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Manitowoc National Crane 900H Service Maintenance Manual

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National Crane 900H
Service/Maintenance Manual

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Summary of Contents for Manitowoc National Crane 900H

  • Page 1 National Crane 900H Service/Maintenance 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

    900H TABLE OF CONTENTS SECTION 1 ..........Introduction General .
  • Page 6 900H Removing Air from the Hydraulic System ....... 2-10 Hydraulic Pump ............2-11 Load Sense Control .
  • Page 7 900H Front Outrigger Manifold ..........3-7 Rear Outrigger Manifold .
  • Page 8 900H Removal............5-3 Installation .
  • Page 9 900H Description ............7-8 Removal .
  • Page 10 900H Mount the Frame Assembly......... . 9-19 Install the Front Outriggers .

  • Page 11: Section 1

    900H SERVICE MANUAL INTRODUCTION SECTION 1 INTRODUCTION SECTION CONTENTS General ........1-1 Hydraulic Fittings .

  • Page 12: Service And Repair

    The boom should be fully retracted and lowered and the If you are the new owner of a National crane, please register load placed on the ground. it with Manitowoc Crane Care so we have the ability to contact you if the need arises. •...
  • Page 13 900H SERVICE MANUAL INTRODUCTION FIGURE 1-2 7141-1A Item Component Item Component Operator’s Console Hydraulic Tank EasyReach™ Pedestal Hydraulic Pump Operators Station Hydraulic Remote Controller (HRC) Load Moment Indicator (RCL) Reel Truck Frame Boom Truck Bed Boom Nose Torsion Box, T-Box Boom Rest Sheave Lift Cylinder...

  • Page 14: General Maintenance

    INTRODUCTION 900H SERVICE MANUAL GENERAL MAINTENANCE All supporting members (chains and cables) need to be parallel to each other and as near perpendicular as possible The suggestions listed below are helpful in analyzing and to the top of the object being lifted. correcting problems: CAUTION •...

  • Page 15: Hoses And Tubes

    900H SERVICE MANUAL INTRODUCTION Hoses and Tubes Installation When installing a new hose, loosely connect each end DANGER and make sure the hose takes up the designed position before tightening the connection. Clamps should be High Pressure/Temperature Hazard! tightened sufficiently to hold the hose without crushing Exercise extreme care around pressurized hydraulic and to prevent chafing.

  • Page 16: Gaskets

    INTRODUCTION 900H SERVICE MANUAL When pressing bearings into a retainer or bore, uniformly batteries in a cool (not subfreezing), dry place, preferably on apply pressure to the outer race. If the bearing is pressed on wooden shelves. Never store on concrete. A small charge the shaft, uniformly apply pressure on the inner race.

  • Page 17: Hydraulic Systems

    Contaminants in a hydraulic system affect operation and will assemblies for correction or replacement. For replacement result in serious damage to the system components. Dirty of hose assemblies, refer to your Manitowoc Crane Care hydraulic systems are a major cause of component failures. Parts Manual.

  • Page 18: Hydraulic Fittings

    INTRODUCTION 900H SERVICE MANUAL Hydraulic Fittings 37° Flared Steel Fitting: Tube or Hose to Fitting Follow the F.F.F.T. method, described above. Flats from Finger Tight (F.F.F.T.) Method Table 1-1: Tube and Swivel Nut/Hose Fittings National Crane recommends that the F.F.F.T. tightening method described here be used when assembling all hydraulic fittings.

  • Page 19: Electrical System

    900H SERVICE MANUAL INTRODUCTION Table 1-3: Straight Thread Fittings BACK OFF Adjustable Fitting to Port FIGURE 1-5 a0030 Inspect both mating parts for burrs, nicks, scratches, or foreign particles. Lubricate O-ring with a light coat of clean oil. T-2-7 Back off locknut as far as possible (A). Screw the fitting into port by hand until the backup Electrical System washer contacts the face of the port and is pushed all the...

  • Page 20: Fatigue Of Welded Structures

    INTRODUCTION 900H SERVICE MANUAL • All Valve Solenoid connections on Hydraulic valves and Ensure grease is applied to each terminal socket. The Transmissions towel with excess grease can be used to fill empty terminal sockets (Figure 1-7). • All Harness Connections Ensure grease is applied to the entire surface of the •...

  • Page 21: Loctite

    900H SERVICE MANUAL INTRODUCTION Loctite Time required to achieve full strength is 24 hours. Maximum ultimate strength is achieved using no primer with this specific threadlocking adhesive. Fasteners and Torque Values CAUTION Skin and/or Eye Hazard! Use bolts of the correct length. A bolt which is too long may bottom before the head is tight against the part it is to hold.
  • Page 22 INTRODUCTION 900H SERVICE MANUAL Torque wrenches are precision instruments and must be misaligned no more than 30 degrees without causing handled with care. To ensure accuracy, calibrations must be serious error in torque. made on a scheduled basis. Whenever there is a possibility •...
  • Page 23 900H SERVICE MANUAL INTRODUCTION Table 1-4 Inch Series with Coarse Threads (UNC) – Zinc Flake Coated (Continued) Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 58.6 57.1 55.7 1/2-13 UNC 82.8 80.7 78.6 84.5 82.4 80.3 9/16-12 UNC...
  • Page 24 INTRODUCTION 900H SERVICE MANUAL Table 1-5 Inch Series with Fine Threads (UNF) – Zinc Flake Coated (Continued) Nominal Size, Threads per Torque (ft/lb) Inch, and Series Grade Maximum Nominal Minimum Designation 132.1 128.8 125.5 5/8-18 UNF 186.7 182.0 177.3 231.0 225.2 219.4 3/4-16 UNF...
  • Page 25 900H SERVICE MANUAL INTRODUCTION Table 1-6 Metric Series with Coarse Threads – Zinc Flake Coated (Continued) Nominal Size, Threads per Torque (Nm) Property millimeter, and Series Class Maximum Nominal Minimum Designation 111.4 108.6 105.8 M14x2 10.9 163.6 159.5 155.4 12.9 191.5 186.7 181.9...
  • Page 26 INTRODUCTION 900H SERVICE MANUAL Table 1-7 Metric Series with Fine Threads – Zinc Flake Coated (Continued) Nominal Size, Threads per Torque (Nm) Property millimeter, and Series Class Maximum Nominal Minimum Designation 46.8 45.6 44.4 M10x.75 10.9 68.7 67.0 65.3 12.9 80.4 78.4 76.4...
  • Page 27 900H SERVICE MANUAL INTRODUCTION Table 1-7 Metric Series with Fine Threads – Zinc Flake Coated (Continued) Nominal Size, Threads per Torque (Nm) Property millimeter, and Series Class Maximum Nominal Minimum Designation 951.4 927.6 903.8 M27x2 10.9 1355.0 1321.1 1287.2 12.9 1585.6 1546.0 1506.3...
  • Page 28 INTRODUCTION 900H SERVICE MANUAL Table 1-9 Inch Series Screws of STAINLESS STEEL 300 (18-8) with Coarse Threads (Continued) Torque Size lb-in lb-ft 1/4-20 5/16-18 3/8-16 17.5 Torque Values for fasteners with lubrication these torque and preload values result in an 80% utilization of the yield strength. Stainless steel fasteners tend to gall while being tightened.
  • Page 29 900H SERVICE MANUAL INTRODUCTION Inch Series with Coarse Threads (UNC) – Untreated (black finish) Table 1-12 (Continued) Torque (ft/lb) Size Grade Maximum Nominal Minimum 7/16-14 1/2-13 9/16-12 5/8-11 259.5 3/4-10 7/8-9 1 1/8-7 1342 1288 1234 1141 1097 1053 1 1/4-7 2043 1964 1885...
  • Page 30 INTRODUCTION 900H SERVICE MANUAL Table 1-13 Inch Series with Fine Threads (UNF) – Untreated (black finish) (Continued) Torque (ft/lb) Size Grade Maximum Nominal Minimum 9/16-18 174.5 5/8-18 299.5 3/4-16 439.5 7/8-14 1-12 1009 644.5 1-14 908.5 1 1/8-12 1500 1440 1380 1251 1203...
  • Page 31 900H SERVICE MANUAL INTRODUCTION Table 1-14 Metric Series with Coarse Threads – Untreated (black finish) (Continued) Torque (Nm) Property Size Class Maximum Nominal Minimum M10x1.5 10.9 12.9 M12x1.75 10.9 12.9 M14x2 10.9 203.5 12.9 M16x2 10.9 12.9 306.5 M18x2.5 10.9 436.5 12.9 M20x2.5...
  • Page 32 INTRODUCTION 900H SERVICE MANUAL Table 1-15Metric Series with Fine Threads – Untreated (black finish) Torque (Nm) Property Size Class Maximum Nominal Minimum M8x1 10.9 39.5 12.9 M10x0.75 10.9 12.9 M10x1.25 10.9 12.9 97.5 M12x1 10.9 12.9 M12X1.25 10.9 141.5 12.9 165.5 M12x1.5* 10.9...

