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TABLE OF CONTENTS
Maintenance Checks .............................................................................................. 3
Maintenance Intervals ............................................................................................. 3
Maintenance Instructions ........................................................................................ 3
Initial Run-In Services ............................................................................................. 3
Maintenance Checklist ............................................................................................ 4
Lubrication .............................................................................................................. 8
Lubrication Symbols............................................................................................ 8
General ............................................................................................................... 8
Lubrication Intervals............................................................................................ 8
Over-Lubrication ................................................................................................. 8
Lubrication Tips................................................................................................... 8
Oil Can Points ..................................................................................................... 8
Wire Rope Lubrication......................................................................................... 8
Cylinder Rod Lubrication..................................................................................... 9
Environmental Protection.................................................................................... 9
Reference Instructions ........................................................................................ 9
CraneLUBE......................................................................................................... 9
Approved Lubricants for Normal Operation....................................................... 10
Grease ........................................................................................................... 10
Open Gear Oil ................................................................................................ 10
Gear Oil .......................................................................................................... 10
Hydraulic Oil ................................................................................................... 10
Hydraulic Filter Replacement ............................................................................ 11
Lubrication Points ............................................................................................. 11
Fluid Capacities ................................................................................................ 12
Approved Lubricants for Arctic Operation ......................................................... 13
Upper and Lower Lubrication — Location ......................................................... 14
Engine Components ......................................................................................... 17
Upper and Lower Lubrication — Identification .................................................. 18
Prior to Use When Crane is Assembled ......................................................... 18
Every 8 Hours of Operation or Daily (whichever comes first) ......................... 18
Every 8 Hours of Operation or Daily Continued.............................................. 19
Every 40 Hours of Operation or Weekly (whichever comes first).................... 20
After First 200 Hours of Operation.................................................................. 20
Every 200 Hours of Operation or Monthly (whichever comes first)................. 21
Every 500 Hours of Operation or Quarterly (whichever comes first)............... 21
Every 1000 Hours of Operation or Semiannually (whichever comes first)...... 22
Boom Rigging Lubrication ..................................................................................... 24
Extended Upper Boom Point Lubrication .............................................................. 26
Luffing Jib Lubrication ........................................................................................... 27
Automatic Lubrication System............................................................................... 37
Operation .......................................................................................................... 37
Daily Inspection................................................................................................. 37
Automatic Lubrication System Troubleshooting................................................ 38
© 2010 Manitowoc
Published 06-22-10 F2109-1
MAINTENANCE CHECKS AND LUBRICATION 16000
F2109-2
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
MAINTENANCE CHECKS
This folio contains a list of inspection and maintenance
checks and the recommended interval at which each check
WARNING
should be made. Performing the checks at the
recommended intervals will help maintain the safety, To prevent serious or fatal injury while servicing crane:
dependability, and productivity designed into your crane. • Lower all loads to ground.
NOTE: Service and maintain the engine according to the • Move all controls to off.
engine manufacturer’s instructions. • Stop engine and wait until all moving parts stop
before servicing crane.
MAINTENANCE INTERVALS Maintenance checks which require engine to be
The letters at the top of the checklist columns correspond to running are identified with a bold dot (•).
the below listed intervals. Use extreme care to avoid contact with moving parts
when servicing crane with engine running.
Perform the checks either at the hourly interval or at the
calendar interval, whichever comes first. At each interval, • Attach WARNING sign to engine start control to warn
perform all previous checks in addition to the ones listed. personnel that crane is being serviced and must not
be started.
A Every 8 Hours or Daily
• Do not operate crane until all safety guards and
B Every 40 Hours or Weekly (includes A Checks) covers are securely reinstalled and all maintenance
equipment is removed.
C Every 200 Hours or Monthly (includes A - B Checks)
Do not place crane into service until all defects are
D Every 500 Hours or Quarterly (includes A - C Checks) corrected.
