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Manitowoc 2250 MAX-ER 2000, Operator'S Manual

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Published 01-08-13, Control # 049-05

TABLE OF CONTENTS

2250 MAX-ER 2000 OPERATOR’S MANUAL

Pin Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-22
Disassembly Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-22

Personnel Handling Policy  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-24
Pedestal/barge Mounted Cranes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-26

Pedestal Mounted Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-26
Barge Mounted Crane  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-27
Capacity Charts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-28
Shock Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-28
Operation On Barge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-28
Crane Inspection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-29
Transporting Crane on Barge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

SECTION 3  . . . . . . . . . . . . . . . . . . . . . . . . . .  Operating Controls And Procedures

Standard Hand Signals for Controlling Crane Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-1
General Instructions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-3
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-3
Principles of Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-3
Drum Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-4
MAX-ER Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-8

Crane Mode Selector – Crane Software Version 5005 and Lower. . . . . . . . . . . . . . . . . . . . . . . .  3-8
Crane Mode Selector – Crane Software Version 5007 and Higher . . . . . . . . . . . . . . . . . . . . . . .  3-8
Symbol Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10
MAX-ER Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Mast Strap Pins Remote Control  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-10
Digital Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-11
System Fault Alert  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-11

Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12
Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12
MAX-ER Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12
Operating Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12
Operating the MAX-ER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13

Handling Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-13
Traveling and Swinging  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-15

Leaving Crane Unattended . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18
Wind Conditions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-18

SECTION 4  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  Set-Up And Installation

MAX-ER 2000 Components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Installation and Removal Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Rigging Drawings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Accessing Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-1
Assist Crane Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Mast Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Identifying Boom/Mast Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Handling Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Counterweight Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-2
Blocked Crawlers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3
Retaining Connecting Pins  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3
Removable Lacings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3
MAX-ER Assembly Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3

Prepare Crane  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-3
Install MAX-ER Attachment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7
Raise Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-15
Install Wheeled Counterweight Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-23
Install Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-26
Install Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-26

Summary of Contents for 2250 MAX-ER 2000

Page 1: ...R e f e r e n c e O n l y MAX ER 2000 Operator Manual Manitowoc 2250 ...

Page 2: ...R e f e r e n c e O n l y ...

Page 3: ...the crane identification plate Always furnish serial number of crane and its attachments when ordering parts or discussing service problems with your Manitowoc dealer or Manitowoc Crane Care To prevent death or serious injury Avoid unsafe operation and maintenance Crane and attachments must be operated and maintained by trained and experienced personnel Manitowoc is not responsible for qualifying ...

Page 4: ...R e f e r e n c e O n l y ...

Page 5: ...ols 2 1 Safety and Information Signs 2 4 Maintaining Signs 2 4 Ordering Signs 2 4 Crane Access Points 2 5 Getting On or Off Crane 2 5 Operator s Manual Capacity Chart Storage 2 8 Storing Manuals 2 8 Safe Operating Practices 2 9 General 2 9 Read Operator s Manual 2 9 Operator Qualifications 2 9 Operator Conduct 2 9 Handling Load 2 11 Signals 2 14 Safety Devices 2 15 Operational Aids 2 15 Category 1...

Page 6: ...ne Software Version 5007 and Higher 3 8 Symbol Identification 3 10 MAX ER Remote Controls 3 10 Mast Strap Pins Remote Control 3 10 Digital Display 3 11 System Fault Alert 3 11 Tire Inflation 3 12 Wheel Nut Torque 3 12 MAX ER Diagnostics 3 12 Operating Precautions 3 12 Operating the MAX ER 3 13 Handling Loads 3 13 Traveling and Swinging 3 15 Leaving Crane Unattended 3 18 Wind Conditions 3 18 SECTIO...

Page 7: ...sembly Capacities 4 41 Operating Conditions 4 41 Machine Travel 4 41 Operating Radius 4 41 Disconnecting Connecting Wheeled Counterweight Trailer With Boom Raised 4 42 General 4 42 Safety 4 42 Disconnecting Trailer from Crane with Boom Raised 4 45 Connecting Trailer to Crane with Boom Raised 4 46 Boom Installation 4 49 Boom Rigging Assembly Drawings 4 49 Install Boom Butt all booms 4 49 Raise Phys...

Page 8: ...ad Block Reeving 4 79 Reeving Diagrams 4 79 Load Block 4 79 Duplex Hook 4 79 Guide Sheaves 4 79 Wire Rope Specifications 4 79 Wire Rope Installation 4 79 Load Block Tieback 4 88 General 4 88 Specifications 4 88 Shackle 4 88 SECTION 5 Lubrication Lubrication 5 1 SECTION 6 Maintenance General Maintenance 6 1 Boom Angle Indicator Adjustment 6 1 General 6 1 Adjusting Angle Indicator 6 2 Replacing Send...

Page 9: ...t 6 12 Maintenance 6 12 Adjustment 6 13 Steering Post Bearing Bolt Torque 6 14 Torque Requirements 6 14 Bolt Replacement 6 14 Boom Hoist Ratchet And Pawl Adjustment 6 15 General 6 15 Limit Switch Adjustment 6 15 Return Spring 6 15 Main Load Drum Ratchet And Pawl Adjustment 6 17 General 6 17 Actuator Removal 6 17 Actuator Installation and Adjustment 6 17 ...

Page 10: ...R e f e r e n c e O n l y TOC vi Published 01 08 13 Control 049 05 TABLE OF CONTENTS 2250 MAX ER 2000 OPERATOR S MANUAL THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 11: ... CONTENTS Crane Data 1 1 Crane Attachment Identification 1 1 Crane Orientation 1 1 Identification of MAX ER Components 1 1 Outline Dimensions 1 3 Weights Of Components 1 4 English and Metric Conversions 1 8 Direct Conversion 1 8 Inverse Conversion 1 8 Change of Ownership Registration 1 9 Manitowoc Dealer 1 9 ...

Page 12: ...R e f e r e n c e O n l y 2250 MAX ER 2000 OPERATOR S MANUAL 1 ii Published 01 08 13 Control 049 05 THIS PAGE INTENTIONALL LEFT BLANK ...

Page 13: ...the exact location of the identification labels on your crane and attachments see the Nameplates and Decals Drawing in Section 2 of this manual CRANE ORIENTATION The terms RIGHT LEFT FRONT REAR used in this manual see 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 upperworks The crawler drive shafts are at the rear of th...

Page 14: ...RE 1 2 Counterweight Straps Mast Hoist Equalizer Mast Straps Boom Hoist Wire Rope from Drum 2 130 ft 39 6 m 44 Mast Carbody Counterweight both ends 79 Boom 2250 Crawler Crane Boom and Mast Adapter Frame Load Drum Drum 9 Load Drum Drum 5 Spreader Beam Trailer Arm Adapter Physical Boom Stop Mast Strap Bracket Physical Mast Stop Gantry Mast Hoist Wire Rope from Drum 4 Wheeled Counterweight Assembly 5...

Page 15: ...L INTRODUCTION 1 OUTLINE DIMENSIONS 37 ft 7 1 2 in 11 5 m Tail Swing 46 ft 11 1 2 in 14 3 m Tail Swing 56 ft 5 in 17 2 m Tail Swing Rotation 1 ft10 1 2 in 0 6 m 5 ft 1 1 2 in 1 6 m 12 ft 4 in 3 7 m 10 ft 2 in 3 1 m 30 ft 9 14 m Radius 40 ft 12 2 m Radius 50 ft 15 2 m Radius 140 ft 3 1 2 in 42 8 m Mast Height ...

Page 16: ...erweight box each 8 required 19 500 8 845 Center top counterweight box each 4 required 15 000 6 803 Center middle counterweight box each 2 required 21 250 9 638 Center bottom counterweight box each 2 required 21 250 9 638 Wheeled counterweight trailer assembly with strap cylinders 77 420 35 117 Front trailer insert 2 565 1 163 Rear trailer insert 2 565 1 163 Adapter arm 2 800 1 270 Total wheeled c...

Page 17: ...34 Equalizer 2 160 979 Equalizer fork with pins 635 288 Equalizer weight box with jaw and hook 3 015 1 367 Upper boom point single sheave 725 328 Lower wire rope guide on 40 ft 12 2 m insert 410 185 Upper wire rope guide on 40 ft 12 2 m insert 410 185 Drum No 9 bare 8 750 3 968 Boom stop each tube 305 138 Boom stop strut each with pins 30 13 NO 79 44 BOOM Additional Components 30 ft 9 1 m top with...

Page 18: ...5 m backstay strap attached to boom butt each 150 68 Luffing jib stop assembly 1 850 839 Upper point single sheave with rollers 1 220 553 Strap each main strut to jib strut 290 131 Strap support each on jib strut 35 15 Link each with pins 115 52 Sheave and sheave support attached to straps 30 13 No 132 JIB 20 ft 0 in 6 1 m butt 1 020 462 20 ft 0 in 6 1 m top with jib point sheaves 1 885 855 20 ft ...

Page 19: ...oad Lines 1 1 8 in 28 6 mm wire rope 2 70 lb per ft 4 02 kg m 4 400 ft 1 341 m No 79 Boom 11 880 5 388 4 200 ft 1 280 m No 79 44 Boom 11 340 5 143 3 500 ft 1 067 m No 44 Fixed Jib 9 450 4 286 1 in 25 4 mm wire rope 2 03 lb per ft 3 02 kg m 4 400 ft 1 341 m No 44 Fixed Jib maximum capacity 8 930 4 050 1 450 ft 442 m No 44 Fixed Jib full hoisting range 2 945 1 335 Whip Lines 1 in 25 4 mm wire rope 2...

Page 20: ... Pull KiloNewton kN 0 00445 Pound Force Per Inch lb in Spring Force Newton per millimeter Nmm 0 1751 Pound Force Per Foot lb ft Newton per meter Nm 14 5939 LENGTH Inch in Adjustments Millimeter mm 25 4000 Foot ft Outline Dimensions Meter m 0 3048 Mile miles Travel Distance Kilometer km 1 6093 POWER Horsepower hp Engine Kilowatt kW 0 7457 PRESSURE Pound Sq In psi Hydraulic Air Bar 0 0689 TEMPERATUR...

