Manitowoc NATIONAL CRANE 900A Manual
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Manitowoc NATIONAL CRANE 900A Manual

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Supplement to Service Manual
Boom Cable Tensioning
© 2017 Manitowoc
Published 03-23-2017, Control# 641-01

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Summary of Contents for Manitowoc NATIONAL CRANE 900A

  • Page 1 Supplement to Service Manual Boom Cable Tensioning © 2017 Manitowoc Published 03-23-2017, Control# 641-01...
  • Page 2 THIS PAGE BLANK...
  • Page 3 This Supplement provides information regarding the proper Cable Tensioning Tensioning of Extend and Retract Cables and Positive Lock Tensioning Setup Procedure of adjustment hardware on National Crane Boom cable assemblies. The information provided here supplements the Tensioning must be done with the boom in the horizontal Service Manual and must be used in conjunction with all position.
  • Page 4 543 retract cables. 123 extend cables. 321 retract cables. Four section boom with two stage cylinder. 234 extend cables. Cable tensioning to be in the following order: 432 retract cables. 321 retract cables Three section boom with one stage cylinder. 123 extend (synchronizing) cables.
  • Page 5 Tightening until the retraction gap between the first and At this time the third, second and first extendable sections second section and the retraction gap between the should extend and retract equally and bottom out against the stops simultaneously. second and the third are equal. At this time the second and first extendable sections should 345 and 543 cable balancing extend and retract equally and bottom out against the stops...
  • Page 6 4- Section Boom w/ 2 Stage Cylinder Cable Positioning 1/2/3 EXTEND 2/3/4 EXTEND 1ST STAGE BASE 2ND STAGE 3RD STAGE 4th STAGE 8860-2 4/3/2 RETRACT 3/2/1 RETRACT FIGURE 3 Cable Tightening Sequence 4 Section Boom with Two Retraction Stage Extend Cylinder Measure the retraction gaps between the first and second section and the second and third section.
  • Page 7 The fourth section should have moved out. Tighten the 432 retract cable located at the front bottom of the second section the difference in the retraction gap Tightening until the extension gap between the third and measurements. fourth section is equal to the extension gap between the second and third section.
  • Page 8 Tightening until the retraction gap between the first and Tightening until the extension gap between the third and second section and the retraction gap between the fourth section is equal to the extension gap between the second and the third are equal. second and third section.
  • Page 9 Extend and retract the boom a few times and then Tighten the 321 retract cable located at the front bottom repeat measuring the extension gaps. of the base section the difference in the retraction gap measurements. The third section should have moved out. Extend and retract the boom a few times and then Tightening until the extension gap between the first and repeat measuring the retraction gaps.
  • Page 10 Third (positive lock) nut installation is to be placed on each of Metric Series with Coarse Threads the extend cables. The retract cables do not require the third (positive lock) nut. Minimum Cable end TORQUE The third nut should be hand tightened until the tapped hole Nut Type Thread Size Property...
  • Page 11 Going forward the recommendation has been changed to replace the extend cables every seven (7) years. OPERATIONS REQUIRED: Please include a copy of this service bulletin in the machines services manuals. If you have any questions regarding this Service Bulletin, please contact Manitowoc Crane Care. Manitowoc Crane Care...
  • Page 13 An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: • You are trained in the safe operation of this crane. Manitowoc is not responsible for qualifying personnel. • You read, understand, and follow the safety and operating recommendations contained in the crane manufacturer’s manuals and...
  • Page 14 SECTION CONTENTS Crane Warm-up Procedures......... . . 1 Engine.
  • Page 15 (40°F). Lubrication section of your crane’s Operator Manual, by Warm-up Procedures: contacting your local Manitowoc distributor, or by contacting Manitowoc Crane Care directly). Without operating the hoist function, warm the hydraulic oil (see Hydraulic Oil System, page 2).
  • Page 16 Axles crane’s hydraulic pumps or motors, stop the operation and engine immediately and contact a Manitowoc NOTE: For National Crane axle warm-up procedures, refer distributor. to chassis manufacturer’s manual. • From 10°C to 4°C (50°F to 40°F): Crane operation with...
  • Page 17 DANGER An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: Manitowoc is not • You are trained in the safe operation of this crane. responsible for qualifying personnel.
  • Page 18 CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. CALIFORNIA PROPOSITION 65 WARNING Battery posts, terminals, and related accessories contain chemical lead and lead compounds, chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 19 Supplement 900A DANGER An untrained operator subjects himself and others to death or serious injury. Do not operate this crane unless: Manitowoc is not • You are trained in the safe operation of this crane. responsible for qualifying personnel. •...
  • Page 20                                                      ...