E Every 1000 Hours or Semiannually (includes A - D Checks)
NOTE: Completed checklists and repair receipts may be
F Every 2000 Hours or Annually (includes A - E Checks) required for warranty claims. Keep these items on
The intervals are based on average operating conditions and file at all times. Give the checklists to the new
should be used only as a guide until adequate experience is owner if the crane is sold.
obtained to establish intervals which meet the specific Additional copies of this publication can be obtained
operating conditions of your crane (frequency and duration from Technical Publications Department at factory.
of operation , loa dings involved , du st y or corrosive
atmosphere, outside air temperature, etc.).
MAINTENANCE INSTRUCTIONS
Before lengthening or shortening the recommended
intervals, study the crane’s performance. Carefully examine S ee S e r vi ce M a n u al f o r sp e ci f ic ma i n te n a n ce a n d
previous checklists and service records to determine if past adjustment procedures.
component failures have been caused by inadequate See Lubrication topic in this Manual for lubrication intervals,
maintenance. types of fluids, and lube point locations.
Perform an oil analysis at regular intervals for each fluid used See Parts Manual for specific torque values of nuts, bolts,
in the crane to determine oil-change intervals. and screws.
This checklist covers 200 hours of operation (approximately
one month working one shift a day); therefore, a new INITIAL RUN-IN SERVICES
checklist must be started each time 200 hours of operation or
one month is completed. The gear boxes and pump drive must be serviced after the
first 200 hours of operation (see Lubrication in this manual).
NOTE: Depending on the options your crane has, some
checks given in this checklist may not apply. The turntable bolts must be serviced after the first 50 hours
of operation (see Turntable Bearing Adjustments in Service
A black box in any column indicates that the item does not Manual).
require service at the corresponding interval.
If further service of any item is required, indicate so in the
box next to the item. For example: indicates Service
Required. Also make a detailed report of the type of service
required (parts replacement, adjustment, overhaul, etc.). in
the space provided at end of this section.
Manitowoc F2109-3
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
MAINTENANCE CHECKLIST
ENGINE HOUR METER READING:
Checkers
Initials
at Start of Checklist ______________
at End of Checklist _______________
A A A A B A A A A B A A A A B A A A A C D E F
SCHEDULE
Check for damaged or missing fiberglass covers.
Clean and check all windows for cracks.
Clean all debris from crane.
Check for leaks (fuel, coolant, gear oil, engine oil,
hydraulic oil); correct cause and fill faulty unit to
proper level.
Grease 8 hour lube points.
Apply open gear oil to ring gear.
Check pump drive oil level.
Check fuel tank level and drain water from bottom
of tank.
Check hydraulic tank level and drain water from
bottom of tank.
Check radiator coolant level when cold.
Service engine (see manufacturer’s instructions).
Check that fire extinguisher (s) is on crane and
fully charged.
Check that Operator’s Manual and Capacity
Charts are in operator’s cab.
• Check fault alarm for proper operation – should
come on for an instant when ignition switch is
moved to RUN position.
• Check seat switch for proper operation — all
control handles and corresponding functions
should be inoperable when operator is out of
seat.
• Check display screen 2 on control console for
proper operation.
• Replace hydraulic filters if filter fault appears on
display screen 2.
• Check engine air cleaner service indicator.
• Check all crane functions for proper operation.
• Check swing lock for proper operation; must
hold crane in position when engaged and allow
crane to swing when disengaged.
• Check all drum pawls for proper operation; must
fully engage and disengage ratchets. Controlled
by park switches.
F2109-4
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
Manitowoc F2109-5
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
SCHEDULE B B B C D E F
Grease 40 hour lube points.
Oil all pins not equipped with grease fittings.
Check battery electrolyte level.
Inspect rotating bed, carbody, and crawlers for cracks or other damage.
Check that all pins and bolts are in place and tight in rotating bed, carbody, and crawlers (see
separate checks for turntable bolts).
Check crawler treads for proper adjustment.
Inspect boom and mast for cracked or deformed members.
Check that all boom and mast pins and bolts are in place and tight.
Inspect all sheaves for wear and damage.
Inspect all wire rope for broken wires or excessive wear and for proper spooling on drums
and reeving through sheaves; lubricate wire rope if needed.
Inspect each hook for cracks or deformation.
Clean breathers on applicable gear boxes and on pump drive.
• Test all disc brakes (load drums, boom hoist, swing, travel) for proper operation.
• Test each limit device for proper operation:
Boom up limit.
