MANITOWOC ENGINEERING CO.

MANITOWOC CRANE MANUAL

4100W
 MANITOWOC ENGINEERING CO.

Approximate weights of material

(In pounds per cubic yard)
(Compiled from various manuals)

Pounds per yard

cubic

Andesite, solid 4,660

Ashes 1,110
Basalt, broken 3,300
Solid 5,076
Slag
Clay 1,150
Dry excavation 1,847
Wet excavation 3,080
Dry doughs 1,822
Wet masses 2,700
Compact, natural bed 2,943
Clay and gravel, dry 2,700
Wet 3,085
Carbon
Anthracite, natural bed 2,546
Route 1,857
Bituminous, natural bed 2,268
Rota 1,413
Diabasa, route 4,752
Solid 3,089
Dolomite, wheel 2,940
Solid 4,887
Land
Moldable land, dry excavation 2,100
Wet excavation 2,430
Wet excavation 2,700
Denso 3,375
Loose soft mud 2,916
Packed 2,565
Gneiss, broken 3.141
Solid 4,833
Granite, broken 2,778
Solid 4,525
Record, release, dry 2,565
Functioning of the hole (sand covered with gravel) 3,240
Dry 1/4" - 2" 2,835
Wet 1/2” - 2” 3,375
Plaster, broken 3,054
Shredded 2,700
Solid 4,698
 MANITOWOC ENGINEERING CO.

Pounds per yard

cubic

Broken halite (rock salt) 2,545

Solid 3,915
Hematite, broken 5,430
Solid 8,262
Ice, solid 1,550
Limonite, broken 4,159
Solid 6,399
Broken limestone 2,625
Solid 4,400
Magnetite, rotates 5,528
Solid 8,505
Marble, broken 2,650
Solid 4,308
Greta, wet excavation 3,780
Mica, wheel 2,700
Solid 4,860
Mud, fluid 2,916
Packaged 3,200
Mud, dry 675
Damp 1,350
Wet 1,890
Porphyry, broken 2,790
Solid 4,293
Phosphate rock, broken 2,970
Sandstone, broken
Solid 3,915
Sand, dry loose 2,700
Slightly damp 3,240
Wet 3,500
Wet packed 3,510
Sand and gravel, dry 2,916
Wet 3,375
I left, broken 2,665
Solid 4,500
Scum, broken 2,970
Solid 3,668
Dross, screening 2,495
Crushed scoria (3/4") 1,998
Slate, broken 2,800
Solid 4,670
Crushed stone 2,700
Snow 405-1,350
Talc, broken 2,931
Solid 4,535
 MANITOWOC ENGINEERING CO.

Pounds per yard

cubic

Trap, rotary 2,950

Solid 4,870

The aforementioned weights may vary according to the moisture content,

texture, etc.

Inflammation of the percentage of different classes of materials.

Material Percentage inflation

Clean sand or recording 5 to 15
Topsoil 11to20
Moldable land 17-1/2 (sandy) to 25 (clay)
Good common land 24 to 35
Clay with sand or gravel 30 to 45
Light and friable clay 35 to 55
Hard and durable clay 42 hard, terrified
62 with rocks or roots
I skit and soft rock 50 to 73
Hard rock 56 bursts
98 poor bursts
 MANITOWOC ENGINEERING CO.

Accessory specifications

Crane serial No. 41097

Make Model Serial

Motor Cummins NTA-855-C380 10225096
Mando ________ ____________ ________
Type ____________
Pump of Cummins AR-40165-2483-B NTA855C380-79315
flammable
Part ____________
Air filter Donaldson ______________ _______________
Starter or
initial motor Delco-Remy 1113872 71H13
Switch of
solenoid _____________________
Generator Delco-Remy 1117095 71H20
Carburetor __________ ___________ ________________
Converter Double disc IF-10027-TC 243077
Spec. No. 61040 Spec. No. 470L
Converter Double disco IF-10027-TC 243922
Spec. No. 61040 Spec. No. 470L
Compressor
of air Gardner-Denver ADK 1001 591017
Light plant _____________ __________ _______________
Spec. No. __________________
Line of
tip _____________ _____________ ________________
Young F-603-EY-1P 243830
Young Exchanger F-603-EY-1P 245564
of heat Young F-602-EY-1P 228207

Cubes: Drag ) Pala ( ) Clam Hoes )

Make ___________ Model ___________ Sleeve ________ Serial No ________

200 tons of load block serial No. 24

 MANITOWOC ENGINEERING CO.

Replacement of the filtering element

Crane serial No. 41097

Engines

Lubricating oil:
To do Luber Finer Replacement _____________________
Make Cummins Replacement _____________________
To make Replacement _____
To do Replacement

Heavy oil:
To do Cummins Replacement
To do Replacement

Converter:
To do Purolator Replacement
To do Replacement

Starting motor:
To do Replacement
To do Replacement

Belt replacement

Main motor

Fan: Cummins No. 178622_ No. Reg. 2_

Generator: Cummins No. 178573_ No. Reg. 1_
Compressor: Manitowoc N° 226969_ N° Reg. 2_
Water pump: Cummins No. 200328_ No. Reg. 1_
Converter pump: Manitowoc No. 227221_ No. Reg. 1_
Oil pump: Manitowoc No. 227237_ No. Reg. 1_
Cooling pump
of converter: Manitowoc No. 227227_ No. Reg. 1_
Bed pump: Manitowoc No. 227241_ No. Reg. 1_
Clutch blower
of oscillation: No. Reg. No.
 MANITOWOC ENGINEERING CO.

GEARBOX AND TANK CAPACITY TABLE

Crane model: 4100W___Vicon Motor:_Cummings NTA-855-B380___

Fuel tank: 118 gallons - left tank 446.63 liters

205 gallons - right deposit 775.93 liters

Cooling system: 24 gallons (add 2 gallons for the water heater)

90.85 liters
7.57 liters

Lifting box of the pen: __Circulating oil system__

Rotary bed of the collector: _55 gallons_ 208.19 liters

Transmission box:
10 gallons 27.85 liters
Drive chain box:

Drum gear box: _Circulating oil system_

Engine sump: 10 gallons (excluding filters) 37.85 liters

Bodywork: 1 1/2 gallons 5.68 liters

Air compressor: 1 3/4 gallon 1.66 liters

Torque converter: _(controlled) 23 gallons 87.06 liters

The capacities are listed in US gallons and liters.

These capacities are approximate, for requesting supplies. Use the rod.
graduated or other gauge for the actual level control.
 MANITOWOC ENGINEERING CO.

Coating and drum table________________________4100W

Tandem drum axes

Application Drum Part DAY. Width Type of Size

number drum or of the cable
coating of steel
Crane
Raising Forward 180533 19" 37-1/4 inches
Drum diameter 1-1/8 inches
Raising Back 48935 27-5/8 inches
37-1/4” Plain 1-1/8 inches
Spoon
Closure Forward 48816 27 inches 37-1/4 inchesRibbed 1-1/8 inch
Cover Backside 48816 27" 37-1/4 inchesGrooved 1-1/8 inches
Dragadora
rotary guide or
able to be knocked down
Drag Forward 48817 24 inches 37-1/4 inchesChannelled 1-1/4”
Lifting Back 48817 27 inches 37-1/4” Ribbed 1-1/8 inches
Tower crane
#22Tower-#23
pen
Raising Forward 48935 27-5/8 inches
37-1/4 inches Plain 1-1/8 inch
Retention line Butt 180533 19 inches 37-1/4 inches
Diameter. drum 1”

Application Drum Part DAY. Type of Size

number drum or of the cable
coating of steel
Crane
Raising Forward 180533 19 inches 37-1/4 inches
Drum diameter 1-1/8 inches
Raising Rear 181614 21" 17-3/8 inches Plain 1-1/8 inches
right
Auxiliary Back 49416 17-1/2" 17-3/8 inches
Drum diameter 1"
left
Spoon
Closure Back 31356 27 inches 17-3/8 inchesGrooved 1-1/8 inches
law
Cover Back 31356 27 inches 17-3/8 inchesRibbed 1-1/8 inches
left
Dragadora
rotary guide or
abatable
Drag Forward 48817 24 inches 37-1/4 inchesRibbed 1-1/4 inches
Raising Back 31356 27 inches 17-3/8” Ribbed 1-1/8 inches
law
MANITOWOC ENGINEERING CO.
 MANITOWOC ENGINEERING CO.

Vicon Machines

Index.
Section II: Controls, identification, function or description of
functioning.

The following list of commands shows options that cannot be included in the
control arrangement of this machine. For its specific control arrangement, see the
proven articles below.
Ref Page / Description Drawing No. Table
. No. No. schematic
1 34-1.1 ( )Control of oscillation blocking.
34-1.3 (/) Control of oscillation blocking (M4100)
2 34-2.1 ( )Control of the car's pinion
lifting of the standard pen.
( )
3 34-3.1 ( )25,000 *Third drum
(3a) Nail control.
Clutch control
(3c) Brake release
34-3.2 ( )5,000 *Third drum
(3b) Clutch control
(3c) Release of the brake
34-3.3 ( )Control of the paddle brake
( )
4 34-4.1 (/) Control of the direction.
Clutch control
Neutral stop
Neutral stop.
34-4.2 ( ) Impulse selector valve of the
34-4.3 ( ) spatula
( ) Direction control - Trolley crane
34-5.1 (/)
5 ( ) Level

34-6.1 ( ) Instrument panels.

6 Elevated cabin of the indicators of 33745
34-6.2 ( ) motor and the converter.
34-6.3 ( ) Solo indicator of the converter. 90067
34-6.4 ( ) Indicator of the converter and of the entire 90108
34-6.5 ( ) motor.
34-6.6 ( ) Converter and tachometer indicator. 90993
Only converter, motor and tachometer. 91179
34-6.7 ( ) Converter and elevated cabin of the 91304
lubrication indicators.
34-6.8 ( ) Lubrication pressure indicator of the
gear.
34-6.9 ( ) Lubrication pressure indicator of
7 chain.
34-6.10 ( ) Alarm device - converters
34-6.15 (/) controlled. 180913
34-7.1 ( ) Engine shutdown control.
8 34-8.1 Indicators and alarm device.
 MANITOWOC ENGINEERING CO.

( )Front converter selector valve.

9 34-9.1 ( )Standard pinion of the lifting car
10 34-10.1 ( )the pen - air control.
11 Car axle - air control
34-11.1 ( )Swing lock - air control.
34-11.2 Stroke locking control.
12 ( )Air.
34-12.1 ( )Manual.
34-12.2 Air indicator.
13 34-13.1 Pressure distributor.
Pressure distributor with low pressure.
14 34-14.1 Drum rotation indicator of the
15 34-15.1 pen lift. M3900W-4100W
34-15.2 Tower - Control of the pen latch.
Auxiliary brake of the boom lifting.
34-15.4 Auxiliary brake for the boom lift
with elevated cabin.
16 Auxiliary brake for the lift of the arm
34-16.1 (M3900- 4100W)
Control of the car's pinion.
34-16.2 With oscillation and lifting of the plume
independent.
34-16.3 With standard oscillation and lifting of the
independent pen.
34-16.4 With oscillation and raising of the plume
standard.
17 34-17.1 With independent oscillation and lifting
18 from the standard pen.
34-18.1 Air oscillation brake regulator.
34-18.2 Oscillation energy regulator.
34-18.3 Track machines.
19 M3900W superior
34-19.1 M3000-4000 superior.
34-19.2 Route control.
Tracked machines.
34-19.3 With air oscillation brake.
34-19.4 Control of the path/oscillation.
34-19.5 Crawler machines.
With air oscillation brake.
34-19.6 With standard lifting control of the
pen
With standard lifting control of the
34-19.7 pen and oscillation brake.
34-19.8 Pedestal mounted machine
Oscillation control.
Oscillation control with brake of
34-19.9 air oscillation.
Magnetized machine.
Line following/oscillation with control
34-19.10 of the piston.
34-19.11 Machines mounted on a barge.
20 Oscillation control and spatula.
34-20.1 Course control (M4100W)
34-20.2 Drum rotation indicator.
34-20.3 Left drum.
34-20.4 Right drum.
 MANITOWOC ENGINEERING CO.

34-20.5 Left and right drum.

34-20.6 Tambor delantero.
21 Rear drum.
34-21.1 Front and rear drum.
34-21.2 Independent oscillation control.
34-21.3 Manual.
22 Air.
34-22.1 With dead control.
34-22.2 Control of the rear converter.
With independent oscillation control.
34-22.3 With independent oscillation control and
air oscillation brake.
34-22.5 With independent oscillation control
23 34-23.1 superior.
24 With independent oscillation control.
34-24.1 Auto upload
34-24.2 Right drum clutch control.
Air.
34-24.3 Manual
34-24.4 Control of the rear drum brake.
Air
34-24.5 Manual.
34-24.6 Control of the right drum clutch.
34-24.7 Con auto subida en tambor izquierdo.
34-24.8 With reduced closing pressure.
25 With MEC control valve.
Front drum control (M4100W)
34-25.1 Control of the crane boom
34-25.2 independent.
34-25.3 Con control manual del convertidor frontal.
34-25.4 With manual control of the converter
34-25.7 frontal.
26 With a winch and a claw.
34-26.1 With clutch release.
34-26.2 Hydraulic lift
27 (M4100W)
34-27.1 Front converter control manual.
34-27.2 With crane lifting control.
34-27.3 With crane lift control.
Left drum clutch control.
34-27.4 Air
34-27.5 With MEC control valve.
Manual.
34-27.6 Control of the front drum clutch.
34-27.7 Air
34-27.9 Manual.
28 34-28.1 Control of the left drum clutch.
34-28.3 Air with spoon descent.
29 With car raised on the right drum.
34-29.1 Rear drum control (M4100W)
34-29.2 Engine regulator - Manual control.
30 Motor regulator control.
34-30.1 Warning horn.
34-30.2 Electric.
34-30.3 Air.
Control of the left drum brake.
 MANITOWOC ENGINEERING CO.

34-30.4 Manual.
34-30.5 Manual with air.
34-30.6 Air
34-30.7 Control of the front drum brake.
31 Manual.
34-31.1 Manual with air.
34-31.2 Air.
34-31.3 Front drum brake (M4100W)
Control of the right drum brake.
34-31.4 Manual.
34-31.5 Manual with air.
34-31.6 Air
34-31.7 Control of the right drum brake.
32 34-32.1 Manual.
34-32.2 Manual with air
33 34-33.1 Air.
34-33.2 Rear drum brake. (M4100W)
34 34-34.1 Engine foot regulator.
35 34-35.1 Front engine regulator. (M4100W)
36 Manual oscillation brake.
34-36.1 Manual oscillation brake. (M4100W)
34-36.2 Control of the front converter's foot.
34-36.3 Cabin heater control.
37 34-37.1 Portal lifting device.
Hydraulic control.
38 34-38.1 Air control.
34-38.2 Hydraulic-electric.
39 Air supply turned off - Low with
34-39.1 elevated cabin.
34-39.2 Air supply turned off - Cabin
34-39.3 superior
40 34-40.1 Air supply selector valve
Hydraulic power drop.
41 34-41.1 With electric-air control
42 34-42.1 With air control.
M4100W
Magnetic controlled.
Truck crane
Control change
Brakes delete route service y
emergency.
 MANITOWOC ENGINEERING CO.

Index.
Section III: Operating instructions.

Ref Page / Description

No. No.
General operating instructions.
60 34-60.1 Control of the direction.
34-60.2 Dashboard, alarm device.
34-60.3 Control of the journey locking - Manual or air.
34-60.4 Air supply - low pressure alarm system.
34-60.5 Independent pen lift - Model 3000-4000 minus 3900T
and 3900W.
34-60.6 Independent pen lift - Model 3900T and 3900W.
34-60.7 Raising of the standard pen.
34-60.8 Independent oscillation.
34-60.9 Independent oscillation - Pedestal-mounted machines.
34-60.10 Standard oscillation - Oscillation energy control included.
34-60.11 Control of the route.
34-60.12 Third drum 25,0000
34-60.13 Third drum 5,000
34-60.14 Raising of the independent pen with/manual control of
34-60.15 converter.
34-60.16 Hydraulic-electric/air descent - air control.
34-60.18 Direction - route - brakes of the route - changes. cranes car.
34-60.19 Raising of the independent pen.
Independent oscillation.
61
34-61.1 Operation instructions.
34-61.2 Crane
34-61.3 Dragoness.
34-61.4 Spoon.
34-61.5 Magnetic.
34-61.6 Shovel
34-61.7 Tower crane
34-61.8 Crane with tandem drums
34-61.9 Backhoe loader.
34-61.10 Spoon with reduced closing pressure.
Crane (M4100W)
 MANITOWOC ENGINEERING CO.

Operation controls Oscillation locking control

The oscillation lock is a mechanical lock

independent, used to block jobs of
the top in any position in
relationship a the bodywork.