  • Page 33: Weld Studs

    900H SERVICE MANUAL INTRODUCTION Table 1-15Metric Series with Fine Threads – Untreated (black finish) (Continued) Torque (Nm) Property Size Class Maximum Nominal Minimum 803.5 M24x2 10.9 1176 1130.5 1085 12.9 1410 1356 1302 1225 1171.5 1130 M27x2 10.9 1718 1652.5 1587 12.9 2063...

  • Page 34: Lubrication

    • Wire rope sets must be replaced as a set. only pre-assembled lengths of wire rope as supplied from Manitowoc Crane Care. Do not build lengths from • Do not paint or coat wire ropes with any substance individual components.

  • Page 35: Wire Rope Inspection

    Periodic Inspection predetermined by state and local regulatory agencies. NOTE: Wire rope is available from Manitowoc Crane Care. Do a periodic inspection of the total length of all boom extension and retraction cables. Use this inspection to monitor degradation and identify damage that requires wire Record any deterioration of the wire rope in the equipment rope replacement or equipment repair.

  • Page 36: Seizing Wire Rope

    INTRODUCTION 900H SERVICE MANUAL The two ends of the annealed wire should be twisted together tightly. Cut off the excess wire and pound the twist flat against the wire rope (Figure 1-12). One Lay One lay is parallel to the rope center-line and is the distance for one strand to make a complete spiral FIGURE 1-11 around the rope.
  • Page 37 900H SERVICE MANUAL INTRODUCTION PREFORMED Before Cutting After Cutting NON-PREFORMED Before Cutting 6 Rope Diameters After Cutting FIGURE 1-14 National Crane 1-27 04-15-2020 Control # 477-01...

  • Page 38: Introduction

    INTRODUCTION 900H SERVICE MANUAL THIS PAGE BLANK 1-28 04-15-2020 Control # 477-01...

  • Page 39: Hydraulic System General Overview

    900H SERVICE MANUAL HYDRAULIC SYSTEM SECTION 2 HYDRAULIC SYSTEM SECTION CONTENTS Introduction....... 2-1 Maintenance .
  • Page 40 HYDRAULIC SYSTEM 900H SERVICE MANUAL cylinder or motor), or internal (the resistance of the To understand how a hydraulic system works, it is important components of the system). Pressure increases as the to understand the following words: resistance to the flow increases. The pump will continue to Flow - The flow through the system is caused by the pump.

  • Page 41: Hydraulic Symbols

    900H SERVICE MANUAL HYDRAULIC SYSTEM HYDRAULIC SYMBOLS The following pages show basic hydraulic symbols as used on the schematics. Description Symbol Description Symbol Hydraulic Reservoir - Stores, cools, and Filter - Removes contamination from cleans machines hydraulic fluid supply. hydraulic fluid. Hydraulic Return Lines - Terminated at (1) Filter with Bypass Valve - Bypass valve below fluid level (2) above fluid level.
  • Page 42 HYDRAULIC SYSTEM 900H SERVICE MANUAL Description Symbol Description Symbol Single Acting Cylinder - Extended Manually Operated - Valve shifted hydraulically and retracted with a spring. manually with check to allow flow back to tank. Double Acting Cylinder - Extended and retracted hydraulically.

  • Page 43: Maintenance

    900H SERVICE MANUAL HYDRAULIC SYSTEM MAINTENANCE When installing metal hydraulic tubes, tighten all bolts finger tight. Then, in order, tighten the bolts at the rigid end, the Preparation adjustable end, and the mounting brackets. After tubes are mounted, install the hoses. Connect both ends of the hose Before maintenance, adjustments and repairs are started on with all bolts finger tight.

  • Page 44: Troubleshooting Aids

    HYDRAULIC SYSTEM 900H SERVICE MANUAL At the same service interval, visually inspect all other be used to find the location of leakage or restriction in hydraulic components and valves for the following: the system. Instructions for installation of the flow meter and the use of the flowmeter are normally included with Leaking Ports the flowmeter.

  • Page 45: General Hydraulic System Troubleshooting

    900H SERVICE MANUAL HYDRAULIC SYSTEM If the problem is two or three circuits, check each circuit NOTE: Do not remove the main relief valve from the circuit. separately. After a circuit is checked, use caps or plugs to The relief valve must be kept in the circuit to inhibit remove that circuit from the system.
  • Page 46 HYDRAULIC SYSTEM 900H SERVICE MANUAL Symptom Possible Cause Remedy Wrong operation (running over the load Change procedure of operation. sense relief pressure setting for long periods). Dirty filters. Change filter. See Section 3. Overheating of hydraulic oil Oil too light. Use correct oil.

  • Page 47: Parts Replacement

    0.118 (3.00) 1 7/8-12 (37.82) NOTE: Contact your National Crane Distributor or Manitowoc Crane Care for O-Ring boss seal kits. SERVICE Cycle the crane through all functions several times. Then return the crane to its stowed position and shut Hydraulic Oil Recommendations down the engine.

  • Page 48: Removing Air From The Hydraulic System

    HYDRAULIC SYSTEM 900H SERVICE MANUAL Connect the cylinder return line and lower the boom to with all cylinders retracted. Fill the reservoir to the full mark its stowed position. Replenish the reservoir hydraulic oil on the reservoir sight gauge. After the reservoir is filled, level as required.

  • Page 49: Hydraulic Pump

    900H SERVICE MANUAL HYDRAULIC SYSTEM Load Sense Control WARNING The Load Sense (LS) control matches pump flow with system demand. The LS control senses the flow demand of High Pressure Hazard! the system as a pressure drop across an External Control Pressurized hydraulic fluid can cause serious injury.

  • Page 50: Valves

    HYDRAULIC SYSTEM 900H SERVICE MANUAL VALVES the circuit they are used in, and their physical location, refer to the table on page 2-12. The description of each valve General given here is for the valve itself. For information on how each valve functions in the individual circuits, refer to the This subsection provides descriptive information for all the description and operation procedures of that circuit.
  • Page 51 900H SERVICE MANUAL HYDRAULIC SYSTEM HRC Pressure Gauge Port 7163 Pilot Pressure Gauge Port HRC Enable Pilot Pressure Radio Remote Solenoid Supply Enable Solenoid Pump Pilot Relief Gauge Port Inlet Port Outlet Port Option 2A Option 2B Option 1A Option 1B Boom Up Boom Down Telescope...

