Manitowoc National Crane 900H Operator's Manual
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Manitowoc National Crane 900H Operator's Manual

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National Crane 900H
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  • Page 1 National Crane 900H Operator Manual...
  • Page 2 WARNING California Proposition 65 Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. • Always start and operate the engine in a well-ventilated area. • If in an enclosed area, vent the exhaust to the outside.
  • Page 3 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 4 THIS PAGE BLANK...

  • Page 5: Table Of Contents

    Table of Contents SECTION 1 ..........Introduction General .
  • Page 6 TABLE OF CONTENTS 900H OPERATOR’S MANUAL Equipment Access ..........2-31 Job Preparation .
  • Page 7 900H OPERATOR’S MANUAL TABLE OF CONTENTS Swing Drive and Turntable Bearing ........3-10 Axles .
  • Page 8 TABLE OF CONTENTS 900H OPERATOR’S MANUAL Internal Cable Sheave Lubrication........5-5 Inner Boom Wear Pad Lubrication.
  • Page 9 900H OPERATOR’S MANUAL TABLE OF CONTENTS WADS Limit............7-8 Boom Angle Limit .
  • Page 10 TABLE OF CONTENTS 900H OPERATOR’S MANUAL THIS PAGE BLANK...

  • Page 11: Section 1

    900H OPERATOR MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS General ........1-1 Notice to Owner/User .

  • Page 12: Supplemental Information

    If you are the new owner of a National crane, please register the manufacturer ’s manual supplied with the crane. it with Manitowoc Crane Care so we have the ability to Manufacturers of rated capacity limiters may refer to them in contact you if the need arises.
  • Page 13 900H OPERATOR MANUAL INTRODUCTION 7141-1 Item Component Item Component Operator Console Extension EasyReach™ Pedestal Turret Operators Station Stabilizer Front Outrigger (SFO), Front Outrigger Jack Rated Capacity Limiter (RCL) Reel Hydraulic Tank Boom Hydraulic Pump Boom Nose Hydraulic Remote Controller (HRC) Boom Rest Truck Frame Lift Cylinder...
  • Page 14 INTRODUCTION 900H OPERATOR MANUAL THIS PAGE BLANK Published 04-13-2020 Control # 476-01...

  • Page 15: Safety Messages

    900H OPERATOR MANUAL SAFETY PRECAUTIONS SECTION 2 SAFETY PRECAUTIONS SECTION CONTENTS Safety Messages......2-1 Environmental Protection.

  • Page 16: General

    National Crane distributor must be immediately advised of the incident and consulted on necessary inspections and repairs. Should the distributor not be immediately available, contact should be made directly with Manitowoc Product Safety at the address below. The equipment must not be CAUTION...

  • Page 17: Operator Qualifications

    900H OPERATOR MANUAL SAFETY PRECAUTIONS each person responsible for assembly, disassembly, Make sure that all personnel working around the equipment operation and maintenance of the equipment. are thoroughly familiar with safe operating practices. You must be thoroughly familiar with the location and content of No personnel shall be allowed to climb onto the equipment or all decals on the equipment.

  • Page 18: Operational Aids

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL Training is ESSENTIAL for proper equipment operation. • When a Boom Angle or Radius Indicator is inoperative Never jeopardize your own well-being or that of others by or malfunctioning, the radius or boom angle shall be attempting to operate equipment on which you have not determined by measurement.

  • Page 19: Anti-Two-Blocking Device

    900H OPERATOR MANUAL SAFETY PRECAUTIONS Anti-Two-Blocking Device to prevent two-blocking the boom tip(s) and the hook block, etc. The closer the load is carried to the boom nose the more This equipment should have a functional Anti-Two-Block and important it becomes to simultaneously let out hoist rope as Control Lock-Out System.

  • Page 20: Load Charts

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL Load Charts Load Charts represent the absolute maximum allowable loads, which are based on either tipping or structural limitations of the equipment under specific conditions. Knowing the precise load radius, boom length, and boom angle should be a part of your routine planning and operation.

