Manitowoc 12000-1 User manual

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©2016 Manitowoc
Published 07-15-16, Control # 254-01
SERVICE/MAINTENANCE MANUAL
This manual has been prepared for and is considered part of -
12000-1/12000E-1
Model Number
1200Ref
Serial Number
This Manual is Divided into the following Sections:
SAFETY SECTION
SECTION 1 REFERENCE MATERIALS
SECTION 2 TEST PROCEDURES
SECTION 3 GENERAL
SECTION 4 POWER TRAIN
SECTION 5 HYDRAULIC SYSTEM
SECTION 6 HOIST SYSTEM
SECTION 7 BOOM HOIST SYSTEM
SECTION 8 SWING SYSTEM
SECTION 9 TRAVEL SYSTEM
SECTION 10 ELECTRICAL SYSTEM
SECTION 11 AIR CONDITIONER
SECTION 12 TRANSLIFTER SYSTEM
SECTION 13 TROUBLESHOOTING
NOTICE
The serial number of the crane is the only method the Manitowoc Crane Care Lattice
Team has of providing you with correct parts and service information.
Always furnish serial number of crane when ordering parts or discussing service
problems with your Manitowoc distributor or the Manitowoc Crane Care Lattice Team.
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
these personnel.
• Do not operate or work on crane or attachments without first reading
and understanding instructions contained in Operator Information
Manual and Service Manual supplied with crane and applicable
attachments.
• Store Operator Information Manual and Service Manual in operator’s
cab.
If Operator Information Manual or Service Manual is missing from cab,
contact your Manitowoc distributor for a new one.

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THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH

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1. REFERENCE MATERIALS
SAFETY
TABLE OF CONTENTS
2. MAINTENANCE STANDARDS TEST PROCEDURES
3. GENERAL WORK STANDARD
4. POWER TRAIN
5. HYDRAULIC SYSTEM
6. HOIST SYSTEM
7. BOOM HOIST SYSTEM
8. SWING SYSTEM
9. TRAVEL SYSTEM
10. ELECTRIC SYSTEM
11. CONNECTOR LAYOUT
12. AIR CONDITIONER
13. TRANSLIFTER SYSTEM
14. TROUBLESHOOTING
Published 07-15-16, Control # 254-01

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Published 07-15-16, Control # 254-01

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112000-1 / 12000E-1
[ TABLE OF CONTENTS ]
SAFETY
1. REFERENCE MATERIALS
1.1 12000-1 SPECIFICATION .................................................................................................... 1-1
1.1.1 CRANE OUTSIDE DIMENSION....................................................................................1-1
1.1.2 CRANE SPECIFICATION, PERFORMANCE............................................................1-2
1.1.3 CRANE WORKING RANGES ........................................................................................1-4
1.2 12000-1 DIMENSION, WEIGHT OF EACH COMPONENT .......................................1-7
1.2.1 BASE MACHINE ................................................................................................................1-7
1.2.2 COUNTERWEIGHT ..........................................................................................................1-9
1.2.3 ATTACHMENT ....................................................................................................................1-11
1.3 12000-1 CLAMSHELL RATED LOADS (OPTION)........................................................1-14
1.4 12000-1 SWING AND TRAVEL STABILITY .................................................................... 1-17
1.5 12000-1 TRAVEL ALLOWABLE SLOPE ANGLE...........................................................1-20
1.5.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION.....1-20
1.6 12000E-1 SPECIFICATION ................................................................................................. 1-27
1.6.1 CRANE OUTSIDE DIMENSION....................................................................................1-27
1.6.2 CRANE SPECIFICATION, PERFORMANCE............................................................1-28
1.6.3 CRANE WORKING RANGES ........................................................................................1-30
1.7 12000E-1 DIMENSION, WEIGHT OF EACH COMPONENT .................................... 1-33
1.7.1 BASE MACHINE ................................................................................................................1-33
1.7.2 COUNTERWEIGHT ..........................................................................................................1-35
1.7.3 ATTACHMENT ....................................................................................................................1-37
1.8 12000E-1 CLAMSHELL RATED LOADS (OPTION).....................................................1-41
1.9 12000E-1 SWING AND TRAVEL STABILITY..................................................................1-44
1.10 12000E-1 TRAVEL ALLOWABLE SLOPE ANGLE........................................................ 1-47
1.10.1 CRANE ATTACHMENT INSTALLED : BOOM INSERT CONFIGURATION.....1-47
1.11 ENGINE MAIN SPECIFICATION........................................................................................1-55
2. MAINTENANCE STANDARDS TEST PROCEDURES
2.1 MAINTENANCE STANDARD .............................................................................................. 2-1
2.1.1 PIN, BUSHING, SPRING, LINING AND SHEAVE....................................................2-1
2.1.2 TRAVEL DEVICE ...............................................................................................................2-7
2.2 PERFORMANCE STANDARD AND TEST PROCEDURE.........................................2-13
2.2.1 OPERATING SPEED ........................................................................................................2-15
2.2.2 HYDRAULIC PRESSURE ...............................................................................................2-16
2.2.3 SWING BEARING..............................................................................................................2-21
3. GENERAL WORK STANDARD
3.1 STANDARD TIGHTENING TORQUE ...............................................................................3-1