  • Page 52: Directional Control Valve

    HYDRAULIC SYSTEM 900H SERVICE MANUAL Access Bolts Directional FIGURE 2-3 Control Valve DIRECTIONAL CONTROL VALVE When the Radio Remote switch is turned on: • the radio remote enable solenoid is energized. Description • all solenoid valves on each section act as proportional The directional control valve (Figure 2-2 and 2-3) is located control valves.

  • Page 53: Maintenance

    900H SERVICE MANUAL HYDRAULIC SYSTEM Maintenance It is only necessary to hold hydraulic pressure long enough (usually a few seconds) in the circuit to gain an accurate Relief pressures are checked by causing a given circuit to reading. Do not overload the hydraulic circuits for long reach its pressure limit (stall).

  • Page 54: Swing

    HYDRAULIC SYSTEM 900H SERVICE MANUAL Start the engine and set to governed rpm. Activate the swing control lever. The relief should read 2975 psi (+100/-50 psi) (20511 kPa (+689/-344 kPa)). The relief valves are in the directional control valve and are preset.

  • Page 55: Outriggers Beam Extend

    900H SERVICE MANUAL HYDRAULIC SYSTEM Extend Hose Retract Hose FIGURE 2-7 FIGURE 2-9 Single Front Outrigger (SFO) Disconnect the single front outrigger extend and retract lines (Figure 2-10). Cap the retract line and install a gauge in the extend line. Start engine and set at governed rpm.

  • Page 56: Hydraulic Remote Control Pressure Setting

    HYDRAULIC SYSTEM 900H SERVICE MANUAL Hydraulic Remote Control Pressure Setting HRC Pressure Gauge Port Check the hydraulic remote control (HRC) pressure with the HRC Relief Valve crane function power switch and the optional radio remote switch off. To check the pressure do the following: Connect a pressure gauge to the HRC gauge port on the DCV.

  • Page 57: Supply Circuit

    900H SERVICE MANUAL HYDRAULIC SYSTEM SUPPLY CIRCUIT A large access cover on the top of the reservoir provides access for cleaning. The cover is secured to the top of the Description reservoir with screws and has a gasket to prevent leaking. The access hole can also be used to fill the reservoir after it The supply pressure and return circuit routes hydraulic oil has been completely drained.

  • Page 58: Hydraulic Valves

    HYDRAULIC SYSTEM 900H SERVICE MANUAL Inspection Inspect the DCV for visible damage, binding spools, and evidence of leakage. If excessive internal leakage is Hydraulic Oil suspected during operation with a spool in its center position, Cooler it is possible that the area between the spool and working section bore of the valve body is worn beyond serviceable limits.

  • Page 59: Hydraulic Remote Controllers

    900H SERVICE MANUAL HYDRAULIC SYSTEM Directional Control Valve Manifold Outrigger Manifolds The outrigger circuits are controlled by two manifolds located Removal at the front and rear outrigger boxes. The front manifold Tag and disconnect the hydraulic and electrical lines contains the extend/retract valve for front and rear from the valve manifold.

  • Page 60: Hydraulic Pump Service

    HYDRAULIC SYSTEM 900H SERVICE MANUAL FIGURE 2-15 Case Drain Rear Pump Mounting Strap To Directional From Tank Control Valve Pump Manifold To Tank Pump Load Sense To Front Outrigger Manifold Manifold HYDRAULIC PUMP SERVICE Bolt the pump to the PTO mounting flange. Bolt the pump rear mounting bracket to the rear Description mounting strap.

  • Page 61: Trouble Diagnosis

    Check the maximum pump pressure and adjust as solution. These are not all inclusive but are designed to help necessary. isolate the problem and should be checked before calling Manitowoc Crane Care. National Crane 2-23 04-15-2020 Control # 477-01...
  • Page 62 HYDRAULIC SYSTEM 900H SERVICE MANUAL Troubleshooting Chart CONDITION ITEM POSSIBLE CAUSE POSSIBLE SOLUTION Insufficient hydraulic fluid causes Check fluid level in reservoir. Fill the reservoir to proper level. cavitation. Air in system causes noisy, Purge air and tighten fittings. Check for air in system. erratic control.
  • Page 63 900H SERVICE MANUAL HYDRAULIC SYSTEM Troubleshooting Chart (Continued) CONDITION ITEM POSSIBLE CAUSE POSSIBLE SOLUTION Insufficient volume of hydraulic Check fluid level in reservoir. fluid will not meet cooling Fill reservoir to proper level. demands of system. Inspect heat exchanger. Check Insufficient air flow, high input air air flow and input air temperature, or undersized heat...
  • Page 64 HYDRAULIC SYSTEM 900H SERVICE MANUAL Troubleshooting Chart (Continued) CONDITION ITEM POSSIBLE CAUSE POSSIBLE SOLUTION Activate pressure compensation Air in system causes erratic allowing system to bleed air. Check for air in system. operation. Check inlet line for leaks and eliminate source of air ingression. Sticking control spools cause Inspect spools for free movement Check control spools.
  • Page 65 900H SERVICE MANUAL HYDRAULIC SYSTEM Troubleshooting Chart (Continued) CONDITION ITEM POSSIBLE CAUSE POSSIBLE SOLUTION Low temperature increases Allow system to warm up before Check fluid temperature. viscosity. High fluid viscosity operating. causes high inlet vacuum. High inlet Vacuum Blocked or restricted inlet Caution Inspect inlet screen.
  • Page 66 HYDRAULIC SYSTEM 900H SERVICE MANUAL THIS PAGE BLANK 2-28 04-15-2020 Control # 477-01...

  • Page 67: Section 3

    900H SERVICE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM SECTION CONTENTS Description ....... 3-1 Troubleshooting .

  • Page 68: Comparing Electrical System To A Hydraulic System

    ELECTRIC SYSTEM 900H SERVICE MANUAL General Maintenance Introduction Resistance - any resistance to flow of electrons in an electrical circuit, measured in Ohms. Electrical system maintenance includes troubleshooting and Ohm’s Law - Electric current increases in direct relation to replacement of damaged components. Observe standard the voltage and decreases in relation to the amount of wiring practices when replacing components.

  • Page 69: Troubleshooting Electrical System

    900H SERVICE MANUAL ELECTRIC SYSTEM cleaner or fine sandpaper to clean them. When the pins or possible. After cutting the pin or socket off, the wire will most sockets show signs of arcing or burning, it will probably be likely be too short. Using a wire that is too short will allow necessary to replace them.

  • Page 70: Ignition Switch

    ELECTRIC SYSTEM 900H SERVICE MANUAL Ignition Switch RCL SYSTEM DESCRIPTION There are two ignition switches on the crane. One is in the The RCL monitors crane operation and alerts the operator of truck cab and the other one is on the EasyReach console. stability or structural limits based on the load chart.
  • Page 71 900H SERVICE MANUAL ELECTRIC SYSTEM A2B Cable Reel Switch A2B Weight Rear of Boom A2B Cable FIGURE 3-2 National Crane 04-15-2020 Control # 477-01...

  • Page 72: Micro Relay/Fuse Block

    ELECTRIC SYSTEM 900H SERVICE MANUAL MICRO RELAY/FUSE BLOCK Loosen the four wing nuts and remove the access panel to gain access to the fuse compartment, control module, T h e r e i s o n e r e l a y / f u s e b l o c k l o c a t e d i n t h e f u s e interface connector and the RCL override keyswitch.

  • Page 73: Directional Control Valve Solenoids

    900H SERVICE MANUAL ELECTRIC SYSTEM DIRECTIONAL CONTROL VALVE SOLENOIDS The solenoids on the directional control valve (DCV) manifold are used to control the mode of operation of the Hoist Jog Switch valve. There are two modes of operation for the valve: •...
  • Page 74 ELECTRIC SYSTEM 900H SERVICE MANUAL Item Solenoid Beam Extend Relief Valve Beam Extend Relief Solenoid Driver Side (Left) Beam Center Front Jack (SFO) (Optional) Passenger Side (Right) Jack Passenger Side (Right) Beam Driver Side (Left) Jack Extend Retract FIGURE 3-7 Front Outrigger Manifold Item Solenoid...