Caution: Do not engage the lock of

oscillation while the upper works rotate.

Note: Always engage the lock of

oscillation when the machine is left to be
attended, moved to a new location or
parked during the night.

The oscillation lock is operated by a

air control valve. The blockage of
oscillation is hooked under tension of
resort, allowing the lock to be applied
against the gear tooth, after
engage as soon as the gear
Move. The oscillation lock is released.
mechanically.

Item Function

Oscillation blocking:

Lever towards the operator. Engage the oscillation lock.

Lever away from the operator. Release the oscillation lock.

 MANITOWOC ENGINEERING CO.

Operating controls Direction control

The steering control is used to turn.

the caterpillars in the desired direction of the path.

Neutral stops are used to hold

the steering clutches to enter the
blocking position, allowing the tracks
empty functions to make gradual turns or
for operation in slippery conditions or in
extreme cold weather.

Caution: Always return the control lever

from the direction to center position if the machine
it must be unattended.

Item Function

4a. Control of the direction: The following description is with the chains
backward caterpillar drivers, and the machine
traveling forward.

If the caterpillar tracks are facing forward,

the following description is reversed.

Control lever forward. The right caterpillar is blocked - the left caterpillar
the driver of the machine will turn right.

Centered control lever. Both caterpillars that lead, travel directly.

Control lever back. The left caterpillar is blocked - the right caterpillar
As you drive, the machine will turn left.

Note: Always move the machine gently.

forward and backward to ensure the
steering clutch commitment
appropriate.

4b. Neutral stop Move the neutral position back in one go to

For the right clutch, make a gradual turn to the right. This prevents
address) that the right clutch of the steering enters the
blocking position and allows the caterpillar to be
unemployed.

4c. Neutral stop Pull the neutral stop forward in one go to

(For the left clutch, make a gradual turn to the left. This prevents
management that the right clutch of the steering enters the
blocking position and allows the strap
 MANITOWOC ENGINEERING CO.

the linked one is unoccupied.

Operational controls Level

Description:

The level is located at the back

to the left of the operator and is used for
check the machine level before
to make an elevation.

Caution: The site of the erection or the

the surface of the route must be clean,
firm and level, and kept free of
debris.

Item Function

5. Level:

Truck cranes. Adjust the truck crane level with the

hydraulic jacks, with the support beams
completely extended and all the
tires on the ground.

Crawlers. Adjust the level of crawler cranes

moving the lift area machine,
and put the framework to obtain an area
leveled for elevation.
 MANITOWOC ENGINEERING CO.

Operating controls Dashboard

Description:

The instrument panel is a group of

oil pressure indicators and of the
temperature including a light of
low atmospheric pressure warning and the
temperature del converter of the
transmission and the alarm device of the
chain box lubrication.

The instrument panel is located in the

left front of the operators.

The alarm device is a system of

alarm that will signal to the operator if the
the converter temperature exceeds the range of
safe operation, or the flow of the oil of
lubrication of the chain box or
transmission failure.

Item Function

6a. Fuel indicator: Indicate the fuel tank level.

6b. The oil pressure gauge indicates the operating pressure of the
motor engine lubrication oil (see the
engine manual.

Caution: If the oil pressure gauge of the

the motor does not indicate the oil pressure, no
operate the engine, (see the engine manual).

6c. Oil pressure gauge of the Indica indicates the oil pressure of the system
converter: converter load. (Approx. 60 PSI)

6d. Temperature indicator Indicates the operating temperature of the

from the engine water: engine coolant liquid. (Approx. 190
at 200 degrees

6e. Temperature indicator Indicates the operating temperature of the

from the posterior converter: post converter. (Approx. 200 to 225)
 MANITOWOC ENGINEERING CO.

degrees

Operational controls Dashboard

Item Function

6f. Indicator of the temperature indicates the operating temperature of the

front converter front converter. (Approx. 200 to 225)
degrees)

6g. Pressure indicator It indicates low air pressure.

low atmosphere

6h. Indicator light of the alarm device if it is turned off,

alarm device the indicator lamp will shine brightly
indicating that the temperature of the converter
it is high or has lubrication problems.

6i. Alarm device: If the device is moved, the alarm sounds.

turned off while traveling, stop the machine
and I reviewed the temperature indicator of the
front converter; the indicators of the
lubrication of the chain or gear in
the dashboard for the reason or the
localization of the cause for the warning.

Caution: If the alarm sounds, turn it off.

while a lift is being done, finish the
elevation, or place the load down as much as
quick, then check the reason or the
localization of the cause for the warning.

Note: When traveling for an extended period,

the full RPM of the engine could make
that the converters will overheat
gradually, due to the demand for
light load. It is recommended that the rpm of the
the motor is slightly fixed below the
full regulator to overcome the trend of
to warm up.

6j. Load gauge indicating the hydraulic pressure of the pump

lifting of the pen: lifting of the pen during the cycle of
upward or downward movement of the pen.

6k. Temperature indicator indicates the oil temperature of the

lifting oil of the hydraulic lift.
 MANITOWOC ENGINEERING CO.

pen

Functioning controls Dashboard

Item Function

6l. Pressure indicator Indicates the atmospheric pressure of the clutch

reduced from the spoon: from the closing line for the operation of the
spoon.

6m. Multi-pressure indicator: Indicates the air system and air pressure
multiple of the control.

6n. Gear lubrication pressure indicator

gear lubrication: it is a direct reading measure, indicating
the flow of oil in the lubrication system
for the drive pinion of the drum, the
swing axis and axle pinions
route, and the gear box of
raising of the pen.

Note: The lubrication system is not a system

of pressure, the measure of pressure indicates
It's just that the oil is flowing.

Caution: If the pressure measurement does not

indicate or flow, or indicate another record
higher than normal, check the filter of
oil as it may require inspection.

6o. Indicator of pressure The chain lubrication indicator is

chain lubrication: a measure of direct position, indicating the
oil flow in the transmission and boxes of
chain.

Note: The minimum operating pressure

it should not be less than 5 PSI.

Caution: Excessively high pressure

it can indicate that the oil filter may
request service.

You can see the instruction sheets of

converter.
 MANITOWOC ENGINEERING CO.

Operating controls Control of the travel lock

Description:
The route blockages are used as
excavation hooks and to prevent that
go back when traveling in
unequal surfaces.

The blocking direction depends on the position

of the body.

Caution: Hook only after

complete a stop, except in case of a
emergency.

Note: The air applied to the blockages of the

route will release the route blockages. The
route blockages are occupied by your
own weight when the air is released.

Item Function

11. Control of the blocking of the route:

Lever forward Both pins of the travel block are

outward or disconnected (lit air).

Back lever Both nails of the journey block are

inside or hooked (air off).

To secure the machine against the wheel at the back of

the desired direction of the route, set the
blocking travel selector valves
for the desired direction of the route. The
selector valves are located at the end
front of the bodywork. Follow the instructions
on the nameplates on the valves
selectors for the appropriate direction.

Caution: In machines that use valves

from the globe to the blocking selectors of the
route, set the control lever of the lock
of the route in the rear position to turn off
the air and to exhaust the system, before setting the
selector valves. In the machines that use
rough stop valves (lever type)
 MANITOWOC ENGINEERING CO.

like selector valves, the air can be

left on, since this type of valve
it will drain the system when it is off.
Operating controls Control of the travel block
Item Function

Air regulator The travel locking system is air.

supplied from the distributor through a regulator
of air located in the operators' area. Adjustment
Recommended is 40 PSI.

Air pressure indicator The air pressure gauge, mounted with the
air pressure regulator, indicates the adjustment of
air regulator. Operate the lock control of the
traveled a few times to test the air pressure.

Note: In the machines built before '67,

all the controls of the path blockage were used
the air pressure of the distributor is complete. On date
from 67, all the controls for blocking the travel
they have an air regulator in the supply line
of air to reduce the air pressure from the blockage of the
route. The air regulator is set at 40 PSI, which
it is broad for the operation of blocking the course,
and will reduce the possibility of damage to the operation
of the route blockage.

Machines mounted on a barge with When a crawler machine is used in a

spatula operation team: sectional barge with operation equipment of
spatula, the air duct of the travel lock
through the pin must be used
for the operation of the spatula brake.

To achieve the change for the spatula operation,

the hooks of the travel lock must be
fixed at the exit or the unconnected position. Then
disconnect the air line from the travel lock
from the union of the upper air and fixed the air line of
spatula brake control. Then connect the
brake control line with the part
lower part of the crosshead of the piston. The second line of
the air from the brake control of the spatula will use the second
air duct through the cotter pin.

Check the operation of the spatula brake with

air and exchange the air lines at the union of the
upper air or pin lock if necessary.
(See page 34-3.3 for the control operation of
spatula brake)

Unattended machines:
When for any reason the machine must be
left unattended for any length of time,
always check the route control for the
central position (clutch released). Hook
 MANITOWOC ENGINEERING CO.

both hooks of the travel lock and move it

control of the pinion to the neutral position.
Functioning controls
Hoisting drum rotation indicator of the crane

Description:
While the rise of the pen
independent in models 3900W is
located at the back of the machine and
the raising drums of the feather
they are outside the normal range of vision of the
operators, the turnover indicator of
the crane hoist drum is used for
point out to the operators when the
lifting drums of the feather are
turning around.

Model 3900W SC135:

The hoisting drum rotation indicator
the pen is located at the front
left of the operators.

Model 4100W:
The drum rotation indicator of the hoisting
the feather is located on the head of the
control lever for the lifting of the
pen

Item Function

13. Turnover indicator The turnover indicator will indicate the turnover
crane hoist drum lighter of the lifting drum of the
pen by visual means or by the
sensation.
 MANITOWOC ENGINEERING CO.

Operating controls
Auxiliary brake of the independent boom hoisting

Descripción:
The auxiliary brake of the crane lifting
independent is located on the shoulder
left of the operators.

This is an additional brake, use only

in case of an emergency and to facilitate the
lower the pen the last feet when descending
feather to the earth.

Item Function

15. Auxiliary brake of the hoisting

independent pen

Lever up Release auxiliary brake.

Lever down Apply auxiliary brake.

Note: The auxiliary hoisting brake of the boom

independent is applied manually. The
braking force is in proportion to the
force exerted on the control lever.
 MANITOWOC ENGINEERING CO.

Operation controls
Route control
Description:
The route control is used to apply
the reverse clutches on the shaft of
route for the operation of the route. To
same time the positioner delete
converter is activated, increasing the
energy outward in proportion to the
movement of the control lever.

Note: The following description is with the

driving chains for the caterpillars for the
inverted the following description.

Item Function

19. Control of the route:

Throttle forward. Front tour: Engage the clutch

right, activate the lifting converter,
increasing the output energy in
proportion with the lever movement
of control.

Back lever. Reverse journey: Engage the clutch

left active el converter of
uplift, increasing the output energy
in proportion to the movement of the
control lever.
 MANITOWOC ENGINEERING CO.

Operational controls Front drum clutch control

Description:
The drum clutch control is a
dual action control valve, engaging
completely the drum clutch,
then applying energy from the converter.

The control valves were designed to

provide the complete clutch gear
in the stop position, then the application
from the variable converter energy. Pulling from
the control lever moves backward
slightly from the stopping position, the energy
the converter is applied by lifting the load.
Reaching the desired height, release the lever.
control forward slightly, matching the
energy output of the converter to the load,
suspending the load. Move the lever of
control later, the load will begin to
lower against the energy output, it will pull towards
atrás la palanca levemente para vencer la
download, suspending the load or facilitating the
load on site.

Caution: To release the clutch

drum, the control lever must be
deliberately moved forward from the
stop at the resting position.

Item Function

24. Control of the drum clutch

frontal

Lever back to stop. Drum clutch engaged: The lever

the control is pulled back to the position of
detention, the front drum clutch is
completely hooked.

Gear back from stop for Converter power: While the lever
stop. the control is pulled back from the arrest, the
energy from the converter is applied, increasing
the energy output concerning movement
from the control lever.
 MANITOWOC ENGINEERING CO.

Lever forward to stop. Converter power off.

Lever forward from stop Drum clutch released.

to stop.
Operating controls Control of the hydraulic crane lifting

Description:
The control of the feather lift
hydraulics is one of several valves used
to make the lifting work
hydraulic press. Two of the valves are
used by the operator, the other ones are in the
operating system of the uprising of the
pen.

The control of the lift of the pen, item

25 is located in front of the operator in the
control bank. The control handle
include a turnover indicator for the
drum that signals the operator when the
lifting drum of the feather are
turning around.

The lift of the pen is equipped with

a trunnion and a nail on the drum of
left lifting of the pen. The nail is
controlled by a control valve located
to the left of the operators, item 25d.
The nail, when it is unbound, opens a
valve, allowing the system of the
pen down to function. This valve is
located in the nail and may require adjustment,
the nail should be released and not function the
pen system down.

Item Function

25. Control of the lifting of the

independent pen

Back lever. Pen up: Lifting pump of

the open hydraulic pen, brake of the
lifting of the automatic pen, released.
The speed and the energy of the lifting of
the pen is in proportion to the
 MANITOWOC ENGINEERING CO.

movement of the control lever.

Lever forward. Feather down: Lifting pump of the

open hydraulic ram, brake of
automatic pen lift, released.
Controls of operation Control of the hydraulic arm lift
Item Function

The speed and energy of the lifting of

the pen is in proportion to the
control stick movement.

Note: The control of the lifting pump

the pen is filled with a valve and a
cam arrangement that provides control
of low positive speed. The engine of
the raising of the pen remains in
low speed until the lever of
control moves approximately one
Halfway in any direction. The
movement of the control lever beyond
from one half, then allows the engine of
raising the pen to change to high
speed if the hydraulic control pressure
the internal pressure is quite low. If the pressure
hydraulics internal remains in
approximately 3,000 PSI, the engine
it will remain at low speed.

25d. Nail control of the

raising of the pen:

Lever towards the operator. Nail inside: The nail cylinder is fixed
to allow the spring tension to pull
the nail of the lift of the feather inside.

Caution: Do not hook the nail of the

lifting of the pen while
the lifting of the pen works.

Lever away from the operator. Nail outwards: The cylinder of the nail gives
return to a lever that pushes the nail towards
out of the gear.
 MANITOWOC ENGINEERING CO.

Operating controls Control of the rear drum clutch

Description:

The control of the rear drum brake is

a dual action control valve, dedicating
completely the drum clutch,
then applying energy from the converter.

The control valve is designed to

provide gear to the complete clutch in
the detention position, then the application
energy variable of the converter. Pulling from
the control lever slightly backwards from the
detention position, the energy of the converter
it is applied by lifting the load. Upon reaching the
desired height, facilitates the control lever
slightly forward, matching the output
from the converter to the load,
suspending the load. Move the lever of
control later, the loading will begin to
pull down against the energy output. Pull from the
slightly pull the lever back to overcome the
lowering, suspending the load or facilitating the
load on site.

Warning: To release the clutch of

drum, the control lever must be
deliberately moved forward from the
stop to the resting position.

Item Function

27. Drum clutch control

posterior
Lever back for stopping. Drum brake engaged: The lever of
control is pulled back for the position of
stopping, the rear drum brake
hook completely.

Back lever from the stop to Converter energy: While the lever of
stop. control is the throwing of the detention, the energy of
converter is applied, increasing the output of
energy in relation to the movement of the lever
 MANITOWOC ENGINEERING CO.

control.

Lever forward for stop. The converter's power is off.

Lever forward from the stop The drum clutch released.

to stop.
Controls of operation Hand throttle of the engine

Descripción:
The motor hand regulator is used.
to control the revolutions per minute
of the motor, for constant power output,
as desired.

For the engine power output, on the

adjustment of the hand regulator or by periods
shorts, use the engine foot regulator (see
page 34 - 34.3)

Item Function

28. Engine hand regulator: The revolutions per minute of the engine
they increased the desired level or at the output of
engine rpm. See the instructions for
management on page 34-61.1.

Note: Traveling the machine during periods

prolonged, tire behind the control of
engine regulator for revolutions per
complete engine minute, afterwards
step back slightly for a better
operation of the route.
 MANITOWOC ENGINEERING CO.

Operational controls Control of the rear drum brake

Front drum brake control

Descripción:
The control of the front drum brake is
used to operate the brakes of
front drum as desired. (see the
operating instructions on page 34
61.10

A brake pedal lock is

provided for each brake pedal of
drum, to lock the pedal in position
with latch

Note: The brake pedal lock is

used to prevent the release
accidental of the drum brakes. Always
engage the brake pedal lock
when the brakes are "latched".

Item Function

30. Drum brake control Press to apply the drum brakes

forward forwards. For to hold the brake
hooked, lean the pedal forward
from the foot and close inside. To release, do
pressure on the brake pedal heel,
then release.

30a. Brake pedal lock:

Lever up. Brake pedal lock released.