Page 21: ...Manitowoc dealer Before calling find the model and serial number of the crane or attachment This information is located on the identification plate on the crane cab or attachment To locate the Manitowoc dealer nearest to you 1 Go to www manitowoccranes com en our company dealers 2 Follow the on screen prompts to locate your Manitowoc dealer VOLUME LIQUID Ounce oz Fluid Capacities Milliliter mL 29 ...

Page 22: ...R e f e r e n c e O n l y INTRODUCTION 2250 MAX ER 2000 OPERATOR S MANUAL 1 10 Published 01 08 13 Control 049 05 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 23: ... 2 11 Size of Load 2 11 Attaching Load 2 11 Lifting Moving Load 2 12 Multiple Load Line Operation 2 14 Holding Load 2 14 Signals 2 14 Safety Devices 2 15 Operational Aids 2 15 Category 1 Operational Aids 2 16 Category 2 Operational Aids 2 16 Assembling Disassembling or Operating Crane Near Electric Power and Transmission Lines 2 17 Electrocution Hazard 2 17 Set Up and Operation 2 18 Electrocution ...

Page 24: ...d 01 08 13 Control 049 05 Definition 2 26 Examples 2 26 Barge Mounted Crane 2 27 Definition 2 27 Examples 2 27 Capacity Charts 2 28 Shock Loading 2 28 Definition 2 28 Operation On Barge 2 28 General 2 28 Definitions 2 28 Crane Inspection 2 29 Transporting Crane on Barge 2 29 ...

Page 25: ...rane are identified in Figure 2 1 WARNING California Proposition 65 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain chemical lead and lead compounds chemicals known to the State of California to cause cancer birth defects and other reproductive h...

Page 26: ... n c e O n l y SAFETY INFORMATION 2250 MAX ER 2000 OPERATOR S MANUAL 2 2 Published 01 08 13 Control 049 05 FIGURE 2 1 Cut or Crush Hazards Cut Hazard Crush Hazards Electrocution Hazard Explosion Hazard Fall Hazard ...

Page 27: ...FIGURE 2 1 continued Fall Hazards Falling Boom Hazards Crush Hazard Falling Load Hazards Crush Hazard Fire Extinguisher Fluid Symbols Engine Coolant Diesel Fuel Hydraulic Filter Hydraulic Oil Flying Object Hazards Overhead Obstruction Hazard Power Line Hazard Electrocution Engine Coolant Vent Engine Oil Level Pump Drive Oil Level ...

Page 28: ...n has been defaced or removed it must be replaced immediately See the Nameplate and Decal Drawing at the end of this section for the installation locations of signs Ordering Signs Order replacement safety and information signs from your Manitowoc dealer When ordering a sign give the crane model number the crane serial number and the name and part number of the sign FIGURE 2 1 continued Personal Fa...

Page 29: ...is spilled on them Keep walkways and platforms clean and dry to prevent slipping on them When non skid material wears out reapply it Wear shoes with a highly slip resistant sole material Clean any mud or debris from shoes before entering the crane cab or climbing onto the crane A shoe that is not clean might slip off a control pedal during operation Do not make modifications or additions to the cr...

Page 30: ... 2 6 Published 01 08 13 Control 049 05 FIGURE 2 2 View E P823 Catwalk View D View A View B View C P824 P821 P822 P825 Catwalk Catwalks Catwalks Catwalk Bolt 4 places A1048 Steps 2 places Tube Steps 4 places Tube Pin 2 places Boom Butt Gantry Rear Load Drums Pin Standard Cab Shown ...

Page 31: ...2 7 2250 MAX ER 2000 OPERATOR S MANUAL SAFETY INFORMATION 2 View E Operator s Cab Stairs Catwalk Platform Back Up Power Plant Catwalk Platform Enter Exit Catwalk Platform Catwalk Platform Between Drums Enter Exit A03893 FIGURE 2 2 continued Elevated Cab Elevated Cab Shown ...

Page 32: ...tor s cab Operator s Manual Capacity Charts Maintenance Checks and Lube Guide and RCL Operation are supplied in an OPERATOR INFORMATION binder A separate binder is provided for the crane and each applicable attachment The Operator s Manuals and Capacity Charts are stamped with the serial number of the crane or attachment The serial number on the manuals and capacity charts must match the serial nu...

Page 33: ...ors and maintenance or test personnel when necessary in performance of their duties Operation of the crane by these personnel shall be limited to the crane functions needed to perform the inspection or to verify the crane s performance after maintenance procedures No personnel shall be allowed to climb onto the crane or enter the crane cab unless performance of their duties requires them to do so ...

Page 34: ... cab for any reason a Park crane and position upperworks so crane does not interfere with operation of other equipment b Apply travel and swing brakes or locking devices c Land any attached load d Lower the boom onto blocking at ground level or onto a boom rest if possible If the boom cannot be lowered as determined by a qualified designated person it must be securely fastened from movement by win...

Page 35: ...sections from dropping Workers shall not go under boom jib or mast sections when removing connecting pins or bolts 17 Each outrigger shall be visible to the operator or the signal person during extension and retraction Handling Load Size of Load 1 The crane shall not be loaded beyond the applicable static or dynamic ratings given in the Capacity Chart for the crane configuration NOTE Capacity char...

Page 36: ...e swing radius of the crane s counterweight 2 While lifting or moving the load the operator shall take the following precautions a Accelerate and decelerate the load smoothly to avoid excessive stress on the crane boom and machinery b Avoid sudden starts and stops while swinging Keep the swing speed under control to prevent the load from swinging out beyond the radius at which the load can be hand...

Page 37: ... the luffing hoist pawl when operating with the luffing jib at a fixed radius 3 While traveling the operator shall take the following precautions a Sound the signal horn before traveling and intermittently while traveling especially when approaching personnel If equipped the automatic travel alarm will sound when the crane is traveled b Carry the boom in line with the lowerworks and facing the dir...

Page 38: ...t side load damage to the boom the jib and the sheaves The load lines must hang as close to vertical as possible to minimize side and forward loads The distance between the load points and the hook points must be a minimum of three times the horizontal distance between the hook point on the load being lifted The load must remain centered on the boom and jib point shafts unless special lift approva...

Page 39: ...ke and a wind direction indicator if the wind is a factor supplied by crane owner or user 4 Boom stops both physical and automatic If a boom stop is damaged or not working properly it must be tagged out or removed if possible 5 Jib stops both physical and automatic for fixed jib and luffing jib If a jib stop is damaged or not working properly it must be tagged out or removed if possible 6 Pedal lo...

Page 40: ...oom or jib point b Clearly mark the hoist cable so it can easily be seen by the operator at a point that will give the operator sufficient time to stop the load a safe distance from the boom or jib point NOTE The temporary alternative measures for the anti two block devise do not apply when lifting personnel in load line supported baskets Personnel shall not be lifted in load line supported basket...

Page 41: ...30 5 American National Standard 1 Keep all personnel and their personal belongings clothing water coolers lunch boxes etc away from the crane if it is being operated near electrical power lines or equipment 2 Before operating the crane in the vicinity of electrical power lines or equipment notify the power utility company Obtain positive and absolute assurance that the power has been turned off Th...

Page 42: ...t stops does not ensure that electrical contact will not occur Even if codes or regulations require the use of such devices failure to follow the rules in this section may result in serious injury or death 2 Be aware that such devices have limitations and you should follow the rules and precautions outlined in this section at all times even if the crane is equipped with these devices 3 Insulating ...

Page 43: ...ainer to refuel the crane the container shall be a safety type can equipped with an automatic closing cap and a flame arrester 2 The engine shall be stopped before refueling crane 3 Smoking and open flames shall be prohibited in refueling area FIRE EXTINGUISHERS 1 A portable fire extinguisher with a minimum rating of 10 BC shall be installed in operator s or machinery cab of crane 2 The operator a...

Page 44: ...n and approved hard hat 5 Never climb onto or off a moving crane Climb onto and off crane only when it is parked and only with operator s permission Use both hands and handrails steps and ladders provided to climb onto and off the crane Lift tools and other equipment which cannot be carried in pockets or tool belts onto and off the crane with hand lines or hoists 6 The boom and gantry are not inte...

Page 45: ...l components and before entering tight areas such as carbody openings containing high voltage components 27 When assembling and disassembling booms jibs or masts on the ground with or without support of boom rigging pendants or straps securely block each section to provide adequate support and alignment Do not go under boom jib or mast sections while connecting bolts or pins are being removed 28 U...

Page 46: ...It should have enough open space to accommodate the crane the length of boom and if required movement of an assist crane or other equipment If possible secure the area to keep unauthorized personnel and vehicles away Pin Removal When removing pins from boom sections stand clear of pins being removed Even though the boom is resting on blocking individual pin connections may still be under load Pins...

Page 47: ...ved A1301 View A WRONG DANGEROUS 3 and there is No Blocking Under Boom Sections View C RIGHT SAFE 1 Equalizer Pinned to Rails and Boom Hoist Wire Rope Slack 5 before Removing Bottom Pins 4 Boom Sections Lowered and Securely Blocked 1 If Boom Point is on Ground 2 Straps Fully Lowered onto Supports Before Removing Pins 3 Boom Butt Supported by Handling Cylinder 4 Boom will COLLAPSE when Lower Pins a...

Page 48: ...d The crane operator and occupants have been instructed in the recognized hazards of personnel platform lifts The crane is in proper working order Load and boom hoist drum brakes swing brakes and locking devices such as pawls and dogs shall be engaged when the occupied personnel platform is in a stationary position The crane must be equipped with a boom angle indicator that is visible to the crane...

Page 49: ... Automatic brakes such that when the equipment operating controls are released the motions are brought to rest A holding device such as a load hold check valve shall be provided in the hydraulic or pneumatic systems to prevent uncontrolled movement of the hoisting equipment in the case of a system failure Manitowoc offers upgrade packages for friction controlled models to install anti two block de...