  • Page 21: Outrigger Monitoring System (Oms)

    This Supplement provides information regarding the stabilizer to identify when the outriggers and stabilizer beams Outrigger Monitoring System, which is standard equipment are extended to a point in which they provide maximum stability. on cranes sold in North America and optional equipment on cranes sold outside of North America.
  • Page 22 Maintenance connector (p/n 80009992). Contact your Manitowoc dealer for further assistance.   Outrigger Cylinder Length Sensor Stabilizer Proximity Switch (version 1) 7939-4 7939-3 FIGURE 3 FIGURE 2 Remove Remove Disconnect electrical connector (1, Figure 3) at switch. Fully retract outriggers.
  • Page 23 Stabilizer Proximity Switch (version 2) Remove Disconnect electrical connector (1, Figure 4) at switch. Remove the two screws (2, Figure 4) securing the switch (4) to the stabilizer box; remove switch. Install Fully extend stabilizer beam (horizontally). Using two screws (2, Figure 4) secure the switch (4) to stabilizer box.
  • Page 24                                                      ...

  • Page 25: Table Of Contents

    TABLE OF CONTENTS Supplement ............a Outrigger Monitoring System (OMS) (Optional—Standard in North America .

  • Page 26: Operation

    Temperature Effects on Hydraulic Cylinders ......1-22   Overload Inspection..........1-23 Boom Inspection .
  • Page 27 Weekly Inspections ..........3-1 Monthly Inspections .
  • Page 28 Four Section Top/Bottom Pad Replacement, Assembled Boom ....6-12   Top Rear Pad Replacement ........6-12 Front Bottom Pad Replacement.
  • Page 29 Configuration 5 - Rear Mount ........9-7 Configuration 6 - 9103A New York City Approved .
  • Page 30                                                      ...

  • Page 31: Safety Information

    CAUTION personal injury accident, immediately contact your Without the safety alert symbol, identifies hazards that Manitowoc dealer. If the dealer is unknown and/or cannot be could result in property damage if the message is ignored. reached, contact Product Safety at:...

  • Page 32: Operator's Information

    The Manitowoc Company, Inc. OPERATOR’S QUALIFICATIONS   1565 East Buchanan Trail Qualified person is defined as one who by reason of Shady Grove, PA 17256-0021 knowledge, training and experience is thoroughly familiar   Phone: 888-777-3378 (888-PSR.DEPT) with crane operations and the hazards involved. Such a...

  • Page 33: Operational Aids

    Never interfere with the proper functioning of operational loads. Manitowoc has been an industry leader in the aids or warning devices. incorporation of operational aids into the design of its cranes.

  • Page 34: Work Area Definition System (Wads) (If Equipped)

    damage to the sheaves, or causing the wire rope to fail, block conditions. It is not a replacement for operator   dropping the lifting device to the ground and possibly injuring awareness and competence. personnel working below. Never interfere with the proper functioning of operational  ...

  • Page 35: Load Charts

    (For cranes with center front stabiliers) Carefully follow the procedures in this Operator’s Manual when extending or retracting the outriggers. Death or serious injury could result from improper crane setup on outriggers. KEEP THE BOOM SHORT. Swinging loads with a long line The operator must select the proper Load Chart and Load can create an unstable condition and possible structural Moment Indicating (LMI) System program for the outrigger...

  • Page 36: Lifting Operation

    (e.g., wind a loss of control in handling the load. Manitowoc on the rear of the boom can result in decreased forward recommends that, if the wind speed (velocity) is between 20  ...

