Page 1 Manitowoc 999 Service/Maintenance Manual...
Page 3 NOTICE The serial number of the crane and applicable attachments (luffing jib) is the only method your Manitowoc dealer or the Manitowoc Crane Care Lattice Team has of providing you with correct parts and service information. The serial number is located on a crane identification plate attached to the operator’s cab and each attachment.
Page 4 THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH...
Page 5: Table Of Contents
Electrical Power to 999 Operator Cab ........
Page 6 TABLE OF CONTENTS 999 SERVICE/MAINTENANCE MANUAL Carbody Jacking System ............1-58 Left and Right Crawler Pin-Pusher Cylinders .
Page 7 999 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS RIN............... . 3-35 Accessory System .
Page 8 TABLE OF CONTENTS 999 SERVICE/MAINTENANCE MANUAL SECTION 6 ........... . Swing Manual Release of Swing Brake and Lock .
Page 9 999 SERVICE/MAINTENANCE MANUAL TABLE OF CONTENTS Guidelines..............10-2 Test Equipment .
Page 10 TABLE OF CONTENTS 999 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK TOC-vi Published 05-16-17, Control # 233-03...
Page 11 Electrical Power to 999 Operator Cab ........
Page 12 999 SERVICE/MAINTENANCE MANUAL Drum Brake and Pawl Switch ........... 1-31 Free Fall Brake/Clutch Operation .
Page 13: Continuous Innovation
Due to continuing product innovation, the information in this CAUTION manual is subject to change without notice. If you are in doubt about any procedure, contact your Manitowoc dealer Used with the safety alert symbol, indicates a hazardous or the Manitowoc Crane Care Lattice Team.
Page 14: Safe Maintenance Practices
Manitowoc cannot foresee all hazards that Never climb onto or off a moving crane. Climb onto and will arise in field; therefore, safety remains responsibil- off crane only when it is parked and only with 999 ity of maintenance personnel and crane owner. Operator permission.
Page 15: Environmental Protection
30. Store tools, oil cans, spare parts, and other necessary heavy-duty gloves to prevent being cut by broken wires. equipment in tool boxes. Do not allow these items to lie around loose in 999 Operator cab or on walkways and 20. Use extreme care when handling coiled pendants. stairs.
Page 16: Crane Operation
HS (hydraulic solenoid) number. The HS numbers ® The Model 999 operating system is an EPIC (Electrical identify actual hydraulic solenoid valves on the P r o c e s s e d I n d e p e n d e n t C o n t r o l ) . W i t h t h i s P C crane for training proposes only.
Page 17: Shut-Off Valve
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION temperatures, exposure to moisture or dust in work Supercharge pump is a fixed displacement gear pump that draws hydraulic fluid from suction manifold and supplies area, high contaminants in the fluid, or adding fluid make-up hydraulic fluid to supercharge filter manifold. Each of unlike viscosity or chemical composition.
Page 18: Main Pressure Monitoring
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL Table 1-1 System Pressure Settings SYSTEM LOAD DRUMS BOOM HOIST SWING TRAVEL FUNCTION Hoist (Port A) Lower (Port B) Down Left/Right Fwd./Rev. PRESSURE 6,090 3,770 6,090 3,770 6,090 6,090 psi (bar) (420) (260) (420) (260) (420)
Page 19 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION occurs on both sides of flow restrictor (21), pressure limiting 999CSM1-101 valve opens and system relief valve relieves system Control pressure. Hydraulic fluid is directed to tank through relief Voltage valve (3) or the flow is transferred to low-pressure side of system through make-up check valves (4).
Page 20: Engine Controls
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-102 Motor Pump M4 M3 350 psi (24 bar) Output Max. Disp. Input FIGURE 1-3 Engine Controls The travel motor servo is opposite of other system motors. Travel variable displacement motors begin operation at See engine manufacturer's manual for instructions.
Page 21: Epic Programmable Controller
Digital display screen shows operating conditions, operating fixed jib components and transmits information to the PC. limits, and system faults monitored by the PC. Access See RIN (Remote Input Node) Display Readings in 999 information by scrolling to the desired display screen with Operator Manual.
Page 22: Standard Mode
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL Boom, luffing jib, and fixed jib monitored components include the PC sends an output signal to pump EDC to decrease component angles, minimum/maximum angle limits, block- pump output flow. When control handle is moved to neutral up limits, and load sensors.
Page 23: Electrical Power To 999 Operator Cab
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Electrical Power to 999 Operator Cab position, power is available to the EPIC programmable computer, air conditioning relay (ACR), power relay (K1), Figure 1-5 engine control module relay (ECM), and start relay (MS1). When power relay K1 is enabled, power is available to...