  • Page 21: Wind Speeds

    900H OPERATOR MANUAL SAFETY PRECAUTIONS NOTE: The wind speed corresponding to the Beaufort scale in the table is mean wind speed at 10 m (33 ft) elevation over a period of 10 minutes. Table 2-1 Beaufort Wind Scale Maximum Wind Speed Beaufort Visible Indicator Description...
  • Page 22 SAFETY PRECAUTIONS 900H OPERATOR MANUAL Simplified Method to Determine Maximum Permissible Wind Speed Determine 3-Second Gust 0.14 V(z) = [(z/10) + 0.4]v [m/s] Wind Speed at boom tip, 0.14 V(z) = [(z/33) + 0.4]v [mph] V(z) 13.4 m/s < V(z) < 20.1 m/s V(z) >...
  • Page 23 900H OPERATOR MANUAL SAFETY PRECAUTIONS Determination of 3-second wind gust speed at boom Size and Shape of the load: tip height: These rated capacities are also based on the assumption that the Wind Resistance Area of load, Awr is not more The following example illustrates how to calculate 3-second (load) wind gust speed at boom tip height based on mean wind...
  • Page 24 SAFETY PRECAUTIONS 900H OPERATOR MANUAL Calculation of Projected Wind Area (Ap) Wind Wind = 8 m = 24 m 25 ft 25 ft Wind Wind 10 ft 3 ft = 75 ft = 250 ft 10 ft 3 ft 8384-1 FIGURE 2-2 Determining Wind Drag Coefficient (Cd) If the exact Wind Drag Coefficient of a shape is not known,...
  • Page 25 900H OPERATOR MANUAL SAFETY PRECAUTIONS Table 2-2 Wind Drag Coefficient Maximum Permissible Wind Speed If the wind resistant area of the load Awr is greater than (load) Shape the allowable wind resistant area Awr , the ratio can be (allow) used to determine a permissible wind speed V(z) for the load 1.1 to 2.0 using Table 2-3.
  • Page 26 SAFETY PRECAUTIONS 900H OPERATOR MANUAL Rated Load Chart Example - Metric 8383-1 FIGURE 2-3 2-12 Published 04-13-2020 Control # 476-01...
  • Page 27 900H OPERATOR MANUAL SAFETY PRECAUTIONS Table 2-4 Example-Capacity Reduction Factors for Wind Speed V(z) Greater than 13.4 m/s - Metric (Only for lifting with main boom on fully extended outriggers, with or without stowed extension) For wind speed V(z) (3-second gust speed at boom tip height) V(z) > 13.4 m/s ≤ 20.1 m/s, the Reduced Capacity shall be calculated by multiplying the Published Rated Capacity by the following factors: Main Boom Length in Meters Wind Speed...
  • Page 28 SAFETY PRECAUTIONS 900H OPERATOR MANUAL At wind speeds greater than 13.4 m/s, it is not permissible to lift a load greater than 12,040 kg, even if the wind resistance Load example 1.3a: area of the load is less than 14.45 m With large wind resistance area of the load Awr (load) Refer to the information from the above configuration,...
  • Page 29 900H OPERATOR MANUAL SAFETY PRECAUTIONS Refer to the above Lifting Limits at wind speed V(z) Ratio = 1.37 > 13.4 m/s and ≤ 20.1 m/s. Comparing the load and wind resistant area to the allowable: From Table 2-5, the maximum permissible wind speed at •...
  • Page 30 SAFETY PRECAUTIONS 900H OPERATOR MANUAL Rated Load Chart Example - Non-metric 8382-1 FIGURE 2-4 2-16 Published 04-13-2020 Control # 476-01...
  • Page 31 900H OPERATOR MANUAL SAFETY PRECAUTIONS Refer to the above equipment configuration for the following load conditions: Example and Sample Calculations (Non-metric) Load example 2.1: The following example illustrates how to calculate allowable load while operating in wind speed (3-second wind gust With known Wind Drag Coefficient of the load Cd, speed) above 13.4 m/s (30 mph) and maximum permissible •...

  • Page 32: Lifting Operations

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL the wind resistance area of load can be estimated as: • Is Awr less than Awr (load) (allow) 216 ft ≤ 149 ft ......NO = Ap x Cd = 180 x 1.2 = 216 ft (load) Conclusion: This load is NOT permissible to lift in wind...

  • Page 33: Counterweight

    900H OPERATOR MANUAL SAFETY PRECAUTIONS Always keep the load as near to the equipment and as close Always use enough parts-of-line to accommodate the load to to the ground as possible. be lifted. Lifting with too few parts-of-line can result in failure of the hoist rope.

  • Page 34: Tilt-Up Panel Lifting

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL • Make sure that all signals are coordinated through the lift • The wire rope and sheaves shall be inspected prior to director or person in charge of the lift. and following the lifting operations for chaffing or scrubbing.

  • Page 35: Equipment

    900H OPERATOR MANUAL SAFETY PRECAUTIONS In addition to the operating requirements that are detailed in showing inspections were performed on the equipment the operating manuals and on the load capacity chart, pile during the time it was used for pile driving or extraction. driving and extracting operations are approved by National •...

  • Page 36: Set-Up And Operation

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL Example decal. For reference only. 8822 Equipment operation is dangerous when close to an The safest way to avoid electrocution is to stay away from energized electrical power source. Exercise extreme caution electrical power lines and electrical power sources. and prudent judgment.

  • Page 37: Electrocution Hazard Devices

    900H OPERATOR MANUAL SAFETY PRECAUTIONS boom nose and a small portion of the boom. Performance of boom cages and boom guards is limited by their physical size, insulating characteristics, and operating environment (e.g. dust, dirt, moisture, etc.). The insulating characteristics of these devices can be compromised if not kept clean, free of contamination, and undamaged.

  • Page 38: Special Operating Conditions And Equipment

    • If a thunder storm is forecast damaged parts are repaired or replaced as authorized by your National Crane distributor or Manitowoc Crane Care. Use electrically conducting material for grounding. Special Operating Conditions and Hammer a metal rod (3, Figure 2-5) (length of Equipment approximately 2.0 m (6.6 ft)) at least 1.5 m (5 ft) into the...
  • Page 39 900H OPERATOR MANUAL SAFETY PRECAUTIONS Also see the optional equipment manual titled Personnel • The equipment operator must remain at the equipment Basket Manual which addresses safety, inspection, testing, controls at all times when personnel are off the ground. operation, installation, and lubrication. •...

  • Page 40: Environmental Protection

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL The following standards and regulations regarding personnel S h u t d o w n t h e e q u i p m e n t w h i l e m a k i n g r e pa i r s o r handling are available by mail at the following addresses: adjustments.

  • Page 41: Lubrication

    If any hydraulic fluid is injected into the skin, obtain medical attention immediately or gangrene may result. • Consult with Manitowoc Crane Care to determine if load testing is required after a structural repair is performed. • Do not attempt to repair or tighten any hydraulic hose or...