Page 50: ... lines fail causing crane to separate from pedestal For this reason great care must be taken to operate a pedestal mounted crane within its rated capacity Careful planning is required before a crane can be operated on a barge Crane user shall verify that barge is capable of limiting crane list and or dynamics to maximum allowable specified in Capacity Charts If specified crane list and or dynamic ...

Page 51: ... by curbing and end stops Figure 2 9 When not working the crane carbody is anchored with tie downs to the foundation Traveling with load is not permitted 3 RINGER crawler mounted carbody mounted supported on blocking screw jacks or steel pedestals which are braced and fastened to the foundation in such a manner as to prevent movement Figure 2 10 4 RINGER platform mounted which has the ring braced ...

Page 52: ...el condition from side to side as measured by the angle between horizontal and a line drawn through the centerline of the crane s boom hinge pins Figure 2 12 This out of level condition creates side load and affects the crane s lifting capacity 2 Barge List also referred to as heel or trim causes swing out of the load and may produce side load When Manitowoc provides a Capacity Chart showing capac...

Page 53: ...before placing the crane into service Boom Counterweight Backhitch Rotating Bed Wire Rope Pendants and Straps Hook and House Rollers When equipped with hook rollers it is recommended that each hook roller assembly be inspected daily for any sign of overloading to include Deformation of roller path Proper hook roller adjustment Deformation or cracks in hook roller hanger Bent hook roller shaft Dama...

Page 54: ...R e f e r e n c e O n l y SAFETY INFORMATION 2250 MAX ER 2000 OPERATOR S MANUAL 2 30 Published 01 08 13 Control 049 05 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 55: ...10 2 Left Counterweight Trailer Jack Control 3 10 3 Center Counterweight Trailer Jack Control 3 10 4 Right Counterweight Trailer Jack Control 3 10 5 All Jacking Cylinders Control 3 10 6 Steering Pins Control 3 10 7 Steering Control 3 10 8 Counterweight Control 3 10 9 Tongue Cylinder Control 3 10 Mast Strap Pins Remote Control 3 10 Digital Display 3 11 System Fault Alert 3 11 Tire Inflation 3 12 Wh...

Page 56: ...R e f e r e n c e O n l y 2250 MAX ER 2000 OPERATOR S MANUAL 3 ii Published 01 08 13 Control 049 05 ...

Page 57: ...ap fist on head then use regular signals USE WHIPLINE Auxiliary Hoist Tap elbow with one hand then use regular signals RAISE BOOM Arm extended finger closed thumb pointing upward LOWER BOOM Arm ex tended fingers closed thumb pointing downward MOVE SLOWLY Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal Hoist slowly shown as an example...

Page 58: ...king a circular motion about each other indicating direction of travel forward or backward TRAVEL One Track Lock the track on side indicated by raised fist Travel opposite track in direction indicated by circular motion of other fist rotated vertically in front of body EXTEND BOOM Telescoping Booms Both fists in front of body with thumbs pointing outward R E T R AC T BO O M Telescoping Boom Both f...

Page 59: ...h loading created by the lifted load The load sensing pin sends a proportional voltage to the programmable controller The programmable controller activates the crane s electric and hydraulic systems to automatically extend and retract the counterweight cylinders raise and lower wheeled counterweight assembly in response to changes in backhitch tension as indicated in Table 3 1 Table 3 1 Counterwei...

Page 60: ... used NOTE 3 If auxiliary hoist is powered by boom hoist circuit only one drum boom or auxiliary can be operated at a time Drum not in use must be parked before other drum can be used If auxiliary hoist is powered by travel circuit auxiliary drum and travel cannot be operated at same time Function not in use must be parked before other function can be used Auxiliary drum is always controlled by Ha...

Page 61: ...Boom Butt Drum 3 Left Rear Drum 5 Aux Hst Mode Standard Crane NOTE 3 4 Boom Hoist Same as Standard Mode 5 Auxiliary Drum 5 Aux Hst Mode MAX ER 2000 NOTE 3 2 Boom Hoist 9 Boom Butt 5 Auxiliary Tandem Drum Mode NOTE 4 Split Rear Drums 2 Drum Crane 4 Boom Hoist 2 Right Rear and 3 Left Rear Front and Rear Drums 2 Drum Crane 4 Boom Hoist 1 Front and 2 Rear Front and Rear Drums 3 Drum Crane 4 Boom Hoist...

Page 62: ...ed Counterweight Up to 459 500 lb 208 430 kg Crane Counterweight 169 200 lb 76 748 kg View E View A P1305 View B Receptacle for MAX ER Remote Control left side of trailer P1311 Left Side of Trailer View D Mast Strap Pins Remote Control OUT P1299 ON Cord from Mast Strap Pins Remote Control P1308a View C Receptacle for Mast Strap Pins Remote Control left side of crane FIGURE 3 3 1 3 2 4 5 6 7 8 9 ...

Page 63: ...mote Control Extend Jack Raise Counterweight Carrier Retract Jack Lower Counterweight Carrier Left Jack Center Jacks Right Jack All Jacks Steering Disengage Pins and Engage Pins Crab Shipping Swing Straight Power Raise Tongue Extend Cylinder Lower Tongue Retract Cylinder Lower Counterweight Retract Cylinder Raise Counterweight Extend Cylinder Mast Strap Pins ...

Page 64: ... wheeled counterweight Crane Mode Selector Crane Software Version 5007 and Higher The crane mode selector is located in the operator s cab See Section 3 in your Crane Operator s Manual for operation of the crane mode selector See Figure 3 2 in this section for drum and control handle identification For MAX ER operation the MAX ER mode must be selected and confirmed in addition to the desired main ...

Page 65: ...n in Figure 3 13 2 Then turn key counterclockwise and release to TURN OFF and confirm MAX ER Off mode Screen shown in Figure 3 14 appears The crane functions operate as follows in MAX ER mode Boom Hoist can be operated at any time independently of Drum 9 and Travel Only one function Drum 9 or Travel can be operated at a time Travel has priority A simultaneous mode is available Figure 3 15 The cran...

Page 66: ...l assembly to STRAIGHT STEERING position 8 Counterweight Control This switch is provided only for assembly or disassembly It allows counterweight straps to be slackened during counterweight installation and removal This switch cannot be operated when MAX ER mode is on Toggle UP to RAISE MAX ER counterweight retract strap cylinders RELEASE toggle to STOP lock counterweight in last position Toggle D...

Page 67: ...Version 5007 and Higher A LOAD PIN fault occurs due to faulty voltage output from the pin at or near 0 volts or at or near 10 volts The fault appears as shown in Figure 3 17 when the operator scrolls to the system faults group of the digital display The cause of the fault could be a blown fuse or a loose electric cord at the pin Check those areas first before replacing the load sensing pin If a fu...

Page 68: ...level see instructions in MAX ER Capacity Chart Manual 8 Make sure load pin is calibrated and operating properly otherwise wheeled counterweight assembly will not rise off ground when required see Sensor Adjustments in Section 6 of this manual 9 Make sure left counterweight cylinder limit switch is adjusted and operating properly otherwise wheeled counterweight assembly will not rise off ground pr...

Page 69: ...from crane make sure all pins are in proper position see Table 3 3 and Figure 3 21 on page 3 17 Wheeled counterweight assembly will fall over if this step is not performed OPERATING THE MAX ER Handling Loads 1 Select and confirm desired main mode Standard Drum 5 Luff Jib Drum 5 Aux Hst and MAX ER mode 2 For Crane Software Version 2007 and higher select and confirm counterweight trailer control eit...

Page 70: ...d for Clarity Hole A Hole B Hole C Hole D Pin 3 Pin 1 Pin 4 Hole E Pin 2 Stop Pin working Stop Pin stored Right Side Shown Left Side Similar View A View B View C View D View E Wheel Assembly typical Steering Arm typical SWING Left Right STRAIGHT Forward Reverse CRAB Left Right and SHIPPING Item Description Pin 1 Stop Pin Pin 2 Stop Pin Pin 3 Steering Pin Pin 4 Stop Pin A1153 P1317 FIGURE 3 20 Stop...

Page 71: ...avel NOTE On current production cranes without a swing lock crab travel is not allowed See Figure 3 19 for following procedure 1 Pin wheels in straight position perform Straight Travel steps 2 Disengage swing lock and release swing brake 3 Counter rotate crawlers 90 to crane upperworks Crane upperworks must be 90 to crawlers to prevent damage to swing drives 4 Raise counterweight with jacking cyli...

Page 72: ...tract jacking cylinders 7 Disengage swing lock and release swing brake 8 Proceed to swing right or left Operating Counterweight Trailer Jacks The counterweight trailer jacking system is used for the following operations To support trailer during shipping assembly and disassembly To raise and lower trailer for steering and swing operations To raise and lower the trailer for tire servicing The axle ...

Page 73: ...ting Leveling Trailer Pin A No Pin Pin B in Either Hole No Pin Pin C Operating Raising lowering Trailer with Jacks Pin A No Pin No Pin Pin B No Pin Pin C Operating NOTE 1 Read MAX ER Assembly Guide in Section 4 of this manual before attempting to install or remove wheeled counterweight trailer NOTE 2 Hole 1 in tongue View C is slotted to allow tongue to be pivoted during assembly and levelling NOT...

Page 74: ... or jib point can be greater than wind speed at ground level Also be aware that the larger the sail area of the load the greater the wind s affect on the load As a general rule ratings and operating speeds must be reduced when Wind causes load to swing forward past allowable operating radius or sideways past either boom hinge pin For wind conditions specific to this crane see Wind Conditions Chart...

Page 75: ...is condition is especially dangerous when the boom is at or near the maximum angle when operating without load Wind forces on the front of the boom reduce the normal forward tipping effect of the boom The crane can tip or the boom can collapse if this condition is not avoided Forward stability is affected by wind on the rear of the boom Wind applies a force to the boom and load that adds to the cr...