Page 24: Pressure Senders And Encoders
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL Pressure Senders and Encoders system pressure, boom hoist system pressure, right/left travel system pressure, swing right/left system pressure and Figure 1-6 auxiliary drum system pressure. Electrical speed encoders monitor front and rear drum shaft, boom hoist drum shaft, Voltage is also available to hydraulic pressure senders and and auxiliary drum flange rotation.
Page 25: System Faults
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION System Faults MAIN CHARGE FILTER – Main charge filter is plugged, replace filter. Opens at 75 psi (5,2 bar). Figure 1-7 AUX DRUM CHRG FILTER – Auxiliary drum charge filter is The PC monitors and enables a red system fault light and plugged, replace filter.
Page 26: Operating Faults And Limit Switches
Limit bypass key switch (1) allows crane to be operated Brake and Drum Pawl Application/Release beyond the limits for crane setup or maintenance only. See Bypassable Limit Identification, Table 3-1 in Section 3 of 999 The load drums brakes and boom hoist drum brakes are Operator Manual.
Page 27 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION 999CSM1-107 ENGINE ENGINE STOP START STOP 50 AMP WD-19 DIGITAL DISPLAY WD-18 SYSTEM FAULT UP SCROLL WB-26 DOWN SCROLL WB-33 BUZZER CRANE MODE OPERATING LIMIT CONFIRM SELECT WB-09 BEEPER WB-10 SEAT SWITCH WB-34 LMI BUZZER P1B-11...
Page 28: Swing System Operation
See Swing Speed/Swing Torque diagnostic power is lost when operating, brakes spring-apply. screen on digital display in 999 Operator Manual. Before shutdown, place swing brake switch in on - park For swing brake and swing lock operation, charge pressure position.
Page 29: Swing Holding Brake Switch
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Swing Holding Brake Switch When swing handle is moved to right, an input voltage of 5 volts or less is sent to the PC. The PC sends a positive Swing holding brake switch (10) on side of swing handle, output voltage to swing pump EDC.
Page 30: Travel System Operation
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL TRAVEL SYSTEM OPERATION When left or right travel handle or pedal is moved in forward direction, an input voltage of 5 volts or more is sent to the PC. See Figures 1-11 1-12 The PC sends a positive output signal to selected travel pump EDC and enables travel brake release solenoid HS-11.
Page 31: Travel Detent Selector
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION 999CSM1-110 ENGINE STOP START STOP 50 AMP WA-01 REGULATED 10V DC OUTPUT SYSTEM FAULT REVERSE FORWARD LEFT TRAVEL HANDLE WA-07 BUZZER FORWARD REVERSE OPERATING LIMIT WA-06 RIGHT TRAVEL HANDLE BEEPER LEFT TRAVEL PEDAL WA-13 LEFT TRAVEL PUMP CONTROL...
Page 32 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-111 RIGHT TRAVEL PUMP FORWARD SHUTTLE VALVE RIGHT 350 PSI PILOT CHARGE PRESSURE PRESSURE FROM REAR DRUM PUMP (24 BAR) SENDER REVERSE SUCTION MANIFOLD PILOT PRESSURE FOR MOTOR SERVOS LEFT TRAVEL PUMP FORWARD HS-11 HS-12 SHUTTLE...
Page 33: Boom Hoist System Operation
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION BOOM HOIST SYSTEM OPERATION speed of boom hoist drum. As drum rotates faster, the indicator pulsates faster. See Figures 1-13 1-14 Continuous changing of closed-loop fluid occurs through Boom hoist handle (1) is inoperable when boom hoist brake leakage in pump, motor, and external sequence/flow valve (2) is applied.
Page 34: Boom Hoist Raise
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-113 BOOM HOIST PUMP LOW PRESSURE SIDE 350 PSI (24 BAR CHARGE PUMP HIGH PRESSURE SIDE SUPERCHARGE MANIFOLD SERVO PRESSURE FROM TRAVEL CHARGE PUMP BOOM HOIST DRUM BOOM HOIST BRAKE HS-14 6 GPM PAWL HS-13 LOW PRESSURE...
Page 35: Boom Stop Cylinders
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Boom Stop Cylinders also sends a signal to reduce the displacement of the motor. The PC is continuously balancing the system pressure and If boom is raised to 81°, springs in boom-stop cylinders slow the motor displacement angle so the motor displacement the boom opposite movement.
Page 36 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL The PC sends a positive output signal to stroke the boom As boom hoist handle is pushed forward, the PC sends a hoist pump momentarily in the up direction to satisfy signal to increase the boom hoist pump swashplate angle.