Lever down. Brake pedal lock engaged.

Note: The rear drum brake 'With latch' the brake pedal, then
It works the same, and the brake pedal lock is also a hook.
closed as described Release the brake pedal lock,
formerly. then release the brake pedal.
 MANITOWOC ENGINEERING CO.

Functioning controls
Control of the gantry lifting device

Description:
The control of the lifting device of the
The gantry is a hydraulic electric unit.
to partially raise the portal in the
preparation to resonate upwards. This
control is also used to lower the
portico to cover the level after the
pen is down.

Caution: See the instructions for the

feather and the portico to give and for the
erection.

Item Function

36. Device control of

elevation of the portico:

Gear forward. Open the pump valve to allow.

Button pressed. the portal lifting device lowers
to cover the level.

Back lever. Hook the pump to push towards

Button pressed. above the hoisting device of the portal,
partially lifting the porch.

Note: The control of the lifting device

the porch is on a rope, located at
side of the door allowing the operator
position oneself on the tracks of the caterpillars to
see the lifting device work.
 MANITOWOC ENGINEERING CO.

Operating controls Hydraulic descent control

Description:
The hydraulic descent control is used for
start loading or to empty the block below.

The hydraulic descent control is located in the

top of the control handle of the
uprising.

Item Function

39. Hydraulic descent control: Engage the drum clutch.

Button pressed. The solenoid valve operates, allowing the

multiple air pressure passing through the cylinder
of hydraulic control valve air. This will open
the pressure line of the hydraulic pump in the
downward motor, which will alternately invert the
drum drive machinery that
the loading line starts at the bottom.

As the descent speed increased, it releases the

down control button. The action of descending
now it is against the converter of the uprising, to
through the driving machinery.

As the downward line continues to fall, it pulls

gradually back on the control lever of the
drum. This will slightly open the converter
forward and will start to delay the action of
descent.

Pulling from the back of the lever of

control further away, it is possible to stop the action of
 MANITOWOC ENGINEERING CO.

descent, holding the suspended load in the

front energy output of the converter. Pulling
from the back of the lever farther away,
increasing the power output of the converter, it is
possible to start lifting the load.

Operating controls Hydraulic descent control

Item Function

Caution: Do not press the control button

of hydraulic descent when the lever of
the converter control is pulled back, or
while any lifting is taking place
 MANITOWOC ENGINEERING CO.

Functioning controls Control of the direction

Control of the direction:

The steering control (see page 34-4.1) is used to control the
direction of the route. The direction control function will allow the
operator make sharp turns, or gradual turns as desired.

The following description is with the driving chains of the caterpillars towards
back.

Direction on leveled ground:

When traveling on flat terrain, engage the travel lock to hold the
machine against an unexpected "ring back".

To turn the caterpillars in the desired direction of travel, use the

control of the steering and neutral stop as desired, see page 34-4.1.

Set the steering control for sharp turns as desired, oscillate.

Gently move the machine back and forth to secure the gear
complete the steering clutch, then continue traveling around
the desired return using route control.

For gradual turns, set the desired neutral stop to prevent the
selected steering clutch between the full lock position.
Gently oscillate the machine to ensure proper clutch adjustment
From the address, then proceed to travel using the route control.

If the gradual turn is not sharp enough, release and engage the control of
traveled several times to bring the machine around the desired turn a
a little sharper.

Direction traveling over a degree:

Caution: Always engage the travel lock to hold the

machine against the wheel behind the desired direction of the route.

Always align the machine in the direction of travel to avoid making a

turn while traveling on the slope.

If a detour is necessary while traveling on the grade, use the stops.

 MANITOWOC ENGINEERING CO.

neutral to execute a gradual turn.

Caution: Do not move the steering clutch in the full lock.

well, the weight of the machine against the steering clutch could hang in
the blocking position.

Controls of operation Direction control

To make a gradual turn while traveling on a grade, fix the

neutral stop for the desired return, move the travel control lever
To center the position, simultaneously release the steering clutch.
corresponding, move the control lever of the course to continue the
desired direction of the route.

If the return is too low, release and engage the clutches of the stroke.
several times to bring the drive caterpillars around a little faster.

When the turn is complete, release the clutches of the travel move the
direction control to center the position, swing the machine in the direction
of the route with the control of the route to ensure the gearing of the
complete steering clutch. Continue traveling in the desired direction.

Caution: While making a turn, while traveling

Above a grade, do not release the travel lock.

Unattended machines:
When for any reason the machine must be left unattended by
any length of time, always return the steering control lever
to center the position and slightly tilt the machine to ensure the
complete gear of the steering clutches.
 MANITOWOC ENGINEERING CO.

Controls of operation
Dashboard - Alarm device

Instrument panel:
The instrument panel, located behind the left operators, shoulder,
it contains the relevant indicators for the operation of the machine, and it is
electronically powered.

The instrument panel contains the indicators for oil temperature and
from the oil pressure for the front and rear converters, the
oil pressure indicators, water temperature, and ammeter
for the power plant, in addition to the indicators on the engine panel.

The indicators of gear lubrication and chain lubrication

they are located on the support of the selector valve and are direct indicators of
the reading. The indicators of gear lubrication and the chain do not
they indicate the pressure, only what flows from oil in the lubrication system, see the
pages 34-6.7 and 34-6.8.

In machines with an elevated cabin, the lubrication indicators of the

the gear and the chain are electrically powered, and are mounted on
the instrument panel in all models.

Los sistemas de la temperatura del aceite del convertidor y de lubricación de la

Chains are protected by an alarm device, see page 34-6.9.

Alarm device:
The alarm device is mounted after the instrument panel, and
warns the operator if the converter's temperature exceeds the working range,
or if the lubrication oil flow of the chain fails.

The alarm device is activated by the oil pressure switch.

of engine lubrication, and it only works when the engine is running.

The alarm system may sound off for a few seconds when the
the engine is turned on first and again when the engine is turned off. This is
It's normal, as the chain's lubrication system will increase the oil flow more.
slow, and loses the oil flow faster than the oil lubrication system
in the engine.
 MANITOWOC ENGINEERING CO.

Operation controls Control of the path blockage

Control of the route blockage:

The course locks are used to prevent rolling back while
travel or work on uneven ground, and to keep the machine in one place to
working with dust.

The travel lock control (see page 34-11.1) will engage both
track locking hooks; by moving the control lever backwards, or to
the posterior position.

Both hooks of the path lock are released by moving the lever of
control forward, or to the front position.

To fix only a locking hook of the travel to hold the

back rolling machine while traveling, use the selecting valves of the
blocking of the route located at the front of the bodywork.

Note: The drive sprocket of the tracks is located at the rear of the body.

Follow the instructions found on the plate next to the selector valve.
for the appropriate fixing direction.*

Caution: Do not engage the travel locks while the machine is

It is moving, except in an emergency. Always engage both locks.
of the journey at any time the machine is placed in a location to
to work or to park for extended periods or overnight.

*Note: In machines that use globe valves for the selector valves
from the stroke lock, set the stroke lock control in its position
first posterior, to turn off the air and to exhaust the system. In the machines
that use rough stop lever valves, like selector valves, the
Air can be left on, as this type of valve will drain the system.
when it is off.

In models built before '67, the blocking control of the stroke uses the
complete multiple air pressure. Like '67 all the lock controls of the
route have an air regulator in the air supply line for
reduce the air pressure of the travel blockage. The air regulator is fixed
at 40 PSI which is ample for the operation of the stroke lock and reduces the
 MANITOWOC ENGINEERING CO.

possibility of damage to the operating mechanism of the travel lock.

Unattended machines:
When for any reason the machine must be left unattended to
any length of time, always hook both hooks of the lock
route.
Controls of operation Air indicator - Multiple pressure

Air indicator - multiple pressure:

The multiple air pressure indicator is located on the locking support of the
itinerary.

In the 4100W model, the air pressure gauge is included on the dashboard.
instruments (see page 34-6.12 or 34-6.15).

The pressure gauge indicates the operating pressure of the control system.
of air in the air manifold.

The air supply is controlled by the discharge valve, mounted to

side of the air compressor and read the pressure of the air tank located underneath
the platform.

The discharge valve is preset at the factory and may require the
periodic adjustment. For operating pressure, see the data plate
mounted in the operator's cabin.

The air supply line from the air tank to the air distributor has
a filter that requires periodic attention.

In addition to the filter, some machines have an alcohol injector mounted to the
side of the filter for operation in extremely cold climates.

For the service and maintenance of the filter and the alcohol injector see the book
of instruction.

Note: (3000W and 4000W models) In machines that are not equipped with
blockages of the route and control of the steering, the pressure indicator for
the multiple pressure is located in front of the operator, on the valve support
of control.
 MANITOWOC ENGINEERING CO.

Preventive Maintenance Checklist

Machine Job change

Daily inspection
The following preventive maintenance checklist is designed as a general guide,
to provide a systematic visual and physical inspection of the machine, before operation
normal.

The preventive maintenance checks and the services required by section 5-2.1.2,
frequent inspection, of the ANSI B30.5 code, are included. Few important components of the
machines should be visually checked as they go through the list of
checkup.

Since this is a general guide, the blank spaces are provided for use, for
insert the additional articles that may require verification of the same applications of
work.

Any discrepancies must be recorded in the observations section.

Daily visual controls Start each item as checked

No. Item to be checked Date
1 Broken or cracked glass.
2 Leaf metal, protectors, gears or chain box covers damaged
the lost.
3 Driving chains and gears for cracked or broken parts.
4 Oil or coolant leaking beneath the bed or the rotating body.
5 Path of the roller, home rollers, hook rollers for shavings or
cracks.
6 Lifting of the pen, keyboard and steel cable - pendants - blocks of the
load - pulleys.
7 Fuel tank - Fuel indicator - Hose and connections.
8 Limit device, mast and boom stops, drum claws.
9 Control valves - levers and connecting rod - instrument panels.
Fire extinguisher available - in startup.
11
12
13

Daily Preventive Maintenance Checklist Start each item as checked

Item No. to be checked Procedure Date
Radiator coolant Check level, add when necessary
necessary.
15*Fluid del converter Check deposit, add acceptance
controlled when necessary.
16 Hydraulic system level. Chequear nivel, agregar cuando sea
necessary.
17Box lubricant Turn the handle twice a day.
chain.
18 Oil filter.
 MANITOWOC ENGINEERING CO.

19Motor oil.
20 Transmission and/or chain boxCheck level, add oil when necessary
the deposit. necessary.
21 Rotating bed collector.
22Entrance cover and/or
converter output.
Air compressor

Observations
Date Item Correction date Start
 MANITOWOC ENGINEERING CO.

Rotating bed

Hook roller adjustment

Two important preliminary steps are required before adjusting the rollers of the
hook
Pivot the machine to locate the house rollers to the point of
less wear on the roller's path. (The machines that work
short oscillation cycles, on the front, will have concentrated wear
in the front portion of the roller's path.

The position pen as soon as the machine is balanced and both the
The front and rear house rollers are loaded approximately equally.

The hook rollers are mounted on the eccentric shafts for adjustment.
quick, easy. The locking plate that holds the shaft in position is designed to
the fine adjustment of the roller. When there is a gap of 1/16 inches between the roller and the
trajectory of the roller, the hook rollers must be adjusted.

A. Remove the locking plate at the outer end of the roller suspension.
hook.
 MANITOWOC ENGINEERING CO.

B. Use the special key to turn the shaft and bring the roller into contact
with the surface of the hook roller's trajectory. The roller should only touch -
this is not a tight fit.

C. Reinstall the locking plate. (The location of the screw holes of

The head and the fixation edges on the locking plate give you fixation positions.
multiple. If you cannot find a position that is exactly correct,
move the plate on top in one pull - this gives an option of the half positions
of the interval).
LIFTING OF THE PEN

Hydraulic system.

Description:
The lifting of the pen receives energy through the hydraulic pump.
driven by the motor (figure 1059E), which drives the hydraulic motor for the
operation of the lift of the pen. A single lever control valve
provides control of the drive and speed for the operation of the
lifting of the pen.

A variable displacement pump controls the operation of the engine.

raising of the pen (figure 1059D). The position of the control lever
determine the volume of oil displaced by the pump. The flow volume of the
the oil from the pump to the engine will determine the speed and torque effort of the
output axis of the engine. The direction and speed of the lift of the boom is
variable from zero to the maximum.
 MANITOWOC ENGINEERING CO.

Fluids of the hydraulic lift approved: (addition)

Whenever it becomes necessary to add oil or refill the system in the

field, what follows is an approved list of plume lifting fluids
hydraulics.

Type A automatic transmission fluid.

2. Mobil Oil Co. Mobilfluid No. 300.
3. Citgo 9087 - ATF Fluid - Type A.

The following procedure should be used to ensure the proper filling of

the pump, of the engine and of the lines:

1. Check the oil level in the tank to see if there is a supply of

oil. The appropriate level is necessary to prevent air from entering the system.

2. Add the oil

recommended if necessary.
 MANITOWOC ENGINEERING CO.

Replacement in the field, filling of the fluid in the pump/the engine and
launch procedure:

Before installing a pump or a motor on a machine in the field, examine

for possible damage that may have occurred during shipping or addressing. All
the tools, buckets, cans, plugs, etc. must be clean before their
use. Never use the drained oil.

1. After the bomb and/or engine have been installed, remove the spark plug
welded at the load pressure port on the main deck side of the
pump (figure 1059E). Install a 600 PSI indicator with a short section of
hose to this port. The threaded spark plug is 7/16-20 straight. (Some pumps
older variables were slightly hit 1/8 NPT in this port.

2. Check all the accessories to make sure they are tight.

3. Loosen the line from the charge pump at the inlet to the charge pump.

4. Fill the pump box with the drain opening of the box with oil
approved. Install the drainage lines of the box.

5. Fill the reservoir with an approved oil (approximately 18 gallons of

capacity). See the fluid paragraph of the approved hydraulic lift.
When oil appears in the loose hose at the pump inlet
Load, tighten the hose and continue filling the tank. Leave the cap loose.
from the deposit, so the air will escape.

Note: If the gravity feed does not fill the charge pump line, it must
to be filled by hand.

6. The pump control must be in the neutral position during filling.

it is recommended that the main connecting rod be left disconnected until after starting
up the procedure.

7. With the coil wire removed or the rock closed, turn the motor.
fifteen seconds.
 MANITOWOC ENGINEERING CO.

8. Start the engine while keeping it at the lowest idle speed possible
for five minutes. During the launch, the pressure waves will be seen in the
600 PSI indicator. While it operates at low idle, the pressure of
load must be over 100 PSI.

9. Increase the pump speed to approximately 1000 RPM. The pressure of

The load on the 600 PSI gauge should be 180-220 PSI.
 MANITOWOC ENGINEERING CO.

10. Close and connect the drive rod to move the valve handle.
control.

11. Check the fluid level in the reservoir and add the approved oil.
case of necessity.

12. Start the pump and the operation at 1500 to 1800 RPM. The pressure of
the load must be 180-220 PSI.
 MANITOWOC ENGINEERING CO.

13. Move the directional control handle slightly to the front position and
reverse. The load pressure will drop to 150-190 PSI when the pump is in
race.

14. If the load pressure drops below 100 PSI during the procedure of
launch, do not continue the start until the problem has been found.

15. Turn off the engine, remove the indicator and replace the spark plug in the port of
indicator. Check the oil level in the tank and tighten the cap of the
oil filling.

The machine is now ready for operation.

Note: The oil temperature should be approximately 150 degrees when it

compruebe la presión y comprobando para saber si hay escapes.

Check of the load pressure indicator:

The following check must be made on the load pressure indicator of the
raising of the pen located in the operators' cabin.
I. With the control of the stick in neutral and the engine at low.
A. The gauge should read 190-210 PSI, if all is well, proceed to step II.
B. If the gauge reads 0-130 PSI and/or is erratic (considerable bouncing).
The charging pump is forming cavitation, please check it.
next:
a. Oil level too low
b. Incorrect oil
c. Dirty filter elements.
d. Restriction on online suction or deposit.
e. Leaks in the suction line or connections that allow air in the
system.
2. Worn out charging pump.
3. Discharge valve in jammed charging pump.
C. If the gauge reads 150-180 PSI.
The shuttle valve in the engine is changed on top and the valve of
download of the engine load is controlling the pressure of the
load.
a. The shuttling valve could be jammed.
b. the pump is not in neutral, check the positioning device of the
bomb.
D. If the gauge reads 250-300 PSI at idle.
1. The return line of the pump box drainage for
exchanging heat, or from the heat exchanger to the reservoir
is restricting the flow of the charging pump, creating one more
higher than the normal rear pressure in the pump box.
Partially closed the discharge valve of the load of the
bomb.
Cold oil.
 MANITOWOC ENGINEERING CO.

E. With the engine at high idle and the temperature system at

working, the load pressure should not exceed 380-400 PSI, if this is the case
check as in case I (D).