  • Page 42: Hoist Rope

    For detailed information concerning synthetic hoist rope, than two (2) broken wires at an end connection. refer to K100™ Synthetic Crane Hoist Line Manual P/N 9828100734 available by contacting Manitowoc Crane Care. • Core deterioration, usually observed as a rapid...

  • Page 43: Sheaves

    900H OPERATOR MANUAL SAFETY PRECAUTIONS ASME and similar organizations. See the Service • Operate the new rope—first through several cycles at Manual for inspection procedures. light load—then through several cycles at intermediate load, to allow the rope to adjust to operating conditions. When inspecting ropes and attachments, keep all parts of your body and clothing away from rotating hoist drums When using a wedge socket:...

  • Page 44: Batteries

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL TRANSPORTING THE EQUIPMENT upon the user’s experience and the demands of his application. Before transporting the equipment, check the suitability of Batteries the proposed route with regard to the equipment height, width, length, and weight. Battery electrolyte must not be allowed to contact the skin or Check load limits of bridges on the travel route and make eyes.

  • Page 45: Work Practices

    900H OPERATOR MANUAL SAFETY PRECAUTIONS WORK PRACTICES Follow the instructions in this manual when preparing the equipment for travel. Personal Considerations If using a boom dolly/trailer, thoroughly read and understand all the steps and safety precautions in this manual for setup Always adjust the seat and lock it in position, and fasten the and travel.

  • Page 46: Job Preparation

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL access steps, or walking/working surfaces could cause a Make sure that all persons are away from the equipment and slipping accident. A shoe that is not clean might slip off a the Travel Select Lever is in the “N” (Neutral) position with control pedal during operation.

  • Page 47: Lifting

    900H OPERATOR MANUAL SAFETY PRECAUTIONS Make sure that the rope is properly routed on the hook block Make sure that the load is well secured and attached to the and boom nose and that all rope guards are in place. hook with rigging of proper size and in good condition.

  • Page 48: Hand Signals

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL Use tag lines (as appropriate) for positioning and restraining Do not remove right side boom nose pins unless the jib is loads. Check the load slings before lifting. properly pinned and secured on front and rear stowage brackets.
  • Page 49 900H OPERATOR MANUAL SAFETY PRECAUTIONS Reprinted from ASME B30.5-2014, by permission of The American Society of Mechanical Engineers. All Rights Reserved. 9580 FIGURE 2-6 National Crane 2-35 Published 04-13-2020 Control # 476-01...

  • Page 50: Parking And Securing

    SAFETY PRECAUTIONS 900H OPERATOR MANUAL PARKING AND SECURING • Chock the wheels, if not on outriggers. • Lock the operator’s cab (if applicable) and install vandal guards, if used. WARNING COLD WEATHER OPERATION Tipping Hazard! Cold weather operation requires additional caution on the When parking the equipment and leaving it unattended part of the operator.
  • Page 51 900H OPERATOR MANUAL SAFETY PRECAUTIONS would retract approximately 196 mm (7 3/4 in) [see Table 2- cool. The load will lower as the telescope cylinder(s) retracts 8]. A cylinder extended 1.5 m (5 ft) in which the oil cools allowing the boom to come in. Also, the boom angle will 15.5°C (60°F) would only retract approximately 38 mm (1 1/ decrease as the lift cylinder(s) retracts causing an increase 2 in).

  • Page 52: Overload Inspection

    50% or higher, crane operation must be for overloads up to 50%. stopped immediately and Crane Care must be contacted for • Stop operating the crane and contact Manitowoc corrective action. Crane Care immediately for overloads of 50% and higher.

  • Page 53: Boom Inspection

    900H OPERATOR MANUAL SAFETY PRECAUTIONS Boom Inspection 9, 10 2, 3 9, 10 Illustration for reference only. Your crane may be different. National Crane 2-39 Published 04-13-2020 Control # 476-01...
  • Page 54 SAFETY PRECAUTIONS 900H OPERATOR MANUAL NOTE: The following checklist includes all features that can be found on National cranes. Your crane may not have some features. Overload less than 25% Sheaves, Inspect all for damage. Rope Guides Collar-Wear Pads, Pad Inspect for damage.

  • Page 55: Superstructure Inspection

    900H OPERATOR MANUAL SAFETY PRECAUTIONS Superstructure Inspection 10,11 Illustration for reference only. Your crane may be different. National Crane 2-41 Published 04-13-2020 Control # 476-01...
  • Page 56 SAFETY PRECAUTIONS 900H OPERATOR MANUAL NOTE: The following checklist includes all features that can be found on National cranes. Your crane may not have some features. Overload less than 25% Lift Cylinder Inspect for leaks. See topic in Introduction section Wire Rope Inspect all for damage.

  • Page 57: Carrier Inspection

    900H OPERATOR MANUAL SAFETY PRECAUTIONS Carrier Inspection 5, 6 Illustration for reference only. Your crane may be different. National Crane 2-43 Published 04-13-2020 Control # 476-01...
  • Page 58 SAFETY PRECAUTIONS 900H OPERATOR MANUAL NOTE: The following checklist includes all features that can be found on National cranes. Your crane may not have some features. Overload less than 25% Stabilizer Inspect for leaks. Cylinders Outrigger Inspect for deformation and cracked welds. Pads Overload from 25% to 49% Stabilizer...

  • Page 59: Section 3

    900H OPERATOR MANUAL CONTROLS AND OPERATING PROCEDURES SECTION 3 CONTROLS AND OPERATING PROCEDURES SECTION CONTENTS Truck Cab Controls ......3-1 Load Charts .