  • Page 37: Counterweight

    The crane is improperly operated. reached instability. The “balance point” for stability testing according to SAE and Manitowoc criteria is a condition of Do not rely on the crane’s tipping to determine your lifting loading wherein the load moment acting to overturn the capacity.

  • Page 38: Electrocution Hazard

    ELECTROCUTION HAZARD operator, are responsible for alerting all personnel of dangers associated with electrical power lines and   To avoid death or serious injury, keep all parts of the crane, equipment. Do not allow unnecessary personnel in the rigging and load at least 20 feet (6 meters) away from any vicinity of the crane while operating.

  • Page 39: Set-Up And Operation

    Set-Up and Operation not assure that electrical contact will not occur. Even if codes or regulations require the use of such devices, failure to During crane use, assume that every line is energized (“hot” follow the rules listed here may result in serious injury or or “live”) and take the necessary precautions.

  • Page 40: Electrical Contact

    29CFRI910.180 for General Industry and 29CFRI926.1431 Special Operating Conditions and   for Construction. Equipment   Use of a Manitowoc crane to handle personnel is acceptable Never operate the crane during an electrical thunderstorm. provided: When operating near transmitter/communication towers   •...

  • Page 41: Environmental Protection

    NEVER use this crane for bungee jumping or any form Manitowoc reminds crane owners to ensure that all safety of amusement or sport. decals are in place and legible. Manitowoc continues to urge crane owners to upgrade their cranes with load moment •...

  • Page 42: Service And Repairs

    Use a piece of cardboard, or piece of paper, to search   for leaks. Wear gloves to protect your hands from • Consult with Manitowoc Crane Care to determine if load spraying fluid. testing is required after a structural repair is performed.  ...

  • Page 43: Tires

    The nominal strength of a wire rope Wire Rope should never be used as its working load. Use only the wire rope specified by Manitowoc as indicated • Each type of fitting attached to a wire rope has a specific on the crane’s Load Chart.

  • Page 44: Sheaves

    periodically. Refer to the Service Manual for more • When a wire rope has been removed from service   information. because it is no longer suitable for use, it must not be reused on another application. • In the U.S.A., regular inspections of the wire rope and  ...

  • Page 45: Batteries

    To attain maximum wire rope life and minimize hook block allow the radiator time to cool before removing the radiator rotation, it is recommended that even numbers of parts-of- cap. line be used in multiple-part reeving whenever possible. Shut down the engine and disconnect the battery before The use of nylon (nylatron) sheaves, as compared with performing maintenance.
  • Page 46 Death or serious injury could result from being crushed by Check load limit of bridges. Before traveling across bridges,   revolving tires. ensure they will carry a load greater than the crane’s weight. If it is necessary to take the crane on a road or highway,  ...

  • Page 47: Work Practices

    Operator’s Manual when extending or retracting the system that have not been evaluated and approved by outriggers. Death or serious injury could result from improper Manitowoc Crane Care. crane set up on outriggers. Do not step on surfaces on the crane that are not approved Be familiar with surface conditions and the presence of or suitable for walking and working.

  • Page 48: Lifting

    Sparks from the crane’s electrical system and/or engine   exhaust can cause an explosion. Do not operate this crane in an area with flammable dust or vapors, unless good ventilation has removed the hazard.   Carbon monoxide fumes from the engine exhaust can cause  ...

  • Page 49: Hand Signals

    Check the hoist brake by raising the load a few inches, If the boom should contact an object, stop immediately and stopping the hoist and holding the load. Be sure the hoist inspect the boom. Remove the crane from service if the brake is working correctly before continuing the lift.
  • Page 50                                                     1-20  ...