II. Control of the pen completely in the up position and the motor in low
slow march (no load on the boom)
A. The gauge should read 150-180 PSI, everything is fine.
B. If the gauge reads 0-130 PSI.
1. Engine load discharge valve - stuck open.
C. If the indicator reads 190-210 PSI.
The shuttle valve got stuck in neutral, and the discharge valve.
de la bomba de carga está controlando la presión de la carga.
2. The discharge valve of the engine load stuck closed
partially or completely closed.
D. If the gauge reads 230-280 PSI at idle.
1. The return line from the engine box to the exchanger
heat is partially blocked creating a higher pressure
normal rear in the engine compartment.
Partially closed the discharge valve for the engine load.
3. Cold oil.
E. With the engine at high idle and the temperature system at
operation, the charge pressure should not exceed 300-320 PSI if it is
this check as in case II.

Other symptoms: The high pressure indicator 0-10000 PSI to disconnect

quickly the connection.
I. The lifting of the pen does not enter high speed.
A. The high pressure gauge reads above 2600 PSI unless
Everything is fine.
B. The high pressure indicator reads below 2500 PSI when rising.
The air is not being applied to the pneumatic brake chamber in the
motor control.
The engine control got stuck in the low-speed position.

II. The rise of the pen rises outward when it lifts loads
heavy.
The high pressure gauge reads less than 4500 PSI.
The defective high-pressure discharge valve on the plume
on the side, I changed the two discharge valves around and
try again.
B. The high pressure indicator reads 4500-5000 PSI.
The motor control got stuck at high or partially at speed
high.
2. The motor control incorrectly adjusted for low speed,
disconnect the control and manually change the motor at the point
I lower with the engine running and the boom lift in neutral.
Worn seals in the engine control piston.
 MANITOWOC ENGINEERING CO.

4. The lifting brake of the crane not released or applied

partially.
5. Also, the increase in air pressure over the engine control must
be 60-65 PSI.

Multiple valve assembly:

The operating pressure of the system can be taken by attaching an indicator.
high pressure (7500 psi) for the parts (1) and the assembly of the manifold valve. The
reading taken at the port (1) indicates the pressure monitored by the valve of
high pressure download "B". The reading taken at port (2) indicates the pressure
supervised by the high-pressure discharge valve "A".

Note: Do not attempt to adjust the high-pressure discharge valves, they are factory set.
set and preset to 5000 PSI. The field adjustment should not be
intentado debido a la posibilidad de presiones excesivamente altas y peligrosas.

The load pressure can be read by tying an indicator (600 PSI for the port
3). This port, however, is blocked by the shuttle valve when the
the system is in neutral. The system must operate in the forward direction or
contrary to obtain a reading at this port.

Note: Ports (1), (2), and (3) are connected with 7/16-20 straight threaded if the
multiple assembly is a square steel block, ring adapters of
High-pressure ones must be used. Old multiple assemblies were emptied.
and were connected 1/8. High pressure 1’8” threaded pipe adapters
they must be used.

Cooling circuit:
The pressure charging system oil is circulating through a
heat exchanger to cool down, then back to the oil reservoir.

Temperature limits:
The maximum continuous operating temperature must not exceed 190°F.
temperatures above 190° could cause oil oxidation, sludge, enamel,
deterioration of the seal, decreased efficiency, and poor lubrication.

Check the check points for overheating, which are; the oil
appropriate, high water temperatures, obstruction of the lines, failure of the
pump or engine, pump control not properly adjusted, (pump that
it still pumps when the control handle is in neutral) or the brakes of the
the rise of the pen is fixed.
MANITOWOC ENGINEERING CO.
 MANITOWOC ENGINEERING CO.

Oil filter change:

The oil filter change (fig. 1059A) must be determined by placing a
vacuum indicator on the ports of the 1/8 inch tube belt
provided in the filter adapter. The vacuum readings should be taken
with the system at normal operating temperature and the engine at high.
vacuum must not exceed 5 PSI or 10 inches of mercury - if so, replace the
filter elements with a type of filter cartridge 10 microns - Char-Lynn No. 5610 -
or number 427056 or an equivalent.

Cleaning of the hydraulic system:

If the hydraulic system becomes contaminated for any reason (dirt) the system
the entire system must be cleaned, new filters installed, and the system refilled with
recommended clean oil. Never clean a hydraulic system with a jet of
water or reuse the oil.

Interval for changing the hydraulic fluid:

It is recommended that the hydraulic fluid for the boom lift be changed.
every 500 hours or 1-1/2 months (whichever comes first).

RAISING OF THE PEN (Hydraulic system) Problem identification

What follows includes the pump, the motor plus all the lines, the valves, the
filters and controls - located between the pump and the engine. As with everything else
Hydraulic equipment, cleanliness is very important. If possible, the pump or the
motors must be cleaned with steam while in the machine before they are
disconnected the hoses. In most cases, it is recommended that
the oil is disposed of and replaced with new oil before the system
it starts to function.

Note: After locating the system problem, it may be necessary

replace a port of the hydraulic pump or the motor.
 MANITOWOC ENGINEERING CO.

A. The system will not work in any direction.

Cause Remedy
Low oil system Check the oil level in the reservoir
and fill it in if necessary. Use only
the approved oils.
2. Localice y fije los escapes que causan la
oil loss.
Defective control Check the lever arm of
bomb control to the neutral position.
Adjust the coupling to the pump arm.
Do not move the pump arm to
find the coupling. The humming noise
the pump indicates a misalignment of the lever
pump control.
2. Check to see if there is slipping
or the broken drive of the engine to pump and
raise the pen.
Low or without load pressure Remove the hose from the pressure line in
the "T" plug of the charging pump.
Install the pressure gauge to check
the pressure. The pressure should read 180-220 PSI,
at approximately 1000 RPM, in the RPM
the increasing oil will bridge and preserve
the 180-220 PSI.
2. Pressure relief valve in pump
of load or distributor of the damaged engine or
open stuck - the filter or the suction line
from the tank to recharge the blocked pump-
pump charging drive shaft
shearing - internal damage to the pump or the
motor - supply of cold or low oil.
Cause remedy
Load pressure that fluctuates and 1. Check for possible air in the system.
Lower the air will cause the system to be noisy.
Check all the accessories,
especially around the filter, on the line
of suction and locate the points where the air
it is stretching within the system. Squeeze
the splices and the accessories.
2. The pressure relief valve of
load on the engine distributor stuck
open.
Internal damage to pump or the motor.
High discharge valve 1. Change both discharge valves of
defective pressure high pressure. If the system operates in the
 MANITOWOC ENGINEERING CO.

address where it would not work, one of the

high pressure discharge valves is
inoperative. Both flushing valves
they must be examined and the valve of
damaged download to be replaced. Reinstall
both valves and retest the system.
Internal damage for pumping or the indicated by:
motor 1. Low or zero load pressure. The pressure of
The load can also fluctuate quickly.
2. The achievable operating pressure
maximum in both upwards and downwards
it is less than the normal discharge adjustment.
Load pressure, which will also be lower
that the normal can drop to zero when
reached maximum pressure.
Pieces or scales of brass in the tank
and the filter.
Note: If any unit is used or damaged
considerably, the other unit must be
checked or cleaned carefully.

B. The system works in only one direction.

Coupling del control 1. Check the entire coupling for
defective to ensure if it is connected and free to
to function.
2. Make sure that the control stop, if
is used, and is not out of adjustment.
Valve of control Note: Do not change the position of any of the
displacement. (located in hexagonal nuts or the slotted socket
displacement units at the end of the control unless it is
variable) necessary to remove the spool from the valve
of control.
Cause Remedy
1. Disconnect the control coupling at the
directional control arm. Move the arm of
control hacia adelante y hacia atrás a mano. Si
moves freely without resistance, the valve
The control must be removed and checked for
to know if there are broken parts or an axis of the
bent control.
.
C. Neutral difícil o imposible para encontrar:
Coupling del control 1. Disconnect the control coupling on the
defective directional control arm. If the system now
returns to neutral, the coupling to the control is
out of adjustment or stuck in a certain way.
 MANITOWOC ENGINEERING CO.

Control valve out of adjustment Note: Do not change the position of any of the
Warning: Use this hexagonal nut adjustment or the slotted socket on the
only when the control has ended unless it is necessary to remove
checked others and they could not reel of the valve of control.
fix the problem. 1. If the hexagonal nuts and the socket
grooves have been moved out, what follows
it must be done:
a. Disconnect the control coupling in the
control arm.
b. Remove both plugs in the rounded piece
from the control cover.
c. Loosen the smaller of the two nuts and
rear parts of the slotted plug giving two
left turns.
d.- Return the slotted spark plug (to the right) until
to feel that it barely makes contact with the seat of the
spring in the control coil.
e.- Hold the grooved spark plug with a
large screwdriver to prevent it from moving and
to tighten the small jam nut.
f.- Loosen the larger of the two nuts.
traffic jam.
g.- Back to the hexagon behind this nut
traffic jam inside or outward due to blockage
enter the two ports, the lands on the reel of the
control appears for to be established
symmetrically in each hole.
h.- Replace the spark plugs and start the system. If
the system silently enters the direction of
return the hexagonal behind the jam nut
larger inside or outside until
find the neutral.
i.- Hold the hexagonal to prevent it from moving
and to tighten the largest jam nut

D. System that works hot:

Cause Remedy
Nivel de aceite bajo Fill the supply with oil.
Oil cooler obstructed 1. Clean air steps
Oil cooler is 1. A bypass valve cooler, if
derived. it is used, open stuck.
Blocked filter and line 1. Replace the filter. Clean and replace it.
suction line suction.
Internal exit (accompanied 1. One of the high discharge valves
generally due to pressure loss it may be partially open
acceleration and energy. attached. Install the gauges and read the pressure
of load and operating pressure in
both directions.
 MANITOWOC ENGINEERING CO.

E. Air system will not work:

Air low system. Check the air compressor belt.
Check for air leaks.
Check to see if there are any failed valves
in the air compressor, or the possible blockage
from the air line.
The system operates on a 1. Failure of the 'Control Valve'. Disconnect
address only. the pen up and the pen down of lines
of air in the control valve. Move the
control in the inoperable direction. If the air does not
If it wears out, repair or replace the valve.
Air extractor of system 1. Failure of the 'rapid release valve'.
inactive or delayed. Disassemble and clean or replace the parts
worn or damaged.
Pen down inoperative. Control valve failure or failure of the
control valve responsible for the 'nail' of the
lifting of the pen. The nail valve
it is a normally closed valve.
Check the adjustment of the pressure screw of
the "nail" or the stem of the valve not
extended to 3/16".
2. Air cylinder failure in 'the brake of
lifting of the pen, union of control of
inoperative brake.
Engine stops. The relief valve of the lifting of the
pen fails, stop the release. Check the
adjustment of the pressure regulator.
Inactive pen. (operation in jam nuts in the control of
high and low speeds uncontrolled compensator. Failure in the
air cylinder in the compensator. Failure in the
air regulator, pressure set to 60 PSI.

Cause Remedy
Resonator inoperable. 1. Low load pressure. Pressure cylinder
the load does not open the valve.

F. Check the air system (engine not working)

Cause Remedy
Low oil level 1. Have the full air pressure on the
air system.
2. Press the closed valve pressure of
load inserting a screwdriver between the
valve closed and sending pressure to the
unit.
 MANITOWOC ENGINEERING CO.

a. Check the adjustment of the positioner of

air (see the instructions.)
b. Check that the automatic lifting
I freed the pen outward.
c. Full air pressure at the valves of
control.

BRAKE DE
OSCILLATION.
4100W
 MANITOWOC ENGINEERING CO.

Description:
The type of external band of the oscillation brake is actuated through the connecting rod.
motorized and applies more force at the live end of the belt than is required in the
foot pedal. A brake band that is tightened too firmly requires
more physical effort on the brake pedal then correctly, brake adjusted.
A properly adjusted brake has a low pedal.

Adjustment:
Adjust the nut (2) to compensate for the wear of the lining.
2. Adjust the pressure screws (1) to maintain equal spacing between the
drum and the band. (Approximately .030")
3. The release of the band and the pedal is governed by the tension in the spring.
(3) and it is adjusted to fit the operator.

INDEPENDENT OSCILLATION AXIS.

4100W

Clutches

Description:
This axis carries the reverse clutches.
what are references like clutches of
oscillation of the independent oscillation.
 MANITOWOC ENGINEERING CO.

They are disc-type clutches, applied by the pressure of the helical cams.
situated on the axis of the driving pressure plate. One arm is maintained
immobile while the other is operated by an air cylinder.

Settings:
In the adjustment of oscillating clutches, two procedures can be
Used. Any is acceptable, but each mechanic can choose their method.

1. Make the least important adjustments by loosening the clamp bolt (3) -
Figure 1050, then tighten the collar adjustment (2) until the shot of the bar
of the air cylinder is 3 1/2"; then tighten the bolt.
2. The adjustment can also be made by adjusting the position of the cam arm.
stationary on the connecting rod adjusting the slot (4). When the end of the
when the slot is reached, return arm (1) back to its starting position. Loosen the
bolt of the clamp (3) and adjust the collar (2) at the end of the shaft of the plate
of the clutch to give the appropriate adjustment of the clutch.
After using 1 1/2 of the adjustments on the fitting bar (4), invert the
friction plate to increase friction because the friction plate on the side of
the stationary pressure plate wears out more quickly. After use
approximately two complete adjustments in the friction of the adapting bar
(4) should be examined and replaced if the friction is worn out on the heads of the
rivet.
3. When the reinforcement of the clutches becomes necessary, remove the collar (2) and
slide the movable pressure plate as far from the driving bolts as possible
possible. This will allow the removal of the friction plate, which is in the middle.
Every time the crane is lubricated, the oil drive bolts with oil
light

VICON OR NON-VICON DRUM CLUTCH 3600-3900B

3900W- 4000
4000W-4100W

Settings:
Adjust the clutch band
using the adjusting bolts (1) and
(2) Figure 824B. When the band
del clutch is adjusted
correctly, the brand (A) Figure
333 will appear flush with the lid
air cylinder - clutch
completely hooked
 MANITOWOC ENGINEERING CO.

cold adjustment, with the air pressure operating completely. Keep the
clutch adjusted to this mark.

Place guides (3), (4), (5), (6), and (7) to support themselves near the separation.
equal around the drum between the drum and the clutch band. When the
guides are placed correctly, the mark (B) Figure 333 on the piston bar
It will appear 1/4 of an inch beyond the cylinder cap, which this also
indicates that the piston cup is not any impact on the bottom of the cylinder.
As the wear of the guides occurs, the mark (B) will become flush with the cover of the
air cylinder and indicates the need for guide readjustment.

Note: The earlier production models used roller-type band guides that
they require the same adjustment.

AUTOTROL LIFT SYSTEM VICON

These instructions are intended only as a guide for operation

that portion of the machine that is performed by the 'lifting system'
autotrol, which includes the operation of the clutches and the front brakes
rear drum. This guide replaces any other form of instructions
of management that may belong to these controls according to what is used in the
operation of the crane and/or the tower.

Section 1.

The front drum (lifting drum), rear drum (key), is equipped

with the automatic springs applied - air brakes released.

The applied springs - the air brakes are controlled by the

normally open pressure switches, solenoid-operated valves
 MANITOWOC ENGINEERING CO.

electronically and the drum rotation sensors operate mechanically.

Manually operated bypass valves are also provided.
to release the automatic spring of the front or rear drum by applying the
brakes, if it becomes necessary.

The following schematic diagrams show the electrical and air circuits.
required for proper operation.

When the engine is turned on, the oil pressure switch, 'OP', will close and
it will provide electrical power (24 volts) to the controls that reduce energy, PL-1 and
PL-2 and the rotation sensors of the front and rear drum. RS-1 and RS-2.

Diagram - Electrical diagram

B Battery.
OP Oil pressure switch in the engine. (Close to 4 PSI).
ESS Start-stop switch for the engine in the operator's cabin.
FS Fuel solenoid.
PL-1 Power down control switch on the lever of
control of the front drum.
 MANITOWOC ENGINEERING CO.

PL-2 Power down control switch on the lever of

control of the rear drum.
PS-1 and PS-2 Air line pressure switch for clutch control
from the front drum (close to 80 psi).
PS-3 and PS-4 Air line pressure switch for clutch control
from the rear drum (close to 80 psi).
S-1 Air that controls the solenoid valve to release the brake of
front drum (side of the lift of the control system)
S-2 Air that controls the solenoid valve to release the brake
of the front drum. (Descent side of the control system)
S-3 Air that controls the solenoid valve to release the brake of
rear drum (Side of the control system lift)
S-4 Air controlled by the solenoid valve to release the brake
of rear drum. (Descent side of the control system)
S-5 Air that controls the solenoid valve to energize the
hydraulic descending control valve.
RS-1 Rotation sensor - front drum.
RS-2 Rotation sensor - rear drum.
 MANITOWOC ENGINEERING CO.