  • Page 75: Rear Outrigger Manifold

    900H SERVICE MANUAL ELECTRIC SYSTEM Rear Outrigger Manifold oil is routed through the cooler when it is cold than when it is hot. The solenoids on the rear outrigger manifold control the rear The cooler electrical system is made up of the following: outrigger components.

  • Page 76: Rcl Communication Overview

    ELECTRIC SYSTEM 900H SERVICE MANUAL RCL COMMUNICATION OVERVIEW • Elimination of a large bundle of wires • Down loading to a laptop computer The RCL needs to communicate with the various sensors, switches, and transducers on the crane in order to perform •...
  • Page 77 900H SERVICE MANUAL ELECTRIC SYSTEM Control Module 2 Computer Interface Crane Frame Connector Display Module EasyReach Fuse/Relay Box EasyReach Control Module 1 Main CAN line Termination Resistor EasyReach Control Module 2 RCL Master and Control Module 3 Crane Frame RCL Sensors and Termination Resistor Under Boom Master Control...

  • Page 78: Troubleshooting

    ELECTRIC SYSTEM 900H SERVICE MANUAL Troubleshooting Main Sensor Calibration Menu 7623-33 This machine incorporates a CANbus Multiplex system. In order to effectively troubleshoot the electrical system, you need a Windows-based PC, CAN-link service software (9999102409), and a connection cable (9999102296). The CAN-link service software and connection cable may be ordered from CraneCARE.

  • Page 79: Boom Angle Calibration

    900H SERVICE MANUAL ELECTRIC SYSTEM Slew Sensor Calibration position. Once the boom is positioned and OK is pressed the next calibration position will be activated. 7655-9 Move boom to 0° position then press OK. Move boom to 40° position then press OK. Move boom to 65°...

  • Page 80: Base Side Pressure Sensor Calibration

    The Main Load Chart Calibration and the Calibration Chart are downloaded to the RCL system using a laptop computer connected to the crane control system through the Diagnostic Connector (1, Figure 3-11). Contact Manitowoc Crane Care for the required software and cables for the crane interface.

  • Page 81: System Configuration (Current Rcl Version)

    900H SERVICE MANUAL ELECTRIC SYSTEM Once enabled, the display will return to the sensor calibration menu. SYSTEM CONFIGURATION (CURRENT RCL VERSION) Use the following procedure to access the System Configuration Menu. The System Configuration menu is where the functions shown in Table 3-4 can be accessed. Table 3-4 System Configuration Menu Icons Icon Description...

  • Page 82: Uploading Charts

    Uploading Charts Use the following procedure to upload charts to the RCL system. Connect a laptop computer to the crane control system. Contact Manitowoc Crane Care or your National Crane distributor for the required software and cables for the crane interface.

  • Page 83: Setting System Date And Time

    900H SERVICE MANUAL ELECTRIC SYSTEM DANGER Incorrectly installed RCL software could prevent the RCL from working properly. Overloading the crane could occur resulting in tip over or structural failure. Death or serious injury could occur. If not already done, copy the updated RCL software onto a USB flash drive.

  • Page 84: Rcl Sensor Calibration (Current Rcl Version)

    ELECTRIC SYSTEM 900H SERVICE MANUAL In the System Configuration menu, select the Time Set Table 3-6 Sensor Calibration Warnings icon Icon Description The Time Set screen appears. Slew Angle — Indicates that the slew sensor needs to be calibrated. Boom Angle — Indicates that the boom angle sensor needs to be calibrated.

  • Page 85: Accessing The Sensor Calibration Menu

    900H SERVICE MANUAL ELECTRIC SYSTEM Calibrating the Slew Sensor Table 3-7 Sensor Calibration Options (Continued) Icon Description The slew sensor requires calibration in the following Boom Length — Use this option to calibrate circumstances: the boom length sensor. For more •...

  • Page 86: Calibrating The Boom Length

    ELECTRIC SYSTEM 900H SERVICE MANUAL Four calibration positions are shown one at a time starting After OK is pressed for the fully retracted position, the fully with the 0° position on the Boom Angle Calibration screen. extended position is activated and appears. After OK is pressed for the 0°...
  • Page 87 900H SERVICE MANUAL ELECTRIC SYSTEM In the Main Sensor Calibration Menu screen, highlight the rod side pressure transducer icon (lower left of the Sensor Calibration icon group). Press the OK function key. The Rod Side Transducer Calibration screen appears. Rod Side Base Side 10081 FIGURE 3-14...

  • Page 88: Calibrating The Outrigger Span/Length

    ELECTRIC SYSTEM 900H SERVICE MANUAL sensor corresponding beam should be checked for proper Press the OK function key. function and wiring. When prompted, reconnect the base side hydraulic line For information about setting the outriggers, see “Outrigger (2) on the transducer block (3). Setup”...

  • Page 89: Theory Of Operation

    900H SERVICE MANUAL BOOM MAINTENANCE SECTION 4 BOOM MAINTENANCE SECTION CONTENTS Theory of Operation ......4-1 Boom Section Installation ..4-10 Boom Removal from Truck .
  • Page 90 BOOM MAINTENANCE 900H SERVICE MANUAL FIGURE 4-2 Item Component Telescope cylinder attach point for the 3 boom section. Proportioning cable attach point. Attach point at the rear of the 2 boom section for the 4 boom section extend cables. Attach point at the rear of the 4 boom section for the 4 boom section extend cables.

  • Page 91: Boom Removal From Truck

    900H SERVICE MANUAL BOOM MAINTENANCE Proportioning cable Sheave at Front of 2 Section. Proportioning Cable Boom Attach Point at Rear Pivot Pin of 2 Section FIGURE 4-3 Lift Cylinder Pivot Pin Turret BOOM REMOVAL FROM TRUCK The boom and hoist are remove from the truck as one assembly.

  • Page 92: Nd , 3 Rd , 4 Th Boom Section Removal

    BOOM MAINTENANCE 900H SERVICE MANUAL Upper Wear Pad DANGER Do not, under any circumstances, work at an elevated height without using proper fall protection as required by local, state or federal regulations. NOTE: The hoist can be removed to facilitate disassembly, Proportion but it is not required.

  • Page 93: Additional Maintenance, Disassembled Boom

    900H SERVICE MANUAL BOOM MAINTENANCE NOTE: The lock bar constrains the vertical movement of 16. Slide the 4 section out of the 2 section. The side the extend cylinder. pads may need to be removed. Tag and remove the side pads and shims if required.
  • Page 94 BOOM MAINTENANCE 900H SERVICE MANUAL Rear of 4 Section Cap Screws Right Side Wear Pad FIGURE 4-7 Install the 4 section boom into the 3 section. Slide in until about 5 feet (150 cm) of the 4 section extends from the 3 section.

  • Page 95: Extend/Retract Cable Installation

    900H SERVICE MANUAL BOOM MAINTENANCE Install the front side wear pads and shims between the Install the cable retainer pin into the anchor plate. and 3 sections. d. Place the uncoiled cable in a safe area to prevent damage (Figure 4-9). NOTE: For boom reassembly with no new sections, reinstall shims per removal tags.

  • Page 96: Telescope Cylinder Installation

    BOOM MAINTENANCE 900H SERVICE MANUAL Anchor Plate Assembly Cable Retainer FIGURE 4-11 FIGURE 4-13 Wear Pad Telescope Cylinder Installation Plate Install the sheave wheels on the telescope cylinder. The Shims holes in the end of the pin must be located as shown in (Figure 4-14).