  • Page 60: Park Brake

    CONTROLS AND OPERATING PROCEDURES 900H OPERATOR MANUAL Park Brake pushed in. The truck gear shift lever must be in neutral and the clutch depressed whenever the knob is moved. The truck parking brake must be firmly set before leaving cab Air Shift Control to begin crane operation.
  • Page 61 900H OPERATOR MANUAL CONTROLS AND OPERATING PROCEDURES EasyReach Pedestal (up position) EasyReach Pedestal (right side down position) FIGURE 3-1 National Crane Published 04-13-2020 Control # 476-01...

  • Page 62: Outrigger Control Box (Pendent)

    CONTROLS AND OPERATING PROCEDURES 900H OPERATOR MANUAL Item Description Outrigger Control Box Stowage Compartment Front Center Stabilizer Switch Outrigger Selector Switches Extend/Retract Switch FIGURE 3-2 Outrigger Control Box (Pendent) Crane Level Indicators The handheld Outrigger Control Box is stowed in a The crane has two Level Indicators on either side of the compartment on the front of the EasyReach pedestal frame that is used to level the crane with the outriggers.
  • Page 63 900H OPERATOR MANUAL CONTROLS AND OPERATING PROCEDURES Rear of Truck Right Left Operator Position FIGURE 3-4 Item Description Item Description 12 V Power Adapter Hoist Speed Switch Pedestal Lock Lever Momentary RCL Override Switch Document Case Option Switches Back Rest Horn Switch Load Charts Optional Control Levers...

  • Page 64: Crane Controls

    CONTROLS AND OPERATING PROCEDURES 900H OPERATOR MANUAL CRANE CONTROLS Boom Telescope Control Lever See Figure 3-4 for item number identification. The Telescope Control Lever (17) is on the left side of the operator console. Push the lever forward to extend the boom Operator Console and pull back to retract the boom.

  • Page 65: Boom Lift Control Lever

    900H OPERATOR MANUAL CONTROLS AND OPERATING PROCEDURES Momentary RCL Override Switch The Monetary RCL Override Switch (13) overrides the RCL system while the switch is pressed in. The RCL is active when the switch is released. 205° DANGER 0° The RCL only aids the operator when programed with the proper load chart and crane configuration.

  • Page 66: Control Levers (Optional)

    CONTROLS AND OPERATING PROCEDURES 900H OPERATOR MANUAL • to see that the hydraulic hoses and fittings are in good condition and show no signs of leaking. Repair damaged The service software and connection cable are or leaking hoses immediately. available through Crane Care to those service technicians who have attended the Grove New •...

  • Page 67: Cold Weather Operation

    Lubrication section of your crane’s Operator Manual, by contacting your local National Crane distributor, or by Without operating the hoist function, warm the hydraulic contacting Manitowoc Crane Care directly). oil (see Hydraulic Oil System, page 3-10). Once the hydraulic system is warm, operate the...

  • Page 68: Swing Drive And Turntable Bearing

    CONTROLS AND OPERATING PROCEDURES 900H OPERATOR MANUAL Swing Drive and Turntable Bearing Anti-Two Block Check Warm-up Procedures for Temperatures Above -7°C (20°F): DANGER Setup the crane on fully extended outriggers, with the Crushing Hazard! boom fully retracted and near maximum lift angle with no load applied.

  • Page 69: Hoist System Operation

    900H OPERATOR MANUAL CONTROLS AND OPERATING PROCEDURES Before Leaving the Truck Cab System (OMS) (Optional—Standard in North America), page 4-2. • Position the truck so that the outriggers can be extended with no obstructions. DANGER • Put the truck transmission in neutral. Tipping Hazard! •...

  • Page 70: Lifting The Load

    CONTROLS AND OPERATING PROCEDURES 900H OPERATOR MANUAL with the load. The loaded boom angle combined with the • the weight of the load to be lifted. boom length approximates the operating radius. • the lifting devices and weights needed. • Working Area - The area measured in a circular arc •...
  • Page 71 900H OPERATOR MANUAL CONTROLS AND OPERATING PROCEDURES 8128-1 FIGURE 3-7 National Crane 3-13 Published 04-13-2020 Control # 476-01...
  • Page 72 CONTROLS AND OPERATING PROCEDURES 900H OPERATOR MANUAL FIGURE 3-8 8128-3 FIGURE 3-9 3-14 Published 04-13-2020 Control # 476-01...

  • Page 73: Shut Down And Preparation For Road Travel

    900H OPERATOR MANUAL CONTROLS AND OPERATING PROCEDURES SHUT DOWN AND PREPARATION FOR ROAD TRAVEL Retract and place the boom in boom rest. Connect the hook block to the tie-down cable so that it cannot swing freely. Use the jog switch at the back bumper of the crane (Figure 3-6) to let out or take up the load line.

  • Page 74: Crane Remote Control (Optional)

    CONTROLS AND OPERATING PROCEDURES 900H OPERATOR MANUAL CRANE REMOTE CONTROL (OPTIONAL) FIGURE 3-11 The optional Crane Remote Control (Figure 3-11) will allow Item Description full remote control of the crane. Refer to the Crane Remote Optional Auger Spin (not used) Control Operator Manual for operating instructions for this optional remote control.
  • Page 75 900H OPERATOR MANUAL CONTROLS AND OPERATING PROCEDURES The LCD Screen (27, Figure 3-11) on the display is used to To use this remote, the red STOP button (10, Figure 3-11) communicate signal strength, battery level, wireless must be twisted and released to turn ON the transmitter. To channel, and remote status (Figure 3-12).
  • Page 76 CONTROLS AND OPERATING PROCEDURES 900H OPERATOR MANUAL THIS PAGE BLANK 3-18 Published 04-13-2020 Control # 476-01...