Page 37 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION 999CSM1-115 BOOM HOIST PUMP LOW PRESSURE SIDE 350 PSI (24 BAR CHARGE PUMP HIGH PRESSURE SIDE SUPERCHARGE MANIFOLD SERVO PRESSURE FROM TRAVEL CHARGE PUMP BOOM HOIST DRUM BOOM HOIST BRAKE HS-14 6 GPM PAWL HS-13 LOW PRESSURE...
Page 38: Front/Rear Drum System
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL FRONT/REAR DRUM SYSTEM Continuous changing of closed-loop fluid occurs through leakage in motor and external sequence/flow valve (7). See Figures 1-17 1-18 Sequence/flow valve opens at 200 psi (14 bar) and removes 6 GPM (23 L/min) of hot fluid from system by dumping fluid in The left drum handle (1) operates front drum while right drum the motor case where fluid returns to tank through cooler.
Page 39: Load Drum Brake And Pawl Switch
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION A high speed option is available for front/rear drums. This The PC requires that front drum pump strokes in hoist option allows increased fluid to two motors on tandem drive direction to satisfy pressure memory. The PC compares front shafts for driving the drum.
Page 40: Load Drum Lowering
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-117 FRONT OR REAR LOAD DRUM PUMP LOW PRESSURE SIDE 350 PSI (24 BAR CHARGE PUMP HIGH PRESSURE SIDE SUPERCHARGE REAR DRUM TO MANIFOLD LOW PRESSURE ACCESSORIES SERVO PRESSURE FROM TRAVEL CHARGE PUMP FRONT OR REAR...
Page 41 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION 999CSM1-118 ENGINE STOP STOP START 50 AMP REGULATED 10V DC OUTPUT WA-01 SYSTEM FAULT RAISE LOWER FRONT DRUM WA-03 BUZZER OPERATING LIMIT LOWER RAISE WA-04 REAR DRUM BEEPER BLOCK UP LIMITS FRONT DRUM WC-05 PUMP CONTROL...
Page 42: Luffing Jib Operation (Optional)
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL solenoid HS-16 to spring-apply brake before front drum engaged. Drum brake release solenoid HS-21 is spring- pump de-strokes. applied to auxiliary drum. When rear drum brake switch is placed in off - park position, drum pawl out solenoid HS-25 is Luffing Jib Operation (Optional) enabled and pawl is disengaged.
Page 43: Free Fall Mode (Optional)
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION FREE FALL MODE (OPTIONAL) Drum Brake and Pawl Switch See Figures 1-21, 1-22, and 1-23 When front drum (8) brake switch is in on - park position, front drum hoist brake release solenoid HS-16 is disabled so The front drum, rear drum or both drums can be equipped brake is spring-applied to drum.
Page 44: Free Fall Hoisting
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL Free Fall Hoisting See Figures 1-21, 1-22, and 1-23 WARNING The following description is for the front drum while operating in free fall. Operation of rear drum is the same, except for Falling Load Hazard! different drum, brake, pawl and brake/clutch. Front drum When operating in free fall, load will lower uncontrolled if hoisting in free fall operates the same as full power hoisting.
Page 45: Free Fall Lowering
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Free Fall Lowering See Figures 1-21, 1-22, and 1-25 WARNING The percent of free fall drum slip to brake/clutch pedal movement is calibrated on the free fall diagnostic display Falling Load Hazard! screen. When operating in free fall, load will lower uncontrolled if front drum brake/clutch pedal is not applied.
Page 46 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL When front drum handle (9) is moved to neutral after raising load, the PC disables front drum brake solenoid HS-16, CAUTION spring-applying front drum brake. When front drum brake is spring-applied, the PC sends an output signal to shift free fall...
Page 47 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION 999CSM1-124 ENGINE STOP STOP START 50 AMP REGULATED 10V DC OUTPUT WA-01 SYSTEM FAULT RAISE LOWER FRONT DRUM WA-03 BUZZER OPERATING LIMIT LOWER RAISE REAR DRUM WA-04 BEEPER FRONT DRUM WC-05 FRONT DRUM PEDAL WA-19 PUMP CONTROL...
Page 48 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-125 FRONT LOAD DRUM PUMP SIDE PUMP DRIVE GEARBOX 350 PSI (24 BAR) ENGINE HIGH SIDE SUPERCHARGE PUMPS MANIFOLD PRESSURE SENDER SERVO PRESSURE FROM BRAKE/CLUTCH TRAVEL CHARGE PUMP MANIFOLD FRONT LOAD DRUM BRAKE COOLING INLET MOTOR...
Page 49: Auxiliary Drum System (Optional)
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION AUXILIARY DRUM SYSTEM (OPTIONAL) When auxiliary drum handle is in neutral position, the PC receives no voltage from control handle, and the PC opens See Figures 1-26 1-27 the circuits to auxiliary drum pump EDC (2), motor PCP (6), and brake release solenoid HS-26.