Diagram - Air Pipe

S Shuttle valve (double check valve).

M Distributor (air supply).
Q Quick release valve.
V-1 Drum clutch control valve (front drum)
V-2 Drum brake bypass valve (front drum)
V-3 Drum clutch control valve (rear drum)
V-4 Drum brake bypass valve (rear drum)
R Rotary air splices (control air line of the
drum brake

Section 2.
 MANITOWOC ENGINEERING CO.

Operation

Uprising:

With the engine running and the regulating valve set for a wide or complete
energy, pull the control lever of the desired drum clutch, V-1 or V-
3, again to stop, (clutch engaged), position (see figure 1190-C).
Air pressure through port 1 has applied the drum clutch with pressure
of the complete distributor air. The pressure switches PS-1 and PS-2 or PS-3
and PS-4, mounted on the air line of the drum clutch control will close
at 80 PSI. These pressure switches are used by the energy that drops the
system and have no function in the operation of the lifting.

Continue pulling the control lever back, gradually applying power.

of the lifting converter.

Open and release the drum brake control pedal for the drum that is
used. The brake pedal is loaded by a spring and the grooves in the lever
The brake motor will allow the pedal to lift and remain in position.
released. The brake of the drum lift is still the spring applied in
this point.

Caution: Do not press the control button that lowers the power while you
Lift a load. It may result in damage to the hydraulic investment system.

As the output energy of the boost converter is increased, the

drum drive machinery will pull against the drum lift brake.
When enough energy from the converter is applied, the drum will turn.
(energy through the brake). As the drum starts to turn, the sensor of the
drum rotation, RS-1 or RS-2 will close an electrical circuit, powering the
brake control solenoids, S-1 or S-2. When either of the valves of
solenoid opens, the air pressure from the control line of the converter of
rising is allowed through to release the appropriate spring by applying the
drum brake. Continue pulling back the control lever for power
desired from the converter, lifting the load.

When the load approaches the desired height, move the control lever of the
drum brake forward to the engaged position of the clutch,
reducing the power output of the converter and smoothly applying the brake
of the drum. While the energy of the lifting converter is being reduced, the
the air pressure released by the applied brake spring also decreases, allowing
that the brake is applied gradually.

Move the drum control lever forward with the stop position of
clutch to the resting position, releasing the drum clutch.
 MANITOWOC ENGINEERING CO.

Schematic - Function of the drum clutch control valve

Valve 1 Drum clutch control valve.

Valve 2 Converter control valve.
The valve diagram is on the right side of the operator's cabin.

Drop:

With the operation of the motor and the fixed regulating valve for a wide or
complete energy, pull the lever of the clutch control valve of
desired drum, V-1 or V-3, back to stop, (clutch engaged), position (see
figure 1190-C). The air pressure from port 1 has engaged the drum clutch.
with the air pressure of the distributor complete. The pressure switches PS-1
and PS-2 or PS-3 and PS-4, mounted on the air line of the clutch control of
The drum will close at 80 PSI. These pressure switches, when closed
they will allow the electric current to flow to the solenoid valve of
brake disengagement when the energy that lowers the button is depressed.

Open and release the drum brake control pedal so that the drum can be
used. The brake pedal is spring-loaded and the slots on the drive rod
The brake will allow the pedal to lift and stay in the released position.
the drum lift brake is still a spring applied at this point.

Press the down control button, PL-1 or PL-2, to start lowering the
Load or the block. The electric current from PL-1 or PL-2 will pass through the
pressure switches PS-1 and PS-2 or PS-3 and PS-4, energizing the solenoid of
control of brake S-2 or S-4 and the solenoid that lowers energy S-5. The brake of
The appropriate drum is released as air pressure from the distributor is allowed to
through the solenoid valve of the brake control to the cylinder applied the spring.
While the air pressure from the distributor is allowed through the solenoid
from the descent control, the machinery starts to turn in the direction
opposite, lowering the load or the block of the load.
 MANITOWOC ENGINEERING CO.

To control the descent speed, pull back on the control lever of the
drum clutch of the stop position (clutch engaged) and apply
gradually a certain energy from the lifting converter. The energy of
The converter of the uprising will act as a retarder and will delay or control the
descent speed.

Note: The energy that lowers the control button, PL-1 or PL-2, must be maintained.
for the entire duration of the descent cycle. If the button is released while it is descending
the load, the solenoid valves for the brake release S-2 or S-4 are
It will get closer causing the drum lift brake to engage, stopping the
downward operation.

To stop the downward operation smoothly, continue holding the button of

pull down and pull the drum clutch control lever of
new to apply additional energy from the lifting converter. This will delay
the descent speed and at a certain point, for the downward action. Hold
the control lever in this position and release the downward energy of the button of the
control. The solenoid for the S-2 or S-4 brake control will close and the brake of
The drum lift will be applied automatically. The downward energy of the
solenoid, S-5 will also close the air release in the control system thus
that the hydraulic control valve will move to the rest position.

Move the drum clutch control lever forward for stop,

(clutch applied), closing position of the energy output from the converter of
lifting. Move the drum clutch control lever forward to the
rest position that releases the drum clutch.

The manual drum brake pedals must be open and in the released position.
for the automatic brake to function normally. The brake pedals are for
the spring and the slots in the brake drive rod will allow the brakes
automatics work normally without the movement of the brake pedal. If so
desired, the manual brake pedals can be used by the operator
to increase the smoothness of the automatic brake.

Closed

The electrical system for controlling the drum lift brake is tied with
wire through the motor start-stop control switch (ESS) in the
operator compartment. The energy for this switch comes from the battery
through the engine oil pressure switch (OP).

The flow of electrical energy can occur in cases of:

1. Loss of engine oil pressure (the oil pressure switch is

it will open)
2. Change the on-off switch to off. (motor closed).
Poor connection or break in electrical wire.
 MANITOWOC ENGINEERING CO.

4. Damage or misalignment of the drive roller of the drum rotation sensor.

The drum lift brake will be applied automatically. In the case of

up, the brake will not release.

In case of loss of air pressure while operating, the switches of

pressure PS-1 and PS-2 or PS-3 and PS-4, in the air lines of the clutch control
The drum will open at 80 PSI, breaking the closed solenoid valves of the
electric circuit S-2 or S-4 causing the automatic brake to apply.

See the maintenance guide for the autotrol lifting system for adjustment and the
lubrication.
 MANITOWOC ENGINEERING CO.

FRONT OF THE DRUM BRAKE

There is only one adjustment needed to compensate for the normal wear of the lining -
adjust the nut (3). Adjust the tension of springs (1), (2) and (4) to support the weight
from the band for the equal separation between the edge of the drum and the band of
brake - brake released. The guide of the brake roller (6) must be fixed in
approximately 0.40 inch of separation between the guide and the brake band -
brake system. To achieve a firm release of the foot pedal, adjust the
spring tension (5). Always adjust the left brake first, then tighten
the right brake up to the beginning of the foot pedal to move. Apply the
Stop slightly with the occupied drum to check if they are synchronized.
the brakes, indication of this can be done by feeling the temperature of the
brake band. Because the tolerance of the lever of the connecting rod can vary
slightly from side to side.

Maintenance notes:
The drum brakes must always be properly fitted to the rim of the drum;
The most important are the dead and live ends of the band.
2. Left side of the band anchored. Check that the brake band
is firmly fixed to the circumference of the drum rim.
3. Pull the foot pedal in the upper notch. Then tighten the nut (3)
up to 1 ¼ inches from the measurement of the lever's arm. Release the pedal
of the foot, then check the gap between the drum edge and the
brake band, to compensate for the separation adjust the guide rollers (6)
then the springs (1), (2) and (4).
 MANITOWOC ENGINEERING CO.

4. With the brake applied - the right side, tighten the nut (3) until the
move to sit on the brake pedal, then release the brake pedal
and adjust the brake, use the same procedure for the left side.

A properly adjusted brake has a low pedal when applied.

complete. This allows the pin (7) in the lever's connecting rod to work
closer to the dead center. A tightened brake has a pedal that is too firm.
high and does not allow the pin (7) to work near the dead center.

Take special care when removing, handling, transporting, or reinforcing the

band. A curvature or around the band will not give the operator the correct
sensación del pedal. El freno funcionará caliente, sosteniendo menos y un
rapid wear. Check periodically 1 ¼ inches of the connecting rod of the
lever - this measure determines the operation of a smooth working brake.
 MANITOWOC ENGINEERING CO.

REAR PART OF THE DRUM BRAKE

ADJUSTMENT:
1 - Adjust the tension of the spring (1), (3) and (5) - figure 1048 - to support the weight of
the band with the equal spacing between the drum edge and the brake band
brake released.
2 - Adjust the nut (2) to compensate for the wear of the lining and the rod of the
correct lever of 1-15/16 inches according to the indications of figure 1048 -
brake system.

MAINTENANCE NOTES:
The brake bands must always be embedded in the rim of the
drum. The dead and alive tips are the most important.

Note: Adjust the left brake first.

2. Raise the brake band anchor. Check that the fixed brake band
firmly on the circumference of the drum rim.
3. Foot pedal of the latch in the upper notch. Tighten the nut (2) until
get 1-15/16 inch of lever. Release the foot pedal, then
check the gap between the drum edge and the brake band;
 MANITOWOC ENGINEERING CO.

adjust the springs (1), (3), and (5) for equal spacing between the rim of the
drum and the brake band.
4. Right brake of the system, with the foot pedal in the upper position of the
groove, (as shown) - open. Tighten the nut (2) for one point
where to start lifting the foot pedal, holding the crank of the
lever at 1-15/16 inches. Release the foot pedal, then adjust the
spring (1), (3) and (5) for the equal separation between the brake band and the
drum rim.
5. Fix the screws on the lever (4) are to synchronize the brakes. This
the adjustment is fixed and sealed from the factory, the only time this is disturbed
need, it is when the axis or components of the are repaired
operation. When replacing the adjustment covers (ONLY) on the nut
The lever dimension may vary slightly when the bands
brake "they work in". The variation in temperatures of the band of
brake will indicate which brake band will need adjustment according to the
synchronization. To achieve the positive pedal of the foot, release the tension of
adjustment in the spring (6).

A properly adjusted brake has a low pedal when applied.

completely. This allows the slider (A) in the lever's connecting rod to
work near the dead center. A brake adjusted too tight
It has a high pedal and does not allow the pin (A) to work close to the center.
Dead, which will require more effort to operate the brakes. Apply the
brake slightly - dedicated clutch - "to operate in" brakes for
check if the adjustment is correct.

Take special care when removing, handling, transporting, or reinforcing the

band. A bent or outward round band will not give the operator the
correct feeling of the brake. The brake could work hot, holds
less and wears out more quickly. Check the connecting rod periodically.
of the lever 1-15/16 inch - this measurement will determine the operation of a
smooth working brake.
 MANITOWOC ENGINEERING CO.

MAIN DRIVE AXIS (VICON)

Axis of the route

Description:
The main drive shaft - figure 1049, carries the reverse clutches.
mainly referred to as the journey clutches, which are applied by
la fuerza de las levas helicoidales situadas en el buje de la placa de presión de
driving. One helical cam arm is held stationary while the other
is turned by the air cylinder.

Clutch travel adjustment:

A) To compensate for the wear of the lining adjustment in the connecting rod - figure
248, the collar (2) - figure 1049. Any adjustment is acceptable, but
favoring the adjustment of the collar could mean a longer life of the
remove. Check the lining through the drainage holes in the spider
to determine if there is still a safe amount of lining.
B) Adjust the clutch to obtain 3 ½ inches of piston rod travel.
Complete air pressure of the system - cold the clutch. Use the hole
external on the movable lever for the use of the air cylinder.
Periodically check the friction lining next to the plate.
static pressure to know if there is wear. After half it is used
its thickness (approximately 3/32 of an inch), turn the plate of the
friction to increase the life of the friction, because the friction next to the
 MANITOWOC ENGINEERING CO.

the stationary pressure plate wears out more quickly. At the same time, the
the right clutch plate must be placed on the left clutch and the
left to right. In this way, there will continue to be a pull on the
rivets in the same direction reducing the possibility of loosening
from the linings. The friction materials should be replaced when there is wear underneath.
from the heads of the rivets.

Replacement of the lining:

When clutch relining becomes necessary, remove the collar.
match 2 – figure 1049, and slide the movable pressure plate as far from the
conduits as much as possible. This will allow the removal of the plates.
of the friction that are halfway.

A. Keep the friction disc joints in pairs as they are removed.

B. Maneje la fricción con cuidado para evitar el doblez.
C. Make sure that the drive disc is perfectly flat before the
new setting of the disc liner.
D. Matching the ends of the disk splices are marked to assist
to keep in pairs, Look at the corresponding teeth that are partially
ground outside.
E. When securing the new lining of the drive disc joints, be
make sure that the lining is positioned and does not extend beyond the
extremes and the inner diameter of the drive disc connections;
also that the lining does not cover any part of the tooth arch. Use the
 MANITOWOC ENGINEERING CO.

sufficient "C" clamps to hold the lining in contact with the disc
of the thrust while it pierces, sinks, and nails.

Maintenance:
Check the tightness of nuts (1) and (8) to ensure that the races
The inner races of the ball and roller bearings are locked above the solid.
of the axis.

A. Tighten the broken nut (8) on the right clutch first, then tighten and
the broken nut of the ingot above (1) on the left clutch. To tighten, turn
these towards the engine, (rear of the machine). The oil outlet may
succeed through the loose parts in the axis.

B. Exercise caution when directing or working around the clutch spiders (6).
A bump on the outer edge of the tooth could cause distortion with the
hot clutches and poor release of the pressure plate friction
immobile. The poor release of clutches could also be caused by the
loss of tension in the springs released from the pressure plate. If this happens,
Remove the six springs, fix them to a flat surface, then the check
for height. Pair as closely as possible, then reinstall.
 MANITOWOC ENGINEERING CO.

Oil pump assembly:

This is a continuous circulation system. The oil is taken from the collector of
oil through a pump eliminated the front torque converter.
oil passes through a Cuno paddle filter and from there goes to the gears
from the drum, to the conical gear of the main drive shaft and to the gear of the
route, then returns to the oil collector.

IMPORTANT: the handle on top of the filter must turn until it completes this turn
loosen it, this should be done several times a day. The drain plug at the
The lower part of the filter must be removed once a week to drain any
sediment in the filter fountain bowl. This procedure should be done as
the first operation of the day, with the operation of the machinery and the
circulation of the oil. This will also help to remove any water that has been
accumulated in the oil collector. Periodically remove the bowl and wash it.
filter element.

The indicator located on the filter cover will normally not show any pressure.
or the pressure very low, depending on the viscosity of the oil. A higher pressure
The gauge reading will indicate that either the filter is blocked or the oil is heavy.
When the filter begins to block, unfiltered oil will bypass the filter and
it will block the holes in the tube bushings, cutting off the oil flow to the
bevel gears on the main drive shaft.

Cleaning of the tube and injector nozzle:

 MANITOWOC ENGINEERING CO.

A. Place the large cloths on the cover to prevent the caps from
tube or the tools fall on the cover of the conical gear. BE
SAFETY OF REMOVING THE CLOTHES BEFORE TURNING THE AXLE
MAIN IMPULSION.
B. Use a small socket wrench or long-handled pliers to remove the
tube sleeves. Do not swing the assemblies in whole or from outside to
remove the sockets. This practice could cause the assembly to loosen
during the operation of the machine and the flow of oil from the bias gears and
of the bevel gear.
C. Remove, clean and replace the filters, remove the rags and machinery
working with the tube bushings until most of the oil has
a cycle completed through the filter, usually around 5 minutes.
Replace the rags, then clean the tube fittings and install in the line.
remove the assembly oil. REMOVE THE RAGS.

Intermediate vertical trajectory axis:

The axis of the intermediate vertical path, driven by the bevel gears in the
backward clutches of the main drive shaft, transmits power to the
gears of the journey.

GENERAL INFORMATION – Air control adjustment data.

 MANITOWOC ENGINEERING CO.

Brief adjustment data of the control 4100 W

of air
Drum brakes See inst.
Oscillation clutches 3 -½ inches
Drum clutches See inst.
Clutch of the route 3 -½ inches
Drum clutch guides See inst.
Drum brake guides See inst.
Minimum air pressure 125 psi
Range (between cut in and cut out) 12 psi
Safety valve 175 psi
Piston rod travel - cold adjustment - complete system pressure

Drum clutch:
Adjust the drum clutch to achieve the piston rod pull shown in
the table.

Adjust the guides to maintain the spacing shown in the table.

The clutches that do not have listed dimensions are marked on the bar of
piston. These marks indicate when the band and the clutch guides are
necesitando de ajuste. Ver las instrucciones del ajuste del embrague de tambor.