Page 76: ...R e f e r e n c e O n l y OPERATING CONTROLS AND PROCEDURES 2250 MAX ER 2000 OPERATOR S MANUAL 3 20 Published 01 08 13 Control 049 05 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 77: ... 9 Connect Mast Straps 4 11 Connect Counterweight Straps 4 11 Raise Physical Mast Stop 4 11 Install Intermediate Suspension Links 4 12 Raise Mast 4 15 General 4 15 Connect Hydraulic Hoses 4 15 Raise Mast 4 19 Install Wheeled Counterweight Assembly 4 23 Install Boom 4 26 Install Jib 4 26 Install Load Line 4 26 Install Block Up Limit Control 4 26 Adjustments 4 26 MAX ER Operation 4 26 Pre Raising Ch...

Page 78: ...bly 79 Boom 4 51 Position Wire Rope Guides 79 Boom 4 51 Connect Boom Straps 79 Boom 4 53 Install Upper Boom Point 79 Boom 4 53 Assemble Boom Inserts 79 44 Boom 4 55 79 Boom Inserts and Transition Inserts 4 55 44 Boom Inserts 4 55 Connect Boom to Boom Butt 79 44 Boom 4 57 Position Wire Rope Guides 79 44 Boom 4 57 Connect Boom Straps 79 44 Boom 4 59 Install Upper Boom Point 79 44 Boom 4 59 Install I...

Page 79: ...3 Winding Wire Rope onto Drum 4 73 Anchoring Wire Rope to Wedge Socket 4 74 Breaking in Wire Rope 4 75 Anchoring Wire Rope to Button Socket 4 76 Pad Eye Usage for Wire Rope Reeving 4 76 General 4 76 Safety 4 76 Load Block Reeving 4 79 Reeving Diagrams 4 79 Load Block 4 79 Duplex Hook 4 79 Guide Sheaves 4 79 Wire Rope Specifications 4 79 Wire Rope Installation 4 79 Load Block Tieback 4 88 General 4...

Page 80: ...R e f e r e n c e O n l y 2250 MAX ER 2000 OPERATOR S MANUAL 4 iv Published 01 08 13 Control 049 05 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 81: ...n and removal instructions are located in the MAX ER Luffing Jib Operator s Manual The MAX ER attachment shall be installed operated and removed by experienced personnel trained in the erection and operation of construction cranes ASSEMBLY PERSONNEL OPERATOR S read and become thoroughly familiar with instructions in this manual and in the Operator s Manuals supplied with crane and MAX ER attachmen...

Page 82: ... Figure 4 1 View B HANDLING COMPONENTS Handle boom and jib components with care to avoid damaging lacings and chords Current production 44 and 79 inserts are equipped with lifting lugs in top chords designed to provide a balanced load and to prevent damage during lifting The terms RIGHT LEFT FRONT REAR used in this section refer to the operator s right left front and rear sides when seated in the ...

Page 83: ...th bolts and stop nuts as shown in Figure 4 2 3 Securely tighten nuts MAX ER ASSEMBLY PROCEDURE Prepare Crane The 2250 crane to which the MAX ER attachment will be assembled must be specially prepared and modified Contact Crane Care Customer Service at factory to determine if your crane is properly prepared and modified Perform the following steps if your crane is equipped with an existing front e...

Page 84: ...ll come on to indicate a boom angle sender fault when engine is started 12 Remove block up limit cable reel from boom butt and store until MAX ER boom is installed 13 Disconnect all air and hydraulic lines from boom butt 14 Remove boom butt from crane 15 If necessary reeve mast hoist equalizer Reeving is same as boom hoist reeving on standard 2250 liftcrane 16 If necessary install appropriate lagg...

Page 85: ...R e f e r e n c e O n l y Manitowoc Published 01 08 13 Control 049 05 4 5 2250 MAX ER 2000 OPERATOR S MANUAL SET UP AND INSTALLATION 4 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 86: ...Vertical Pin Mast Sections Blocking 12 in 305 mm 40 ft 12 2 m Insert Removable Horizontal Pin with Cotter Pins Hook From Assist Crane Slings View A View D View E View C Mast Butt with Adapter Frame 10 ft 3 0 m Insert Mast Sections Blocking 12 in 305 mm Pin A with Keeper Plate Hole C2 Hole C1 Pin B View B A1152 View F Four Leg Chain Sling Assist Crane ...

Page 87: ...rts are in line and install removable pins View D e Block under top end of insert Blocking must be at least 12 in 305 mm high to allow for installation of mast top 4 Pin inserts to butt a Attach nylon lifting slings to chords at top end of mast butt View E b Hook assist crane to slings Crane must have sufficient capacity to lift 40 000 lb 18 144 kg 1 2 the weight of assembled mast c Lift butt and ...

Page 88: ...lizer Rails Gantry intermediate position View D Dimension A 151 25 in 3 8 m Dimension B 212 5 in 5 4 m 8 8 A B 9 Line from Assist Crane Item Description Item Description 1 16 ft 10 1 4 in 5 1 m Strap 6 3 ft 9 1 8 in 1 15 m Strap 2 17 ft 0 1 8 in 5 8 m Strap 7 Strap Connecting Links typical 3 26 ft 10 5 8 in 8 2 m Strap 8 Strap Rest Assembly 4 34 ft 7 3 4 in 10 6 m Strap 9 Mast Hoist Equalizer 5 26...

Page 89: ...t crane to connecting holes in end of mast hoist equalizer 3 Start 2250 engine Select set up mode and confirm 4 Slowly pay out 2250 mast hoist wire rope Drum 4 and carefully lift equalizer clear of tie down clips on gantry View B must guide equalizer forward slightly 5 Continue until equalizer is pulled about 1 ft 0 3 m out of clips Equalizer must remain clear of gantry guide rollers 6 Haul in ass...

Page 90: ...p 6 8 8 7 7 5 4 stored 4 working 3 3 Rod End stored working ToMast Stop View G Right Side of Adapter View H Lug 11 6 Strap 7 Shipping Stored 7 6 Stored Mast Hoist Equalizer 12 13 15 15 16 View D 17 2 4 9 16 in 116 mm 9 in 229 mm 1 2 in 12 7 mm 19 18 20 View A View B View C 14 17 17 17 see Views M1 and M2 7 Shipping 4 To Boom Stop Standard 21 25 23 24 24 View M2 View M1 View K Strap Bracket Stored ...

Page 91: ...te links and pin to strap using retaining pins collars and connecting pins Raise Physical Mast Stop See Figure 4 5 for following procedure 1 If not installed add four shims 17 to each side of strut 14 mounting lugs View D 2 Add shims 5 View A so distance between rod end and mast stop tube is approximately 1 2 in 13 mm 3 Adjust length of air cylinder strut 14 View C and rod end 19 View B to dimensi...

Page 92: ...ate suspension is required for boom lengths of 320 ft 98 m 400 ft 122 m 1 Unpin and remove standard mast stop 21 View M1 from both sides of mast butt store for future use 2 Install and pin intermediate suspension mast stop 22 View M2 to both sides of mast butt 3 Pin both mast stops 22 to brackets 23 4 Pin suspension links 25 View M2 to mast stops 22 Pendant pin holes in end of links must face mast...

Page 93: ...R e f e r e n c e O n l y Manitowoc Published 01 08 13 Control 049 05 4 13 2250 MAX ER 2000 OPERATOR S MANUAL SET UP AND INSTALLATION 4 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 94: ...tor View A 2 A1152 A1247 P1620 P1619a Gauge 1 1 5 View C2 View C3 Gauge 2 Accumulator 4 2 3 behind fitting Mast Stop Drain To Accessory System Valve Hose H4 Must be Coupled to Hose H5 Prior to Starting Engine when Mast is Removed View B Left Inboard Side of Rotating Bed From Accessory System Pump H5 H4 Drum 9 Hydraulic Connections H1 H2 H3 H1 H2 H3 6 ...

Page 95: ...is fully raised The SETUP mode must be selected and confirmed MAX ER mode turned off in order to raise the mast In this mode the 80 mast stop limit is automatically bypassed The following controls are used to raise the mast Drum 2 boom hoist Drum 4 mast hoist Drum 2 and Drum 4 park and pawl switches A qualified operator is required to raise the mast The operator must be experienced with the 2250 l...

Page 96: ...en line on valve stem in line with piping 9 Start engine Mast stop cylinders should extend 10 Check accumulator cut in and cut out pressure settings as follows Pressure settings can vary 50 psi 3 4 bar a Crack open valve knob 4 View C3 so accumulator circuit cycles will continue cycling until valve knob is closed b Observe gauge 1 on accumulator Pressure should bleed down to approximately 2 400 ps...

Page 97: ...R e f e r e n c e O n l y Manitowoc Published 01 08 13 Control 049 05 4 17 2250 MAX ER 2000 OPERATOR S MANUAL SET UP AND INSTALLATION 4 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 98: ...rs in Illustrations Correspond to Numbered Steps in Raise Mast Procedure 6 4 10 14 Mast at 75 Mast at 35 View A View C 3 2 View D 8 1 or 14 40 75 MAST CAN BE USED AS A BOOM See Mast Capacities for Self Assembly and Disassembly View B View E Pin B Pin A Pin C 5 7 11 13 12 Link Boom Strap 14 A1152 A1193 Weight Box and Hook Fork Assembly Equalizer 9 9 ...

Page 99: ...ll be used as a boom see Mast Capacities for Self Assembly and Disassembly for instructions If not turn off and park Drum 2 during boom installation When using mast as a boom operate crane in STANDARD mode to enable automatic mast stop set at 80 MAX ER mode must be off 8 Install desired length of boom View C See Boom Rigging in this section for instructions Minimum boom length required for mast ra...

Page 100: ...qualizer Spreader Beam Mast Stop View D Gantry Pin 18 23 Shims Circled Numbers in Illustrations Correspond to Numbered Steps in Raise Mast Procedure View B left side of crane ON OUT Remote Control P1299 View A View F viewed from above A Air Cylinder Rod End 21 24 Gantry Air Activated Pin 21 24 27 15 16 Strut B D E C F G 20 19 20 15 16 16 1 4 in 6 mm 16 17 17 26 ...

Page 101: ...ntacts upper portion of pins 1 3 1 2 down upper side c Tighten jam nuts A and B 20 If saddles do not align horizontally a Loosen jam nuts C and D View F b Turn threaded rod E in or out as needed c Tighten jam nuts C and D d If saddle does not align properly with gantry pin after adjusting length of strut rod adding removing or repositioning shims at pin points F and or G will be necessary 21 Using...