Page 50: Auxiliary Drum Brake And Pawl Switch
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL Auxiliary Drum Brake and Pawl Switch charge pressure drops below 200 psi (14 bar), brakes spring- apply. When auxiliary drum brake switch (14) is in on - park position auxiliary drum pawl in solenoid HS-27 is enabled and pawl Auxiliary Drum Raise (11) is engaged.
Page 51: Auxiliary Drum Lower
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Auxiliary Drum Lower The PC requires that auxiliary drum pump strokes in hoist direction to satisfy pressure memory. The PC compares See Figures 1-28 1-29 auxiliary drum holding pressure to value stored in pressure memory. When auxiliary drum handle (1) is moved forward to lower,...
Page 52 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-128 ENGINE STOP START STOP 50 AMP WA-01 REGULATED 10V DC OUTPUT SYSTEM FAULT RAISE LOWER AUXILIARY HANDLE WA-09 BUZZER OPERATING LIMIT BLOCK UP LIMITS BEEPER WD-19 WE-36 DIGITAL DISPLAY WD-18 AUXILIARY DRUM UP SCROLL WB-26...
Page 53 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION 999CSM1-129 AUXILIARY DRUM PUMP LOW PRESSURE SIDE 350 PSI (24 BAR CHARGE PUMP HIGH PRESSURE SIDE SUPERCHARGE MANIFOLD HS-26 BRAKE AUXILIARY DRUM HS-28 LOW PRESSURE PAWL PILOT FIGURE 1-29 HS-27 Manitowoc 1-41 Published 05-16-17, Control # 233-03...
Page 54: Crane Setup Systems
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL CRANE SETUP SYSTEMS reducing valve to supply pilot pressure for shifting the spools. Upperworks accessory valve system includes boom pin See Figure 1-31 pusher cylinder (7), gantry cylinders (8), and mast raising cylinders (9) that are electrically enabled. When an...
Page 55: Gantry System
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Gantry System Each gantry cylinder (6) has a counterbalance valve (7) at each cylinder port. These valves ensure smooth control See Figures 1-32 1-33 when raising or lowering gantry and locks the cylinder in place when gantry is at a desired position or if a hydraulic The PC controls the gantry and mast raising sequence.
Page 56 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-130 GANTRY CYLINDERS MAST RAISING CYLINDERS 3,500 PSI (240 BAR) 3,500 PSI (240 BAR) BOOM HINGE CYLINDER LOAD EQUALIZING LOAD EQUALIZING VALVE VALVE 4,000 PSI (275 BAR) 4,000 PSI (275 BAR) LOW PRESSURE ACCESSORIES HIGH HIGH...
Page 57 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION To raise gantry in Crane Setup mode after rigging is installed, to block tank port and open port from low-pressure side of move boom hoist handle (1) all the way forward. The handle closed-loop to boom hoist brake cylinder spring, releasing neutral switch closes, sending an input voltage of 5 volts or brake.
Page 58 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL The PC sends a negative output voltage to rear drum pump T h e f r e e - f l o w c h e c k v a l v e s e c t i o n s o n s i d e “ B ” o f...
Page 59: Gantry Cylinders Lower
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Gantry Cylinders Lower releasing brake. The PC sends a negative output signal to enable boom hoist pump EDC that tilts pump swashplate to See Figures 1-34 1-35 stroke boom hoist pump in the raise direction. Place boom hoist brake switch (9) in off - park position. Boom...
Page 60 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-133 ENGINE STOP START STOP 50 AMP REGULATED 10V DC OUTPUT SYSTEM FAULT RAISE LOWER BOOM HOIST HANDLE WA-05 BUZZER OPERATING LIMIT WA-35 MAST ANGLE SENSOR WB-22 BEEPER GANTRY BOOM HOIST UP LIMIT WC-14 PUMP CONTROL...
Page 61 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION equalizing valves is approximately 2,670 psi (185 bar). control handle neutral switch opens, the PC sends an output Restraining section on side “A” of load equalizing valve signal to disable brake release solenoid HS-13 to spring- opens, controlling fluid out of both cylinders and ensuring apply brake before hoist pump de-strokes.
Page 62: Mast System
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL Mast System Mast accessory valve is “motor spool” where both cylinder ports and tank port of the valve spool section are connected See Figures 1-36 1-37 in center position. This type of spool prevents premature opening of equalizing valves (8). Hydraulic pressure for mast...
Page 63 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION 999CSM1-135 ENGINE STOP STOP START 50 AMP REGULATED 10V DC OUTPUT SYSTEM FAULT RAISE LOWER BOOM HOIST HANDLE WA-05 BUZZER OPERATING LIMIT WA-35 MAST ANGLE SENSOR WD-19 BEEPER DIGITAL DISPLAY WD-18 BOOM HOIST WC-14 PUMP CONTROL...