Important: Keep the clutches properly adjusted. Too much pull or

the journey will result in sliding, heating, and wear when the piston
reach the end of your journey.

Oscillating clutches:
Adjust the clutches to acquire a piston stroke as shown in the table.
Too few trips will cause both clutches to collide with each other.
other: slipping, heating, and wear will result. Too much pull
It results in an incomplete clutch gear when the piston bases.

For the complete adjustment procedure of the oscillation clutch refer to the
adjustment of the oscillation clutches in the drive shaft instruction
principal.
 MANITOWOC ENGINEERING CO.

Drum brake:
When adjusting the brakes, use the same method; pull or piston travel, to
check. The initial adjustment, if applicable, is listed in this table.
Too little travel or shot will result in insufficient release; causing
heat, unnecessary wear, and poor brakes.
 MANITOWOC ENGINEERING CO.

Problem Possible cause Remedy

Clutch release - Quick release of the Check to see if there is
the brake to slow down. non-operational valve. dirt or worn parts.

Dry drive white. Lubricate.

Release of the broken spring. Replace.

- Cilindro pegajoso. Load the supply line of the

aire con aceite ligero.
Slow application of the Low pressure. Check with the indicator of
brake. air. (See the instructions)

Dry drive white Lubricate.

Clutch or brake if Enameled ceiling. Take off the band and clean with
slide or it will not hold. rasp. Or use other methods
approved.

Incorrect firing of the cylinder of the Check the fit or interference

air. in the connecting rod.

Low pressure to ventilate the Check with the indicator.

cylinder. the instructions in the procedure.

Also see after the Obstruction on the line.

section.
Warming of the Oil in the drum. Apply carbon tetrachloride or
clutch or brake. earth.

Insufficient separation. Adjust the guide rollers and springs.

Band formed Quite and formed the band again.

incorrectly.

Jamming nut on the bolt Tighten.

from the live eye of the end, it releases.
Escape port of the - Adjustment of the hand lever - See the instructions for adjustment.
control valve. too tight.
Dismantle the valve and replace it.
Broken diaphragm.
Disassemble the valve and clean it.

Dirt under the diaphragm.

System that increases the Escape valves of the Replace the valves.
slowly pressure. compressor.

Lines or connections that are Replace the pipes or linings.

they escape.

Excessive carbon in the Dismantle and clean the coal.

compressor, hot cylinder or
download line.
 MANITOWOC ENGINEERING CO.

Problem Possible cause Remedy

System that increases the Belt slipping - Tighten the belt.
slowly pressure. compressor drive.
(continuation)
Worn piston and rings. Replace.

Clogged air filter. Clean.

Drop in pressure Escape from the pipe or from Tighten or replace the pipe or
quickly with the the connections. accessories.
motor stopped and the brake and
clutch released. Pedal or valves of Clean and replace.
escape.

Escape from the valves of clean and replace.

compressor discharge.
Drop in pressure Escape brooch in the Replace the cups.
with the engine stopped and cups in the brake cylinder.
clutch or brake
applied. Missing sleeves or lines of Tighten or replace.
escape.
The compressor builds The flush valve does not Disassemble and clean the screen
the pressure beyond the works correctly or the Adjustment.
maximum adjustment of the the pressure was set too high Replace the valve, if it is
indicator pressure or up necessary.
the outbreaks of the The flush valve was fixed
flush valve too low.
constantly.
MANITOWOC ENGINEERING CO.
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MANITOWOC ENGINEERING CO.

VALVE 2-HA-1 PILOT

 MANITOWOC ENGINEERING CO.

SERVICE INFORMATION

MAINTENANCE:
Periodically dismantle the valve for cleaning, inspection, and lubrication.
Wash all metal parts with kerosene or a solvent with characteristics
similar. Wash all rubber parts with soap and water. Dry all the
parts with low pressure air.
Examine the inlet valve (7) and the rubber packing ring (9), (13), (15)
and replace them if they are cracked or worn out.
During the new assembly, lubricate all friction surfaces, including
the packing rings, with a low temperature grease such as MIL-L-4343A
LUBRIPLATE.

ADJUSTMENT:
The notch force on the notch cam (22) can be adjusted by the
pressure screw (28). Turn the screw down to increase the force of the
notch. Turn the screw out to decrease the force.
MANITOWOC ENGINEERING CO.
 MANITOWOC ENGINEERING CO.

VALVE 2-HA-2 PILOT

Manitowoc No. 714494 Manitowoc No. 714495

SERVICE INFORMATION

Manitowoc No. 714495

2-HA-2 Model (P54426-0312)
An opposing spring of the notched cam holds the handle in its center.
(vertical) and two extreme positions of the path when the handle is released. See
Figure 1.

Manitowoc No. 714495

2-HA-2Z Model (P54425-0310)
Just like in the model 2-HA-2 except that the handle returns to the spring to the
central position of all the other positions when released. See Figure 1.

MAINTENANCE:
Periodically disassemble the valve for cleaning, inspection, and
lubrication. Wash all metal parts with a suitable solvent such as
 MANITOWOC ENGINEERING CO.

Stoddard's solvent or kerosene. Wash all rubber parts with soap and
water. Dry all parts with low pressure air.
Examine the check valve 23, rubber packing rings 17.19 and 24.
Replace all parts that are cracked or worn.
During the new assembly, lubricate all friction surfaces, including
the packing rings, with a grease for a wide range of temperatures.

ADJUSTMENT:
The PILOTAIR valve type 2-HA-2 does not require adjustment.
The force of the notch in the notch cam (22) can be adjusted by the
pressure screw (28). Turn the screw down to increase the force of the
groove. Turn the screw back out to decrease the force.
 MANITOWOC ENGINEERING CO.

PILOT AIR VALVE 'A'

Block type

["Manitowoc No. 714417","Manitowoc No. 714423","Manitowoc No. 714496"]

SERVICE INFORMATION

MAINTENANCE:
A PILOTAIR 'A' valve must be kept in reserve at all times for each
four valves in service. Schedule the maintenance periods accordingly
que las unidades completas puedan ser giradas. La unidad substituida puede
then be maintained without causing delays in production.
Disassemble the complete valve. The heart of the valve is easily disassembled.
after the retaining ring (2). Clean all parts with a non-solvent
flammable and wash all rubber parts with soap and water. Rinse the pieces.
Well and dried with low pressure air.
Examine all the parts for wear, particularly noting the condition of
the "O" rings and the intake valve. Worn parts or those that can
allow excess output before the next maintenance period should be
replaced.
Lubricate all the metal for the metal surfaces with a thin film of the
Lubriplate No. 107 and all the rubber parts with Cosmolube grease. The lubricant
equivalent to those recommended can be used.
Reassemble the valve heart in the body in the order as it was.
show in the schematic view and then install the valve operator. If the
PILOTAIR valve will not be returned to service immediately, put the
complete device in a waterproof bag for the return to
storage.
 MANITOWOC ENGINEERING CO.

ADJUSTMENT:
The PILOTAIR valve type 'A' block does not require any adjustment.
FLEXAIR VALVES

MAINTENANCE:
Clean and lubricate the notch latch (38) and the cover (37) every 500 hours of
operation with calcium base grease #2 or an equivalent low-temperature grease.
Access to these pieces is obtained first by loosening the adjustment nut
(41) to loosen the tension of the spring in the latch cover (39) and the latch of
the notch (38). Then I removed the ring (42) and the pin (43) from the handle (44). The
The handle and the details of the latch cover can now be removed.
The notch latch (38) can be lifted by removing the pin (33).
Every 1000 hours of operation, clean and lubricate the contact ends of the
screw (31), the handle axis (30a), the contact area of the bushings (16), the
extension (25), and the interior of the bearing (28).
Remove the complete valve periodically from the installation for inspection.
cleaning and lubrication. All maintenance that requires disassembly must be
work on a clean workbench. To disassemble the FLEXAIR valve first
remove the handle (44), the cover of the notched latch (39) and the latch of the
groove (38) according to the contour above. The screw (35) at the base of the cover
(37) is removed and the cover (37) slides off the body exposing the mechanism
of operation. The operating lever (30) is removed by expelling the
spacer (27). The valve caps (16) can then be lifted off the
place.
To disassemble the valve portion, remove the three socket screws (2) from
the bottom part of the valve and lift the spring cover (29) from the body (4).
The working valve mounts must not be removed. These
montajes no deberían ser intercambiados mientras que esto puede cambiar las
operating characteristics of the valve. The valve assemblies of
graduation (15) are fixed in the factory and should not be disassembled. When removing
These valve mounts can have a shimming layer on top of them. These
Lines are essential and must be returned to their proper place to return to
assemble the valve. The number of shims required is stamped on the
lower surface of the spring cover (29).
Before removing or installing the retaining ring (13) to examine the portion of
the fountain valve, press the piston (10) with your finger until the small
cross pierces the hole at the bottom of (10) is exposed beyond the part
bottom of the body (4). Insert a pin into this 1/16” hole to keep the
spring (7) caged.
If an operating valve is installed in cavity #3 of the valve
These parts can be removed by lifting the plunger (20) and the guide (22).
complete fountain valve assembly (17) can then be lifted from the
valve cavity. If a throttling valve assembly is installed, it is
it is necessary to remove the retaining ring before the valve assembly of the
source can be removed.
 MANITOWOC ENGINEERING CO.

All metal parts must be cleaned with a non-flammable solvent.

Wash all rubber parts in a mild soap and water solution. All
the pieces should be thoroughly dried with low pressure air. Check all the
parts to check for wear, cuts, and defects and replace them when necessary
necessary.
Before reassembling, lubricate all contact surfaces of the cavity of
the valve with Lubriplate 107 and the O-rings with a low silicone grease
temperature as MIL-L4343A. A lubrication table in gold leaf
self-adhesive is available for mounting near the valve for a
reference list. If desired, ask for E4-72.03-4.
When installing the adjustable valve assemblies in cavities #1 and #2 of the
valve make sure that the flat side of the faces of the spring washer (f) is
toward cavity #3 of the valve so that the washers do not mount on the
part of the valve in cavity #3. Also, before tightening the cover of the
spring (29) to the body (4), make sure that the washers (f) are seated
entirely in the grooves in the body (4). A screwdriver blade
it can be used to slide these pieces into their proper place.
 MANITOWOC ENGINEERING CO.

ADJUSTMENT:
Do not attempt to adjust the settings of the calibration valve (15). These
assemblies are factory-made for the required operating pressure range and
blocked in position. Complete assemblies must be replaced if
there is wear or if you want to change the operating range.
The adjustments can be made regarding the upper portion of the valve.
FLEXAIR and the full pressure feature of the valve assemblies.
operation that is accessible without the complete removal of the valve
installation.
The force of the handle (44) can be adjusted as desired through the
nut with grooves of the cover (41). The excessive force of the notch must be
avoided, as this creates undue wear on the notches and the latch of the
groove (38).
The characteristic of the handle of the friction grip in the FLEXAIR valves
that incorporate the friction brake can be adjusted to provide the
desired operating characteristics by turning the head pin
hexagonal (64) inside or outside as desired.
After a reasonable service life, it may be necessary to readjust the
pressure screws (31) to eliminate the free play of the handle (movement
lost) when moving from the central position to the operating area.
Ordinarily, the delivery of pressure from any port must begin
approximately 3° off the central position. When the distance is greater than
this occurs without the accumulation of pressure, the pressure screws (31) must be
adjust as follows. With the handle perfectly vertical in the center of the slot
From the handle guide, adjust the pressure screws (31) until there is 0.001" to
0.003" of separation between it and the sleeve (16).
 MANITOWOC ENGINEERING CO.

QUICK RELEASE VALVE

Service information

The Quick Release Valve shortens the time required to express the pressure.
atmospheric of a cylinder or a pneumatic device. This fact is possible
exhausting atmospheric pressure directly to the atmosphere in the Quick Valve
Release instead of back through the control device. Maximum pressure of
The operation of the quick release valve is 250 psi.

Installation
Install the Quick Release Valve as close as possible to the device
to be depleted. If the distance between the control device and the device for
being exhausted is very long, I installed a second Quick Release Valve
around half of the point.

Adjustment
The Quick Release Valve does not require adjustment.

Maintenance
Periodically disassemble the Quick Release Valve for cleaning and
Inspection. Wash all metal parts with paraffin or a solvent with
similar characteristics. Wash all rubber parts with soap and rinse with water.
Blow all dry parts with low pressure air. Inspect the diaphragm and
the gasket and replace if it is cracked or worn.

Operation
The quick release valve has three ports, as indicated in the view.
schematic. The atmospheric pressure entering the supply port forces
the diaphragm of the valve against its exhausted port, closing it. This pressure
 MANITOWOC ENGINEERING CO.

Atmospheric also diverts the edge of the diaphragm to open a direct passage.
around the diaphragm for the delivery port of the valves, to be
always open.

When the atmospheric pressure at the supply port is reduced

approximately 5 psi or more, a pressure differential acting on the
diaphragm is created. This differential in pressures lifts the diaphragm from
the exhausted port and it sits at the supply port of the valve. This
diaphragm movement opens the exhausted port, allowing air to flow
freely from the delivery port of the valve to the atmosphere, and closes the port of
supply of the valve.

If the air pressure in the Quick Release Valve drops to a value of

approximately 1 psi below this at the supply port, this differential
 MANITOWOC ENGINEERING CO.

in the pressure, it moves the diaphragm, then this settles in the exhausted port,
stopping the additional air flow through that port.

SHUTTLE VALVE
MANITOWOC N° 714647
INFORMATION SERVICE

ADJUSTMENT
The shuttle valve does not require adjustment.

MAINTENANCE
By removing only the screws (1) and washers (2), the cover can be removed for the
easy diaphragm replacement (4) without disturbing the pipe joints.

When complete disassembly is necessary, clean all metal parts.

with a non-flammable solvent and wash all rubber parts with soap and discard
water. Rinse thoroughly and dry with a stream of low-pressure air.
Replace the diaphragm (4) and the gasket (5) if they are damaged. Repeat
assemble the valve, using the assembly and the explosion as points of view and
Reference. Lubrication is not necessary and no tools are required.
special.
 MANITOWOC ENGINEERING CO.

GARDNER – DENVER UNLOADER PILOT 15-AUX-525A

MANITOWOC No. 558902

DESCRIPCION
The downloader pilot is set for an approximate variety of 12 pounds and
it will cut inside and outside the minimum and maximum atmospheric pressure shown in the
data plate for cabin air control adjustment for operators.
the range differential is fixed (by the areas of the upper seats and
inferiores) and it can only be slightly changed by the addition or removal of lining.
of adjustment (5). These adjustment shims are mainly used to compensate
minor variations in the machine's work or in various parts and not for the
variation of the differential.

ADJUSTMENT
The operation ranges can be adjusted by loosening the locking nut (3).
In order to raise the operating pressure, tighten the screw that fits below.
If a lower pressure is desired, the fitting screw can be cast.
back. Then adjust the operating range, be sure to tighten the nut
block (3) to prevent future pressure changes in the operation.
 MANITOWOC ENGINEERING CO.

MAINTENANCE:
If the unloading pilot gets stuck or causes a mess, take it apart and clean it thoroughly.
with gasoline. Be sure to clean by straining with the help of a strainer and wash
full throttle on the gasoline. Make sure it will be replaced, it is important that there is no
matter inside the valve chamber.
In case of poor performance, the following points must be checked
in the order indicated:

1. Check the diaphragms of the discharge valve of the suction

compressor operation due to the rupture.
2. Remove the receiver airline in the pilot; blow out the oil.
the mud, the scale, etc.
3. Disassemble the entire pilot, wash the parts and filter (10) in the gasoline and
gather.
4. In the case of a major repair job, it is advisable to return the
pilot to the Gardner-Denver factory in Quincy, Illinois, due to the
special instruments and testing equipment required for the return and
align the surface of the seat.
 MANITOWOC ENGINEERING CO.

ALCOHOL INJECTOR
MANITOWOC No. 511111

OPERATION
The power of the maximum pressure and temperature is 250 psi at 250 °F.
Fill it through the filler plug (13)
To start the injector, close the needle valve completely. After that
the air ignited, open the needle valve to adjust. Normally 1 to 3 drops
per minute is enough.
The throttling disk (7) provides the accuracy of the feed adjustment.
in low flow ranges (1-6 drops per minute). In higher flow ranges this
disk filtering can restrict flow, if this is done it should be removed.

MAINTENANCE
Dismantle by closing the atmospheric pressure. Remove the screw (15). After
remove the deposit, unscrew the siphon tube assembly (19) and the assembly
control valve (22)
Remove the upper plug assembly (4) and unscrew the drip gland (8)
with an Allen key. Then push the Venturi tube (12) from the bottom.
Clean and inspect all parts carefully. If necessary, order a
repair kit or the list of replacement parts that appears on the sheet of
parts.
 MANITOWOC ENGINEERING CO.