  • Page 77: Section 4

    900H OPERATOR MANUAL SET-UP SECTION 4 SET-UP SECTION CONTENTS Outrigger Setup ......4-1 Stowing Procedure ......4-6 Proper Leveling of the Crane .

  • Page 78: Site Selection

    SET-UP 900H OPERATOR MANUAL Site Selection Extend all four stabilizers until the truck tires are about four inches off the ground. The outrigger floats must be on a firm solid surface that is Adjust the stabilizers until the bubble in the level level.

  • Page 79: Extension Safety Information

    900H OPERATOR MANUAL SET-UP EXTENSION SAFETY INFORMATION Ensure extension is stowed correctly (Figure 4-3): Removal of swing around pins, C1, without proper installation of stow pin A and extension swing pin B, may allow extension to fall off. b. Extending boom with extension stowed and failure to remove swing pins, C1, will damage unit upon extension.

  • Page 80: Side Folding Swing Around Extension Operation

    SET-UP 900H OPERATOR MANUAL NOTE: When lowering the boom below horizontal, two persons may be required. With the telescope control in neutral, the boom may creep out when below horizontal. Remove cable keeper pins from boom sheave case and extension. Remove hook block. Pivot extension slightly to allow for loadline to be removed from boom sheave case.
  • Page 81 900H OPERATOR MANUAL SET-UP Extension in Operating position Stow Pin Extension Swing Pin Extension Deployment Pins Stowage Loop Extension Retaining Pin Extension in Stow Position Stowage Bracket on Extension Left Side Right Side FIGURE 4-3 National Crane Published 04-13-2020 Control # 476-01...

  • Page 82: Stowing Procedure

    SET-UP 900H OPERATOR MANUAL Remove the jack handle and check that the jack release valve is closed. WARNING b. Extend the jack so that the lower C2 pin holes are aligned. Crushing Hazard! Use caution when swinging extension into deployed Install the lower C2 pin and spring clip.

  • Page 83: Extension Removal

    900H OPERATOR MANUAL SET-UP Disconnect twist lock anti-two block wire connector at 17. Reinstall loadline over boom sheave case. rear of 1 section extension. Connect twist lock connector to anti-two block switch connector on boom tip. Move weight/chain assembly to boom tip. DANGER Attach tag line to sheave case end of extension.

  • Page 84: Anti-Two Block Weight Installation

    ** The hook block must be sized to the number of line parts. For example, do not use a six part line hook block on a three part line reeving. Contact your National Crane Distributor or Manitowoc Crane Care to order the proper hook block.

  • Page 85: Installing Cable On The Hoist

    900H OPERATOR MANUAL SET-UP INSTALLING CABLE ON THE HOIST CAUTION If cable is wound from the storage drum, the reel should be rotated in the same direction as the hoist. NOTE: The cable should preferably be straightened before 7196 installation on the hoist drum. Slowly rotate the drum, ensuring the first layer of cable is Install cable on the hoist drum in accordance with the evenly wound onto the drum.

  • Page 86: Wedge Socket Installation

    SET-UP 900H OPERATOR MANUAL Terminator Wedge Socket Torque Value Table Cable Size (inches) 7/16 9/16 1-1/8 1-1/4 Torque lb-ft Torque values shown are based upon clean dry threads free of lubrication. FIGURE 4-6 Wedge Socket Installation cable and wedge are secure in the socket. The length of dead end that is exposed must be at least 20 x cable To attach a wedge socket, use the following procedure: diameter (Figure 4-7).

  • Page 87: Section 5

    Specific recommendations of brand and grade of lubricants extreme condition lubrication, contact your local National are not made here due to regional availability, operating Crane distributor or Manitowoc Crane Care. conditions, and the continual development of improved Environmental Protection products. Where questions arise, contact your National Crane distributor or Manitowoc Crane Care.

  • Page 88: Chassis Grease

    Hydraulic Oil National Crane distributor or Manitowoc Crane Care. NOTE: All fluids and lubricants may be purchased by Oil in a hydraulic system serves as the power transmission contacting the Manitowoc Crane Care Parts medium, system lubricant and coolant.

  • Page 89: Hydraulic Oil Inspection

    Boeshield T-9 Premium Metal Protectant. level and must meet John Deere Standard JDM J20C. Manitowoc Crane Care has Boeshield T-9 Premium Metal Contact your National Crane distributor or Manitowoc Crane Protectant available in 12 oz. cans that can be ordered Care if you have any questions.

  • Page 90: Lubrication Points

    LUBRICATION PROCEDURE AND CHARTS 900H OPERATOR MANUAL Symbol Description Manitowoc Lube Specification GL-5 Extended Service Interval Gear Lubricant - SAE Grade 80W-90 6829012964 AFC - 50/50 50/50 Blended Fully Formulated Antifreeze/Coolant, SAE J1941, ASTM D6210 6829101130 HYDO Hydraulic Oil - Must meet ISO 4406 cleanliness level 17/14...

  • Page 91: Internal Cable Sheave Lubrication

    WARNING (National Crane P/N 955045). Fall Hazard! • Contact Manitowoc Crane Care to obtain this tip. Do not, under any circumstances, work at an elevated height without using proper fall protection as required by local, state or federal regulations. National Crane...

  • Page 92: Inner Boom Wear Pad Lubrication

    LUBRICATION PROCEDURE AND CHARTS 900H OPERATOR MANUAL Lubrication of the extend and retract sheaves is as follows: Extend the boom to line up the access holes (2) on the section with the wear pads on the 4 section. Apply Extend the boom until the grease access holes on the grease to the 4 section wear pads with a grease gun.