3.1.1 TIGHTENING TORQUE OF CAP SCREWS AND NUTS ...................................... 3-1
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3.1.2 TIGHTENING TORQUE OF HYDRAULIC FITTINGS............................................. 3-5
3.2 STANDARD PARTS ............................................................................................................... 3-7
3.2.1 BOLT ......................................................................................................................................3-7
3.2.2 O-RING .................................................................................................................................3-8
3.2.3 BACK-UP RING..................................................................................................................3-9
3.2.4 BITE TYPE FITTING .........................................................................................................3-10
3.3 CONVERSION TABLE...........................................................................................................3-12
3.3.1 UNIT CONVERSION.........................................................................................................3-12
3.3.2 MILLIMETER : INCH CONVERSION TABLE ............................................................ 3-13
3.3.3 METER AND FOOT CONVERSION TABLE..............................................................3-15
3.3.4 GRADE CONVERSION TABLE.....................................................................................3-16
3.3.5 UNIT WEIGHT TABLE ......................................................................................................3-17
3.3.6 SYSTEM INTERNATIONAL (SI) UNIT CONVERSION TABLE............................3-18
4. POWER TRAIN
4.1 APPARATUS AND COMPONENTS LOCATION ...........................................................4-3
4.2 ENGINE......................................................................................................................................4-6
4.2.1 REMOVAL OF THE ENGINE..........................................................................................4-6
4.2.2 REPAIR AND MAINTENANCE OF THE ENGINE....................................................4-9
4.2.3 INSTALLATION OF THE ENGINE ................................................................................4-10
4.3 PUMP DRIVE ASSEMBLY ...................................................................................................4-14
4.3.1 CONSTRUCTION OF THE POWER DIVIDER.........................................................4-15
4.3.2 CONSTRUCTION OF THE COUPLING......................................................................4-20
4.3.3 REMOVAL OF EACH PUMP ..........................................................................................4-21
4.3.4 REMOVAL OF THE POWER DIVIDER .......................................................................4-22
4.3.5 REMOVAL OF THE COUPLING.................................................................................... 4-23
4.3.6 DISASSEMBLING THE POWER DIVIDER................................................................4-24
4.3.7 CHECK AND REPAIR OF THE POWER DIVIDER.................................................. 4-26
4.3.8 ASSEMBLING THE POWER DIVIDER.......................................................................4-27
4.3.9 INSTALLATION OF THE COUPLING ..........................................................................4-28
4.3.10 INSTALLATION OF EACH PUMP.................................................................................4-29
4.4 ASSEMBLY AND DISASSEMBLY OF RADIATOR........................................................4-30
4.4.1 CONSTRUCTION OF THE RADIATOR ...................................................................... 4-30
4.4.2 REPLACEMENT ORDER OF RADIATOR CORE....................................................4-31
4.5 DEF/AdBlue®SCR SYSTEM ...............................................................................................4-32
4.5.1 DEF/AdBlue®TANK ...........................................................................................................4-37
4.5.2 INDUCEMENT CONTROL SYSTEM ...........................................................................4-40
5. HYDRAULIC SYSTEM
5.1 LOCATION OF MAIN HYDRAULIC COMPONENTS...................................................5-3
5.1.1 COMPONENTS LOCATION ON THE HYDRAULIC SCHEMATIC .....................5-3
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5.1.2 HYDRAULIC COMPONENTS LIST..............................................................................5-11
5.1.3 LAYOUT OF HYDRAULIC COMPONENTS...............................................................5-16
5.2 CONSTRUCTION AND FUNCTION.................................................................................. 5-26
5.2.1 OIL FLOW FROM No.1 AND No.2 PUMPS ...............................................................5-26
5.2.2 OIL FLOW FROM No.3 AND No.4 PUMP ..................................................................5-28
5.2.3 OIL FLOW FROM No.7 PUMP.......................................................................................5-30
5.2.4 OIL FLOW FROM No.8 PUMP.......................................................................................5-34
5.2.5 OIL FLOW FROM No.5 AND No.6 PUMPS
(12000-1 : STD. / 12000E-1 : OPT.) ............................................................................. 5-42
5.3 VALVE .........................................................................................................................................5-44
6. HOIST SYSTEM
6.1 APPARATUS AND LOCATION OF COMPONENTS .................................................... 6-1
6.2 CONSTRUCTION AND FUNCTION.................................................................................. 6-6
6.2.1 HYDRAULIC SCHEMATIC..............................................................................................6-6