FLOREG ° VALVE
SERVICE INFORMATION
MANITOWOC No. 702533

The FLOREG valve is an adjustable device that works with others

components of a fluid journey over time, in sequence, or to coordinate
operations. This controls the range in which a gas or liquid can flow in a
direction still allows free flow in the opposite direction.

OPERATION
The maximum operating pressure of the FLOREG Valve is 250 psi.
temperature range of -40 F to 160 F.

Type A Standard Flow Regulation

FREE FLOW - the Fluid forces the valve (4A) upwards to compress the
spring (3) and the hole increases to maximize the size.

THE CONTROLLED FLOW---Valve (4A) is held in its seat in the body

(12) by the spring (3). This sharp valve is lifted from its seat by the
screw that adapts (10) allowing a controlled flow of air. The movement
The upward advance of the screw that fits will lift the valve for the flow.
aumentado o máximo.
 MANITOWOC ENGINEERING CO.

ADJUSTMENT
The adjusting screw (10) regulates the flow of the fluid in the direction of control-
flow only. Loosen the locking nut (9) and turn the screw that fits the
right to increase the flow - left to decrease the flow. Press the
lock nut to secure this position.

MAINTENANCE
Periodically disassemble the valve for cleaning, inspection, and lubrication.
Clean all metal parts with a non-flammable solvent, and wash all the
rubber parts with soap and add water. Rinse thoroughly and dry with air.
low pressure. Replace any part that is damaged or worn.
Reinstall the valve, using the schematic view as reference. None
A special tool is required. When proceeding to assemble, lubricate everything.
metal - metal surfaces with lubricant number 107 and all parts of
sealant with Dow Corning 5.
 MANITOWOC ENGINEERING CO.

ENGINE COOLING SYSTEM

Raw water is out of fashion and has no place in the cooling system.
modern engine. Use only clean water (preferably soft). The
raw water from streams, wells, etc., can be highly corrosive due to the
industrial waste, dissolved minerals or soil compounds, or drainage of
surface waters (wastewater, fertilizers, etc.). The scale formed by
hard water should also be avoided. Contact a distributor
engine authorized, for the approval of municipal water in your area.

ALWAYS KEEP THE COOLING SYSTEM WITH THE AMOUNT

OF RECOMMENDED WATER. USE A RECOMMENDED ADDITIVE
ENGINE MANUFACTURER.

ADDITIVES:
These are the ratings to consider when purchasing an additive for the
cooling system

Corrosion and mold inhibitors ('young 3-1-2' or the equivalent)

are available and offer protection for all engines of
internal combustion. They effectively control the formation of mold,
they protect all the metal parts of the cooling system of the
corrosion and do not deteriorate hoses or non-metallic parts. They
they are completely compatible with all standard types of
antifreezes without harming their effectiveness. None is required.
caution or special protection to handle them.
Soluble oil is recommended for use in refrigeration systems.
for some time. This recommendation has not been taken seriously by
some clients and as a result some lines of the cylinder where it
introduce the water, they must have been discarded due to corrosion. The
mold and corrosion can be greatly reduced or completely
removed thanks to the use of soluble oil in the appropriate amount in the
engine coolant.
Use Superla soluble oil, or its equivalent, as a liquid additive.
coolant in all Cummins engines with cooling system by
radiator to prevent mold and corrosion. The proportions must be
3% to 4% of soluble oil and 97% to 96% of water. Once used
the antifreeze, the soluble oil will be according to the amount of water
used. Example: in a total capacity of 100 pints, 4 pints of oil
soluble - capacity of 100 pints, 50 pints of antifreeze, 48 pints of
water and 2 pints of soluble oil.
The exception to the aforementioned specification is those engines
equipped with water filters, which resist engine corrosion.
The concentration of the solution can be verified by the following
method:
 MANITOWOC ENGINEERING CO.

a) Extract the antifreeze liquid directly from the hot radiator and
Place 96 cc in a 100 cc glass tube.
Put 1 tablespoon of common salt and shake the tube to dissolve it.
salt in the liquid.
Leave the glass tube in a warm room for 15 to 30 minutes.
to allow time for the complete separation of the oil soluble with the water.
(d) The amount of cc of oil soluble at the top of the tube gives the
percentage.

CAUTION: Do not return the tested fluid to the radiator because the salt will conduct
the soluble oil will cause corrosion.

SAFETY CHECKLIST
(1) Exit of the pressure cap of the radiator.
(2) The pressure lid that doesn't work.
3 Loose plate (upper tank of the radiator)
(4) Overflow pipe blocked.
(5) The bent fins of the radiator (prevents proper airflow)
air through the radiator core
(6) The airflow of the blocked radiator (between the fins), caused by
for leaves, bugs, dirt, etc.
(7) Radiator heart outlet.
(8) Output from the radiator tank union.
(9) Dirty or damaged fan blades.
Radiator pipes blocked by mold, oil dirt, or
other materials.
Mold deposits in the lower tank of the radiator.
Loose bolts holding the radiator.
Loose hose clamps.
Worn or loose fan belts.
Worn or damaged hoses.
Water pump outlet.
Wear of the water pump (air drag at the outlet of
cooling system).
Drainage key outlet.
Coolant liquid outlet in the engine.
Cracked head.
Loose main pins.
Main joints that escape.
Mold formation on the cylinder head.
The thermostat is not working - thermostat blocked - air trap an
prevents the filling of the system.
Gas escape leak in the cooling system
Cracked head.
(b) Union of the cylinder head is loose.
 MANITOWOC ENGINEERING CO.

Filling the cooling system:

The cooling system must be completely full before the engine.
sea operated. Sometimes the mechanic, when having excess coolant liquid in the
radiator, assume that the system is full. The false idea has led to the fact that the
engines were returned to maintain only partial filling with the
coolant. Occasionally, the lack of coolant has led to
engine damage.

WHAT TO DO!
The mechanic must follow the recommendations for filling the coolant.
that are found in the manufacturer's engine operator manual. After
that the cooling system has been filled, the engine must run until
the thermostat opens and the radiator tank is hot. If necessary,
Add coolant until the radiator is full.
The engine must not operate under any circumstances when the top of the heart
the radiator is exposed. The air will be trapped in the coolant that passes through
the radiator and the engine this could cause overheating.
Wear of the water pump (air drag at the outlet of the
cooling system joint.
Drainage key outlet.
Exit of the cooling liquid in the engine.
Cracked head.
b. Main bolts loose.
c. Main joints that escape.
Mold formation in the cylinder head.
The thermostat does not work - thermostat clogged - air trap an
prevents the filling of the system.
Gas escape leak in the cooling system.
a. Cabeza agrietada.
b. Union of the cylinder head loose.
 MANITOWOC ENGINEERING CO.

TORQUE CONVERTER POSITIONER

Manitowoc 714532 – 714531

Periodically disassemble the cylinder for cleaning, inspection, and lubrication.

maintenance periods should be scheduled approximately every nine
(9) to (12) months without causing production delays.
A. Care must be taken when disassembling the cylinder due to the strong return of the
spring (7) fig. 997, at the end of the cylinder bar. Referring back the
flat nuts (2) on the extension of the struts, the pre-load of this
resort (7) can be relieved. It may be necessary to hold the screw with
straps-clamp grips to prevent it from turning. After backing up the
nuts around ¾", the previous preload must be completely
released. Mark one end of the piston tube (8), this is used for the
reassembly.
B. Clean all metal parts with a non-flammable solvent, wash all
the rubber parts with soap and water. Any piece that shows
evidence of wear or any damage must be replaced, note in
specifically the condition of the 'O' rings. Seals (3) and (10), 'O' ring (4), (5)
y (11) can be purchased as a kit. Generally, the 'O' ring (9) never
needs to be replaced.
C. When the new 'O' ring and seals are installed, the piston tube
it should be installed at the end. Due to its continuous operation, and the weight of
the piston the tube will wear slightly. The change of terminals
it will restore the correct I.D. for the piston and ensure a longer life
of the ring 'O' and of the seal.
 MANITOWOC ENGINEERING CO.

D. When remounting, care must be taken to protect the rubber seal.

of the piston or another product from the damages. Use adjusting lining or materials
similar ones to cover the threads and sharp edges, as these can
cut the seals when they are mounted.
Static seals such as "O" rings must be covered with grease.
Pneumatic Number 55 from Dow Corning. The piston rod along with other
areas to the east must be covered with abundant antioxidant fat
similar to Sun Oil Co. No. 1897. Any grease similar to this is allowed.
to use.
The loop bars (1) are made of special tempered steel, they must be
tightened evenly as much as possible, at 25 pounds of torque.
The Manitowoc 714531 positioner has a 9/16" (6) spacer installed.
in front of the spring (7), positioner 714532 has a 3/8" spacer.
unit 714531 is designed for circulation at 30 PSI with a
2" race, unit 714532 starts moving at 20 PSI with a
2-3/16” point race, this must be stopped externally for
prevent possible damage when the spring returns. After the
the assembly is complete, the bench test can be done for
test the output and the appropriate operation. It is advisable that a source
Adjustable pressure to be used for the test.

NOTE: Check the mounting pin fasteners (12) for any

wear, new O.D. is 1 inch. Before January 1968, two 1/8"
Washers were used behind the spring (7) to pre-load the
positioner at 30 PSI.
 MANITOWOC ENGINEERING CO.

MAINTENANCE OF THE VICON AUTOTROL LIFTING SYSTEM

DESCRIPCIÓN:
The Autotrol lifting system is an arrangement that involves an applied spring -
drum brake air released, which is controlled by the rotation of the drum
while raising a load.
When the drum clutch is applied, the energy of the converter
lifting increases, drum rotation. An electric switch in the sensor of
the drum rotation is closed, activating an electromagnetic valve,
releasing the applied spring brake. When the energy of the
lifting converter, the brake applied from the spring is applied
automatically.
When lowering a load, the drum brakes are automatically controlled by a
electric system.
For the complete description and its operation see Folio 802.
 MANITOWOC ENGINEERING CO.

LUBRICATION:
The flexible shaft adapter in each of the rotation sensors requires
lubrication. All the others are sealed bearings and do not require
additional lubrication.
Lubricate point 1 (each of the sensors) fig. 1191-A, with a shot of grease.
multi-use once a week. (40 hours of operation).

ADJUSTMENT:
The only adjustment that may be required is the pressure of each drive roller of the
rotation sensor, against the respective edge of the drum.
Drum front drive roller, item (C), is located within the outer edge.
below the right rim of the drum. A flexible shaft connects the drive roller with
the front sensor of the drum rotation, item (A).
Drive roller of the rear drum, item (D), is located outside the outer edge.
under the left edge of the drum. A second flexible shaft connects the roller
impeller with the rear drum rotation sensor, item (B).
The pressure of both driving rollers against their respective edge of the drum,
It should be quite firm so that the roller cannot be turned by hand.
To increase the pressure, adjust the bolt (F) to increase the tension of the spring.
(E).
The drive rollers should be inspected weekly and kept clean of
the dirt and grease.
The rotation sensors, items (a) and (b), have been sealed and fixed at the factory.

NOTE: Be careful when replacing the front wire rope of the drum for
do not damage the driving roller of the rotation sensor.
 MANITOWOC ENGINEERING CO.

VICON IMPULSION

MAINTENANCE:

Twice a day:
1) Turn the handle of the lubrication system filter VICON.
2) Check the VICON lubrication pressure (normal 3-5 psi, 80 psi at
start of cold weather.

Diary:
1) Check the fluid level of the converter, the tank must work
approximately at 125 degrees.
2) Check if there is 45-80 PSI in the fluid pressure converter.
load.
3) Check the temperature of the fluid converter (Maximum range 250
degrees).
4) Check the level of the lubricating oil in the chain case.
5) Check the greaser air line. (approximate consumption of one cup
per week).
6) Remove the condensation from the breather tube of the filter.

Weekly:
1) Check the piston bar stroke in the air drum clutches.
applied. (3-7/8" drop, cold adjustment, after breaking inside, pressure of
weigh at least 100 pounds
2) Cleaning of filters and screens or purge holes in the hole of the
valve located in the converter, every 40 hours or if the pressure
increase beyond the range.
Drain the sediment separator in the suction line.

200 hours:
Drain the cuno filter in the VICON lubrication system.
Check the lubrication pressure of the pumps and the tension of the belt.
charging pump.
3) Clean the cone air filter.

1000 hours
1) Drain and fill the chain and transmission box with SHELL-X100,
10W30 MULTIGRADE, KENDALL HYKEN 052 or MARATHON OIL CO.
[Link] 20W20 or CITY SERVICE C320.
2) Change the converter fluid (TEXACO 10W HEAVY DUTY HAVOLINE
the MARATHON [Link] 10W).
3) Change the liquid filters of the converter.
 MANITOWOC ENGINEERING CO.

4) Drain and fill the final output of the converter. Fill with the same grade.
of oil that is used in the engine.

6 months
1) Check the adjustment of the control arm stop screws.
converter. See instructions for the torque converter - Folio 546.
2) Check the air pressure activation for the positioners of the
control of the converter (Rear converter, 20 PSI. - Front converter,
30 PSI.
3) Check the motor governor adjustment.

Liquid filters:
A) The main liquid filter is located at the back of the converter.
of the torsion force. Replace the filter kit at the intervals
previously indicated.
B) A filter screen is connected to the side of the loading pump
driven by the motor. Clean the filter screen at the interval
previously indicated. Extreme care must be taken in the assembly of the
new filter. Any leak in the new filter will result in it entering
air in the liquid converter system while it is functioning.
C) The filter holes are located in the converter. Clean them.
holes of the filters in the previously indicated intervals. The hole of the
the hole in the body of each assembly port is very small and
requires special attention when cleaning. The screen must also be cleaned,
make sure that the hole of the hole is also clean.

NOTE: If you find that the liquid is dirty, carry out this action more often.
to have more favorable conditions.
 MANITOWOC ENGINEERING CO.

DESCRIPCION:
The operation of the telephone alarm system is similar to any indicator of
pressure. However, it works electrically, and it is connected to a bell.
situado en la cabina del operador, en caso de falta de flujo de aceite o
excessive converter temperatures.

NOTE: The oil pressure line has to be around five pounds or

less, or the converter temperature must exceed 270ºF before
let the alarm ring.

ENGINE STARTUP:
When starting the engine, the alarm will usually sound for some time.
seconds until the appropriate oil flow has been reached.

ENGINE STOP:
 MANITOWOC ENGINEERING CO.

When stopping the engine, it is usual for the alarm to take a few seconds to stop.
because the electrical connection of the oil pressure switch will not break
until the engine squeezes the last drop of oil.

ALARM CHECK SYSTEM:

To check the alarm system, press the test button on the panel.
alarm in the cabin. This allows the electrical current to bypass the switch
of engine pressure while the engine is stopping and indicates that the system is
in working conditions.

TEMPERATURE ALARM SYSTEM OF THE CONVERTER AND OIL

 MANITOWOC ENGINEERING CO.

COIL VALVE

ADJUSTMENT:
The coil valves must be properly adjusted to prevent leakage.
of oil, through the chambers of the coil. The incorrect adjustment
It will reduce the efficiency of the unit.
Always have the air system pressure full when making adjustments.
1) Disconnect the pin (A). Apply pressure to the air regulator (set to 60.
PSI) to the cylinder (D) at the entrance (C).
2) Check that the coil valve is in the neutral position. If it is
necessary adjustment at the end of the bar (E), so that the pin (A) is
free in that position.
3) The air inlet (B) must have the air pressure of the control system.
complete to make the coil valve work and be able to reverse it
energy.
 MANITOWOC ENGINEERING CO.

CRANE BOOM HOIST BRAKE

ADJUSTMENT:
To compensate for the wear of the lining, adjust the nut (1). This will restore the
dimension of 1-5/8 inches and will compress the springs (A) to their original of 4-1/4
of one inch in dimension. Review all dimensions and adjustment
weekly.

Auxiliary brake of the crane's boom

ADJUSTMENT:
Only one adjustment is necessary for
compensate for the wear of the brake lining,
tighten the nut (1). A separation of
360º of 0.030" should exist between the
drum and the brake lining. IF they remain
too close, the brake will heat up and
will cause poor brake performance
auxiliary. All the connecting rod comes fixed from
factory and never requires adjustment.
Periodically remove the layer of dust and
check the operation of the band of
brake. Lubrication allows for the work
of the drive rod is more free. When the
lubrication is necessary, it must be had
care in exceeding the lubrication in the
brake bands.
 MANITOWOC ENGINEERING CO.