  • Page 51: Boom Extension

    However, Manitowoc recognizes that certain jobsite conditions may not permit the If applicable to your crane, frequently check all air tanks for boom and boom extension of a crane to be fully lowered to water in freezing weather.
  • Page 52 If applicable to your crane, always handle propane tanks movement of the boom may be undetected by the operator   according to the supplier’s instructions. unless a load is suspended for a long period of time. To minimize the effects of thermal contraction or “Stick-slip” it is Never store flammable materials on the crane.
  • Page 53 50%. stopped immediately and Crane Care must be contacted for corrective action. • Stop operating the crane and contact Manitowoc Crane Care immediately for overloads of 50% and higher. NOTE: If your crane is equipped with CraneSTAR, an overload warning will be posted to the web site for review by the crane owner.
  • Page 54 Boom Inspection           9, 10       2, 3           9, 10                           1-24  ...
  • Page 55 Overload less than 25% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect for damage. Retainers Overload from 25% to 49% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect all for damage. Retainers Collar-welds Inspect all for damage. Pinning Areas Inspect all for cracks.
  • Page 56 Superstructure Inspection                             10,11                         1-26  ...
  • Page 57 Overload less than 25% Lift Cylinder Inspect for leaking. See topic in Introduction section Wire Rope Inspect all for damage. of Service Manual. Turntable See topic in Swing section of Check bolts for proper torque. Bearing Service Manual. Overload from 25% to 49% Lift Cylinder Inspect for leaking.
  • Page 58 Carrier Inspection                                   5, 6                   1-28  ...
  • Page 59 Overload less than 25% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Overload from 25% to 49% Stabilizer Inspect for leaking. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Outrigger Inspect for deformation and cracked welds. Beams Outrigger Inspect for deformation and cracked welds.
  • Page 60                                                     1-30  ...
  • Page 61 OPERATION CONTROLS Operation Below -40 TRUCK CAB CONTROLS ° For crane operation below -40°F, capacities shall Power Take-Off be derated 2 percent of the rated load shown on the Manual Shift Control – The PTO’s are engaged capacity charts for each degree below -40°F. when the knobs on dash or floor are pulled out and dis- engaged when the knobs are pushed in.
  • Page 62 NATIONAL CRANE 900A SERIES Stabilizers – Extend/Retract – Operate the lever Boom Length Indicator – Located on either side to move beams out and to to move of the second boom section. The letters on the interme- EXTEND RETRACT beams in.
  • Page 63 &5$1( 120(1&/$785( BOOM WINCH TELESCOPING TURN O/R THIS SIDE O/R OTHER SIDE FUSE OVERLOAD LIGHT * OVERRIDE BUTTON * ATB LIGHT * O/R OTHER SIDE O/R THIS SIDE PRESSURE GAUGE KILL SWITCH * HCA LOAD HORN BOOM RANGE GAUGE WINCH TELESCOPING CROSS-FRAME O/R THIS SIDE TURN...
  • Page 64 1$7,21$/ &5$1( $ 6(5,(6 23(5$7,1* 352&('85(6 (48,30(17 )$0,/,$5,=$7,21   '$1*(5 All members of the crew should become thoroughly familiar with the location and operation of controls, the   correct operating procedure, the maximum lifting ca- 7KH IROORZLQJ WHVWV VKDOO EH SHUIRUPHG ZLWK FDUH pacities and the safety precautions applicable to the unit WR SUHYHQW GDPDJH WR WKH PDFKLQH RU LQMXU\ WR SHU  ...
  • Page 65 • Check that the display of the main boom length that outriggers can be fully extended and leg comes agrees with the actual boom length. down on firm level surface. Particular care must be • Check that the display of the main boom angle taken in selecting a site position to the location of over- agrees with the actual boom angles.
