-System Fault Alert84
C8-Rotation Indicators84
C9-Wind Speed Indicator84
C10-Engine Hour Meter84
C11-Boom Angle Indicator84
C12-Drum Direction Indicator84
D-Gauges85
D1-Hydraulic Tank Temperature Display85
D2-Fuel Level Gauge85
D3-Engine Water Temperature Gauge85
D4-Engine Oil Pressure Gauge85
E-Special Controls and Indicators86
D5-Battery Voltage Gauge86
D6-Air Pressure Gauge86
E1-Drum 1 Free Fall Light86
E2-Drum 2 Free Fall Light86
E3-Drum 3 Free Fall Light86
E4-Crane Mode Selector86
Main Modes86
Crane Setup86
Luffing Jib Setup87
Auxiliary Modes87
E5-Limit Bypass Switch88
E6-Drum Selector88
E7-Load Drum Indicator Lights89
E8-Seat Switch89
E9-MAX-ER Controls89
E10-Aircraft Warning Beacon (Optional)89
E11-Dome Light (Optional)89
E12-Dome Light Dimmer Control (Optional)89
E13-Clam Closing Control and Air Pressure Gauge89
E14-APU Cab Key Switch (Optional)89
Drum Identification90
Handle-To-Drum Identification91
F-Boom/Luffing Hoist Controls92
G-Load Drum Controls92
F1-Boom Hoist Handle92
F2-Drum 4 Park Switch92
F3-Drum 5 Park Switch92
Full Power Mode (Either Load Drum)92
Free Fall Mode (Either Load Drum)92
G1-Left Handle93
G2-Right Handle93
G3-Drum 1 Park Switch93
G4-Drum 2 Park Switch93
G5-Drum 3 Park Switch93
G6-Left Working Brake Pedal93
G7-Right Working Brake Pedal93
H-Swing Controls94
J-Travel Controls94
G8-Drum 9 Park Switch94
G9-Auxiliary Drum 5 Handle (Optional)94
H1-Swing Handle94
H2-Swing Holding Brake Switch94
H3-Swing Brake Switch94
J1-Left Crawler Handle94
J2-Right Crawler Handle94
J3-Travel Detent Selector94
Limit Devices95
Boom up Limit95
J4-Travel Park Switch95
J5-Travel Speed Selector95
Boom up Limit Bypass Test95
Boom down Limit (if Equipped)96
Block-Up Limit96
Luffing Jib up Limits96
Luffing Jib down Limits97
Maximum Bail Limit97
Minimum Bail Limit97
Load Indicator98
Mast up Limit98
Seat Controls98
Preparing Crane for Operation99
Operation99
Engine Startup99
Boom/Luffing Hoist Operation101
Swing Operation102
Load Drum Operation103
Liftcrane Operation-Full Power103
Liftcrane Operation-Free Fall104
Clamshell Operation-Standard105
Selecting Clamshell Mode105
Closing Bucket (Digging)105
Hoisting Bucket105
Dumping Bucket105
Lowering Bucket105
Travel Operation106
Stopping Engine/Leaving Crane Unattended108
Special Controls109
Clamshell Operation-Manually Operated Clutch109
General109
Manual Clutch Control110
Automatic Clutch Control110
Manual and Automatic Clutch Control111
Clamshell Operation-Independent Drums112
General112
Operating Options112
Drum 5 Operation-Boom Hoist Diverted113
Synchronized Control Options113
Digging113
General113
Load Drum Operation113
Drum 5 Operation-Travel Diverted114
Luffing Hoist Operation114
General114
Load Drum Operation114
Remote Controls117
General117
Controls Identification and Operation117
1-Engine Run/Stop Switch117
2-Engine Start Switch117
3-Engine Speed Switch117
4-Hydraulic Disconnect Switch (Rotating Frame Quick-Disconnect)117
5-Power Switch118
6-Not Used118
7-Gantry Cylinders Switch118
8-Boom Butt Cylinder Switch118
9-Backhitch Pins Switch118
10-Boom Hinge Pins Switch118
11-Upper Counterweight Pins Switch118
12-Lower Counterweight Pins Switch118
13-Right Crawler Frame Pins Switch118
14-Left Crawler Frame Pins Switch118
Programmable Controller Calibration Procedures119
General119
Calibrating the Pressure Sender119
20-Right Rear Jacking Cylinder Switch119
21-Left Rear Jacking Cylinder Switch119
22-Right Front Jacking Cylinder Switch119
23-Left Front Jacking Cylinder Switch119
24-All Rotating Frame Jacking Cylinders Switch119
Controls Calibration120
Digital Display Readings120
General120
Selecting Display Language121
Operating Conditions121
Operating Limits121
System Faults122
Diagnostic Display123
Swing (Crane)123
Mast Accumulator125
A1 (Handles)126
A2 (Programmer's Screen)126
Engine Diagnostics136
General136
Diagnostic Lights137
Engine Diagnostics137
Drum Interlock137
General137
1-Engine Stop Light137
2-Engine Warning Light137