6.2.2 LIFTING A LOAD................................................................................................................6-8
6.2.3 HOLDING A HOISTED LOAD ........................................................................................6-10
6.2.4 LOWERING A LOAD (POWER LOWERING)............................................................6-12
6.2.5 FREE FALL OPERATION ................................................................................................6-14
6.2.6 G WINCH MODE LIFTING.............................................................................................. 6-22
6.2.7 G WINCH MODE LOWERING.......................................................................................6-24
6.3 WINCH .......................................................................................................................................6-26
6.3.1 WINCH INSTALLATION ...................................................................................................6-26
6.3.2 WINCH ASSEMBLY ..........................................................................................................6-27
6.3.3 REDUCTION UNIT ASSEMBLY ....................................................................................6-28
6.3.4 ADJUSTMENT OF DRUM LOCK..................................................................................6-30
6.4 BRAKE PEDAL ........................................................................................................................6-31
6.4.1 ASSEMBLY DRAWING ....................................................................................................6-31
6.4.2 ADJUSTING THE BRAKE PEDAL................................................................................6-34
6.4.3 BLEEDING AIR FROM BRAKE CIRCUIT...................................................................6-35
7. BOOM HOIST SYSTEM
7.1 APPARATUS AND COMPONENTS LOCATION ...........................................................7-1
7.2 CONSTRUCTION AND FUNCTION.................................................................................. 7-2
7.2.1 HYDRAULIC SCHEMATIC..............................................................................................7-2
7.2.2 RAISING BOOM.................................................................................................................7-3
7.2.3 NEUTRAL (HOLDING BOOM).......................................................................................7-4
7.2.4 LOWERING BOOM ...........................................................................................................7-5
7.3 BOOM HOIST WINCH...........................................................................................................7-7
7.3.1 BOOM HOIST WINCH INSTALLATION ......................................................................7-7
7.3.2 REDUCTION UNIT ASSEMBLY ....................................................................................7-8
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7.3.3 BOOM DRUM LOCK ASSEMBLY.................................................................................7-10
7.3.4 ADJUSTMENT OF BOOM DRUM LOCK ...................................................................7-11
8. SWING SYSTEM
8.1 APPARATUS AND COMPONENTS LOCATION ...........................................................8-1
8.2 CONSTRUCTION AND FUNCTION..................................................................................8-3
8.2.1 HYDRAULIC SCHEMATIC..............................................................................................8-3
8.2.2 SWING ..................................................................................................................................8-4
8.2.3 STOPPING...........................................................................................................................8-6
8.3 CONSTRUCTION OF THE SWING SYSTEM................................................................8-9
8.3.1 SWING REDUCTION UNIT ............................................................................................ 8-9
8.3.2 REDUCTION UNIT ASSEMBLY ....................................................................................8-10
8.3.3 SWING BEARING..............................................................................................................8-11
8.3.4 SWING LOCK .....................................................................................................................8-12
9. TRAVEL SYSTEM
9.1 APPARATUS AND COMPONENTS LOCATION ...........................................................9-1
9.2 CONSTRUCTION AND FUNCTION..................................................................................9-2
9.2.1 HYDRAULIC SCHEMATIC..............................................................................................9-2
9.2.2 TRAVELING (RIGHT SIDE FORWARD)..................................................................... 9-3
9.2.3 STOPPING...........................................................................................................................9-4
9.3 CRAWLER.................................................................................................................................9-5
9.3.1 DRIVE ASSEMBLY............................................................................................................9-5
9.3.2 REDUCTION UNIT ............................................................................................................9-6
9.3.3 MOTOR.................................................................................................................................9-7
9.3.4 ADJUSTMENT OF SHOE ...............................................................................................9-10
10. ELECTRIC SYSTEM
10.1 ELECTRICAL ...........................................................................................................................10-3