Page 64: Mast Cylinders Raise
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL Mast Cylinders Raise When boom hoist brake is released, an input signal is sent to PC. The PC sends a negative output voltage to rear drum See Figures 1-36 1-37 pump EDC (13) that tilts rear drum pump swashplate to stroke pump in the low-pressure side direction.
Page 65: Mast Cylinders Lower
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Load equalizing valve ensures mast-raising cylinders rear drum pump. The PC also sends an output signal to shift operate in unison, protecting mast from structural damage mast extend cylinder solenoid HS-1 back to center position. caused by twisting. Load equalizing valve also provides...
Page 66 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-137 ENGINE STOP STOP START 50 AMP REGULATED 10V DC OUTPUT SYSTEM FAULT RAISE LOWER BOOM HOIST HANDLE WA-05 BUZZER OPERATING LIMIT WA-35 MAST ANGLE SENSOR WD-19 BEEPER DIGITAL DISPLAY WD-18 BOOM HOIST WC-14 PUMP CONTROL...
Page 67 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION The fluid exiting side “A” of load equalizing valve enters and To continue lowering mast, the gantry must be lowered. passes through control valve section of accessory system When lowering gantry support cylinders to fully retracted...
Page 68: Boom Hinge Pins
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL Boom Hinge Pins When power button is pressed and boom hinge pins switch (2) is placed in engage position and held, the PC sends an See Figures 1-40 1-41 output signal to boom hinge pins cylinder engage hydraulic solenoid HS-5.
Page 69 999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Low-pressure side hydraulic fluid flows to boom hinge pins output voltage to rear drum pump EDC (13) that tilts rear engage solenoid HS-5 of accessory valve. Hydraulic fluid drum pump swashplate to stroke pump in the low-pressure leaves the accessory valve and enters piston end of boom side direction.
Page 70: Carbody Jacking System
INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL Carbody Jacking System Figure 1-42 WARNING The two-stage telescopic type jacking cylinders are mounted on each corner of carbody. Jacking cylinder operation is Collapsing Hazard! controlled with hydraulic valve handles on the carbody and Keep rotating frame as level as possible while jacking.
Page 71: Carbody Jacking Cylinder Raise
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Each carbody-jacking cylinder (1) has a counterbalance Hydraulic fluid then flows through free-flow check valve (5) valve (2) at the cylinder ports. Counterbalance valves ensure section of flow control valve before entering lower accessory smooth control when raising or lowering the crane.
Page 72 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-142 GANTRY BOOM PIN MAST CYLINDERS CYLINDERS CYLINDERS LOW PRESSURE ACCESSORIES HIGH FRONT DRUM REAR DRUM PUMP DRIVE GEARBOX PUMP DRIVE GEARBOX UPPERWORKS ACCESSORY MANIFOLD TO REAR HOIST MOTOR LOOP FLUSHING VALVE PRESSURE SWITCH SWIVEL LOWERWORKS ACCESSORY MANIFOLD...
Page 73: Left And Right Crawler Pin-Pusher Cylinders
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Left and Right Crawler Pin-Pusher Cylinders Hydraulic fluid exhausting from rod end of both crawler pin pusher cylinders returns to lower accessory valve and is Crawler pin pusher cylinder operation is controlled with returned to tank.
Page 74 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-143 GANTRY BOOM PIN MAST CYLINDERS CYLINDERS CYLINDERS LOW PRESSURE ACCESSORIES HIGH FRONT DRUM REAR DRUM PUMP DRIVE GEARBOX PUMP DRIVE GEARBOX UPPERWORKS ACCESSORY MANIFOLD TO REAR HOIST MOTOR LOOP FLUSHING VALVE PRESSURE SWITCH SWIVEL LOWERWORKS ACCESSORY MANIFOLD...
Page 75: Counterweight Pins
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION Counterweight Pins When setup remote power push button (3) is pressed and counterweight pins switch, is held in the disengage position, See Figures 1-45 1-46 counterweight pins disengage solenoid HS-7 is enabled, to retract the pins. Fluid from rear drum low-pressure...
Page 76 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL 999CSM1-145 REAR LOAD DRUM PUMP LOW PRESSURE SIDE 350 PSI (24 BAR CHARGE PUMP HIGH PRESSURE SIDE SUPERCHARGE LOW PRESSURE MANIFOLD ACCESSORIES HS-7 COUNTERWEIGHT PINS FIGURE 1-46 1-64 Published 05-16-17, Control # 233-03...