ADJUSTMENT - FRONT DRUM BRAKE

DESCRIPTION:
The external contraction brake band on the right and left edges of the
drum works through a lever mechanism and coupling by the
resort working automatically applied the air released from the cylinder
lifting system AUTOTROL. A brake pedal in the operator's cabin is
can be used to manually apply the brakes with slotted couplings
and reach the bars of the mechanism that controls, providing an advantage
mechanics for proper brake function. Both bands operate through the
same control axis. (For more information on the Autotrol Lifting System,
see folio 802).
The brake band support guides and a return spring release the
bands that provide separation between them and the drum edges for
an appropriate operation of the drum. The control bars and levers are
factory fixed and do not require any adjustments. For replacement or review, see the
Store manual.

GENERAL:
 MANITOWOC ENGINEERING CO.

For a proper adjustment of each band, it is necessary to maintain the adjustment of the
lever and cylinder, as shown in detail 'A' and 'B' for a good
brake performance. The manual brake pedal is used when adjusting the bands of
brake.
A properly adjusted brake will have a low brake pedal when it is
completely applied, providing the best feeling and advantage
brake system mechanics. The adjustment of the band must set the pedal of
brake at approximately the second notch past the pedal lock
when applied. Additional effort on the brake pedal will still allow
that the operator should hold the pedal in the last notch for maximum retention.
Wear of the lining, the lever will work closer to the center (see detail A), the
the cylinder will work closer to the base (see detail B), and the brake pedal will be
lower. These are indications that the band adjustment requires.
To adjust the brakes, the springs in the cylinder (9) must be released.
applying air pressure through the bypass valve (2) or through a line
direct air into the cylinder from another source. Release the manual brake pedal of
drum and lower the load block to ground. Adjust the left strap first
when the brake is cold. When the adjustment nut (1), check the head of the
adjustment pin to ensure it is seated at a right angle

ADJUSTMENT:
With the brake released, slightly retract the right band. Adjust the nut (1)
from the left side until you achieve the desired feeling in the pedal.
Apply the brake by exhausting the air from the cylinder (9). Check the dimension of the
lever of the left band and of the cylinder according to the indications of detail 'A'
and "B". Release the brake, then press the pedal slightly down against
the mechanism and adjust the nut (1) on the right band until the movement
Sits on the pedal. Apply the brake and check the dimension of the lever.
the right band and the cylinder as shown in details 'A' and 'B'.
When the lever dimension is set according to the indications of detail 'A', the
the total dimension of the cylinder will be as shown in detail 'B'. Wear of
forro, both dimensions will be reduced. An alternative method to determine if
It is necessary to make an adjustment, it is to check the total dimension of the cylinder with the brake of
front drum pressed.
With the brake pressed, adjust the bolt (4) to achieve a gap
approximately 0.40 "between the roller (3) and each band. With the brake released,
adjust the support guide of the band (5), (6) and (7) to achieve the separation of
brake lining around the edge of the drum. Check the spring adjustment of
return (11) for a complete release of the brake mechanism.

LUBRICATION NOTE:
If the brakes are applied while greasing, the pressure on the components can
block the passage of fat. Release the brake when lubricating.

CYLINDER:
The cylinder is factory fixed and does not require any adjustments. Lubricate the
assembly and the bar and the pins weekly with machine oil. Remove the
 MANITOWOC ENGINEERING CO.

air line and inject several shots of machine oil into the cylinder at once
every 3 months or 1000 hours.
CAUTION: This cylinder is equipped with a pre-loaded spring. For the
review or repair of the cylinder, see the store manual.
ADJUSTMENT - REAR DRUM BRAKE

DESCRIPCION:
The external contraction brake band on the right and left edges of the
drum works through a lever mechanism and coupling by the
automatic functioning spring applied the air released from the cylinder of
AUTOTROL lifting system. A brake pedal in the operator's cabin is
can be used to manually apply the brakes with slotted couplings
and reach the bars of the mechanism that controls, providing an advantage
mechanism for good brake operation. Both bands operate by the
same control axis. (For more information about the Autotrol Lifting System,
see folio 802).
The brake band help guides and a return spring release the
bands that provide separation between them and the drum rims for
an appropriate operation of the drum. The control bars and the levers are
factory set and do not require any adjustment. For replacement or review, see the
Store manual.

GENERAL:
For an appropriate adjustment of each band, it is necessary to maintain the adjustment of the
lever and the cylinder, as shown in detail 'A' and 'B' for a good
brake performance. The manual brake pedal is used when adjusting the bands of
brake.
 MANITOWOC ENGINEERING CO.

A properly adjusted brake will have a low brake pedal when it is

fully applied, providing the best feeling and the advantage
mechanics of the brake system. The adjustment of the band should place the pedal of
brake at approximately the second notch past the pedal lock
when applied. Additional effort on the brake pedal will still allow
that the operator locks the pedal in the previous notch for maximum holding.
Wear of the lining, the lever will work closer to the center (see detail A), the
the cylinder will work closer to the base (see detail B), and the brake pedal will be
lower. These are instructions that the band adjustment requires.
To adjust the brakes, the springs in the cylinder (9) must be released.
applying air pressure through the bypass valve (2) or through a line
direct air into the cylinder from another source. Release the manual brake pedal of
drum and lower the ground load block. Adjust the left strap first
when the brake is cold. When adjusting nut (1), check the head of
adjustment pin to ensure it is set at a right angle

ADJUSTMENT:
With the brake released, slightly reverse the right band. Adjust the nut (1)
from the left side until you achieve the desired feel on the pedal.
Apply the brake by exhausting the air from the cylinder (9). Check the dimension of the
left band lever and the cylinder according to the details in 'A'
and "B". Release the brake, then press the pedal slightly down against
the mechanism and adjust the nut (1) on the right band until the movement
sit on the pedal. Apply the brake and check the lever dimension.
the right band and the cylinder as shown in details "A" and "B".
When the dimensions of the lever are set according to the specifications of detail 'A', the
The total dimension of the cylinder will be as shown in detail 'B'. Wear of
forro, both dimensions will be reduced. An alternative method to determine if
a adjustment is necessary, it is to check the total dimension of the cylinder with the brake of
front drum pressed.
With the brake pressed, adjust the bolt (4) to obtain a gap.
approximately 0.40 "between the roller (3) and each band. With the brake released,
adjust the support guide of the band (5), (6) and (7) to obtain the separation of
brake drum around the rim of the drum. Check the spring adjustment of
Return (11) for a complete release of the brake mechanism.

LUBRICATION NOTE:
If the brakes are applied while greasing, the pressure on the components can
block the passage of fat. Release the brake when lubricating.

CYLINDER:
The cylinder is factory fixed and does not require any adjustments. Lubricate the
assembly and the bar and the pins weekly with machine oil. Remove the
air line and inject several shots of machine oil into the cylinder at once
every 3 months or 1000 hours.
CAUTION: This cylinder is mounted with a preloaded spring. For the
review or repair of the cylinder, see the store manual.
 MANITOWOC ENGINEERING CO.

PEN DEPLOYMENT

HYDRAULIC PUMP ADJUSTMENT CHAIN

DESCRIPTION:
The hydraulic pump adjustment chain is mounted on the rear side of the box.
impeller of the pump. Its purpose is to remove the loose part of the chain that
connect the output axis of the converter to the hydraulic lift pump of the
There is only one adjustment needed for the correct chain tension.

AJUSTE:
To adjust the chain, loosen the jam nut on the adjustment bolt. Then
tighten the adjustment pin firmly, now give the adjustment pin a
additional 60-degree turn of the bolt, diameter and tighten the locking nut.
 MANITOWOC ENGINEERING CO.

LOWERING OF THE ENERGY LOAD OF THE COMPLETE VICON RANGE

DESCRIPCIÓN:
The reduction of the energy load of the full VICON range, sometimes referred to as
energy reversal, is a setup of the hydraulic pump and motor to put
reverse the rotation of the output shaft of the lifting converter. The
The RPM power plant determines the operating speed. When in
neutral, the oil flows freely between the pump and the coil valve
of the control.
The low system control is at the operator's position.

BOMB OR RECOMMENDED ENGINE THAT STARTS PROCEDURE:

Before installing a new or rebuilt pump or motor, back out the valve.
main discharge in the coil valve of the control until it is relieved
spring tension of the adjustment screw. This prevents the possibility of damage
immediate to the replacement unit if the adjustment or control valve is
manipulated with.
Before connecting any line, the blush of all the pieces, then fill
all ports with clean oil to provide internal lubrication.
After connecting the lines and assembling the replacement unit, operate the
Pump or the engine for at least two minutes at zero pressure and the lowest RPM.
possible. During this adaptation period, the unit must operate freely
and not develop excessive heat. If the unit operates normally, the speed and
the pressure can be increased to the normal operating determination.
The internal parts of the pump and the motor are lubricated by the oil used in
the low system. Care must be taken to maintain the oil system
clean. Check the system regularly to avoid contamination. If there is
an internal failure of the pump or the motor, the oil must be drained, the system
entire cleaned and the filter cartridge replaced. Fill the entire system with
new oil.
The original filter cartridge should be replaced after a maximum of 50 hours.
machine. The subsequent replacement of the filter cartridge will depend on the
working conditions. See the lubrication instructions for the oils
recommended and the maintenance schedule. For conditions of
severe operation, the interval between the oil and the cartridge changes
filter must to be shortened.

ADJUSTMENT OF THE DRAIN VALVE:

To adjust the discharge valve, install a hydraulic pressure indicator at
any of the "INPUT" ports. (Adapt the plug to install the
pressure indicator or calibrator
Engine speed increased to full RPM.
 MANITOWOC ENGINEERING CO.

Apply the drum brakes and the clutches.

Apply the 'system for reducing energy load from the range
complete VICON.
Slowly apply converter energy to create a 'stop'.
in the low system, causing a hydraulic pressure up to the
adjustment of the discharge valve. Increase the discharge valve
which is set at 1,800 P.S.I.

ALWAYS USE A PRECISE INDICATOR OR CALIBRATOR WHEN ADJUSTING

THE ADJUSTMENT OF THE DISCHARGE VALVE PRESSURE.
 MANITOWOC ENGINEERING CO.

TRINKET AND NAIL OF THE RISE OF THE PEN

DESCRIPCIÓN:
A nail and a ratchet wheel provides a positive lock against the
resonate below, when it is busy.
Previous models 4100W have the ratchet wheel on the drum of
left lifting of the pen. A spring is used to pull the nail in.
according to the instructions of figure 1138A.
Later models have the ratchet wheel tied to the screw gear without
end, inside the gear cover. Figure 11388-1 and 2. The hooked claw to
the gravity ratchet wheel.
In both versions, a "cam fixation" detaches the claw from the teeth of the
trapeze. When it is released, the claw is occupied (by the tension of gravity
or the spring), locking the drums against resonating below. The nail can the
freely resonate upwards.
A two-way valve on the left of the operator operates the air cylinder.
A lock on the valve handle must be lifted before the valve
it can be moved from the positions of 'TRIGGER ON', or from 'TRIGGER TO'
"OUT", preventing unintentional operation.

NOTE: It may be necessary to slightly 'lift the pen' to separate the nail.
before resonating below.

A normally closed valve in the air line of the downstem prevents the
resonate below when the nail is used. This valve of the 'device of
"security" must be adjusted carefully to ensure operation
appropriate.

ADJUSTMENT:
With the air pressure system, move the control valve of the nail to the
position "TRIGGER OUTWARD". Make sure the nail is free and clear the
ratchet teeth. Fix the adjustment screw so that it presses the plunger of the
valve NO MORE THAN 3/16", but enough to ensure that the valve is
completely open.

CAUTION: The nail control valve should never be moved to the

"trigger position on" while the machinery of the lift of the plume is
turning around.
MANITOWOC ENGINEERING CO.
 MANITOWOC ENGINEERING CO.

LUBRICATION

Model 4100W

KEY TO THE LUBRICANTS

CG Grease gun
OE Engine oil from the sump
GO Gear lubricant
CW Open gear lubricant.

The first symbol is a type of lubricant.

Second is the interval. Example: GO8.
Gear lubricant, 8-hour interval.
See the lubricant specification.
TEMPERATURE CONDITIONS
OE Around 32ºF. Use SAE No. 30 - Below 32ºF. Use SAE No. 10
GO Around 32ºF. Use No. 140 - Below 32ºF. Use SAE No. 90
CW Around 32°F. Use Grade No. 2 - Below 32°F. Use Grade No. 1

NOTE: Special formulation may be required for temperatures below -10°F.

The following pages cover lubrication points in the 4100W model. One
certain lubrication indicates for example the control-union, cross shafts, yokes and
passers that could have been omitted to promote the clarity of the table
lubrication. The lubrication points not yet shown will still require
 MANITOWOC ENGINEERING CO.

lubrication with any grease gun or motor oil at the intervals of

40 hours.
The intervals shown for the lubrication points are a guide.
recommended for the operator or greaser to follow. Due to the variations in
jobs and the quality of lubricants, it can be more sensitive to slightly expand
certain intervals while others may require shorter intervals of
lubrication. Therefore, deviation from this lubrication guide must be given to
the close consideration before adapting it.

LUBRICATION INSTRUCTIONS:
Regular attention, careful knowledge of the lubrication points, and
Quality lubricants are important factors for good maintenance.
to help keep dirt away from lubricated parts, we suggest the following:
1) Keep the containers of oil and grease tightly closed and
located as free of dirt as possible.
2) Keep the dispensing equipment free from dirt – pressure accessories
clean before and after applying the grease.
3) Apply the grease until the bushings are full so that the sand does not have
opportunity to penetrate.
4) Replace the spark plugs or the filler covers to restrict dirt
when adding the oil

ABOUT THE LUBRICANT:

Applying the additional dose of fat with the intention of ensuring lubrication
longer or better - it is a generally harmful test. Excess of
lubrication will be lost very quickly at most points; in others
such as included gears, too much oil or grease can immediately
immediately turn into damage and cause heating or unpleasant discharge. In
in some places, excess lubrication is released onto friction surfaces and
causing to stick or grasp under light loads or heating and to slide under loads
heavy

OPEN THE GEARS:

The gears that operate outside or do not have a tight cover of the
Oil (ring gear) requires regular lubrication. The best lubricant
for the open gears it is a thick adhesive oil in nature
tarred from which it will not drip or be thrown when the gears give.
high-speed return. Ordinarily, a lubricant of this type will require
warning in advance for your easy application. A lubricant that has been
thinned with a solvent until it can be applied with a brush, no
requires no preheating and will be found favorable for lubrication
the open gears. When the solvent evaporates, the oil regains its
original sticky form and leave the protective cooling on the teeth of the
gear. The drying process generally takes three to four hours. This
reason is more desirable to lubricate open gears when the machine
it has closed at night. In case of twenty-four hours of duties, or of another
reason that does not allow for an extended free period, or for the operators who
 MANITOWOC ENGINEERING CO.

they prefer the gear lubricant that needs to be heated, we suggest the use of
a conventional grade. In cold weather, use a medium grade grease. Remove
the dirt from the open gears before applying any lubricant.
Use a brush or clean each surface of the tooth with a film of
lubricant. Do not rely on the gear rotation to distribute the lubricant.

WIRE ROPE:
To achieve maximum life and service from the wire rope, it is necessary to
that it is regularly lubricated just like the other moving parts of the machine.
Lubrication protects any wire rope.
Externally applied lubricants are used to replace the lubricant.
original used at the time of manufacturing. Lubrication should be applied before
that the original has an opportunity to completely dissipate. A humidity is
allowed to enter between the filaments, corrosion will soon follow. Any
externally applied lubricant must penetrate the wire rope to take
the place of the original that is being forced out. For a lubricant to be
Before use, the wire rope must be cleaned of abrasive material.
Air or steam does a good job, but where neither is available.
another, a wire brush can be used. The finer the wire, the
oil is finer. The same goes for temperature - the colder the weather,
the oil is lighter. Lubrication reduces abrasion, promotes flexibility,
reduces corrosion and extends the life of the wire rope.

OPEN CHAINS:
The open chains of the roller must be regularly lubricated using a
brush and keep free from dirt and abrasives as much as possible. The
the same grade oil used in the engine can be used on the chains. The
oil should be applied inside the chain so that the force
I worked the centrifuge out. Heavy lubricants are not satisfactory.
due to its inability to penetrate the small gaps between the bushings
and the bolts.

OIL CAN THE POINTS:

Grease all moving parts at the operation junction with OE once.
every forty hours.

BODY GEARBOX:
Check and add oil to the gearbox every forty hours for
maintain a level of three to six months depending on the conditions of
functioning. Drain immediately after the operation.
.
HORIZONTAL AXIS OF THE ROUTE:
To ensure the clutches of the free steering operation, use a
lighter fat in autumn and winter.
NOTE: Where the cold weather makes it difficult to change the clutches,
they can be cleaned by operating in the fuel oil for a
easier operation.
 MANITOWOC ENGINEERING CO.

MOTOR:
Check the oil level in the engine crankcase before starting and add the
oil when necessary to maintain the appropriate level. Refer to the manual of
motor for detailed instructions.