Manitowoc 4000W User manual

MANITOWOC CRANES, INC.
2401 SO. 30TH STREET ●PO BOX 70 ●PHONE [phone] ●FAX [phone]
MANITOWOC, WI 54221-0070 USA
LAMINATED
LUBRICATION GUIDE
Model
Serial Number
4000W
40614
03/27/03

LAMINATED LUBRICATION GUIDE MANUAL INDEX
MODEL 4000W - SERIAL 40614
PUBLICATION DATE TITLE
LUBRICATION
Folio 852 06/08/88 Preventive Maintenance Check List
Folio 529 03/04/81 Tank & Gear Capacities 4000-4000W Vicon
Folio 328/417 Supplement 05/10/83 3900/4000W Lubrication
Folio 417 02/11/87 Lubrication Instructions
Bulletin Service/Parts Bulletin 18-1 04/27/01 Lubricant Specifications
Bulletin Service/Parts Bulletin 18-2 01/08/93 Approved Lubricants for Arctic Operation
03/27/03

MANITOWOC ENGINEERING, CO.
Division of The Manitowoc Company,inc. Manitowoc, Wisconsin54220
PREVENTIVE MAINTENANCE CHECKLIST
3000 through 4100W
GENERAL
This folio contains a checklist of the inspections, main-
tenance, and service parts replacements required by
this machine and the recommended interval at which
each check should be made. Performing each check at
the recommended interval will help maintain the safety,
dependability, and productivity designed into this
machine.
NOTE Optional items that may not be on your crane are
indicated by this symbol (1).
Maintain engine(s), air compressor(s), and light
plant according to the manufacturers' instructions.
MAINTENANCE INTERVALS
The letters in the right columns of the checklists corres-
pond to the following intervals.
Peform the checks at the hourly interval or the calendar
interval, whichever comes first.
A -- Every 8 to 10 Hours or Daily
B -- Every 40 to 50 Hours or Weekly
C -- Every 200 Hours or Monthly
D -- Every 1000 Hours or 3 Months
E -- Every 2000 Hours or 6 Months
The above maintenance intervals are based on average
operating conditions, and should be used only as a
guide until adequate experience is obtained to establish
intervals which meet the operating conditions of your
machine (frequency and duration of operation, loading
involved, dusty or corrosive atmosphere, outside air
temperature, etc.).
Any change in the recommended intervals, either
increasing or decreasing, should be preceded with a
complete analysis of how the machine is performing.
Carefully study previous maintenance checklists and
service records before making any changes; an oil analy-
sis of each fluid used in the machine should be the major
factor used in determining oil-change intervals.
USING MAINTENANCE CHECKLIST
This checklist covers 200 hours of operation (approxi-
mately one month working one shift a day); therefore, a
new checklist must be started each time 200 hours of
operation or one month has been completed.
E#
Check each item in the 'A' interval columns every
8-10 hours of operation or daily.
Check each item in the 'B' interval columns every
40-50 hours of operation or weekly. The 'B' interval
column also includes the 'A' checks.
Check each item in the 'C' interval column every 200
hours of operation or monthly. The 'C' interval
column also includes the 'A' and 'B' checks.
E#
O
E]
When a 'D' interval is reached (every 1000 hours of
operation or 3 months), check each item in the'D'
interval column only. The 'D' interval column also
includes the 'A', 'B', and 'C' checks.
When an 'E' interval is reached (every 2000 hours of
operation or 6 months), check each item in the 'E'
interval column only. The 'E' interval column also
includes the 'A', 'B', 'C', and 'D' checks.
The shaded boxes in any column indicate that the
items do not require service at the corresponding
interval.
If further service of any item is required, indicate so
in the box next tothe item (for example: 'S' indicates
Service Required); furthermore, make a detailed
report of the type of service required (parts
replacement, adjustment, overhaul, etc.).
~~.j~,~': "~ ........ .........~ Serious or fatal injury can result if
~~i~ safety precautions which follow are
not taken:
--Stop engine and wait until all moving parts are com-
pletely stopped before servicing machine.
--Attach CAUTION tag or "Out-of-Order" sign to engine
start controls in operator's cab and at each engine to
warn personnel that machine is being serviced and
must not be started.
--Do not operate machine until all safety guards and
covers are Securely reinstalled and all maintenance
equipment is removed.
Maintenance checks which require the engine(s) to be
run are identified with a bold dot (*).
NOTE Completed maintenance checklists should be
kept on file at all times, and given to the new
owner if the machine is sold Maintenance
checklists and repair receipts may be required
for warranty claims.
MAINTENANCE INSTRUCTIONS
Refer to the instructions in the Service Manual for spe-
cific maintenance and adjustment procedures. Refer to
the Lubrication Guide for lubrication intervals, types of
fluids, and lube point locations.
Specific torque values for nuts, bolts, and screws are
provided in the Parts Manual for the machine.
This checklist can be reproduced locally, or additional
copies can be obtained through the Service Department
at the factory.
©Manitowoc 1988
(Continued)
3-26-76 (Rev. 6-8-88) 3000-4100W PM CHECK LIST FOLIO 852-1