Page 77: Hydraulic Solenoid Valve Identification
999 SERVICE/MAINTENANCE MANUAL INTRODUCTION HYDRAULIC SOLENOID VALVE ABBREVIATIONS IDENTIFICATION Amber Light Each hydraulic solenoid valve is assigned an HS number. Air Conditioning Relay The HS numbers are for training proposes only and do not Auxiliary Hoist identify actual hydraulic solenoids on the crane.
Page 78 INTRODUCTION 999 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 1-66 Published 05-16-17, Control # 233-03...
Page 79 Operating Drum Speed Checks..........2-27 Manitowoc...
Page 80 999 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 2-ii Published 05-16-17, Control # 233-03...
Page 81: Inspecting Hydraulic Hoses
The technicians shall read, hydraulic components and valves for the following: understand, and comply with the instructions in this section and to the display screen instructions in Section 3 of the 999 Leaking ports Operator Manual. Leaking valve sections or manifolds and valves...
Page 82: Hydraulic System Maintenance
HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Zone D and E • Do not unpack parts or remove port plugs until parts are needed. Inspect hydraulic hose assemblies per Step 1. Cold temperatures will negatively impact service life of hose • Once unpacked, carefully inspect each part for damage assemblies operating in these climate zones.
Page 83 999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM • Replace tubes that are cracked, kinked, or bent. • Wrong oil (viscosity too high) • Replace hoses that are cracked, split, or abraded. Look for signs of overheating: heat peeled parts, burned and scorched oil odor, and darkening and thickening of •...
Page 84 HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL P1580 Left Enclosure Left Enclosure 81014032 P1432 M102000 Item Description Item Description Free Fall Hydraulic Return Oil Filter (1 or 2) Return Oil Diffuser Thermal Bypass Valve Hydraulic Tank Hydraulic Tank Sight Gauge Suction Filter...
Page 85 999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM OPEN CLOSE OPEN CLOSE Bottom of Hydraulic Tank Accessible from Under Rear of Rotating Bed Item Description Auxiliary Drum Hydraulic Oil Filter Charge Filter Shut-Off Valve Hydraulic Tank Shut-Off Valve (suction tube) Hydraulic Oil Charge Filters (3)
Page 86: Replacing Filter Elements
(see Digital Display fuel tank. The two tanks are next to each other on right Readings in 999 Operator Manual). The alert indicates which side of crane. Hydraulic tank is to rear of fuel tank.
Page 87: Tightening Hydraulic Connections
999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM 10. Replace all filter elements (1, 14 and 17). 11. Fully close drain valve (18) and remove rubber hose. 12. Fill hydraulic tank to proper full (cold) level on tank sight O-Ring gauge (3). Use proper hydraulic oil (see Lubrication Guide supplied with crane).
Page 88: Sae Straight Thread Connection
HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL SAE Straight Thread Connection Back up jam nut and washer to end of smooth portion on fitting as shown in Figure 2-4, View A. This type connection leaks most often because the jam nut Lubricate O-ring with clean oil; this is very important.
Page 89: Ors Connection
999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM ORS Connection Table 2-5. ORS Leakage • Lubricate install O-ring adapter groove Causes Cures (Figure 2-5). Nut Loose. Tighten to proper torque. • Lubricate threads. O-ring cut. Replace. • Tighten nut to torque value given in Table 2-4..
Page 90: Split Flange Connection
HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Split Flange Connection Table 2-6. Split Flange Assembly Torque Lubricate and install O-ring in shoulder groove (see "A" Dimension Torque Figure 2-6). (inch) Align shoulder with port and assemble flanges over Flange shoulder. Size in-lb N•m...
Page 91: Sae Flare Connection
999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM SAE Flare Connection Using wrenches, tighten connector nut the number of flats shown in Table 2-8. (Figure 2-7, View B). Tighten nut finger tight until sealing surfaces touch. Misalignment of marks will show how much nut has Mark a line (use felt pen or marker) on adapter and been tightened, and that it has been tightened.
Page 92: Hydraulic System Calibration
HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM CALIBRATION Once all items are calibrated, turn crane mode switch CLOCKWISE to SELECT position to turn off calibration To ensure proper operation of the crane functions, the sequence. Cursor (*) will disappear from screen.
Page 93: Charge Pressure
999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM If 0 appears, all items have passed. Charge Pressure b. If any number other then 0 appears, use Table 2-10. The charge pressure screen (Figure 2-10) indicates if each to determine which items have failed.
Page 94: Control System
HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Control System When calibration starts, percent (%) of completion is displayed on screen. The control system calibration screen (Figure 2-11) indicates NOTE: It takes approximately 2 minutes to complete whether the pump center is within the allowable range for check.