5-DPF Regeneration Inhibited137
Free Fall Mode137
Installing Drum Interlock138
Removing Drum Interlock138
Full Power Mode138
Swing Speed/Torque Adjustment140
General140
Adjustment140
Swing Limiter Operation140
Programming Swing Limits140
Swing Limit Switch Adjustment143
Swing Drive Disconnect Operation143
General143
Disconnecting Crane Swing Drive144
Connecting Crane Swing Drive144
Pile Driving System Controls146
General146
Components Function146
Hydraulic Tank146
Hydraulic Pump146
Hydraulic Filter146
Directional Control Valve146
Spotter System Dump Valve146
Cylinder Operating Controls146
Wind Conditions148
General148
Cold Weather Heater Package151
General151
Heaters151
Thermostats151
Turning Heaters on151
Turning Heaters off151
Auxiliary Power Unit (APU)153
General153
Engine153
Generator and Interlock Switch153
Key Switches153
Safety Switches153
Side Access Panel Safety Switches153
Starting with the Side Access Panel Opened153
Starting Aids153
Control Panel154
Control Panel Screens155
Control Module155
Fault Codes155
Starting the Auxiliary Power Unit (APU)156
Stopping the Auxiliary Power Unit (APU)156
Identifying the Connectors156
Preparation for Cold Weather157
Crane Limitations157
Wire Rope157
Cold Weather Starting Aid157
Cooling System157
Battery157
Engine Oil157
Fuel Oil157
Coolant and Oil Pan Heaters157
Gear Oil158
Hydraulic Oil158
Air System158
Circuit Breakers158
Hydraulic Cranes158
General158
Rigging Drawings163
Optional Attachments163
General Safety163
Self-Erecting Equipment164
Assembly and Disassembly Notes164
Assembly and Disassembly Area164
Accessing Parts164
Crane Weights164
Retaining Connecting Pins164
Miscellaneous Loose Parts Box164
Shipping Crane Components166
Component Weights167
Special Blocking Requirements170
General170
Blocking170
Undercarriage Lubrication at Assembly171
Crane Assembly with Self-Erect172
Operating Controls172
Pre-Start Checks172
Remove Rotating Bed from Trailer175
Remove Adapter Frame and Carbody from Trailer179
Connect Upper Boom Butt to Lower Boom Butt185
Connect Equalizer to Boom Butt187
Install Assembly Block191
Raise Gantry191
Install Crawlers192
First Crawler Installation192
Remove Carbody Pedestals197
Second Crawler Installation197
Install Counterweight and Assemble and Attach Boom198
Pre-Raising Checks199
Crane Disassembly with Self-Erect199
Disconnect Boom Butt from Boom199
Install Assembly Block199
Remove Counterweight and Disassemble Boom199
Install Carbody Pedestals199
Remove Crawlers200
Connect Equalizer to Gantry201
Disconnect Lower Butt from Upper Butt202
Install Adapter Frame and Carbody on Trailer202
Install Rotating Bed on Trailer202
Elevated Cab Assembly (35-Foot Tower)205
General205
Safety205
Installing Elevated Cab205
Attaching Cab Tower to Crane205
Installing Catwalks and Railings205
Installing Operator's Cab205
Make Cab-To-Machine Connections207
Remove Cab Tower208
Drum Spacer/Lagging Installation210
General210
Torque Values210
Installation of Mast Self-Erecting Wire Rope210
Gantry Raising and Lowering (with Boom Butt Handling Cylinder)212
General212
Raising and Lowering Gantry with Boom Butt215
Requirements for Raising and Lowering Gantry with Boom Butt215
Raising Gantry with Boom Butt215
Lowering Gantry with Boom Butt216
Raising and Lowering Gantry with Fully Rigged Boom217
Requirements for Raising and Lowering Gantry with Fully Rigged Boom217
Raising Gantry with Fully Rigged Boom217
Lowering Gantry with Fully Rigged Boom217
Counterweight Installation and Removal219
General219
Operating Controls219
Handling Counterweight219
Lifting Lug Identification220
Assembling Upper Counterweight (Series 1 and 2)220
Lower Tray220
Center Box220
Side Box220
Assembling Upper Counterweight (Series 3)221
Installing/Removing Counterweight224
Requirements224
Installing Carbody Counterweights (Series 2)224
Removing Carbody Counterweights (Series 2)224
Installing Upper Counterweight (Series 1 and 2)224