  • Page 66 1$7,21$/ &5$1( $ 6(5,(6 If specific outrigger foot loading is required for an 3. Rear Mount Units Equipped with Rear Stabilizer individual crane, contact National Crane with actual chas- A rear stabilizer is required when loads are to be sis weights and crane details. lifted over the rear of the vehicle.
  • Page 67 5($',1* $1' 81'(567$1',1* 7+( /2$' 10. The loads are lifted in the proper area around &+$576 the truck. The structures and components of your unit are de- A stability test should have been performed on this signed to provide satisfactory service if the unit is not crane and can be repeated by referring to the Installa- loaded in excess of the maximum rated loads specified tion Section.
  • Page 68 1$7,21$/ &5$1( $ 6(5,(6 2SHUDWLRQ capacity chart, the smallest load shall be used. 1. Operation of this equipment in excess of maxi- 9. It is safe to attempt to telescope or retract any mum load rating and disregard of instructions is load listed if rating is not exceeded.
  • Page 69 4. Freely Suspended Load-Load hanging free with The following examples are for illustrative purposes no direct external force applied except by the only. The examples utilize the capacity chart shown. loadline. The load chart ratings, component weights and dimen- 5. Side Load-Horizontal side force applied to the sional data may not be the same as the actual unit.
  • Page 70 1$7,21$/ &5$1( $ 6(5,(6 ([DPSOH  ([DPSOH  Assume a load of 9000 pounds (4082 kg) at 10' A load of 2900 pound (1315 kg) is to be lifted from (3.04 m) radius on the ground beside the truck to be the roof of a building at a radius of 30' (9.14 m) and a picked up, swung over and placed on the truck bed at height of 115' (35.05 m) and placed on the ground on...
  • Page 71 877725 1$7,21$/ &5$1( &25325$7,21 80° 127( 2ND JIB 6(5,(6 $ 70° 1. Operate with jib by radius when main boom is 44FT :,7+ fully extended. If necessary increase boom )7 -,% 60° angle to maintain loaded radius. /0, &$3$&,7,(6 1ST JIB 2.
  • Page 72 1$7,21$/ &5$1( $ 6(5,(6  3$57 /,1(  3$57 /,1(  3$57 /,1(  3$57 /,1(  3$57 /,1(  3$57 /,1(  3$57 /,1(           MAX. PULL MAX. PULL MAX. PULL MAX. PULL MAX. PULL MAX.
  • Page 73 heavy loads. The control should be slightly actu- for the unit. ated to begin movement and then slowly in- creased to desired operating speed. The results 237,21$/ :,1&+ %8567 2) 63((' obtained from metering the oil flow with the con- 23(5$7,21 trol lever can also be aided by carefully coordi- The “Burst of Speed”...
  • Page 74 1$7,21$/ &5$1( $ 6(5,(6 $17,7:2 %/2&. 6<67(0   '(6&5,37,2123(5$7,21 on the switch. At this point the contacts in the switch With untrained or inexperienced or distracted op- open, breaking electrical continuity through the circuit   erators, two blocking the winch cable is a very real pos- provided by the internal anti-two-block cord routed with sibility.
  • Page 75 237,21$/ +<'5$8/,& &$3$&,7< $/(57 6<67(0 6<67(0 '(6&5,37,21 sition can be used as an aid in determining the load The hydraulic capacity alert system is a hydrauli- condition of the crane. The lift control lever must be cally operated, maximum capacity sensing device that moved from boom up position to the neutral position to will stop all of the normal crane functions that cause get the most accurate reading when using load range...
  • Page 76 1$7,21$/ &5$1( $ 6(5,(6 237,21$/ :,5(/,1( +<'5$8/,& &$3$&,7< $/(57 6<67(0 +&$6 6<67(0 '(6&5,37,21 boom down, extend out and winch up functions to be-   The Hydraulic Capacity Alert (HCAS) is available in come inoperative. These are the functions that increase two configurations: a Single (Boom only) or Dual (HCAJ) the over capacity condition.
  • Page 77 +&$6 6<67(0 23(5$7,21 tem solenoid will deactivate and the boom will remain Once an over-capacity condition is reached, the sys- locked at 80°. To correct this condition, momentarily tem will not allow the operator to move the load to a actuate the override switch and boom down approxi- greater radius.