Boom down limit.
Minimum bail limit.
Maximum bail limit.
Block-Up limit.
Any other limit crane is equipped with.
F2109-6
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
NOTES
Manitowoc F2109-7
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
LUBRICATION
Lubrication Symbols CAUTION
Machinery Damage!
The following symbols are used in decals on the crane to
identify lubrication points. Before lengthening lubrication intervals, check that all
parts are receiving an adequate supply of clean lubricant;
o th e r w is e , pa r ts wi ll b e da m a ge d f r om a la ck o f
Hydraulic lubrication. Contact your Manitowoc distributor for
Engine Oil
Filter recommendations on lengthening lubrication intervals.
Level
General • Too high an oil level can cause churning and foaming of
the oil and result in excessive heat and over-flow from
This section describes the major lubrication considerations the reservoir.
for this crane. Some points requiring lubrication (linkage in
• An extra shot of grease, if too stiff or under too much
control members not equipped with grease fittings) have
pressure, can pop out a bearing seal.
been omitted, but they should be lubricated in accordance
with good maintenance practices (see Oil Can Points).
Lubrication Tips
The lubrication intervals for vendor-supplied parts (engine,
• Check all oil levels before start-up so the oil has had a
light plant, etc.) have also been omitted from this Lubrication
chance to run down from the reservoir walls and moving
Guide; service vendor-supplied parts according to the
parts.
original equipment manufacturers’ manuals.
• Avoid introducing dirt into reservoirs. Carefully clean the
Depending on the options your crane is equipped with, some area around dipsticks, level plugs, fill plugs, and
lube points given in this Lubrication Guide may not apply to breathers before removing.
your crane.
• Replace level plugs, fill plugs, drain plugs, and breathers
Lubrication Intervals snugly and wipe up any spillage.
The intervals listed in this Lubrication Guide are for average • Keep oil and grease dispensers and containers tightly
operating conditions based on experience gained by closed and stored in a dirt and moisture-free locations.
testing lubricants at the factory and on recommendations • Clean grease fittings before and after applying grease.
given by the lubricant suppliers. Severe operating conditions
(excessively dusty or corrosive atmosphere, unusually high • Apply grease until the bushing or bearing is purged so
or low outside temperature, extreme loadings, uncommonly dirt and water cannot enter. Wipe up excess grease.
frequent or long operating cycles) may require shortening
the lubrication intervals. Follow the intervals given in this
Oil Can Points
Lubrication Guide until adequate experience is obtained to Oil all pins not equipped with grease fittings with engine oil
establish intervals which meet your operating conditions. every 40 hours of operation (even if the crane is not being
Bearings and bushings that are too warm, excessive play in operated).
moving parts, binding in moving parts, excessive or
abnormal wear in gears and chains, and rust accumulation
Wire Rope Lubrication
indicate a lack of lubrication. If these conditions are found New wire rope is lubricated during manufacturing, but this
during regular inspection, the lubrication interval for the lubricant is only adequate for initial storage and the early
faulty parts should be shortened. stages of operation. To prevent the damaging effects of
corrosion and to reduce wear, the wire rope must be
lubricated at regular intervals.
Contact your wire rope manufacturer/dealer for lubrication
recommendations. The lubrication interval and the type of
lubricant used depends on the type of wire rope, the severity
of duty, and the type of corrosive elements the wire ropes is
subjected to.
F2109-8
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
• The wire rope must be properly protected at all times. Inherently, however, the chrome plating has cracks in its
structure which can allow moisture to corrode underlying
• The lubricant must be fluid enough to fully penetrate the
steel. Depending on ambient temperature and the frequency
strands and rope core. Use one of the methods shown in
of cylinder operation, the crane’s hydraulic oil may not
Figure 2 to lubricate the wire rope.
penetrate these cracks and protect the rods. And, even if the
• For maximum penetration, apply lubricant where the cylinders are operated on a regular basis, many cylinders
wire rope “opens up” as it travels around a sheave or have portions of exposed rod even when the cylinders are
winds onto a drum. fully retracted.