  • Page 97: Nd /3 Rd /4 Th Boom Section Installation

    900H SERVICE MANUAL BOOM MAINTENANCE Cap Screws FIGURE 4-15 Install the telescope cylinder the rest of the way into the boom assembly. Base End of 2 Section Insert the extend cable anchor assembly into the base end of the 2 section (Figure 4-16).

  • Page 98: Cable Tensioning

    BOOM MAINTENANCE 900H SERVICE MANUAL CABLE TENSIONING Washer NOTE: The boom must be horizontal to get proper tension Cap Screw on the cables. Shim A boom assembly is considered properly timed when (as required) telescoping sections extend equally relative to each other and bottom out simultaneously at full retraction and do not spring back out after retract pressure is returned to neutral.

  • Page 99: Cable Tension Sequence

    900H SERVICE MANUAL BOOM MAINTENANCE 8860-5 8860-6 FIGURE 4-19 Cable Tension Sequence 432 retract cables. Four section boom with one stage cylinder. Four section boom with two stage cylinder. Cable tensioning to be in the following order: Cable tensioning to be in the following order: 123 extend cables.
  • Page 100 BOOM MAINTENANCE 900H SERVICE MANUAL Tighten 321 retract cable located at the front bottom of 234 and 432 cable balancing the base section the difference in the extension gap Extension measurements. Measure the extension gaps between the third and Extend and retract the boom a few times and then fourth section and the second and third section.

  • Page 101: 4- Section Boom W/ 1 Stage Cylinder Cable Positioning

    900H SERVICE MANUAL BOOM MAINTENANCE 4- Section Boom w/ 1 Stage Cylinder Cable Positioning 2/3/4 EXTEND 1/2/3 EXTEND BASE 1ST STAGE 2ND STAGE 3RD STAGE 4th STAGE 8860-3 4/3/2 RETRACT 3/2/1 RETRACT FIGURE 4-21 Cable Tightening Sequence 4 Section Boom with (1) Tighten the 321 retract cable located at the front bottom of the base section the difference in the retraction gap Stage Extend Cylinder...

  • Page 102: Cable Retention

    BOOM MAINTENANCE 900H SERVICE MANUAL Retraction Extend and retract the boom a few times and then repeat measuring the retraction gaps. Measure the retraction gaps between the second and The fourth section should have moved in. third section and the third and fourth section. Tightening until the retraction gap between the third and If the retraction gap is greater between the third and fourth fourth section is equal to the retraction gap between the...

  • Page 103: Boom Installation On The Truck

    900H SERVICE MANUAL BOOM MAINTENANCE BOOM INSTALLATION ON THE TRUCK TORQUE VALUES for Second Nut: Inch Series with Coarse Threads (UNC) CAUTION Minimum Cable end TORQUE Fall Hazard! Nut Type Thread Size Strength ft lbf Do not, under any circumstances, work at an elevated GRADE height without using proper fall protection as required by Hex Jam...
  • Page 104 BOOM MAINTENANCE 900H SERVICE MANUAL THIS PAGE BLANK 4-16 04-15-2020 Control # 477-01...

  • Page 105: Section 5

    900H SERVICE MANUAL HOIST SECTION 5 HOIST SECTION CONTENTS Description ....... 5-1 Programming the 3rd Wrap Indicator (Optional) .

  • Page 106: Maintenance

    HOIST 900H SERVICE MANUAL MAINTENANCE Inspect the hoist daily for oil leaks, loose bolts, and worn hoist cable. Check the gearbox and brake oil every 500 hours. Do an oil change every 1000 hours. Refer to Lubrication, page 8-1. Inspect the hoist from the deck of the crane.

  • Page 107: Drum Rotation Indicator

    900H SERVICE MANUAL HOIST Reinstall the hydraulic hoses as per removal tags. DRUM ROTATION INDICATOR Retaining Screws The drum rotation indicator (DRI) is located on the left side of the hoist and transmits a rotation signal to a solenoid (thumb thumper) located in the hoist control lever on the operator’s control panel.

  • Page 108: Programming The 3Rd Wrap Indicator (Optional)

    HOIST 900H SERVICE MANUAL With a ballpoint pen or small punch, push and hold the learn button (Figure 5-6) and return power to the 3rd wrap indicator by reconnecting the DRI cable. Release the DRI learn button. Breather Run the hoist to the start of the second layer. Press and hold the learn button for a few seconds.

  • Page 109: Reassembly

    900H SERVICE MANUAL HOIST Reassembly Remove the brake sub-assembly from the hoist by removing the eight capscrews (9) holding the brake NOTE: See Figure 5-9 for item number identification. housing to the side plate (41). Re-install two of these capscrews into the two extra tapped holes and tighten Thoroughly clean all parts.

  • Page 110: Hoist Service

    HOIST 900H SERVICE MANUAL HOIST SERVICE 13. Install the stator plates (19) and friction discs (18) into the brake housing starting with a stator and alternating Brake friction discs and stator plates. There is one more stator plate than friction disc so the last item installed is a stator NOTE: See Figure 5-9 for item number identification.
  • Page 111 900H SERVICE MANUAL HOIST 302 10 308 303 24 7155 FIGURE 5-9 National Crane 04-15-2020 Control # 477-01...
  • Page 112 HOIST 900H SERVICE MANUAL Item Quantity Description Item Quantity Description Plate, Side NCC Label Capscrew Capscrew Snap Ring Screw, Buttonhead Gear Set Cord Set Drum Housing Fitting, Tee Race, Bearing Fitting, Straight Adapter Gear, Input Sun Fitting, Reducer Hose Assy Capscrew Brake Piston Fitting, Tee Adapter...

  • Page 113: Planetary Set

    900H SERVICE MANUAL HOIST Planetary Set Motor NOTE: See Figure 5-9 for item number identification. Remove the hose and the counterbalance block (42) from the motor assembly. Remove the spiral retaining rings from the planet pins. To remove the counterbalance block (42), loosen and Remove the pins from the carrier by carefully tapping remove the 4 capscrews (55).
  • Page 114 HOIST 900H SERVICE MANUAL THIS PAGE BLANK 5-10 04-15-2020 Control # 477-01...

  • Page 115: Section 6

    900H SERVICE MANUAL SWING SECTION 6 SWING SECTION CONTENTS Description ....... 6-1 Assembly .
  • Page 116 SWING 900H SERVICE MANUAL Item Component Pinion Gear Swing Gearbox Swing Motor Swing Brake Release Line Swing Speed Control Swing Control Valve Swing Brake Oil Level Plug Oil Fill/Breather Pinion Bearing Grease Fitting Oil Drain Plug FIGURE 6-1 04-15-2020 Control # 477-01...
  • Page 117 900H SERVICE MANUAL SWING Breather Grease Fitting Fill Plug Level Plug Output Planetary Gear Set Input Planetary Gear Set FIGURE 6-2 Item Component Item Component Brake Mounting Capscrews (8) Gearbox Housing Drain Plug Pinion Shaft Output Planetary Gear Set Outboard Seal Retaining Washer Outboard Bearing Output Planetary Pin...

  • Page 118: Swing Gearbox And Brake

    SWING 900H SERVICE MANUAL SWING GEARBOX AND BRAKE Remove the race (11a) from the input planetary assembly (13). The swing drive is a double planetary gear set with an Install three 1/4” eyebolts into the three planet pins of the integral brake.

  • Page 119: Pinion Shaft Repair

    900H SERVICE MANUAL SWING Pinion Shaft Repair preload is determined by the rolling torque method. This method involves increasing press load on the bearings (See Figure 6-2 for reference numbers.) (4 and 7) until drag or rolling resistance of 75 to 85 in-lb (8.4 to 9.6 Nm) is achieved when rotating the case.