  • Page 78 1$7,21$/ &5$1( $ 6(5,(6 plumb the system according to the sche- +&$6 6<67(0 $'-8670(17 matic and illustrated parts page or replace The dual hydraulic capacity alert system should be faulty pressure gauge. checked for proper adjustment during initial crane start  ...
  • Page 79 jib compensating pressure switch. Jib HCA Adjustment 8. Check Rated Radius: 1. Set HCA Selector Switch to “JIB” position. Raise the test weight with the winch 2. Remove the console cover depending on the crane b. Boom down very slowly until the jib model.
  • Page 80 1$7,21$/ &5$1( $ 6(5,(6 Wireline Jib Min. Angle Switch 5. Ensure that the Mercury Switch retainer is firmly attached to the Junction Box. 6. Loosen the Junction Box Mounting Screws and adjust Adjustment   the angle of the junction box. Adjust the angle of the Mercury Switch 1.
  • Page 81 &$87,21 The LMI or (optional) Hydraulic Capacity Alert Systems are intended to be used as aids to prevent most overload conditions. 'R QRW XVH WKH /0, RU RSWLRQDO +\GUDXOLF &DSDFLW\ $OHUW 6\VWHP DV VXEVWLWXWHV IRU VDIH RSHUDWLQJ SUDF WLFHV DV RXWOLQHG LQ WKH 6$)(7< $1' 23(5$ 7,21 VHFWLRQ RI WKLV PDQXDO 'R QRW H[SHFW WKH /0, RU RSWLRQDO +\GUDXOLF &DSDFLW\ $OHUW 6\VWHP WR GHWHFW DOO SRVVLEOH RYHUORDG FRQGLWLRQV They ZLOO QRW prevent structural or stability overloads to the crane or winch caused by:...
  • Page 82 1$7,21$/ &5$1( $ 6(5,(6 -,% 6$)(7< $1' 23(5$7,21       C (4 PLCS)         STOW -,% ,1 23(5$7,1* 326,7,21 LOOP   '$1*(5   ,03523(5 672:(' -,% :,// 5(68/7 ,1 '($7+ 25 6(5,286 ,1-85<   6WRUDJH ORFN SLQ PXVW EH LQ VWRZ EUDFNHW 127 KHUH ZKHQ MLE LV VWRZHG  ...
  • Page 83 6$)(7< 7,36 )25 -,% 23(5$7,21 Also, on manually extendable jib options: 1. The anti-two-block switch weight and cord must 1. Extension retaining pin, E, must always be in- be attached to the jib when deployed. stalled when operating. 2. Do not lift load with the boom tip when the jib is 2.
  • Page 84 1$7,21$/ &5$1( $ 6(5,(6 15. Route loadline over jib sheave and install keeper. 10. Using extend function, extend boom approxi- Install line block to end of loadline. mately 1 foot. 16. Remove anti-two-block weight/chain assembly 11. Using tag line attached to jib sheave case, slowly from boom tip switch and install on jib tip switch.
  • Page 85 -,% -$&. 23(5$7,21 peated. To relieve the jack, use the flattened end of The jib pin alignment device consists of a hydraulic jack handle to slowly turn relief valve counter clockwise jack mounted horizontally on the underside of the jib. A no more than one full turn.
  • Page 86 1$7,21$/ &5$1( $ 6(5,(6 $'-867$%/( 6:,1* 63((' 9$/9( The Series 900A is equipped with an adjustable   swing speed valve. This valve allows the operator to limit the maximum swing speed of the machine to suit   operator preference or varying applications. An adjustment dial is located on the swing holding  ...
  • Page 87 67$1'$5' +$1' 6,*1$/6 )25 &21752//,1* &5$1( 23(5$7,216 6:,1* Arm extended, point with 6723 Arm extended, palm down, (0(5*(1&< 6723 Both arms +2,67 With forearm vertical, /2:(5 With arm extended finger in direction of swing of move arm back and forth extended, palms down, move forefinger pointing up, move hand downward, forefinger pointing...
  • Page 88 1$7,21$/ &5$1( $ 6(5,(6 237,21$/ +<'5$8/,& &$3$&,7< $/(57 6<67(0 6<67(0 $'-8670(17 schematic and illustrated parts page or replace   The hydraulic capacity alert system should be faulty pressure gauge. checked for proper adjustment during initial crane start-   up and quarterly thereafter. The procedure for proper '$1*(5 adjustment should be performed as follows:  ...