Manitowoc Engineering Co.
ENGINE HOUR METER READING:
Start of Checklist
End of Checklist
Checkers
INITIALS
SCHEDULE
Grease all 4 hour and 8 hour lubepoints.
Check for damaged or missing sheet metal.
Clean and check all windows for cracks and breakage.
Clean all debris from floors, stairs, and catwalks.
Check that all machinery guards are in place.
Check radiator coolant level.
Check fuel tank level.
Check engine air cleanerservice indicators.
Check that all railings, catwalks, and non-skid material are in place.
Check crawler treads for cracks, missing keepers and pins, and proper
adjustment.
Inspect rol!er path for damageand lubricate with gear oil.
Check ring gear and lubricatewith open gear iubricant. , ,
Drain water from rotating bed sump and boom hoist housing.
Clean Cuno oil fiiter (1 or 2 places)by turning handleseveral times daily.
Check for fluid leaks (oil, fuel, coolant).
Fill all lubricators.
Check all oil levels (dipsticks, sight gauges, and level plugs):
Rotating bed sump.
Drum gear case.
Converteroutput housings.
Chain case.
Transmission case (VlCON only).
Converter reservoir (at operating temperature).
Hydraulic reservoir.
Power lowering reservoir (VICONonly). '
Power lowering retarder (Non-VICON).
I
Power,lowering'chaincase.
Boom hoist h0usirig (independentor standard).
Planetary gear housing (hydraUlic boom hoist only).
Check that the fire extinguisheron crane is fully charged.
Operator's guide and capacity charts are in operator's cab.
eCheck gauges on enginesand in operator's cab for proper readings.
eCheck that machinery warning buzzer and light are operational(should come on
briefly when engine is started).
• Check all brakes for proper operationand adjustment (must hold load):
Each drum working.
Each drum parking.
Swing.
Boom hoist automatic.
Boom hoist auxiliary.
Auxiliary drum.
VlCON® tagline.
(Continued)
FOLIO 852-2

Manitowoc Engineering Co.
SCHEDULE E
eCheck all clutches for proper operationand adjustment (must not slip under load):
Each drum.
Interlock (3950D only).
Main drive.
Engine clutch (Non-VICON only).
Independent swing.
Independent boom hoist.
Auxiliary drum.
eCheck steering clutches for proper operation.
• Check all limiting devices (must stop load or boom when contacted):
Hoist load limit.
Bail limit.
Automatic boom stop (maximum angle).
Automatic boom stop (minimum angle).
eOheck miscellaneous controls for proper operation:
Swing lock,
Travel locks.
Drum pawls.
Slide pinion
Drum rotation indicators.
Main drive blowers.
eCheck that automatic controls operate properly:
Automatic drum hoist brake system.
Dead man control system.
Check adjustment of detents in drum controls, main drive control, independent
swing control and boom hoist control.
eCheck oil flow indicator (1 or 2 places) for proper operation.
eCheck air moisture ejectors and air dryers for proper operation.
eCheck alcohol injector for proper operation.
eCheck all air controls and valves for proper operation and for air leaks.
Check drum brake pedals for proper operation and that pedal latch holds pedal
in fully applied position.
Drain water from air system filters and moisture ejectors at shut-down.
eVisuallycheck that oil is flowing from main drive shaft and, if equipped, independent
swing oil nozzels.
(Continued)
FOLIO 852-3