Page 102: ... Pin Pin B No Pin Pin C No Pin Shipping Raising and Lowering Adapter Arm No Pin Pin A Pin B No Pin Pin C No Pin Shipping Raising lowering Trailer with Jacks Pin A No Pin Pin B No Pin Pin C No Pin Shipping Trailer ATTACHED to Crane Operating Jacks Retracted Pin A No Pin Pin B in Either Hole No Pin Pin C Operating Leveling Trailer Pin A No Pin Pin B in Either Hole No Pin Pin C Operating Raising lowe...

Page 103: ...t tire damage If trailer is standing on tires support inserts on blocking so trailer cannot tip over 3 Position rear of 2250 so it is centered in line with trailer and holes in crane counterweight are aligned with connecting holes in adapter Figure 4 10 View C 4 Connect hydraulic hoses from trailer Figure 4 11 View D to quick connect couplers on crane Figure 4 11 View C DANGER Trailer Tipping Haza...

Page 104: ...e trailer pins to proper positions for Trailer ATTACHED to Crane Figure 4 9 10 Once adapter is connected to crane move tongue pin A Figure 4 9 to hole 1 and extend retract tongue cylinder to level trailer with relation to crane 11 Extend jacks until tires are clear of ground or most of bulge is out of tires and rotate wheels to desired position See Section 3 in this manual for instructions 12 Remo...

Page 105: ...ane engine Select STANDARD mode and confirm b Using counterweight switch on trailer remote control extend or retract strap cylinders to align cylinder rod ends with holes in counterweight strap links c Pin counterweight strap links to strap cylinders FIGURE 4 12 View A A1152 Strap Cylinder stored Locking Pin Strap Cylinder working View B Viewed from front of Trailer Front of Trailer A1153 Counterw...

Page 106: ...alled and properly retained Boom inserts and straps are installed in proper sequence Intermediate suspension pendants are installed if required All insert and strap connecting pins are installed and properly retained Jib inserts and pendants are installed in proper sequence Proper crane counterweight and if required MAX ER counterweight is installed Load lines are spooled tightly onto drums and en...

Page 107: ...arm inserts so trailer cannot tip over 4 If trailer will be supported on jacks extend jacks until trailer is level and most of bulge is out of tires WARNING Tipping Hazard Alternate removal of counterweight boxes from front to rear and from side to side to prevent unbalanced loading of trailer DANGER Trailer Tipping Hazard Support trailer on a firm level uniformly supporting surface in either of f...

Page 108: ...rely attached Figure 4 6 View D The assist crane must be capable of providing horizontal and vertical holdback forces listed in the following table Assist crane can tip if it is too small or improperly positioned Fully rigged boom 120 ft 36 6 m minimum If desired the MAX ER mast can be used as a boom to disassemble and remove the MAX ER boom If the mast will be used as a boom see Mast Capacities f...

Page 109: ...R e f e r e n c e O n l y Manitowoc Published 01 08 13 Control 049 05 4 29 2250 MAX ER 2000 OPERATOR S MANUAL SET UP AND INSTALLATION 4 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 110: ... Numbers in Illustrations Correspond to Numbered Steps in Lower Mast Procedure View D left side of crane ON OUT Remote Control P1299 5 7 View E Equalizer Spreader Beam 6 Gantry Air Activated Pin 5 8 11 10 19 18 17 or View C Pin B Pin B Pin A 18 View G 14 13 Link Boom Strap 4 6 See View G 8 9 9 10 10 or 12 11 or 12 15 Stop Pin Equalizer stored Forks 18 Pin C Pin B CAUTION Continuing to boom up afte...

Page 111: ...ire rope so mast moves smoothly forward past vertical 10 As mast moves past vertical a Lower mast by slowly paying out mast hoist wire rope Haul in boom hoist wire rope as needed to keep boom hoist equalizer off ground b Have ground personnel use taglines to guide counterweight straps around gantry as mast is lowered 11 Pin boom hoist equalizer to rails 120 ft 36 6 m or 140 ft 42 7 m boom View G a...

Page 112: ...is snug against forks Stop when equalizer is snug against forks Continuing to boom up may result in mast or equalizer damage e Insert Pin B to store equalizer on forks f Using outside assist swing forks up and insert Pin A View C g Using outside assist swing weight box and hook up and pin to equalizer with Pin C View C 19 Lower mast onto blocking on ground Disconnect Hydraulic Hoses See Figure 4 6...

Page 113: ...R e f e r e n c e O n l y Manitowoc Published 01 08 13 Control 049 05 4 33 2250 MAX ER 2000 OPERATOR S MANUAL SET UP AND INSTALLATION 4 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 114: ...eight Backhitch Straps 5 6 7 Equalizer Rails Gantry intermediate position View D 8 8 9 Line from Assist Crane Item Description Item Description 1 16 ft10 1 4 in 5 1 m Strap 6 3 ft 9 1 8 in 1 15 m Strap 2 17 ft 0 1 8 in 5 8 m Strap 7 Strap Connecting Links typical 3 26 ft 10 5 8 in 8 2 m Strap 8 Strap Rest Assembly 4 34 ft 7 3 4 in 10 6 m Strap 9 Mast Hoist Equalizer 5 26 ft 6 in 8 1 m Strap 10 Equ...

Page 115: ...es View D 4 Lift mast top to disengage from fixed vertical pin of upstream insert View C 5 Store mast top 6 Repeat steps 2 5 for mast inserts to up to mast butt 7 Remove mast butt and mast adapter frame as follows a Hook chain sling to lifting lugs on mast butt b Insert Pin B to secure mast butt to adapter frame for shipping View B It may be necessary to lift mast butt slightly to align holes c Re...

Page 116: ...m front of Trailer trailer supported on jacks 1 6 3 7 2 4 1 5 5 9 6 4 7 1 1 3 5 This illustration shows maximum counterweight arrangement See Counterweight Arrangements chart in your MAX ER Capacity Chart Manual for other counterweight arrangements See MAX ER Capacity Charts to determine proper counterweight arrangement for your lifting requirements 8 ...

Page 117: ...s 1 alternating from side to side until all side boxes are installed To prevent lifting lugs from breaking do not lift more than two boxes at a time 4 Connect slings from assist crane to lifting eyes 4 places and install front and rear adapter plates 6 and 7 on each side Retain adapter plates 6 and 7 and boxes 1 with eye bolts 8 5 Install left hand boxes 3 and right hand boxes 4 To prevent lifting...

Page 118: ...m front of Trailer trailer supported on jacks 5 This illustration shows maximum counterweight arrangement See Counterweight Arrangements chart in your MAX ER Capacity Chart Manual for other counterweight arrangements See MAX ER Capacity Charts to determine proper counterweight arrangement for your lifting requirements 5 1 4 7 6 1 3 7 6 5 3 1 2 4 1 9 8 ...

Page 119: ...es 1 alternating from side to side until all side boxes are installed To prevent lifting lugs from breaking do not lift more than two boxes at a time 4 Connect slings from assist crane to lifting eyes 4 places and install front and rear adapter plates 6 and 7 on each side Retain adapter plates 6 and 7 and boxes 1 with eye bolts 8 5 Install left hand boxes 3 and right hand boxes 4 To prevent liftin...

Page 120: ...7 Item Description 1 130 ft 39 6 m 44 Mast 2 Gantry in Intermediate Position 3 169 200 lb 76 750 kg Crane Counterweight 4 60 000 lb 27 220 kg Carbody Counterweight 5 0 lb Wheeled Counterweight 6 Boom Hoist Equalizer 7 Links remain with equalizer 8 Weight Block 9 Hook Table 4 1 Load Handling Capacities MAX ER Mast Mast Operating Radius ft m Mast Operating Angle Degrees Mast Capacity lb kg 36 65 11 ...

Page 121: ... gantry in intermediate position as shown in Figure 4 17 The automatic mast stop must be adjusted for 80 maximum angle as instructed in Section 6 of this manual The crane operator s judgment must be used to allow for the dynamic load effects of swinging hoisting and lowering the load traveling wind and other adverse operating conditions and the crane s physical condition Crane must be operated in ...

Page 122: ... ER attachment and its operation Contact Crane Care Customer Service at factory for a detailed explanation of any procedure not fully understood The area in which the trailer is disconnected and connected must be firm level and free of ground and overhead obstructions The area selected must be large enough to accommodate the crane with wheeled counterweight assembly and selected boom length WARNIN...

Page 123: ...R S MANUAL SET UP AND INSTALLATION 4 Counterweight Straps Mast Straps 130 ft 39 6 m 44 Mast Carbody Counterweight both ends 2250 Crawler Crane Crane Counterweight A1152 Trailer Arm Adapter Wheeled Trailer 50 ft 15 2 m position shown 79 or 79 44 Boom Trailer Arm Inserts Counterweight Boxes FIGURE 4 19 ...

Page 124: ... not Shown Locking Pin Strap Cylinder working Counterweight Strap Pin D Front of Trailer Viewed from Front of Trailer Axle Wedge Bolted in Shipping Position Remove for Operation Steering Post Axle Tire VIEW B 4 Places P1624 Pin C Stored in Hole 6 VIEW C 2 Places Hole 5 Pin C Removed P1625 P1627 Pin B in Hole 3 Front of Trailer VIEW D 2 Places P1626 Hole 4 Strut Tongue Hole 2 Pin A in Hole 1 ...

Page 125: ...r 7 Remove Pins B from Holes 4 and install in Holes 3 View D 8 Remove Pins C from Holes 6 and install in Holes 5 View C 9 Disconnect counterweight straps from strap cylinders on trailer View A a Attach taglines to counterweight straps b Turn off MAX ER mode c Using trailer remote control extend strap cylinders as required to loosen strap Pins D d While supporting straps with taglines remove Pins D...