Page 95: Pump Pressure
999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pump Pressure Testing will not start if engine is not running faster than 900 rpm. The pump pressure screen (Figure 2-12) cycles through the NOTE: Pump pressure test will not start if engine is not hoist pumps to make sure each pump is capable of running.
Page 96 HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Table 2-10. Binary System 2-16 Published 05-16-17, Control # 233-03...
Page 97 999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Table 2-10. Binary System (continued) Manitowoc 2-17 Published 05-16-17, Control # 233-03...
Page 98: Pressure Sender Replacement
HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL PRESSURE SENDER REPLACEMENT Stop engine. Place a suitable container under pressure sender to catch oil leakage. Disconnect electric plug from pressure sender. WARNING Slowly loosen pressure sender only enough to allow High Pressure Oil Hazard! any remaining pressure to exhaust.
Page 99 999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM FIGURE 2-13 continued Manitowoc 2-19 Published 05-16-17, Control # 233-03...
Page 100: Pump Components
HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Pump Identification Item Description Front Load Drum Rear Load Drum or Luffing Hoist Supercharge Pump Boom Hoist Swing Right Crawler Left Crawler Auxiliary Load Drum A817 Pump Components Item Description EDC (Electronic Displacement Control) Manual Override Control...
Page 101: Pump And Motor Port Identification
999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Pump and Motor Port Identification Oil Flow From Pump Ports Oil Flow to Motor Ports System Front Load Drum Raise Lower Raise Lower Rear load Drum Raise Lower Raise Lower Boom Hoist Raise Lower Lower...
Page 102 HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL FIGURE 2-16 2-22 Published 05-16-17, Control # 233-03...
Page 103: Disc Brake Operational Test
Contact the Manitowoc Crane Care Lattice Team for a Start engine and allow it to idle at 1,000 rpm. detailed explanation of any procedure not fully understood.
Page 104: Initial Oil Fill
HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Initial Oil Fill Remove bleed cap from outlet fitting of auxiliary drum filter (Figure 2-20). Check that hydraulic oil flow between auxiliary drum Remove bleed plug from top of tee in suction tube pump and auxiliary drum filter is correct as shown in (Figure 2-20).
Page 105 999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM Suction Tube Return Oil Manifold Bleed Plug Charge Filter Manifold Pressure Gauge Fitting Auxiliary Drum Charge Filter Bleed OPEN CLOSE Rear of Pumps in Left Rear Enclosure Front of Pumps in Left Rear Enclosure Charge Filter Shut-Off Valve...
Page 106: Accessory System Checks And Adjustments
HYDRAULIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Accessory System Checks and Adjustments b. Use gantry toggle to raise and lower gantry several times to remove air from system. High Pressure Accessory Systems Scroll to accessory screen on diagnostic display to The high-pressure side of the rear drum system is the source verify that 3,000 psi (241 bar) is present when for upper and lower accessory systems.
Page 107: Travel Handle And Speed Check
999 SERVICE/MAINTENANCE MANUAL HYDRAULIC SYSTEM counterweight pins, swing lock, swing brake, travel brakes, Have an assistant count number of revolutions timing and travel 2-speed. Reconnect all electrical connections mark makes. (DIN plugs) that were disconnected for hydraulic system Number should be 8-1/2 – 9 revolutions in one minute checks.
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Page 109 Dielectric Grease ..............3-42 Manitowoc...
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Page 111: Inspect Electrical Components
999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM SECTION 3 ELECTRIC SYSTEM INSPECT ELECTRICAL COMPONENTS Excessive corrosion or dirt on the junction boxes Loose junction box mounting hardware I f a n y o f t h e s e c o n d i t i o n s e x i s t , a d d r e s s t h e m DANGER appropriately.
Page 112: Circuit Breaker And Fuse Id
ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL CIRCUIT BREAKER AND FUSE ID Refer to Figure 3-1 for the location and identification of the fuses and circuit breakers on this crane. Item Description Fuse Junction Box in Operator’s Cab page 3-3 Cold Weather Circuit Breaker Load Center...
Page 113 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM 268436_1 Fuse Junction Box in Operator’s Cab Fuse or Amps Wire No. Description of Items Protected Relay Transient Suppressor Diode Cab Power Horn LMI & Gauges Computer Inputs Defogger Fan Boom & Jib Top Swing Lock / Park Pressure Transducers &...
Page 114 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL 81012573D Cold Weather Circuit Breaker Load Center Circuit Amps Description of Items Protected Breaker Main Load Center Circuit Breaker Hydraulic Reservoir Heaters (2), Cab Console Heater Engine Coolant Heater, Engine Oil Heater Battery Pad Heaters (2)
Page 115 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Engine Node Item Amps Wire No. Description of Item Item Amps Wire No. Description of Item Circuit Breakers Relays CB-1 Main System — ECM Power CB-2 Engine ECM — Auto Lube 1 CB-3 Engine Diagnostics —...