  • Page 89 7528%/( 6+227,1* The following step-by-step analysis will be helpful in isolating and correcting almost every service problem if fol- lowed in a step-by-step systematic manner. Use this information with the Hydraulic Schematic and the Illustrated Parts Catalog to identify parts and follow flow paths. Start at top box and work downward step by step – don’t try to start in the middle or skip steps.
  • Page 90 1$7,21$/ &5$1( $ 6(5,(6 Overload Trips and will not Reset   Has Overload Condition been Eliminated     Loadline Downhaul Weight Lifting Eliminate Overload Anti-Two-Block Weight   Lower Loadline Weight     Do Crane Functions Boom Down, Telescope Out, Winch up work  ...
  • Page 92                                                      ...
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  • Page 103 • Exposure to harsh environmental hazards such as alkaline, acids, or other chemicals that can attack the Manitowoc Crane Group's cranes are manufactured to high crane's paint finish. quality standards, including the type of paint finish While the surfaces of the crane that are easily seen have the demanded by today's industry.
  • Page 104   • and allow to dry thoroughly. Please contact Manitowoc Crane Care should you have any • Prepare the surface prior to applying the finish coat of   questions. paint.
  • Page 105 Areas include; Valves, hose end and fittings, Swivel, unpainted fasteners and hardware, valves, slew ring, all pumps, axles, drive lines, transmission, all interior bare metal surfaces. surfaces of the frame • Boom applications areas are; pivot pins, hose end and •...
  • Page 106                             Item Description   Hook Block/Headache Ball Item Description   O/R Hose Connections Hoist Plumbing Connections O/R Pins, Clips All Hardware, Clips, Pins, Hose Connections   not painted O/R Pins, Clips Power Train Hardware Pivot Shaft  ...
  • Page 107 6(59,&( The information supplied in this section of the ing and covering apply when access covers or inspec- manual is designed to assist you in service and repair tion plates are removed. of your National Crane. Inspection, lubrication and gen- Clean and inspect all parts.
  • Page 108 /$%(/ 3$576 :+(1 ',6$66(0%/,1*   When removing or disconnecting a group of wires or cables, tag each one to ensure proper identification   during re-assembly. When shims are removed, tie them together and   identify them as to location. Keep shims clean and flat until they are reinstalled.
  • Page 109 Loctite types are suitable for all applications.Various types of Loctite are specified throughout the Service Manual. The The torque tables are provided by Manitowoc for reference following types of Loctite brand adhesives are available from when performing maintenance.
  • Page 110 Use of proper torque values is extremely important. Improper NOTE: If multipliers and/or special tools are used to reach   torquing can seriously affect performance and reliability. hard to get at areas, ensure torque readings are accurate. Identification of fastener grade is always necessary. When  ...
  • Page 111 SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8 and Grade 2 HHCS HHCS HHCS HHCS Socket Head Socket Head Serrated Capscrew Shoulder Flange Head Screw FIGURE 5-2 Table 5-1: UNC (Course) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners Bolt Diameter - Inches Torque Values (Pounds-Foot, Maximum/Minimum) SAE Grade...
  • Page 112 Table 5-3: Metric Fasteners, Coarse Thread, Zinc-Flake Coating   Bolt Diameter - Metric   Torque Values (Nm) Grade   0.157 0.197 0.236 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18 1.18 1.18 21.6 42.4 73.1 1195 1608 2072  ...
  • Page 113 Table 5-7: UNC (Course) Thread: Torque Values for Table 5-8: Metric Course Thread: Torque Values for Stainless Steel Fasteners with Oil Lubrication Stainless Steel Fasteners with Oil Lubrication Torque Value Torque Size Value Size lb-in lb-ft #5 (0.125) — M2.5 #8 (0.164) —...