  • Page 120: Swing Brake

    SWING 900H SERVICE MANUAL FIGURE 6-3 Item Component Item Component Brake Housing Spring Stator Plate Brake Driver Friction Disc Retaining Ring Back-up Ring End Plate O-Ring O-Ring Brake Housing O-Ring O-Ring Brake Mounting Capscrews (8) Back-up Ring Drain Plug Brake Piston Brake End Plate End Plate Capscrews (8) SWING BRAKE...

  • Page 121: Assembly

    900H SERVICE MANUAL SWING Connect a port-a-power or other hydraulic pressure source to the brake release port and slowly apply 0.080 in (2 mm) pressure until the brake piston (8) clears the brake 0.085 in (2.16 mm) housing (1). NOTE: Replace if the NOTE: Note the position of the dowel-pin hole with respect thickness is below...

  • Page 122: Swing Bearing

    SWING 900H SERVICE MANUAL TORQUING SWING BEARING BOLTS Bolt the brake end plate (18) to the brake housing (1) with the capscrews (19). Alternately tighten the General capscrews one turn at a time until the cover is tight against the brake housing. NOTE: This keeps the pressure on the end plate WARNING...
  • Page 123 900H SERVICE MANUAL SWING FIGURE 6-6 Inner Race Outer Race FIGURE 6-7 National Crane 04-15-2020 Control # 477-01...

  • Page 124: Torque Values

    SWING 900H SERVICE MANUAL Torque Values Place the dial on the top of the swing bearing (Figure 6-8). Torque all swing bearing bolts to a final torque of 600 lb-ft Power the boom down onto the boom rest. ±60 lb-ft (813 Nm ±81 Nm). Set the dial indicator at zero.

  • Page 125: Bearing Replacement

    900H SERVICE MANUAL SWING FIGURE 6-9 BEARING REPLACEMENT Attach a suitable lifting device to the turret. Remove any slack in the sling. Do not pull up on the turret. Removal DANGER Fully extend and set the outriggers enough to take up the slack in the pads.

  • Page 126: Installation

    SWING 900H SERVICE MANUAL Carefully lift the turret with bearing off the truck and set it on blocking that will not allow the turret to tilt or shift. Leave the lifting device attached. NOTE: If the current bearing is to be reinstalled, mark the position of the bearing on the turret before removal.

  • Page 127: Slew Potentiometer Calibration

    900H SERVICE MANUAL SWING Slew Potentiometer FIGURE 6-11 Slew Potentiometer Calibration Go to the RCL slew angle calibrate screen as described in the RCL service manual. The slew potentiometer (slew pot) located inside the turret, is Rotate the slew pot gear until the reading on the RCL is used by the RCL to determine swing position and limits the 0°...
  • Page 128 SWING 900H SERVICE MANUAL THIS PAGE BLANK 6-14 04-15-2020 Control # 477-01...

  • Page 129: Section 7

    900H SERVICE MANUAL OUTRIGGERS SECTION 7 OUTRIGGERS SECTION CONTENTS Description ....... 7-1 RSOD Assembly .

  • Page 130: Outrigger Beam Removal

    OUTRIGGERS 900H SERVICE MANUAL FIGURE 7-1 Item Component Item Component Stabilizer Cylinder Extension Cylinder Bolts Outrigger Box Side Wear Pad (One Side) Outrigger Beam Top Wear Pads Outrigger Box Bottom Wear Pads Outrigger Beam Side Wear Pad (Both Sides) Outrigger Beam Outrigger Box Access Hole (Outrigger Beam) Outrigger End Plate (Outrigger Box)

  • Page 131: Inspection

    900H SERVICE MANUAL OUTRIGGERS FIGURE 7-3 Use lifting straps. Do not use chains. Blocking material must be capable of supporting the outrigger beam. FIGURE 7-4 Item Component Outrigger End Plate DANGER End Plate Bolt Crushing Hazard! Outrigger Hydraulic Tubes Extension Cylinder Bolts Blocking material must be able to support the outrigger beam and not allow the beam to tilt or slide.

  • Page 132: Extension Cylinder

    OUTRIGGERS 900H SERVICE MANUAL Adjust the wear pads as described in Wear Pad Remove the rod end of the extension cylinder (5) from Adjustment, page 7-5. the keyhole on the stabilizer end of the outrigger beam. Retract the outrigger after wear pad adjustment. Slide the extension cylinder out from the outrigger beam.

  • Page 133: Stabilizer Cylinder

    900H SERVICE MANUAL OUTRIGGERS Installation outrigger beam and are adjusted from inside the outrigger box. Reconnect the hydraulic hoses for the stabilizer cylinder to the base of the extension cylinder per removal tags. Outrigger Beam Wear Pad Adjustment Secure the stabilizer hydraulic hoses to the extend Wear pad adjustment is as follows: cylinder with the clamps as shown in Figure 7-5.

  • Page 134: Rear Outriggers (Rsod)

    OUTRIGGERS 900H SERVICE MANUAL pedestal. When the outrigger extension is activated the selected beam or stabilizer is extended or retracted. Extension Cylinder Bolts RSOD Assembly The RSOD assembly consists of the following: • outrigger beams • stabilizers • required hoses and mounting hardware •...

  • Page 135: Extension Cylinder

    900H SERVICE MANUAL OUTRIGGERS Remove the extension cylinder from the outrigger beam. Installation Slide the extension cylinder into the outrigger beam. Install the extension cylinder wear pads. Install the cylinder rod pin. RSOD Stabilizers The RSOD stabilizers extend down to provide stability for crane operation.

  • Page 136: Outrigger Monitoring System (Oms) (Optional-Standard In North America)

    OUTRIGGERS 900H SERVICE MANUAL OUTRIGGER MONITORING SYSTEM (OMS) (OPTIONAL—STANDARD IN NORTH AMERICA) Description The outrigger monitoring system (OMS) utilizes string potentiometers to monitor the outrigger’s extension beam positions together with the RCL. Four monitoring string potentiometers are used on the crane, one at the end of each outrigger extension beam to monitor if beams are at full, mid or retracted positions.

  • Page 137: Installation

    900H SERVICE MANUAL OUTRIGGERS NOTE: prevent damage string Attach the OMS string potentiometer connector (2) to potentiometer, do not allow the cable (3) to retract the attaching point on the outrigger beam. freely. NOTE: prevent damage string Disconnect the electrical cable (6) connector and secure potentiometer, do not allow the cable to retract to avoid damage.
  • Page 138 OUTRIGGERS 900H SERVICE MANUAL THIS PAGE BLANK 7-10 04-15-2020 Control # 477-01...

  • Page 139: Section 8

    Potentially harmful waste used in National Cranes includes products. Where questions arise, contact your National — but is not limited to — oil, fuel, grease, coolant, air Crane Distributor or Manitowoc Crane Care. National Crane 04-15-2020 Control # 477-01...

  • Page 140: Arctic Conditions Below -9°C (15°F)

    If you are in doubt about the +10°C (+50°F) suitability of a specific fluid, check with your authorized National Cranes distributor or Manitowoc Crane Care. Open Gear Lubricant NOTE: All fluids and lubricants may be purchased by...

  • Page 141: Arctic Hydraulic Oil

    ISO 17/14 or better cleanliness Arctic Hydraulic Oil level and must meet John Deere Standard JDM J20C. Contact your National Crane distributor or Manitowoc Crane Temperature Down to -9°C (15°F) to -29°C (-20°F) Care if you have any questions.
  • Page 142 LUBRICATION 900H SERVICE MANUAL Worn grease fittings that do not hold a grease gun, or those that have a stuck check ball, must be replaced. DANGER When wear pads or rotation bearings are lubricated, cycle Do not, under any circumstances, work at an elevated the components and lubricate again to ensure complete lubrication of the entire wear area.