• The wire rope must be clean and dry before applying Exposed cylinder rods on cranes that are stored,
lubricant; an air jet, or wire brush are some cleaning transported, or used in inclement environments (high
methods. humidity, rain, snow, and salt air) are at high risk of corrosion.
Do not use grease to lubricate wire rope. Grease will not Protecting Cylinder Rods
penetrate rope properly and will buildup in valleys
between wires and strands. This buildup will inhibit rope All exposed cylinder rods must be protected by applying a
inspection and could trap moisture in rope’s interior. thorough coat of cylinder-rod protectant available from
Manitowoc in 12 oz. aerosol cans — order part number
9999101803. The cylinder-rod protectant contains solvents
Casing filled with and lubricants that penetrate metal pores, displace moisture,
Swab and Lubricant dissolve existing corrosion, and then dry to a resilient waxy
coating.Cylinder operation and weather will remove the
protectant over time. Therefore, inspect all cylinder rods
weekly and reapply protectant to exposed rods.
See Crane Service Manual for detailed information on
Pouring onto Slow specific maintenance checks and procedures.
Moving Sheave.
Environmental Protection
Dispose of waste properly! Improperly disposing of waste
can threaten the environment.
Potentially harmful waste used in Manitowoc cranes includes
Bathing — but is not limited to — oil, fuel, grease, coolant, air
conditioning refrigerant, filters, batteries, and cloths which
Brushing have come into contact with these environmentally harmful
substances.
Handle and dispose of waste according to local, state, and
federal environmental regulations.
Spraying When filling and draining crane components: do not pour
Hand waste fluids onto the ground, down any drain, or into any
Swabbing source of water.
• Always drain waste fluids into leak proof containers that
are clearly marked with what they contain.
WARNING • Always fill or add fluids with a funnel or a filling pump.
Moving Rope Hazard! • Immediately wipe up any spills.
Take every precaution to protect hands from injury
when rope is moving. Wear heavy gloves and move Reference Instructions
rope as slowly as possible.
See Crane Service Manual for detailed information on
specific maintenance checks and procedures.
FIGURE 2
CraneLUBE
Cylinder Rod Lubrication
Manitowoc highly recommends the use of CraneLUBE
General l u b ri c a n ts t o i n c re a s e y o u r cr a n e ’s r e l i a b i l i t y a n d
performance. Contact your Manitowoc distributor for detailed
The cylinder rods on Manitowoc cranes have a layer of
information about our CraneLUBE lubrication program.
chrome plating on their surfaces to help protect them from
corrosion.
Manitowoc F2109-9
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
This type oil requires heating or thinning for proper When the expected ambient temperature will be
application to gear teeth. Apply a light film of oil to each gear below 0°F (-18°C), the hydraulic oil must be heated
tooth; do not rely on gear rotation to distribute oil. to at least 0°F (-18°C) prior to start-up. Tank
heaters are available from Manitowoc.
Manitowoc Factory Fill
Cloud point of oil selected must be equal to or less
• CraneLUBE 375 NC. than expected ambient temperature.
Gear Oil Field Make-Up
Manitowoc Factory Fill Do not dilute the oil in the hydraulic tank with more than 25%
• CraneLUBE 75W-90 for all gear boxes except of another brand oil. Dilution beyond the 25% maximum
crawler. could effect the crane’s operating performance at
certain temperatures.
• CraneLUBE 80W-140 for crawler gear boxes.
If in doubt as to how much make-up oil has been added to
Table 2 Gear Oil the tank on your crane, Manitowoc recommends that a
laboratory viscosity test be performed to determine if the oil
Ambient
SAE Grade still meets the viscosity targets given above OR that the
Temperature Where Used
Gear Oil system be completely drained and refilled.
Range
75W-90 below -10°F Drums, Swing, Boom Hoist
(-23°C)
75W-90 all temperatures Pump Drive
to 100°F (38°C)
80W-90 -10°F to 100°F Drums, Swing, Boom Hoist
(-23°C to 38°C)
85W-140 above 100°F Drums, Swing, Boom Hoist,
(38°C) Pump Drive
80W-140 all temperatures Crawlers
F2109-10
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
MCC No. System The letters before the item numbers in the illustrations
correspond to the following intervals:
A00652 Charge Pumps and In-Tank Return
(Past Production) • A = At Assembly
A17924 Charge Pumps and In-Tank Return • D = Daily
(Current Production)
• W = Weekly
• M = Monthly
CAUTION • Q = Quarterly
Hydraulic System Damage! • S = Semiannually
Original Equipment Manufacturers’ filter elements – • O = At Overhaul
available from Manitowoc – must be used on this crane.