  • Page 93: Hoist Brake Oil

    +150° F). For operation outside this range, contact NOTE: Brake lubricants are satisfactory for operation in Manitowoc Crane Care for recommendations. temperatures from -23° C to 66° C (-10° F to +150° F). For operation outside this r a n g e , c o n ta c t M a n i t o w o c C r a n e C a r e f o r recommendations.

  • Page 94: Wire Rope Lubrication

    LUBRICATION PROCEDURE AND CHARTS 900H OPERATOR MANUAL necessary. Characteristics of a good wire rope lubricant are that it should be: Fill Between Marks • free from acids and alkalis. • have sufficient adhesive strength to remain on the rope. • of a viscosity capable of penetrating the interstices between wires and strands.

  • Page 95: Cleaning Procedures

    900H OPERATOR MANUAL LUBRICATION PROCEDURE AND CHARTS Grove cranes will be treated with a rust inhibitor called • on roads where large quantities of salt or calcium are applied to treat icy and snowy road surfaces; Carwell T32-CP-90. While a rust inhibitor cannot guarantee ®...

  • Page 96: Application

    • Cover all bare metal with a primer that is compatible with the original paint finish and allow to dry thoroughly. Please contact Manitowoc Crane Care should you have any questions. • Prepare the surface prior to applying the finish coat of paint.
  • Page 97 900H OPERATOR MANUAL LUBRICATION PROCEDURE AND CHARTS 10076 10077 FIGURE 5-13 National Crane 5-11 Published 04-13-2020 Control # 476-01...
  • Page 98 LUBRICATION PROCEDURE AND CHARTS 900H OPERATOR MANUAL Item Description Item Description Jib Hanger Hardware (Not shown) O/R Hose Connections Boom Nose Pins, Clips Hose Connections O/R Pins, Clips Hoist Tension Springs Hook block Tiedown Cable Mirror Mounting Hardware O/R Beam Wear Pad Adjustment Hardware Hoist Hose Connections Hook Block \ Overhaul Ball Powertrain Hardware...

  • Page 99: Crane Inspection And Maintenance

    An inspection log book is Fall Hazard! available from your National Crane distributor or Do not, under any circumstances, work at an elevated Manitowoc Crane Care. height without using proper fall protection as required by local, state or federal regulations WARNING...

  • Page 100: Inspections

    MAINTENANCE CHECKLIST 900H OPERATOR MANUAL Loose parts or damage to structures or welds. Lubrication as specified by the Lubrication Procedure and Charts, Section 5. Operation of lights, safety equipment and gauges. Torque the T-box mounting bolts during the first month of Condition of tires and suspension.

  • Page 101: Special Boom Inspection

    Damaged rods state and local regulatory agencies. b. Dented barrels NOTE: Wire rope may be purchased through Manitowoc Drift from oil leaking by the piston Crane Care. d. Leaks at rod seals, welds, or holding valves. Any deterioration observed in the wire rope should be noted...

  • Page 102: Precautions And Recommendations During Inspection

    MAINTENANCE CHECKLIST 900H OPERATOR MANUAL • Lifting a load that is beyond the rated capacity of the Pay particular attention to areas of the rope where wear and lifting mechanism, such as overloading. other damage is likely to occur: • Pick-up Points: Sections of wire rope that are repeatedly Precautions and Recommendations During stressed during each lift, such as those sections in Inspection...

  • Page 103: Wire Rope Replacement

    900H OPERATOR MANUAL MAINTENANCE CHECKLIST Wire Rope Replacement • Manitowoc recommends for cable extended booms, that boom extension cables be replaced every seven (7) It is difficult to determine the exact time for replacement of years. wire rope (hoist cable) since many variable factors are involved.

  • Page 104: Crane Adjustments And Repairs

    If a cable replacement is required for the boom extension system, the replacement cable must be obtained through HYDRAULIC SYSTEM Manitowoc Crane Care. Extension cables are pre-stretched and have special connections for proper installation Oil Cooler Extension Jack Service and Maintenance The heat exchanger must be kept clean for efficient operation of the hydraulic cooler system.
  • Page 105 900H OPERATOR MANUAL MAINTENANCE CHECKLIST Tire and Load Inflation Tables Letters in parenthesis denote the load range for which the bold face loads are a maximum. International load index numbers are shown after the load range. The load range letters and corresponding ply rating are shown below.
  • Page 106 MAINTENANCE CHECKLIST 900H OPERATOR MANUAL Radial Ply Metric Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15° Drop Center Rims Tire and Rim Association Standard Radial Ply Metric Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15°...
  • Page 107 900H OPERATOR MANUAL MAINTENANCE CHECKLIST Metric Wide Base Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Tires Used as Singles Mounted on 15° Drop Center Rims Tire and Rim Association Standard Radial Ply Tires for Trucks, Busses, and Trailers Used in Normal Highway Service Radial Ply Tires Mounted on 15°...

  • Page 108: Specifications

    MAINTENANCE CHECKLIST 900H OPERATOR MANUAL SPECIFICATIONS Hydraulic Pump Type ................Variable displacement, axial piston with load sense Total Flow ..............46.6 GPM (176.4 LPM) at 2400 RPM Hydraulic System Requirements: Outrigger System ............14 gpm (52.9 lpm) Boom Up ............... 21 gpm (79.4 lpm) Boom Down..............