  • Page 143: Lubrication Points

    900H SERVICE MANUAL LUBRICATION Lubrication Points Oil Fill/Breather Oil Level 7141-1A FIGURE 8-1 Table 8-1: Lubrication Intervals Recommended Item Application Procedure Frequency Lubricant Weekly As Required Semi- Hydraulic oil reservoir HYDO Check fill change Annually After first 40 Hrs. Quarterly Oil filter, Hydraulic oil reservoir Change or clean thereafter.

  • Page 144: Internal Cable Sheave Lubrication

    4 section. Apply • Contact Manitowoc Crane Care to obtain this tip. grease to the 4 section wear pads with a grease gun. Lubrication of the extend and retract sheaves is as follows: Raise the boom to at least 75°.

  • Page 145: Outrigger Beam Lubrication

    900H SERVICE MANUAL LUBRICATION Raise the boom to 75° and retract the boom. Repeat as necessary. Extend and retract the boom several times until the grease is evenly spread. Item Description Boom Section Access Holes for 4 Section Wear Pad Access Holes for 3 Section Wear Pad Access Holes for 2...

  • Page 146: Hoist Gearbox Oil Level Check

    LUBRICATION 900H SERVICE MANUAL Hoist Gearbox Oil Level Check should be visible within the bottom of the inspection hole. If more fluid is needed, add through the brake oil vent and fill To check the hoist gearbox oil level: plug hole until oil is at the bottom level of the inspection hole. •...

  • Page 147: 900H Hydraulic Oil Reservoir Level

    900H SERVICE MANUAL LUBRICATION WIRE ROPE LUBRICATION Wire rope is lubricated during manufacture and the lubricant applied does not last the life of the rope. The wire rope must be lubricated as part of a regularly scheduled maintenance program. The lubricant applied must be compatible with the original lubricant and not hinder visual inspection of the rope.

  • Page 148: Carwell© Rust Inhibitor

    To help protect against corrosion of your National Crane, crane owners must provide proper maintenance and care to Manitowoc Crane Care recommends washing the crane at help ensure long-term protection of their crane against least monthly to remove all foreign matter. More frequent corrosion.

  • Page 149: Inspection And Repair

    To the extent any damage is structural in nature, potential issues before they grow into larger problems. Manitowoc Crane Care must be contacted and consulted as to what repairs may be required. CAUTION...

  • Page 150: Areas Of Application

    • Boom applications areas are: pivot pins, hose ends and Please contact Manitowoc Crane Care should you have any fittings, jib pins and shafts, all bare metal surfaces, questions. overhaul weight/ hookblock pins and fasteners. •...
  • Page 151 900H SERVICE MANUAL LUBRICATION National Crane 8-13 04-15-2020 Control # 477-01...
  • Page 152 LUBRICATION 900H SERVICE MANUAL Item Description Item Description Hook Block/Overhaul Weight Hoist Plumbing Connections O/R Hose Connections All Hardware, Clips, Pins, Unpainted Hose O/R Pins, Clips Connections Power Train Hardware Pivot Shaft Entire Underside of Unit Hose Connections Turntable Bearing Fasteners, Pins Mirror Mounting Hardware Valve Bank, Hose Connections Wire Rope...

  • Page 153: Section 9

    900H SERVICE MANUAL CRANE INSTALLATION SECTION 9 CRANE INSTALLATION SECTION CONTENTS General ........9-1 Install the Rear Bumper .
  • Page 154 CRANE INSTALLATION 900H SERVICE MANUAL • Wheelbase (WB), Cab-to-Trunnion (CT) and Cab-to- suspension must have the minimum SM and RBM Axle (CA) - The WB, CT and CA requirements are because reinforcing through the front suspension is determined by: often difficult because of engine, radiator mounts and steering mechanics.
  • Page 155 900H SERVICE MANUAL CRANE INSTALLATION Typical Location of Serial Number Identification Tags FORWARD Turret Frame 1st Section Boom 2nd Section 3rd Section Booms Boom Nose RSOD Stabilizer Lift Cylinder FIGURE 9-1 National Crane 04-15-2020 Control # 477-01...

  • Page 156: Mounting Configuration

    CRANE INSTALLATION 900H SERVICE MANUAL SFO Required 900H Minimum NOTE: Front SFO mount Measurements requires extended front frame rails on the truck. 9500 BARE Min 8800 BARE Min 40000 GARW MIN 20000 GARW MIN FIGURE 9-2 MOUNTING CONFIGURATION NOTE: Gross Vehicle Weight Rating...
  • Page 157 900H SERVICE MANUAL CRANE INSTALLATION 900H Dimensional Drawing FIGURE 9-3 Units in inches unless specified 9.95 7165 G in H in Weight lb 969H 66.9 53.7 18,206 995H 95.4 59.2 20,352 9105H 104.9 60.6 21,090 Weight and centers of gravity includes boom, hoist, rope, turret, lift cylinder, frame, controls, outriggers, platforms, torque box, boom rest, bumper, and downhaul weight.

  • Page 158: Pto And Hydraulic Pump

    CRANE INSTALLATION 900H SERVICE MANUAL PTO AND HYDRAULIC PUMP The engine must be operated at a speed such that the horsepower developed is adequate to run the pump under Horsepower pressure and provide the required flow. An axial piston pump is furnished with this crane. The pump Diesel Engine Optimum uses a load sense system to supply flow to the crane PTO Ratio...

  • Page 159: Truck Frame Strength

    900H SERVICE MANUAL CRANE INSTALLATION View from Rear of Truck Engine CCW Engine CCW PTO CCW PTO CW FIGURE 9-6 TRUCK FRAME STRENGTH section modulus [1,650,000 in-lb [186,424 N.m] RBM) at the front spring rear hanger, 10 in (163 cm ) section modulus [1,100,000 in-lb (124,283 N.m) RBM] through the front spring For a truck frame to be suitable for a Series 900H crane, the...
  • Page 160 CRANE INSTALLATION 900H SERVICE MANUAL NOTE: All dimensions are in (cm) (304) (274) (243) (213) (182) (152) (121) (91) (61) (30) FIGURE 9-7 The following tables determine the section modulus of the the section modulus of the channel obtained from truck frame.
  • Page 161 900H SERVICE MANUAL CRANE INSTALLATION TABLE A Section Modulus in Thickness 3/16 in. (4.76 mm) Thickness 1/4 in. (6.35 mm) W in. (mm) W in. (mm) D in. (mm) D in. (mm) 2.5 (64) 3 (76) 3.5 (89) 4 (102) 2.5 (64) 3 (76) 3.5 (89)
  • Page 162 CRANE INSTALLATION 900H SERVICE MANUAL TABLE B Section Modulus in Thickness 3/16 in. (4.76 mm) Thickness 1/4 in. (6.35 mm) W in. (mm) W in. (mm) D in. (mm) D in. (mm) 2.75 (70) 3.25 (83) 3.75 (95) 4.25 (108) 2.75 (70) 3.25 (83) 3.75 (95)

  • Page 163: Truck Preparation

    900H SERVICE MANUAL CRANE INSTALLATION TABLE D Section Modulus in Thickness 3/16 in. (4.76 mm) Thickness 1/4 in. (6.35 mm) W in. (mm) W in. (mm) D in. (mm) D in. (mm) 3 (76) 3.5 (89) 4 (102) 4.5 (114) 3 (76) 3.5 (89) 4 (102)