Substituting with any other brand or type filter element is • Y = Yearly
prohibited.
Filter elements made by other manufacturers may
collapse under pressure. This action will allow unfiltered
oil to be drawn into hydraulic system — pumps, motors,
and valves can be destroyed.
Manitowoc will reject warranty claims for damaged
hydraulic components if proper hydraulic filter elements
are not used.
Manitowoc F2109-11
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
Capacity Approved
System
Gallons Liters Lubricant
Cooling System 30 114 See NOTE 1
Crawler Gearbox - Input/Output (each) 20 76 Gear Oil
Crawler Grease Reservoir 1 3,8 Grease
Drum 1 (Main Load Hoist) 27.5 104 Gear Oil
Drum 2 (Whip Line Hoist — Standard) 25 95 Gear Oil
Drum 2 (Whip Line Hoist — High Speed Drum) 16 61 Gear Oil
Drum 3 (Luffing/Auxiliary Load Hoist) 8 30 Gear Oil
Drum 4 (Boom Hoist) 18 68 Gear Oil
Fuel 250 946 See NOTE 1
Hydraulic System (Initial Fill) 300 1136 Hydraulic Oil
Hydraulic Tank 168 636 Hydraulic Oil
Pump Drive 1.50 5,7 Gear Oil
Swing 5.5 21 Gear Oil
Turntable Bearing Grease Reservoir 1 3,8 Grease
F2109-12
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
CAUTION
Machinery Damage!
Do not operate main crane functions (swing, travel,
drums, boom hoist) with approved arctic lubricants when
ambient temperature is above 60°F (16°C). Crane
machinery will be damaged.
When ambient temperature is above 60°F (16°C), limit
operation to crane setup functions (i.e. jacking cylinders).
Switch back to standard lubricants listed in lubrication
guide when ambient temperature will be above 60°F
(16°C).
Manitowoc F2109-13
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
Typical 8 Places
M1
A1
S2 A2a
W1 D2
P2285
P2238a
2 Places at
D1
Front of
P2253a Adapter Frame
Near Air
P2250
Filter
D3
D9
S1
P2237a
Bottom Rear of D5
Hydraulic Tank
P2246
D10
D4
D8
P2247
A10740-22
D7
A3 D6 A2b
F2109-14
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
P2239a
W2 W4
D16
M11
W3
Current Production
M10 OR
Past Production
W4
P2252
D17 D16
Display
Screens
P2254
P2239
P2338
D18b
D15b
Current Production
OR
Past Production
P2251 D15a
D19 Filters 2
D18a S6 A10740-22
P2240
W5 P2271
M2
D17 S3
W6 Current Production
S5 OR
P2241a Past Production
M12
S4
Inside
Hydraulic
Tank M2
P2248b S3
D20 Filters 1
P2271a
S6
FIGURE 4
Manitowoc F2109-15
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
P2270
Q1 M3a
P1687
M14
S7a
P2270a
M3b
W7
P2242 P2270b S7b
M16
A10740-22
S9
M17
S8
P2287 P2286
P2243
M4
S10 FIGURE 5
F2109-16
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
Engine Components
1 2
P2284b P2249a
P2284a P2284c
FIGURE 6
Manitowoc F2109-17
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
F2109-18
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
NOTE 1 Check hydraulic tank display on information NOTE 2 When a filter needs replacement, fault alarm will
screen in cab (see Operator’s Manual Section come on and fault symbol will appear on active
3): d isp la y s cr e e n . F I LTE R FA U LT i co n a n d
corresponding filter number will appear on fault
• FULL COLD LEVEL
screen. Replace BOTH corresponding filter
(approximately 60°F – 16°C)
elements immediately.
Screen should read 87-90%.