  • Page 109: Outrigger Speeds

    900H OPERATOR MANUAL MAINTENANCE CHECKLIST Crane Operating Speeds Rotation 360°................. 50 ± 5 sec (1.2 ± 0.2 rpm) Adjustment Knob Closed Boom up -10° to 80° .............. 30 ± 5 sec Boom Down 80° to -10° ............30 sec ± 5 sec Boom Extend/Retract Four Section Extend (Angle 60°) ............
  • Page 110 MAINTENANCE CHECKLIST 900H OPERATOR MANUAL THIS PAGE BLANK 6-12 Published 04-13-2020 Control # 476-01...
  • Page 111 900H OPERATOR MANUAL RATED CAPACITY LIMITER SECTION 7 RATED CAPACITY LIMITER SECTION CONTENTS RCL System Description ....7-2 Step 2: Configuring the Boom ....7-17 Step 3: Configuring Outriggers .

  • Page 112: Rcl System Description

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL potentiometer, four outrigger length sensors and two lift cylinder pressure transducers. The RCL has the crane load charts loaded into the RCL module and are displayed on the screen as needed. When a load is picked, the RCL compares the actual conditions with the load chart.
  • Page 113 900H OPERATOR MANUAL RATED CAPACITY LIMITER MAIN Menu 7623-5 FIGURE 7-2 The MAIN Menu screen (Figure 7-2) is divided into the The Main Menu screen has five function keys (1, Figure 7-2) following three major sections which are used to set-up, that are used to select the functions shown on the display operate, calibrate and troubleshoot the Rated Capacity screen above each key.

  • Page 114: Alert And Limit Symbols

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL Alert and Limit Symbols • A2B Override Warning (Red) — Indicates that the The left and right sides of the operating screen display active A2B is bypassed by the operator. Use extreme caution alert and/or limit symbols. Only those limits that are set are when the A2B is bypassed.

  • Page 115: Rcl Setup (Legacy Rcl Version)

    900H OPERATOR MANUAL RATED CAPACITY LIMITER • Outrigger (O/R) Configuration Change — Indicates that the current O/R position has changed from the previously configured O/R setup. Buzzer sounds to warn operator of discrepancy, but no functions are locked out. • Last Layer Indicator (LLI)/3rd Wrap —...

  • Page 116: Tare Function

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL Screen 9 # - Reeving selecting screen; pressing this button returns to the number of parts of line selection 7655-7 screen. LIMIT - Pressing enables the RCL Limits Menu screen. TARE - Pressing temporarily zeros out the Actual 7521-15 Load indicated on the screen to show the weight of the load only.

  • Page 117: Rcl Operating Modes

    900H OPERATOR MANUAL RATED CAPACITY LIMITER RCL Operating Modes Operating Modes 001-014: 100ft or 110ft Main Boom. Full Span O/R’s. SAE 85% Chart Description Main boom, no jib stowed Main boom, jib stowed 25 ft tele jib 44 ft tele jib Personnel basket on main boom Personnel basket on 25 ft tele jib Personnel basket on 44 ft tele jib...

  • Page 118: Operational Limits (Legacy Rcl Version)

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL OPERATIONAL LIMITS (LEGACY RCL Select the SET function key (#1 or #3, Figure 7-2) to store the current slew angle. VERSION) Select DEL function key (#2 or #4, Figure 7-2) to Operational limits are set by the operator to limit crane remove the current setting.

  • Page 119: Boom Angle Limit

    900H OPERATOR MANUAL RATED CAPACITY LIMITER Tip Height Limit FIGURE 7-4 Center Line of RCL Limit #4 Truck with Boom 7623-28 in Boom Rest Center Line Move the crane boom to the desired boom tip height point (it of Rotation will appear on the display screen) then select the following: Select SET, function key (#1, Figure 7-2) to store Boom Angle Limit...

  • Page 120: Delete All Limits

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL Delete All Limits Tools Screen 7623-42 RCL Limit #6 7623-31 The Tool Screen will contain the following set up, calibration, tools and measurement display information. The RCL Limit #6 screen will allow the operator to delete all Each selection on the Tools Screen is made by using the limit values that exist.

  • Page 121: Diagnostic (Legacy Rcl Version)

    900H OPERATOR MANUAL RATED CAPACITY LIMITER DIAGNOSTIC (LEGACY RCL VERSION) The Diagnostic Menu screen is divided into five different displays that provide software version and revision, crane To get to the Diagnostic Menu screen, turn on the crane and truck operating information and warnings, an hour ignition switch and use the following screens.
  • Page 122 RATED CAPACITY LIMITER 900H OPERATOR MANUAL Machine information/warnings (upper left hand corner of Truck Regeneration Needed - the Diagnostic Menu screen) When the truck is in need of regeneration (first stage and all Engine Water Temperature - If the subsequent stages), the general engine water temperature rises warning light is shown on the above 300°F the general warning...

  • Page 123: Current Rcl System

    900H OPERATOR MANUAL RATED CAPACITY LIMITER (3) - Group Number codes, the button with the fault code icon and red “X” can be depressed. (4) - Index Lift Cylinder Pressure Sensor (5) - Error Number displays the real time pressures in psi and bar for the base and the rod side Logged Fault Box (B) - Logged faults are not currently pressures.
  • Page 124 RATED CAPACITY LIMITER 900H OPERATOR MANUAL MAIN Menu Tools RCL Setup Diagnostics Return to Operating Mode Screen 8717-2 FIGURE 7-6 The MAIN Menu screen (Figure 7-6) is divided into the • Diagnostic — Use the Directional button to scroll following three major sections which are used to set-up, and highlight the Tools icon, then press OK operate, calibrate and troubleshoot the Rated Capacity This menu includes Software Versions, Load Chart...