10.1.1 ELECTRICAL WIRING SCHEMATIC........................................................................... 10-3
10.1.2 WIRE COLOR LIST...........................................................................................................10-25
10.1.3 LOCATION AND USE OF FUSE ...................................................................................10-26
10.1.4 WIPER CONTROL RELAY..............................................................................................10-31
10.1.5 PRESSURE SWITCH (FOR TRAVEL MOTION DETECT) ................................... 10-32
10.1.6 PRESSURE SWITCH (FOOT BRAKE) .......................................................................10-33
10.1.7 PRESSURE SENSOR......................................................................................................10-34
10.1.8 INCLINATION SENSOR................................................................................................... 10-37
10.1.9 BUZZER UNIT ....................................................................................................................10-38
10.1.10 RELAY BOX.........................................................................................................................10-39
10.1.11 RELAY BOX.........................................................................................................................10-50
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[ TABLE OF CONTENTS ]
10.1.12 LOAD DETECTOR (CRANE) .........................................................................................10-53
10.1.13 ANGLE SENSOR............................................................................................................... 10-55
10.1.14 HOW TO CHECK THE FAILURE CONTENTS .........................................................10-56
10.1.15 WARNING DISPLAY CONDITION................................................................................10-66
10.1.16 ENGINE ECU ......................................................................................................................10-77
10.1.17 DCU........................................................................................................................................10-80
10.2 LOAD SAFETY DEVICE ....................................................................................................... 10-84
10.2.1 CONFIGURATION OF SCREENS................................................................................ 10-85
10.2.2 SYSTEM DIAGRAM..........................................................................................................10-86
10.2.3 MONITOR DISPLAY..........................................................................................................10-87
10.2.4 DETAIL OF ML CONTROLLER .....................................................................................10-94
10.2.5 SHIFTING TO MAINTENANCE SCREEN..................................................................10-107
10.2.6 INPUT / OUTPUT SIGNAL.............................................................................................. 10-109
10.2.7 ML FUNCTION SETTING................................................................................................ 10-118
10.2.8 DATA COPY, FORMAT .....................................................................................................10-120
10.2.9 LANGUAGE, UNIT SETTING.........................................................................................10-124
10.2.10 ML ADJUSTMENT (NORMAL).......................................................................................10-125
10.2.11 ML ADJUSTMENT (TEMPORARY)..............................................................................10-148
10.2.12 OPERATION PROGRESS ..............................................................................................10-149
10.2.13 VERSION INFORMATION .............................................................................................. 10-152
10.2.14 FAILURE HISTORY........................................................................................................... 10-153
10.2.15 ADJUSTMENT DATA........................................................................................................10-156
10.2.16 TEST FACILITY .................................................................................................................. 10-162
10.2.17 DOWNLOAD ML PROGRAM .........................................................................................10-164
10.2.18 DOWNLOAD OF MONITOR PROGRAM ...................................................................10-166
10.3 MAIN CONTROLLER.............................................................................................................10-171
10.3.1 ARRANGEMENT OF MAIN CONTROLLER..............................................................10-171
10.3.2 COMPOSITION OF SYSTEM ........................................................................................10-172
10.3.3 FUNCTION OF MAIN CONTROLLER.........................................................................10-173
10.3.4 MAIN CONTROLLER 1, 2 (HARDWARE)..................................................................10-209
10.3.5 SPECIFICATIONS OF MAIN CONTROLLER INPUT/OUTPUT .......................... 10-210
10.3.6 ARRANGEMENT OF MAIN CONTROLLER CONNECTOR PIN ........................ 10-224
10.3.7 ADJUSTMENT OF MAIN CONTROLLER .................................................................. 10-240
10.3.8 CONTROLLER MALFUNCTION EMERGENCY MEASURES.............................10-245
11. CONNECTOR LAYOUT
12. AIR CONDITIONER
12.1 NAME OF THE AIR CONDITIONER PARTS.................................................................. 12-1
12.2 ELECTRIC WIRING DIAGRAM ..........................................................................................12-7
12.3 PARTS ILLUSTRATION ........................................................................................................ 12-8
Published 07-15-16, Control # 254-01