  • Page 164: Reinforcing After Frame Extension

    CRANE INSTALLATION 900H SERVICE MANUAL • Overhang - The amount of overhang allowed varies the pump must be supported regardless of the mounting from state to state. Check on your state requirements. method. • Federal Bridge Law - The Federal Bridge Law in effect NOTE: Some of the pipe fittings are sealed by means of currently states that in order to carry 54,000 lb (24,493...
  • Page 165 900H SERVICE MANUAL CRANE INSTALLATION FIGURE 9-8 Plan the location of the crane mounting anchors so they don’t Remove bolts, clamp on reinforcing, interfere with the bolts, etc. and mark the bolt hole location from the inside of the frame (Ref) Truck frame The bolt hole clearance is 1/16 (1.58) to 1/8 (3.17)
  • Page 166 CRANE INSTALLATION 900H SERVICE MANUAL 2 (51) Min 2 (51) Min 4 (101) 8 (203) Typ Note: All dimensions are in (mm) FIGURE 9-10 If the frame through the rear suspension does not meet Slide the reinforcing angle up from the bottom, butt it to the minimum specifications for RBM and section existing forward reinforcing and weld rear suspension modulus, it can be reinforced by adding a reinforcing...
  • Page 167 900H SERVICE MANUAL CRANE INSTALLATION Reinforcing under crane Cut outs Replace as much material as possible. Butt weld Butt weld Overload spring stop. Remove and replace. Weld 6 (152) Skip 6 (152) Weld 6 (152) Skip 6 (152) Weld 12 (304) Truck frame (REF) 6 (152) 6 (152)

  • Page 168: Mounting The Crane

    CRANE INSTALLATION 900H SERVICE MANUAL MOUNTING THE CRANE • Connect the electrical interface (9-23). • Install the hydraulic system (9-24). DANGER • Complete the initial crane run in procedure (9-28). It is mandatory that swing bearing and crane anchor bolts •...
  • Page 169 900H SERVICE MANUAL CRANE INSTALLATION Torsion Box (T-Box) Frame Assembly FIGURE 9-12 Tubes for the Anchor Bolts Note: The reinforcing plates must extend out past the RSOD mounting brackets. Reinforcing Plates T-Box Mounting Brackets for RSOD Outrigger Truck Frame FIGURE 9-13 National Crane 9-17 04-15-2020 Control # 477-01...

  • Page 170: Attach The Rsod

    CRANE INSTALLATION 900H SERVICE MANUAL T-Box 3/4 in Grade 8 Bolts for the Crane Anchor Brackets. Torque refer to Fasteners and Torque Truck Frame Values, page 1-11. FIGURE 9-14 Attach the RSOD Use the holes in the brackets as a template and drill three 5/8 in holes in each anchor bar.

  • Page 171: Mount The Frame Assembly

    900H SERVICE MANUAL CRANE INSTALLATION Weld Upper Brackets Gusset Upper Brackets Weld (both sides) Note: All welds must be.31, grade 70 or better. Weld Anchor Bars Gusset RSOD Gusset Mounting Brackets 5/8 in Grade 8 Bolts Torque refer to Fasteners and Torque Values.

  • Page 172: Install The Boom Rest

    CRANE INSTALLATION 900H SERVICE MANUAL Anchor Saw the Anchor Retaining Retaining Bracket to fit Bracket inside the truck frame. Truck Frame 1-1/8 in Grade 8 Front Anchor Bolts. Torque refer to Fasteners and Torque Values. Square Spacer 1-1/8 in - UNC Grade 8 Crane Anchor Bolts.

  • Page 173: Mount The Operator Platforms And Install The Foot Throttles

    900H SERVICE MANUAL CRANE INSTALLATION 3/4 in Grade 5 Bolts Boom Rest 5/8 in Grade 5 Note: Allow a 20 to 23 in Bolts (50.5 - 58.4 cm) ground clearance. Bumper FIGURE 9-17 Back Rest Foot Throttle Operator’s Platform Throttle Connector FIGURE 9-18 Mount the Operator Platforms and Install the...

  • Page 174: Install The Boom, Lift Cylinder, And Hoist

    CRANE INSTALLATION 900H SERVICE MANUAL Mount the throttle pedal on the platform as shown in NOTE: The RCL must be mounted as shown to get the (Figure 9-18). Plug the connector on the wiring harness into proper clearance. the throttle pedal. CAUTION Make sure there is adequate clearance between the RCL reel and adjacent components so that the RCL reel does...

  • Page 175: Connect The Slew Potentiometer

    900H SERVICE MANUAL CRANE INSTALLATION The bracket attached to the RCL reel must C-bracket be mounted on the top side of the C-bracket as shown Mounting Mount with the Connectors on the Bottom Clearance between the RCL reel and adjacent components must adequate so that no damage occurs when the boom is fully...

  • Page 176: Install The Hydraulic System

    CRANE INSTALLATION 900H SERVICE MANUAL Truck Battery Harness Wire Truck Function (-) Ground (+) Positive Truck Interface Harness Wire # Truck Function From Truck Ignition 901A To Truck Ignition To Truck Start PTO Mode Enable 1159 Remote Throttle 1592 Remote Throttle 1593 Remote Throttle FIGURE 9-23...
  • Page 177 900H SERVICE MANUAL CRANE INSTALLATION Hoist Up Hoist Down Case Drain Mounting Bolt (3X) Boom Down Boom Pilot Boom Up Note Notch Locations Telescope Retract Telescope Extend Bulkhead Plate (Top Side View) FIGURE 9-25 National Crane 9-25 04-15-2020 Control # 477-01...

  • Page 178: Front Outrigger Hydraulic Line Connections

    CRANE INSTALLATION 900H SERVICE MANUAL Front Outrigger Hydraulic Line Connections R = Retract Item Solenoid JE = Jack Extend Right Front Outrigger BE = Beam Extend Outrigger Enable Center Front Jack (SFO) (Optional) Passenger Side Stabilizer (Right) Passenger Side Beam (Right) Driver Side Beam (Left) Driver Side Stabilizer (Left) Extend/Retract...

  • Page 179: Rsod Hydraulic Line Connections

    900H SERVICE MANUAL CRANE INSTALLATION RSOD Hydraulic Line Connections Left Side From Front Outrigger Manifold Right Side JE = Jack Extend RSOD Manifold JR = Jack Retract BE = Beam Extend BR = Beam Retract NOTE: See page 3-9 for RSOD manifold detail.

  • Page 180: Can Bus System Setup

    CRANE INSTALLATION 900H SERVICE MANUAL CAN BUS SYSTEM SETUP Operate all crane functions and outriggers slowly at least six (6) times to purge cylinders of air. Check that Before the engine is started from the crane for the first time, the movement of the outriggers, boom, and hoist the CAN Bus system needs to be initialized.
  • Page 181 900H SERVICE MANUAL CRANE INSTALLATION counterweight. Extend the boom to the maximum boom For the stability test, select the load from the capacity chart extension and matches length and hoist the stability load off the ground. Slowly that is listed at the longest boom the radius listed below.

  • Page 182: Specifications

    CRANE INSTALLATION 900H SERVICE 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 (79.5 lpm) Boom Down..............

  • Page 183: Outrigger Speeds

    900H SERVICE MANUAL CRANE INSTALLATION Crane Operating Speeds Rotation 375°................. 48 ± 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 30 ft to 95 ft (Angle 60°) ........
  • Page 184 CRANE INSTALLATION 900H SERVICE MANUAL THIS PAGE BLANK 9-32 04-15-2020 Control # 477-01...

  • Page 185: Section 10

    900H SERVICE MANUAL SCHEMATICS SECTION 10 SCHEMATICS For your convenience, the latest version of schematics available at the time of printing are placed in this section. National Crane 10-1...
  • Page 186 SCHEMATICS 900H SERVICE MANUAL THIS PAGE BLANK 10-2...
  • Page 187 Alphabetical Index Boom Section Installation ........4-9 900H RCL CANbus .
  • Page 188 Swing Gearbox and Brake ..........6-4 System Configuration (Current RCL Version) .

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