Removing Upper Counterweight (Series 1 and 2)225
Installing Carbody Counterweights (Series 3)225
Removing Carbody Counterweights (Series 3)226
Installing Upper Counterweight (Series 3)229
Removing Upper Counterweight (Series 3)229
Counterweight Disassembly230
Drum 5 Installation and Removal230
Drum 5 Installation230
Drum 5 Removal230
Boom Ladder Assembly (#44 Boom)232
General232
Removal from Boom Butt232
Installation on Boom Inserts232
Storage in Boom Butt232
Boom Rigging Guide (#44 HL and LR)234
General234
Assist Crane Requirements234
Blocked Crawler Requirement235
Extended Outriggers235
Handling Components235
Handling Boom235
Rigging Assembly Drawings235
Identifying Boom and Jib Components236
Identifying Inserts237
Removable Lacings237
Boom Installation239
General239
Assemble Boom Sections239
Connect Boom Straps239
Install Intermediate Suspension Pendants241
Install Upper Boom Point241
Install Jib241
Connect Boom Butt to Boom241
Install Load Line243
Connect Straps and Pendants to Equalizer243
Install Block-Up Limit Control and Connect Electric Wiring244
Boom Removal245
Lower Boom245
Remove Block-Up Limit Control245
Remove Load Block and Weight Ball245
Disconnect Straps and Pendants from Equalizer245
Disconnect Boom Butt from Boom246
Install Assembly Block246
Remove Jib246
Remove Upper Boom Point246
Remove Intermediate Suspension Pendants246
Store Boom Straps246
Disassemble Boom Sections246
Lower Boom Point Sheaves255
General255
Removing Outer Two Sheave Clusters255
Installing Outer Two Sheave Clusters255
Greasing Sheave Bearings255
Adjusting Bearing End Play255
Extended Upper Boom Point Rigging Guide257
General257
Assist Crane Requirements257
Assembly Drawing257
Installing Extended Upper Boom Point257
Prepare Boom257
Attach Extended Upper Boom Point257
Install Spreaders261
Install Pendants261
Raise Extended Upper Boom Point Strut261
Connect Stop pendant261
Install Load Line263
Install Block-Up Limit Control and Connect Wiring263
Removing Extended Upper Boom Point264
Lower Extended Upper Boom Point Strut264
Lower Boom264
Remove Pendants264
Remove Spreaders264
Remove Extended Upper Boom Point264
Boom Handling with Intermediate Gantry Position267
General267
Machine Equipment267
Preparing Crane for Travel267
Traveling267
Returning Crane to Normal Operation268
Jib Installation (#132 Jib)268
General268
Jib Assembly Drawing268
Prepare Boom270
Install Jib Butt270
Install Jib Inserts270
Install Jib Top270
Install Jib Pendants273
Install Backstay Pendants273
Install Jib Stop Pendants and Links273
Raise Jib Strut275
Connect Jib Stop275
Install Load Line275
Install Block-Up Limit Control and Connect Wiring275
Jib Removal (#132 Jib)275
Lower Boom and Jib276
Lower Jib Strut276
Remove Backstay Pendants276
Remove Jib Pendants276
Remove Jib Top and Inserts276
Remove Jib Butt276
Wire Rope Installation278
Wire Rope Storage278
Removing Wire Rope from Shipping Reel278
Seizing and Cutting Wire Rope278
Anchoring Wire Rope to Drum279
Winding Wire Rope Onto Drum279
Anchoring Wire Rope to Socket and Wedge280
Breaking in Wire Rope282
Anchoring Wire Rope to Button Socket282
Pad Eye Usage for Wire Rope Reeving282
General282
Safety282
Load Line Reeving284
Wire Rope Specifications284
Wire Rope Installation284
Load Block284
Universal Anchor Joint284
Duplex Hook284
Guide Sheaves285
Drum Spacers285
Standard Liftcrane - Heavy Lift Boom287
10-Part Continuous Reeving293
Lines up Top of Boom294
Container Handling Reeving-Heavy Lift Boom296
Clamshell Reeving-Heavy Lift Boom with Clamshell Upper Boom Point297
Universal Anchor Joint298
Load Block Tie-Back299
General299
Specifications299
Universal Anchor Joint299
Sling Length299
Sling Capacity299
Shackle299
Section 5301
Lubrication Guide303
Lube and Coolant Product Guide303
Inspection and Maintenance Checklist307
Fiberglass Maintenance307

Manitowoc 2250 - Inspection and Maintenance Checklist; Fiberglass Maintenance

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