  • Page 125: Alert And Limit Symbols

    900H OPERATOR MANUAL RATED CAPACITY LIMITER Table 7-1 RCL Function Keys (Continued) RCL Operating Mode Screen (Sample) Icon Description The Directional button is used to highlight and select applicable choices and navigate to multiple screens. For more choices, press the right arrow function key.
  • Page 126 RATED CAPACITY LIMITER 900H OPERATOR MANUAL Table 7-2 RCL Screen Symbols (Continued) Table 7-2 RCL Screen Symbols (Continued) Icon Description Icon Description Tip Height Limit — The tip height is measured Hoist 1 (Main) Raise High Speed from the ground to the tip of the boom. This monitors the height of the boom tip to alert the operator of a user set limit (assumes maximum Hoist 1 (Main) Lower...

  • Page 127: Rcl And A2B Override Warnings

    900H OPERATOR MANUAL RATED CAPACITY LIMITER RCL and A2B Override Warnings Step 1: Configuring a Personnel Platform Table 7-3 shows the RCL and ATB warning overrides that Screen 1 appear on the RCL screen. The RCL override bypasses the RCL for both overload and ATB alerts. DANGER Use extreme caution when operating the crane with the RCL system overridden.

  • Page 128: Step 3: Configuring Outriggers

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL Screen 3-1A The position of each outrigger is shown graphically on the right of the screen and will be either Full-Span, Mid-Span, Zero-Span (Figure 7-8). 8807-10 Selected 1 on Screen 2. Select 1 or 2 on Screen 3-1A: Mid-Span Zero-Span Full-Span...

  • Page 129: Operating Mode (Current Rcl Version)

    900H OPERATOR MANUAL RATED CAPACITY LIMITER automatically returns the RCL to the configuration used at • Actual Load (AL) = 8550 lbs. shutdown. Re-configuration of the RCL is not required. • All Active Limits Screen 9 Accessing Operating Mode Screen Use this procedure to access the Operating Mode screen.

  • Page 130: Overriding The Rcl System

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL Overriding the RCL System Operating Modes 801-802: 100ft or 110ft Main Boom, Zero-Span O/R’s, SAE 85% Chart DANGER Description Main boom Use extreme caution when operating the crane with the RCL system overridden. Use of the RCL system override Main boom, jib stowed to operate the crane in a non-permissible range can result in death or injury to personnel and/or damage to...

  • Page 131: Slew Angle Limit

    900H OPERATOR MANUAL RATED CAPACITY LIMITER WADS Limit Table 7-5 Operational Limits Selections Use the following procedure to set the Work Area Definition Icon Description System (WADS).The WADS limits allow the operator to Set a slew angle limit. For more information, create virtual “walls”...

  • Page 132: Boom Angle Limit

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL RCL Limit #4 • Select OK to store each position after input. 10065 • to return to previous screen with no inputs. Boom Angle Limit Use the following procedure to set the boom angle limit. The minimum (MIN), maximum (MAX), or MIN and MAX boom angle limits can be set.

  • Page 133: Delete All Limits

    900H OPERATOR MANUAL RATED CAPACITY LIMITER Delete All Limits • Use the directional arrows to highlight the Tools icon. Press the OK key. RCL Limit #6 The Tools Menu appears. 10067 Tools Screen 10068 The RCL Limit #6 screen enables the operator to delete all limit values that exist.

  • Page 134: Setting Rcl Screen Brightness

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL About the Diagnostics Screen Table 7-7 Hydraulic Filter Reminder Icons (Continued) Icon Description Table 7-9 shows the navigation buttons on the bottom of the Set Interval—Highlight and select the Diagnostics screen. Use the function key to use the interval using the directional control keys and appropriate function key to navigate to the next screen.

  • Page 135: Accessing The Diagnostics Menu

    900H OPERATOR MANUAL RATED CAPACITY LIMITER Table 7-10 Diagnostics Screen Icons (Continued) Table 7-10 Diagnostics Screen Icons (Continued) Engine Water Temperature — If the Hydraulic Filter Reminder Warning — engine water temperature rises above If the hydraulic filter reminder limit has 220°F the general warning light is shown been reached, the general warning light on the operating mode screen and this...

  • Page 136: About Faults And Real-Time I/O Diagnostics

    RATED CAPACITY LIMITER 900H OPERATOR MANUAL Highlight and select the Diagnostics icons. The Diagnostics menu appears. Diagnostic Menu Screen #1 FIGURE 7-10 7623-46n The following describes the fault code screen (Figure 7-10): • Active Fault Box (Red, A, Figure 7-10) — The crane 10070 control system displays up to 20 active faults or errors in the crane and RCL control system(s).
  • Page 137 900H OPERATOR MANUAL RATED CAPACITY LIMITER Viewing the Fault Codes List • Module Status • CAN Status Access the list of fault codes (diagnostics screen #2) from the Diagnostics menu. Use the directional button to scroll • RCL Status through the list of faults. To view real-time I/O diagnostics: To access the fault codes menu: Navigate to the Diagnostics Menu.
  • Page 138 RATED CAPACITY LIMITER 900H OPERATOR MANUAL THIS PAGE BLANK 7-28 Published 04-13-2020 Control # 476-01...
  • Page 139 900H OPERATOR MANUAL Alphabetical Index Accidents ............. 2-2 Anti-two Block Weight Installation .
  • Page 140 OPERATOR MANUAL 900H Tire Load and Inflation Table ..........6-6 Tools (Current RCL Version) .

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