Manitowoc Engineering Co.
: ;t
I SCHEDULE
Grease all upper and lower 40 hour lube points.
Oil all upper and lower pins and linkages not equipped with grease fittings.
Clean converter orifice filters (Non-VlCON only).
Clean converter charge pump sediment bowl filters (Non-VICON only).
Check boom hoist housing oil level.
Check carbody gear case oil levels.
Lubricate wire ropes.
Inspect wire rope for broken wires, excessive wear, and proper
spooling and reeving.
Inspect all sheaves, hooks, and oth.er rigging for wear or damage.
Tighten fairlead anchor pins and sheave clamp bolts.
Check electrolyte level in batteries.
Check :battery connections and wires for corrosion.
Check that all boom and gantry pins, bolts and riggincj are in place.
Inspect boom and gantry for cracked or damaged members.
Check r0tating bed, carbody, and crawlers for cracks or damage.
Clean breathers on all casesand reservoirs.
Lubricate all open chains and check for unusual wear.
Check that all air and hydraulic hoses are free of abrasions,
swelling and kinking.
Clean and lubricateflexair valves. :
Check transmission, chain case, and interlock;chains (if equipped) for, ' i
cracked or broken links, broken rollers, and:propertension.
Check that oil floWs:through oilers:and orilic'e~at transmission and.chain case. '
Clean converter orifice filters andicheck positioner adjustment(VICON only).
Check house rollers for wear or damage.
Check hook rollers for proper adjustment and tighten all mounting bolts.
Tighten swing pinion capscrews.
Inspect all V-belts for wear and proper tension (adjust or replace as required).
Check that all V-belt pulleys are tight on shafts.
Check that all Iowerworks bolts and pins are in place and tight.
Check that all upperworks bolts and pins are in place and tight.
Service air system filters.
Tighten drum journal bolts.
, I
ill
J
(Continued)
FOLIO 852-4

Manitowoc Engineering ""
%J~.l.
t
t
t
I SCHEDULE
Drain and refill oil in transmission and transmission heat exchanger
(VICON only).
Drain and refill power lowering chain case (VICON only).
Remove and clean transmission case oilers and orifices (VICON only).
Drain and refill oil in converter reservoir, converter housing and converter
heat exchanger (VlCON only).
"C;lean converter filter, orifice filter, and suction screen (VICON only).
Drain and refill oil in converter output housings (VICON only).
Clean and lubricate flexair valves.
Clean transmission oil filter (VICON only).
Replace diaphragms in air system relay, quick release and shuttle valves.
Inspect king pin bushing for excessive wear or damage.
Drain and refill oil in drum gear case (past production).
Drain and refill oil in rotating bed sump; clean filter and suction
screen, if equipped, (Folio 1027).
Remove and clean all gear case oil nozzels.
Drain and refill oil in carbody gear cases.
Clean steering clutch pans once a year.
Drain and refill coolant in radiator and heat exchangers and
replace water filters if engine is so equipped.
Drain and refill hydraulic systems.
Clean suction screens and diffusers in hydraulics reservoirs.
Replace hydraulic filters.
:l'ighten ring gear and king pin bolts.
Service air dryer.
Drain and refill boom hoist housing.
Check boom hoist bronze gear and worm shaft for proper wear.
Check that radiator fan is correct for season.
FOLIO 852-5

MANITOWOC ENGINEERING CO.
division of The Manitowoc Company, Inc.
TANK AND GEAR CAPACITY TABLE
MODEL 4000-4000W VICON ®
.lIanitou'oc, IVisconsin 54220
The following capacities, listed in gallons and liters
are approximate for ordering supplies. Use dipstick,
sight gauge or level plug for actual check of level.
CAPACITIES
RESERVOIR, CI~IN AND/OR GEAR CASE GALLONS LITERS
FUEL TANK: 210 794.92
COOLING SYSTEM:
CUMMINS -
CATERPILLAR -
GENERAL MOTORS 6-110
12V-71
15*f
17.t
18.*
56.78
75.70
64.35
68.14
ROTATING BED SUMP:
W/STANDARD BOOM HOIST - 21 79.49
W/INDEPENDENT BOOM HOIST - 29 109.77
TRANSMISSION CASE AND
DRIVE CHAIN CASE: 8 30.28
CARBODY: I-1/2 5.68
TORQUE CONVERTERS: 23 87.06
AIR CLEANER - OIL BATH TYPE:
CATERPILLAR D-343 ENGINE -
i
*When equipped with a cab water heater
1-I/2
(7.57 Liters)
Add 2 Gallons
t When equipped with heat exchanger cooling of converters Add 9 Gallons
SEE MANUFACTURERS MANUAL
ENGINE CRANKCASE:
AIR COMPRESSOR:
STARTING ENGINE:
5.68
(34.07 Liters)
9-29-67 (Rev. 3-4-81) TANK & GEAR CAPACITIES 4000-4000W VICON FOLIO 529-'I

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