FILTERS 1 are charge filters and FILTERS 2 are
• FULL HOT LEVEL
return filters. See Service Manual Section 2 for
(approximately 180°F – 82°C)
filter replacement procedure.
Screen should read 95%.
It is normal for this fault alert to come on at start-
Do not fill tank to 100%. Oil will flow out of
up when hydraulic oil is cold. Alert should shut
breather.
off as oil warms up.
If oil level drops to 50%, fault alarm will come on
and fault symbol will appear on active display
screen. HYDRAULIC FLUID LOW icon will
appear on fault screen. Fill tank immediately. WARNING
Fill tank either through plug opening (D18a) in Burn Hazard!
return manifold or through power fill coupler Oil in h ydraulic tank may be under pressure and
(D18b). Do not fill tank through breather cap extremely hot.
port or through top of either filter.
Hot oil can escape when you remove either filter cover.
See Section 2 in Service Manual for fill Relieve pressure through air valve on top of hydraulic tank
procedure. before servicing.
Manitowoc F2109-19
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
Current Production
Desiccant Breather
F2109-20
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
Manitowoc F2109-21
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
F2109-22
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
Manitowoc F2109-23
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
A10740-3
A10882
A11993
A4
M1
M1
M1
M1 W1
W1
W1
W2
W3 W2
D2
W6 W4
W5
A543
W4
Y1 Plastic Plug
P2315
A2 A3
A1
Y1
P2267
M2
FIGURE 7
F2109-24
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
Manitowoc F2109-25
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
M1
M1
A1
M1
A1
W1
W2
M1
W1
W2
W3
Wind Attachment
FIGURE 8
F2109-26
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
A2
A1
A2
W1
W2
W3
A5
A4a
A4 Current Production
Strut Stop Winch
Y1
A3
LJ4-1
FIGURE 9
Manitowoc F2109-27
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
M3
M3
W1
W2
W3
A1
M3
M3
W1
W1
W2
M5-1a
W3
Extended Upper Point
D2
2 A2
W5
M1
1
S1
W4
D1
M1-2a
M5-1b
See
Figure 11
W6 4 3
FIGURE 10
F2109-28
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
M1-2b
W9
W7 W8
M2
S2
M5-2 W10
W11
(through hole)
W12
(from below) W14
W13
B1
M4
(from below)
FIGURE 11
Manitowoc F2109-29
Published 02-22-10
Item Description Required Service
At Assembly
A1 Extended Upper Point Rollers (1 fitting, 2 places) Grease prior to raising boom.
A2 Boom Hoist Gear Box Check level (see NOTE 1).
Every 8 Hours of Operation or Daily (whichever comes first)
D1 Boom Hinge Pin (2 fittings, 2 places) Grease each.
D2 Load Drum Wire Rope Guide Sheave Shafts Apply grease to entire length of both shafts.
Every 80 Hours of Operation or Bi-Weekly (whichever comes first)
B1 Turntable Bearing (4 fittings, 2 places) Grease each.
Every 40 Hours of Operation or Weekly (whichever comes first)
W1 Swivel (1 fitting each) Grease each.
W2 Load Block Sheaves (1 fitting, each sheave) Grease each.
W3 Hook Swivel and Trunnion Bearings Grease.
W4 Wire Rope Roller Bearings (1 fitting, 2 places) Grease each.
W5 Boom Hoist Gear Box Check level (see NOTE 1).
W6 Boom Hoist Pawl Apply open gear oil to contact surfaces between cam
and pawl.
W7 Swing Gear Box Breathers (8 places) Soak in non-flammable solvent and blow clean and
dry with compressed air.
W8 Swing Gear Box Dipstick (4 places) Check level of each. Fill to MAX mark with gear oil
through dipstick opening.
W9 Lifting Cylinder Pivot Pins (1 fitting, 2 places) Grease each.
W10 Beam Pivot Pins (1 fitting, 2 places) Grease each.
W11 Telescopic Cylinder Ends (1 fitting, 2 places) Grease each.
W12 Swing Gear and Pinion (2 places) Coat teeth with open gear oil.
W13 Axle Pivot Pins (1 fitting, 4 places) Grease each.
W14 Beam Connecting Pins (1 fitting, 2 places) Grease each.