Page 126: ... on crane View B 4 Connect electrical cord from trailer to receptacle on crane View B 5 Using remote control extend or retract tongue cylinder as needed to align holes in trailer arm adapter with holes in counterweight lugs Install pins Figure 4 21 View A See Figure 4 20 for remaining steps 6 Once trailer is attached move pins to following positions Pin A in Hole 1 View E Pins B in Holes 4 View D ...

Page 127: ...weight straps b Turn off MAX ER mode c Pull straps to cylinders with taglines and align connecting holes d Using remote control extend or retract strap cylinders to align holes in cylinder rod ends with holes in links of counterweight straps e Pin counterweight straps to strap cylinders Figure 4 20 View B f Remove taglines g Turn on MAX ER mode DANGER Collapsing Mast After straps are pinned to cyl...

Page 128: ...ght Side of Load Drum 7 High Pressure Hydraulic Lines Left Side of Load Drum 8a Brake Charge Pressure Hydraulic Line Right Side of Load Drum 8b 2 Speed Charge Pressure Hydraulic Line Right Side of Load Drum 9 Case Drain Line Left Side of Load Drum FIGURE 4 22 P1324 Boom Stop STORED POSITION View B 3 View C Boom Stop OPERATING POSITION 5 4 P1323 View D 3 1 2 View F Mast Boom Butt Front of Crane P13...

Page 129: ...s 6 Lower butt onto blocking approximately 12 in 305 mm high View A Raise Physical Boom Stop all booms See Figure 4 22 for following procedure Raise boom stop to operating position as follows 1 Attach a nylon sling from assist crane to boom stop in stored position View B 2 Raise boom stop to operating position View C 3 Raise strut 3 View B from stored position to operating position 3 View C 4 Pin ...

Page 130: ...st Equalizer 3 Horizontal Pin 8 Wire Rope Guide 4 Snap Pin 9 Pin 5 Deflector Sheave Assembly FIGURE 4 23 View B each insert View E A1152 P1326 Sling from assist crane P1327 View A View C each insert 1 2 3 4 Lugs View G 5 View D operating 5 stored Hole 2 Hole 1 6 Boom Top View F 7 Hole 3 9 8 8 7 operating Boom Top Transition Insert Insert with Equalizer Rails Insert with Wire Rope Guides Blocking B...

Page 131: ...om connecting holes line up 4 Insert both horizontal pins 3 View C and safety pins 4 View C Raise Deflector Sheave Assembly 79 Boom The deflector sheave assembly may be shipped in the stored position in the boom top as shown in Figure 4 23 View D If assembly is stored on transition insert 1 Attach slings from assist crane to frame of sheave assembly 5 2 Hoist just enough to loosen pins 6 holding a...

Page 132: ...e Note 1 6 Retaining Pin with Cotter Pins 7 Boom Hoist Equalizer 8 Stop Pin 9 Equalizer Strap Link 10 Pin 11 Pin with Snap Pin Note 1 Collar must face inside of boom FIGURE 4 24 A1152 View C View E SHIPPING POSITION from inside of boom Equalizer Rail Insert B3 See Figure 4 29 7 3 2 7 1 6 5 4 2 1 typical 8 View B 9 10 11 A B View D Blocking View F WORKING POSITION from inside of boom View A 1 View ...

Page 133: ... to holes in equalizer rails with stop pins 8 View B Stop pins must be installed to prevent equalizer from accidentally sliding back on rails during link assembly c Remove retaining pins collars and connecting pins 4 5 6 View B from equalizer link 9 d Rotate links forward and pin to strap on adjacent insert e Unpin equalizer from rails Install Upper Boom Point 79 Boom If required install upper boo...

Page 134: ...ch insert 4 5 View A 79 Boom Inserts Insert Insert View E P524 P523 6 3 Insert View F P527 P526 7 A1152 Blocking View G 1 2 3 A1193 6 7 79 44 Transition Insert see View G 79 44 Transition Insert 44 Boom Insert Item Description 1 Fixed Horizontal Pin 2 Safety Pin with Cotter Pin 3 Hook Connector 4 Horizontal Pin 5 Snap Pin 6 Fixed Vertical Pin 7 Removable Horizontal Pin with Cotter Pin 79Transition...

Page 135: ...w B 7 Lower insert until bottom connecting holes line up 8 Insert both horizontal pins 4 View C 9 Install safety pins 5 View C 10 Block under top end of insert 11 Remove chain slings 12 Repeat steps 3 11 for remaining 79 boom inserts 79 transition insert and 79 44 transition insert 44 Boom Inserts The 44 boom sections have FACT connectors top connectors joined by fixed vertical pins that hook into...

Page 136: ...ol 049 05 Item Description 1 Deflector Sheave 2 Boom Hoist Equalizer 3 Pin FIGURE 4 26 View B A1152 Sling from assist crane View A Additional Inserts Insert with Equalizer Rails Blocking First Insert Boom Butt View C 2 Hole 1 3 1 1 stored 1 stored Lower Sheave Assembly Shown Upper Sheave Assembly Similar 79 44 Boom ...

Page 137: ...e up 5 Insert both horizontal pins and safety pins Figure 4 22 View C Position Wire Rope Guides 79 44 Boom See Figure 4 26 for following procedure Two wire rope guide assemblies 1 View B may be shipped in the stored position on first boom insert NOTE It is not necessary to raise the wire rope guides if the upper boom point is not installed 1 Attach slings from assist crane to frame of sheave assem...

Page 138: ... 9 Equalizer Strap Link 4 Connecting Pin 10 15 ft 4 6 m Transition Insert 5 Collar See Note 1 11 Strap 6 Retaining Pin with Cotter Pins 12 Strap Storage Pin 13 Pin Note 1 Collar must face inside of boom A1193 Fixed Vertical Pin for 44 Boom Insert MANITOWOC A1193 View F View G 11 A B Boom Top Upper Point 79 44 Boom Equalizer Rail Insert B3 See Figure 4 29 7 8 View B 9 4 5 6 View C SHIPPING POSITION...

Page 139: ...stalled to prevent equalizer from accidentally sliding back on rails during link assembly c Remove retaining pins collars and connecting pins 4 5 6 View B from equalizer link 9 d Rotate equalizer links 9 forward and pin to strap on adjacent insert 3 Remove equalizer stop pins and store NOTE See Figure 4 28 View A for strap connections on booms 320 ft 98 m 400 ft 122 m with intermediate suspension ...

Page 140: ...spreader 14 View A between shafts of sheaves 4 Adjust spreader with eye bolts so distance between shafts is 5 ft 6 in 1 7 m Load lines must be routed under wire rope spreader FIGURE 4 28 Item Description 1 Strap Insert 2 Pin with Collar Note 1 3 Strap 11 ft 10 3 4 in 3 6 m 4 Sheave 5 Pendant Guard Pin Note 2 6 Strap 3 ft 1 1 2 in 0 95 m 7 Pin with Collar Note 1 8 Strap Insert 9 79 44 Transition In...

Page 141: ...isconnected and stored with the equalizer Install pins 2 Figure 4 24 View E to secure the links and straps in stored position CAUTION Avoid Pendant Damage Watch intermediate suspension pendants as boom is raised lowered Do not allow pendants to get caught on adjacent parts CAUTION Pendant Damage Use extreme care when lowering 79 44 boom when equipped with intermediate suspension Boom straps can la...

Page 142: ...t Inserts B6 and B7 on butt side of insert with equalizer rails B3 must have straps and links removed if equipped FIGURE 4 29 A1149 B5 B2 B7 B7 B5 B4 B3 B6 B1 B7 B7 B7 B7 B7 B7 B1 B6 B3 B4 B5 B7 B7 B2 B7 B7 B5 B4 B3 B6 B1 B7 B7 B7 B7 B1 B6 B3 B4 B5 B7 B7 B7 B7 B5 B4 B3 B6 B1 B2 B7 B7 B5 B4 B3 B6 B1 B7 B5 B4 B3 B6 B1 B2 B7 B5 B4 B3 B6 B1 B7 B5 B4 B3 B6 B1 B2 B5 B4 B3 B1 B2 B1 B6 B3 B4 B7 B5 B4 B3 B...

Page 143: ...12 2 m B11 44 Insert 40 ft 1 2 m NOTE 1 All straps and links are shipped in the stored position on the applicable boom sections NOTE 2 Only one insert B9 is allowed per boom length B3 B4 B2 B1 B8 B10 B8 B1 B2 B4 B3 B4 B2 B1 B8 B10 B8 B1 B2 B4 B4 B2 B1 B3 B8 B4 B2 B1 B8 B4 B2 B1 B3 B8 B4 B2 B1 B8 B4 B2 B1 B3 B10 B8 B1 B2 B4 B3 B3 B4 B2 B1 B8 B10 B5 B6 B11 B7 B11 B11 B7 B10 B3 B3 B3 B5 B6 B6 B5 B7 B...

Page 144: ...ovable Horizontal Pin 10 27 32 in 275 mm with Cotter Pins FIGURE 4 31 View E1 Insert Connector Insert Lug Outside of Boom 1 3a 2 4 View A View C View D Boom Top A1069 View B A1069 A1080 Fixed Vertical Pin Backstay Link 40 ft 12 2 m Boom Insert Boom Top Jib Strut Stored Backstay Link Jib Butt Jib Butt Jib Top Removable Horizontal Pin Pin 4 3a 3a Erecting Position Stored Position View E2 Backstay Li...

Page 145: ...t a backstay link into position on either side of required insert Lug at bottom connecting holes in link must be toward outside of boom Figure 4 31 View E1 c Lift backstay link upward and engage hole in link with washer 2 Figure 4 31 View E1 on underside of insert connector d For Location A install retaining pin 3a Figure 4 31 View E1 through holes on butt side of link to prevent link from falling...

Page 146: ...5 Basic Backstay Pendant 65 ft 7 in 20 m 6 Jib Stop Pendant 7 ft 7 in 2 3 m 7 Adjusting Links 5 Offset Only P1 P2 See Figure 4 34 FIGURE 4 32 P1 or P2 A1076 A1076 Boom Top Heavy Lift Top Lug Boom Top Pin Pin Jib Butt Pin View C View D View E Pin and Collar Pin Pin P1 A1080 Jib Top Pin 5 4 2 3 1 A1080 6 7 6 7 5 Offset 4 5 View B 15 and 30 Offset Jib Butt Jib Top View A 7 Pin Pin ...