  • Page 114 86,1* 72548( :5(1&+ (;7(16,216 1. Torque wrench extensions are designed to ex-   tend the range or versatility of torque wrenches. Torque wrench scale readings or limit settings   shall be computed with the following formulas when an extension handle is employed. The  ...
  • Page 115 :,1&+ 2,/ /(9(/ To check or fill winch drum and rotation gearbox with oil, remove fill plug and bushing. The oil should be level with this opening. If more oil is needed, refer to one of the manufacturer’s recommended lubricants listed in this manual. BREATHER OIL LEVEL OIL LEVEL &...
  • Page 116 7528%/( ',$*126,6 The following chart lists malfunctions which may occur during equipment operation, followed im-   mediately by possible cause and possible solution. These are not all inclusive but are designed to help isolate the problem and should be checked before calling the factory Service Department.  ...
  • Page 117 7528%/( ',$*126,6 FRQWLQXHG &21',7,21 3266,%/( &$86( 3266,%/( 62/87,21 6ZLQJ ZLOO • Attempting to swing up too much of incline. • Level machine. QRW WXUQ • Turn circuit relief valves sticking. • Clean and check circuit pressure. • Turntable bearing drag. •...
  • Page 118 7528%/( ',$*126,6 FRQWLQXHG   &21',7,21 3266,%/( &$86( 3266,%/( 62/87,21 %RRP • Boom sections need lubrication. • Grease boom. FKDWWHUV   • Wear pads not shimmed correctly. • Reshim as described in boom assembly GXULQJ section. H[WHQVLRQ   • Worn wear pads. •...
  • Page 119 $17,7:2 %/2&. 7528%/( ',$*126,6  (/(&75,&$/ $QWL7ZR %ORFNLQJ 6\VWHP IDLOV WR VKXW GRZQ ZLQFK XS DQG ERRP H[WHQG Check for voltage across leads of limit switch with weight supported Check limit switch or actuator arm for sticking - Repair or Fuse blown replace switch Test HCAS &...
  • Page 120 $17,7:2 %/2&. 7528%/( ',$*126,6  (/(&75,&$/ &217,18('   $QWL7ZR %ORFNLQJ 6\VWHP VKXWV GRZQ FUDQH IXQFWLRQV ZKHQ   ZHLJKW LV IUHHO\ VXVSHQGHG   12 volts at limit switch       Fuse blown     Test HCAS & ATB relays for Replace fuse proper operation (see  ...
  • Page 121 $17,7:2 %/2&. 7528%/( ',$*126,6  +<'5$8/,& $QWL7ZR %ORFNLQJ 6\VWHP IDLOV WR VKXW GRZQ ZLQFK XS ERRP GRZQ DQG ERRP H[WHQG HYDRAULIC ELECTRICAL Check to ensure ATB electrical system is working Do all three functions fail to properly. Refer to ATB shut down electrical diagnosis Examine solenoid valve for...
  • Page 122 $17,7:2 %/2&. 7528%/( ',$*126,6  +<'5$8/,& &217,18('   $QWL7ZR %ORFNLQJ 6\VWHP VKXWV GRZQ FUDQH IXQFWLRQV ZKHQ $7%   ZHLJKW LV IUHHO\ VXVSHQGHG   Purge air from unloader   circuits. See procedure in this manual     Functions operate correctly ? Problem solved  ...
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  • Page 169 CONFIGURATION 5 – REAR MOUNT (69’, 90’, 103’ CONFIGURATION 6 – REAR MOUNT (125’ BOOM) BOOMS) This configuration allows the rear mount installa- tion of the Series 900A. This configuration is 360° stable This configuration allows the rear mount installa- and allows the effective use of close working area to lift tion of the Series 900A.
  • Page 170 CONFIGURATION 7 - 9103A NEW YORK CITY CONFIGURATION 8 - 9103A NEW YORK CITY APPROVED APPROVED This configuration allows the installation of the Se- This mount requires front stabilizer for full capacity ries 9103A on a chassis by using the sub-base for a 22' 360°...
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  • Page 202 67$%,/,7< &+(&. ORDG GRZQ VR WKH ORDG ZLOO VZLQJ RXW XQWLO WKH The chassis weight, before the crane is mounted, is   ORDGHG UDGLXV LV UHDFKHG $V WKH ERRP LV ORZ intended for use only as a guideline in determining the HUHG NHHS ZLQFKLQJ WKH ORDG XS WR NHHS LW DERXW total weight required for the unit to be stable with an 85%  ...
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This manual is also suitable for:

National crane 969aNational crane 990aNational crane 9103a

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