NOTE 2 Service at 200 hour interval is required to drain oil. Crane owner must supply a funnel
remove metal particles and other impurities and hose so oil can be routed from drum to
collected during initial operation of gear boxes. suitable container at ground level.
NOTE 3 To drain and refill boom hoist gear box when • Rotate drum so pipe (3) is horizontal and
mast is in transport position with top chords of facing boom.
mast butt horizontal:
• Refill drum through valve (4) so oil is at level
• Drain major volume of oil from drum barrel at of pipe (3).
valve (4).
NOTE 5 A drain plug is installed in end of each drain
• Drain remaining oil from drum barrel at pipe hose. To drain a swing gear box:
(3) by removing cap from pipe.
• Uncoil hose and stick through hole in bottom
• Refill drum with gear oil through plug (2) to of tray.
middle of sight gauge (1).
• Extend hose into a suitable container.
NOTE 4 To drain and refill boom hoist gear box when
• Remove plug and drain.
mast is in operating position (mast raised):
• Reinstall plug, pull hose through hole, and
• Rotate drum so pipe (3) is vertical and
coil hose around swing gear box.
pointing down. Remove cap from pipe to
Manitowoc F2109-31
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
M3
W1
W2
W3
A1
M3
M3
W1
W1
W2
HM5-1a
W3
Extended Upper Point
2 A2
W4
W5
M1
1
D1 S1
HM1-2a
HM5-1b
W7
W7
W6 4 3
HM1-2a FIGURE 12
F2109-32
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
NOTE 1: To check level of boom hoist gear box when To check level of boom hoist gear box when
mast is in transport position with top chords of mast is in operating position (mast raised):
mast butt horizontal:
• Rotate drum so pipe (3) is horizontal and
• Oil should be a middle of sight gauge (1). remove cap from pipe.
• If necessary add oil through plug (2). • Oil should be up to pipe opening.
• If necessary add oil through valve (4).
Manitowoc F2109-33
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
F2109-34
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
Manitowoc F2109-35
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
P1942
6
3
5 8
P2256
14
4 10
5
2
10
7
View A View C
2 Places on Front of Adapter Frame 2 Places:
Right Side – Turntable Bearing Front of Rotating Bed – Turntable Bearing
1
Left Side – Crawlers Right Side Carbody – Crawlers
10 5
13
11
P2257
13
13 5
10
P2255
14
12
View B
Both Crawlers
View D
13 2 Places on Rotating Bed -
A10740-22 Turntable Bearing
FIGURE 13
F2109-36
Published 02-22-10
16000 MAINTENANCE CHECKS AND LUBRICATION
The crane has two grease systems which automatically 2. Check and fill reservoirs when the grease level reaches
grease points on the turntable bearing and rollers on each the MIN mark.
crawler. Grease is pumped to each point at the intervals 3. Fill reservoirs to the MAX mark with a hand operated
given in Table 5 when the ignition switch is on. grease pump through grease fitting on pump housing.
Table 5 Automatic Greasing Intervals Use a recommended grease (see Table 1 for factory fill).
Manitowoc F2109-37
Published 02-22-10
MAINTENANCE CHECKS AND LUBRICATION 16000
3. Pump operated with an Grease in reservoir is low. Fill reservoir and test system with grease gun at system
empty reservoir. manual grease fitting.
Disconnect main delivery hose from pump and watch until
solid grease with no bubbles flows from outlet.
Reconnect main delivery hose to pump outlet.
4. Grease is discharged at There is blockage in meter Test system with grease gun at system manual grease fitting.
pressure relief valve. valves, hose, tubing, or at Loosen each outlet line at primary valve, one at a time. The
bearing. blocked outlet line will start flowing grease and indicator pin
starts indexing.
Retighten all outlets at primary valve.
Trace hose that flowed to its secondary valve.
Repeat process of loosening each outlet one at a time until
blocked line is found.
Retighten all outlets.
Repair bearing blockage.
If a metering valve is causing blockage, replace valve.
5. Indicator pin on primary See item 4. See item 4.
valve does not move.
6. Lubrication point is not Cut in hose or tubing. Replace hose or tubing.
receiving grease.
F2109-38
Published 02-22-10