Page 147: ...nks 1 on jib strut as shown in Figure 4 32 View B Install Backstay Pendants For the following procedure see Figure 4 32 View B 1 Lift spreader 4 into position and pin to links 2 on jib strut 3 2 Lay spreader 4 on jib strut 3 3 Pin basic backstay pendants 5 to spreader 4 Lay basic backstay pendants 5 on ground along boom top Install Jib Stop Pendants and Links Choose correct jib stop pendants and l...

Page 148: ...ublished 01 08 13 Control 049 05 FIGURE 4 33 Item Description 1 Basic Backstay Pendant 65 ft 7 in 20 m 2 Backstay Pendant 7 ft 4 in 2 2 m 3 Link 3 ft 8 in 1 1 m 4 Link 12 in 0 3 m A1080 Jib Point 5 Offset 15 Offset 30 Offset View B View A Jib Strut Jib Backstay Link A1076 4 3 4 2 2 1 4 1 1 3 ...

Page 149: ... as outlined earlier in this section prior to raising boom and jib Install load lines Install block up limit control system Make necessary adjustments Perform pre raising checks JIB REMOVAL Lower Boom and Jib 1 Lower boom until jib point is approximately 1 ft 0 3 m from contacting ground 2 Disconnect jib stop pendants 6 Figure 4 32 View D from adjusting links 7 or from boom top lugs 3 Lower boom a...

Page 150: ...backstay pendants 5 from spreader 4 Figure 4 32 View B 2 Coil backstay pendants and store pendants and links for future use NOTE Spreader 4 can be stored on jib strut for shipping Remove Jib Pendants See Figure 4 32 for following procedure 1 Disconnect jib pendants P1 or P2 from links 1 on jib strut 3 and lugs on jib top 2 Coil jib pendants and store for future use Remove Jib Top and Inserts 1 Unp...

Page 151: ... J3 J3 J3 P1 P2 P2 P2 P1 P2 P2 P2 P2 P2 P2 P1 P1 P1 J3 J3 J3 J3 J1 J2 J2 J1 J3 J3 J1 J2 J2 J1 A1076 FIGURE 4 34 Section Type Length Pendant Type Length J1 Jib Butt 20 ft 6 1 m P1 Basic Jib 40 ft 12 2 m J2 Jib Top 20 ft 6 1 m P2 Jib Insert 19 ft 2 in 5 8 m J3 Jib Insert 20 ft 6 1 m 60 ft 18 3 m 120 ft 36 6 m 100 ft 30 5 m 80 ft 24 4 m 40 ft 12 2 m ...

Page 152: ...to drum wind from top of reel to top of drum or from bottom of reel to bottom of drum as shown in Figure 4 36 4 Avoid dragging wire rope in dirt or around objects that can scrape nick cut or crush wire rope Seizing and Cutting Wire Rope Apply tight seizings of annealed wire to the ends of all wire rope If not done the rope wires and strands may slacken This action will result in overloading of som...

Page 153: ...re rope to wear or be cut If defects cannot be fixed replace faulty parts FIGURE 4 37 Place free end of seizing wire in valley between two stands Then wind seizing wire over free end as shown Finally twist and pull two ends of seizing wire together until seizing is tight View A A925 Rope Diameter 1 in 26 mm and Larger View B Rope Diameter Smaller than 1in 26 mm Wind seizing wire around wire rope a...

Page 154: ...ot shock load socket and wedge CAUTION Wire Rope Damage Voids or spaced wraps in first layer see Figure 4 39 View B will permit movement and a wedging action with subsequent layers Wedging action will cause crushing and abrasion of wire rope Never allow wire rope to cross wind on drums FIGURE 4 39 P448 First Wrap Tight Against Flange for 3 4 of Diameter Wraps of First Layer Tight Against Drum and ...

Page 155: ...ly wind the dead wraps of wire rope onto the drum If left uncorrected a wedging action with subsequent layers will occur and the resultant abrasion may cause broken wires in the dead wraps WARNING Falling Load Hazard Wire rope can break if following precaution is not observed Do not attach dead end of wire rope to live end of wire rope with wire rope clip Wire rope clip will transfer load from liv...

Page 156: ...ope A sucker line can be attached to the pad eye to make it easier to reeve the load block Safety 1 For No 1 5 pad eye do not exceed 1 000 lb 4 45 kN single line pull 2 Make sure sucker line and rope clips are rated for at least 1 000 lb 4 45 kN line pull 3 Inspect pad eye prior to each use Replace it if Any original dimensions have changed Cracks or breaks exist in metal or weld Button Socket Ass...

Page 157: ...ON 4 Rope Clips P1519 Sucker Line FIGURE 4 42 A1189 Pad Eye Wire Rope from Drum Pad Eye Sucker Line Load Block Sheaves EXAMPLE Boom Point Sheaves Pull Sucker Line with Winch or Fork Lift Truck B D F A E G C No 1 5 Pad Eye Wire Rope Item Inch mm A 0 63 16 00 B 0 25 6 35 C 1 00 25 40 D 0 44 11 18 E 1 13 28 70 F 0 16 4 06 G 1 31 33 27 ...

Page 158: ...R e f e r e n c e O n l y SET UP AND INSTALLATION 2250 MAX ER 2000 OPERATOR S MANUAL 4 78 Published 01 08 13 Control 049 05 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 159: ...ched as shown in Figure 4 44 Guide Sheaves See Figures 4 45 4 48 for guide sheave identification Once wire rope is routed through guide sheaves be sure to install rope guard pins bars and rollers to retain rope on guide sheaves Wire rope and sheaves can be damaged if rope is not properly retained on sheaves Wire Rope Specifications See Wire Rope Specifications chart in Capacity Chart Manual for pa...

Page 160: ...om Butt Drum 5 Drum 3 Drum 2 See NOTE 2 See NOTE 1 NOTE 1 If load line from Drum 3 is routed over small boom top guide sheave to upper point boom top guide sheave and upper boom point sheave must be grooved for 1 1 8 in 29 mm wire rope Past production sheaves were grooved for 1 in 26 mm wire rope Sheaves cannot be machined New sheaves must be installed 3 O Upper Boom Point Dead End Options 1 in 26...

Page 161: ... 5 8 in 16 mm NOTE 2 S2 2 1 16 in 52 mm NOTE 3 S3 4 15 16 in 127 mm NOTE 3 S4 10 11 16 in 272 mm NOTES 3 4 Dimension B S6 10 7 16 in 265 mm NOTE 3 S7 4 15 16 in 127 mm NOTE 3 S8 2 1 16 in 52 mm NOTE 3 S9 5 8 in 16 mm NOTE 2 NOTE 1 Hand position clamps tight against bearing Before torquing bolts check that sheave turns freely Torque bolts lubricated with S A E 20 oil to 120 ft lb 163 Nm NOTE 2 This...

Page 162: ...r 5 O 9 O See NOTE 1 See NOTE 2 A791 CAUTION Wire Rope Damage Prevent wire rope from disengaging sheaves Install all guide sheave rope guards and rollers after wire rope is reeved 79 44 Boom Wire Rope Routing O Route OVER Sheave U Route UNDER Sheave 3 Drum 3 5 Drum 5 9 Drum 9 NOTE 1 See Figure 4 46 for guide sheave positioning NOTE 2 Install rope retaining pin in this hole for 79 44 operation 5 O ...

Page 163: ...S MANUAL SET UP AND INSTALLATION 4 FIGURE 4 48 79 Boom Butt 79 Boom 40 ft 12 2 m Insert A1152 5 O 5 U A1193 5 9 3 O 3 U 3 3 44 Boom 132 Jib 5 U 9 O 3 U 3 U or 5 U 9 U Wire Rope Routing O Route OVER Sheave U Route UNDER Sheave 3 Drum 3 5 Drum 9 Drum 9 Drum 9 Boom Butt Drum 5 Drum 3 132 Jib on 79 44 Boom ...

Page 164: ... For 2 or 4 Parts 1 Must be removed when 2 or 4 part line is dead ended at upper dead end lug or when 3 part line is used Jib Point Load Block Load Sensing Sheaves 132 Jib on 79 44 Boom WARNING Avoid Death or Serious Injury If you are using a load block that can be stood up vertically for reeving exercise care as the potential for tipping exists Potential causes of tipping are unstable work area b...

Page 165: ...PERATOR S MANUAL SET UP AND INSTALLATION 4 Suggested Location of Weight for Block Up Limit Control See Figure 4 46 for 44 Heavy Lift Top Guide Sheave Location A712 Lower Boom Point 7 PART 8 PART 9 PART 10 PART 6 PART 2 PART 3 PART 5 PART 4 PART Load Block Wire Rope Guide FIGURE 4 50 79 44 Boom ...

Page 166: ...shed 01 08 13 Control 049 05 FIGURE 4 50 continued Wire Rope Guide Upper Boom Point Lower Boom Point Dead End for Even Parts Weight Ball Dead End for 2 Parts Dead End for Odd Parts Load Block A483 Heavy Lift Boom Load Sensing Sheaves 11 PART 12 PART 13 PART 14 PART 15 PART 16 PART 18 PART 17 PART ...

Page 167: ...TOR S MANUAL SET UP AND INSTALLATION 4 FIGURE 4 51 VIEW A Without Luffing Hoist A769 Item Description 1a Tieback Lug 1 3 4 in Diameter 1b Tieback Lug 1 5 16 in Diameter 2a Shackle 1 1 2 in 2b Shackle 1 1 8 in 3 Tieback Sling 4 Load Block M AN IT O W O C 4 1a 2a 3 3 3 2b 1b VIEW B With Luffing Hoist ...

Page 168: ...suspended from the boom point When sizing the sling take into account the dynamic affects of traveling and swinging the crane It is the crane users responsibility to calculate this load Shackle See Figure 4 51 for identification of tieback hole diameter and shackle size CAUTION Avoid damage to boom Haul in load line only until tieback sling is taut Purpose of tieback is only to prevent load block ...

Page 169: ...R e f e r e n c e O n l y Manitowoc Published 01 08 13 Control 049 05 5 i 5 SECTION 5 LUBRICATION TABLE OF CONTENTS Lubrication 5 1 ...

Page 170: ...R e f e r e n c e O n l y 2250 MAX ER 2000 OPERATOR S MANUAL 5 ii Published 01 08 13 Control 049 05 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 171: ...R e f e r e n c e O n l y Manitowoc Published 01 08 13 Control 049 05 5 1 2250 MAX ER 2000 OPERATOR S MANUAL LUBRICATION 5 SECTION 5 LUBRICATION LUBRICATION See F2105 at the end of this section ...

Page 172: ...R e f e r e n c e O n l y LUBRICATION 2250 MAX ER 2000 OPERATOR S MANUAL 5 2 Published 01 08 13 Control 049 05 THIS PAGE INTENIONALLY LEFT BLANK ...

Page 173: ...6 9 MAX ER Counterweight Cylinder Limit Switch Adjustment 6 9 Block Up Limit Control 6 10 General 6 10 Operation 6 10 Block Up Limit Control Deactivated 6 10 Block Up Limit Control Activated 6 10 Installation 6 10 Storing Electric Cord 6 10 Disconnecting Block Up Limit Control 6 12 Removing Jib or Boom Point 6 12 Maintenance 6 12 Adjustment 6 13 Steering Post Bearing Bolt Torque 6 14 Torque Requir...

Page 174: ...R e f e r e n c e O n l y 2250 MAX ER 2000 OPERATOR S MANUAL 6 ii Published 01 08 13 Control 049 05 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 175: ...ither a pendulum type potentiometer or a sensor which sends an electric signal to the crane s programmable controller The programmable controller converts the electric signal into an angle which can be monitored on the digital display in the operator s cab Three angles see Figure 6 1 can be monitored 1 Boom angle 2 Luffing jib angle 3 Boom to luffing jib angle The sending unit for the boom and for...

Page 176: ...current production Pendulum Type Potentiometer When replacing parts in the pendulum type potentiometer sending unit take the following precautions see Figure 6 4 View A 1 Mount potentiometer at angle shown 2 Connect black green and white wires from receptacle to proper terminals on terminal strip 3 Connect wires from potentiometer to proper terminals on terminal strip 4 Make sure all parts are sec...

Page 177: ...ype Potentiometer M E C 575885 Vendor CP17 0693 1 Boom Angle Sending Unit Solid State Sensor 60 M C C A09716 Vendor CS17 VIEW B Input Wire Colors From Sensor Wire Colors To Operation Code Black Black Ground Green White Signal White Red 10 Volts DC Green N C A1294 VIEW A Red White Position Sensor Like This FIGURE 6 4 87FA White 87FA White 82BA Green 3 Pole Receptacle With Protective Cap 0 Black Bla...

Page 178: ...r travel if positioned too high in slots MAX Actuator View B View A View at Right Side Boom Hinge Pin Actuator Bracket Centerline Boom Butt MAX Limit Switch Crane Connect electric wires to normally closed contacts 2 and 5 inside limit switches Boom Angle Actuator Position 83 All 79 or 79 44 Boom Lengths with Luffing Jib Removed A 85 Less than 200 ft 61 m of 79 Boom with 44 Luffing Jib Installed B ...

Page 179: ...eck position of MAX limit switch with relation to actuator bracket View A 3 Loosen capscrews retaining MAX actuator to actuator bracket 4 Rotate MAX actuator CLOCKWISE in its slots so it does not contact limit switch roller when step 5 is performed 5 Raise boom a Slowly raise boom to specified angle 85 or 87 while monitoring angle on digital display b Check boom angle using an accurate protractor ...

Page 180: ... be fully extended Limit switch will not trip open if positioned too low in slots Limit switch could be damaged from over travel if positioned too high in slots View B View C Protractor Level 80 MAX Angle Mast Butt Actuator Bracket Mast Butt C L Limit Switch Electric Cord to Junction Box Equal Distance Rise in actuator bracket depresses limit switch roller as mast angle reaches 80 Depressed roller...

Page 181: ...llow readjustment 1 Mount actuator bracket to mast hinge pin View A 2 Adjust position of limit switch in relation to actuator bracket View B a Move limit switch up or down in slots so edge of roller is even with edge of actuator bracket and roller is fully extended b Rotate actuator bracket to assure that overtravel will not damage limit switch c Tighten bolts holding limit switch in slots 3 Using...

Page 182: ...View C Stored Position Limit Switch stored Rod End Limit Switch Limit Switch Mounting Bracket Mounting Bracket Capscrews Bracket Support Cylinder Rod View B 30 or 40 ft 9 1 or 12 2 m Carrier Extender Arm 15 5 8 in 397 mm Top of Cylinder View A 50 ft 15 2 m Carrier Extender Arm LOWER Counterweight Cylinder Extends RAISE Counterweight Cylinder Retracts Electric Cord typical all views Rod End Limit S...

Page 183: ...t switch mounting bracket in stored position View C 2 Extend cylinder rod past dimension shown in View A or B 3 Mount limit switch mounting bracket to bracket support for desired operating radius View A or B Be sure to use correct mounting bracket holes see table and View D Limit switch roller must be below cylinder rod end 4 Verify that center of limit switch roller is at specified dimension Adju...

Page 184: ...rotates the actuating lever against the limit switch lever This action causes the corresponding limit switch to open the load drum UP and boom DOWN electric circuits The load drum and boom hoist pumps stroke to off At the same time the load drum and boom parking brakes apply to stop the load drum from hoisting and the boom from lowering The BLOCK UP fault alarm in operator s cab will come on to al...

Page 185: ...ultiple Part Line Limit Switch Assembly Junction Box Electric Cords 79 Boom Shown All other Booms and Jibs Similar FIGURE 6 11 A1179 Cable Reel 79 Boom Butt To Junction Box on Boom Point Left Front Corner of Upperworks Adapter Shows cable reel mounting on 79 boom butt and 44 jib butt For 132 and 140 fixed jibs extra cable is stored on a bracket on outside of jib butt Cable Reel 44 Luffing Jib Butt...

Page 186: ...ing plugs Be sure to reconnect electric cord to proper block up limit switch when corresponding attachment is reinstalled Maintenance Inspect and test the block up limit control weekly or every 40 hours of operation as follows Do not operate crane until cause for improper operation and all hazardous conditions have been found and corrected 1 Lower boom and jib if equipped onto blocking at ground l...

Page 187: ...t 79 lower boom point has two springs 2 Loosen setscrew in limit switch lever so lever is free to rotate 3 Manually lift weight so actuating lever rotates upward 4 Hold lever at Dimension A 5 Hold roller on limit switch lever against actuating lever while performing step 6 6 Turn limit switch shaft CLOCKWISE only enough to click limit switch open and hold Then securely tighten setscrew in limit sw...

Page 188: ... first 50 hours of operation YEARLY OR EVERY 2 000 HOURS OF OPERATION whichever comes first torque all bolts to the specified value Bolt Replacement If at the yearly inspection interval one or more bolts are found to be torqued to less than 1 300 ft lb 1 763 Nm replace each loose bolt Also replace the bolt on each side of each loose bolt If at the yearly inspection interval four or more bolts for ...

Page 189: ...imit switch must be adjusted if parts are replaced and checked if the drum is not operating properly Limit Switch Adjustment 1 Loosen screw so limit switch lever is free to rotate on shaft 2 Disengage Drum 2 pawl by toggling DRUM 2 PARK switch to OFF It may be necessary to hoist slightly before pawl will disengage ratchet 3 Rotate lever and hold it so roller is against pawl 4 Turn limit switch sha...

Page 190: ...oom Butt 2 Main Load Drum 3 Ratchet Tooth 4 Pawl 5 Pin 6 Actuator 7 Actuator Pin 8 Bracket 9 Bracket Nuts 10 Jam Nut 11 Adjusting Screw 12 Leaf Spring Dimension A Dimension B 1 9 16 in 40 mm 21 32 in 17 mm View A View B FIGURE 6 16 2 4 10 6 7 9 8 11 3 1 Measure Dimension A Here 2 1 3 12 6 Measure Dimension B Here 4 7 9 8 5 12 A1148 ...

Page 191: ... cab power switch to ON position and engine run stop switch to RUN position Do not start engine 2 Toggle DRUM 9 PARK switch to OFF to disengage pawl 4 3 Connect electrical cord to actuator 6 Actuator will retract 4 Insert pin 5 to connect leaf spring 12 to actuator 6 5 Pin actuator 6 to bracket 8 6 Set Dimension A View A a Loosen bracket nuts 9 b Adjust position of bracket 8 until dimension betwee...

Page 192: ...R e f e r e n c e O n l y MAINTENANCE 2250 MAX ER 2000 OPERATOR S MANUAL 6 18 Published 01 08 13 Control 049 05 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 193: ...Diesel Engine Exhaust 2 1 Disconnecting Connecting Wheeled Counterweight Trailer With Boom Raised 4 42 Drum Identification 3 4 English and Metric Conversions 1 8 Environmental Protection 2 21 Fire Extinguishers 2 19 General Instructions 3 3 General Maintenance 6 1 Getting On or Off Crane 2 5 Handling Components 4 2 Identification of MAX ER Components 1 1 Identifying Boom Mast Components 4 2 Instal...

Page 194: ... Usage for Wire Rope Reeving 4 76 Pedestal barge Mounted Cranes 2 26 Personnel Handling Policy 2 24 Pre Raising Checks 4 26 Principles of Operation 3 3 Refueling 2 19 Removable Lacings 4 3 Retaining Connecting Pins 4 3 Rigging Drawings 4 1 Safe Maintenance Practices 2 19 Safe Operating Practices 2 9 Safety and Information Signs 2 4 Safety Devices 2 15 Safety Information 2 1 Safety Messages 2 1 Set...

Page 195: ...R e f e r e n c e O n l y ...

Page 196: ...R e f e r e n c e O n l y ...

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