Page 116 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL CraneStar TCU Fuses Fuse Amps Wire No. Description of Item Protected 24VDC Power Bus System 24VDC Fused Power FIGURE 3-6 Engine Exhaust Aftertreatment Junction Box Fuse Amps Description of Item Protected DEF Supply Module Aftertreatment Sensors...
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Page 118: Test Voltages
ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL TEST VOLTAGES Controller Board Layout This section contains test voltages sorted into four The board locations in the programmable controller are categories: shown below. Identification......page 3-9...
Page 119: Pin Identification
999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Pin Identification Test Voltage Board Wire Description (DC unless otherwise specified) (Signal Type) A-01 10 VDC Regulated Bus 10 Volts CPU J1-01 0 Volts Neutral; 1.4 to 5 Volts Lower; A-03 Front Drum Handle I/O 1 J5-50 (AI) 5 to 8.6 Volts Raise...
Page 120 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Test Voltage Board Wire Description (DC unless otherwise specified) (Signal Type) B-05 89ZZ Boom/Jib Maximum Angle Bypass 12 Volts Nominal I/O 1 J6-11 (DI) B-06 89J5 Mast Raise Switch 12 Volts Nominal I/O 1 J6-12 (DI)
Page 121 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Test Voltage Board Wire Description (DC unless otherwise specified) (Signal Type) C-20 68CB Engine Clutch Cylinder Speed Variable 0-12 Volts I/O 1 (DO) C-21 Computer Bus 12 Volts DC C-22 Main System Ground Bus 0 Volts 0 to 2.8 ±...
Page 122 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Test Voltage Board Wire Description (DC unless otherwise specified) (Signal Type) 0 Volts to 1/3 Handle Motion D-24 80MC Front Drum Motor Control I/O 1 J6-06 (AO) 0.96 to 2.19 Volts 1/3 to Full Handle Motion...
Page 123: Wire Identification
999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Wire Identification Test Voltage Board Wire Description (DC unless otherwise specified) (Signal Type) C-02 Main System Ground Bus 0 Volts C-04 Main System Ground Bus 0 Volts C-13 Main System Ground Bus 0 Volts C-22...
Page 124 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Test Voltage Board Wire Description (DC unless otherwise specified) (Signal Type) 7.5 Volts or 0 Volts Not Moving 80MA D-01 Front Drum Flange Encoder CH A I/O 1 J6-01 (DI) 3.5 Volts Moving 7.5 Volts or 0 Volts Not Moving...
Page 125 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Test Voltage Board Wire Description (DC unless otherwise specified) (Signal Type) 0 to 2.8 ± 10% (110 mA) Volts Reverse; C-15 Right Track Pump Control (Servo Driver 4) I/O 2 J8-42 (AO) 0 to -2. 8 ± 10% (-110 mA) Volts Forward 0 Volts Neutral;...
Page 126 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Test Voltage Board Wire Description (DC unless otherwise specified) (Signal Type) 89E5 B-31 Boom Hinge Pins Extend Switch 12 Volts Nominal I/O 3 J10-09 (DI) 89EC B-04 Engine Clutch Disconnect Switch 12 Volts Nominal I/O 1 (DO)
Page 127: Description Identification
999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Description Identification Test Voltage Board Description Wire (DC unless otherwise specified) (Signal Type) 10 VDC Regulated Bus A-01 10 Volts CPU J1-01 Accessory Pressure Switch B-36 89G5 12 Volts Nominal I/O 3 J10-14 (DI) Accessory System Hydraulic Pressure...
Page 128 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Test Voltage Board Description Wire (DC unless otherwise specified) (Signal Type) Computer Bus C-03 12 Volts DC Computer Bus C-12 12 Volts DC Computer Bus C-21 12 Volts DC Computer Bus C-30 12 Volts DC...
Page 129 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Test Voltage Board Description Wire (DC unless otherwise specified) (Signal Type) Gantry Cylinder Extend Solenoid C-32 12 Volts Nominal I/O 2 J8-31-32 (DO) Gantry Cylinder Retract Solenoid C-33 12 Volts Nominal I/O 2 J8-33-34 (DO)
Page 130 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Test Voltage Board Description Wire (DC unless otherwise specified) (Signal Type) Rear Drum Park Brake Switch D-09 89X3 12 Volts Nominal I/O 3 J10-16 (DI) Rear Drum Pawl Disable Solenoid D-35 81RA 12 Volts Nominal...
Page 131: Controller Board Identification
999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Controller Board Identification Board Test Voltage Wire Description (Signal Type) (DC unless otherwise specified) CPU J1-01 A-01 10 VDC Regulated Bus 10 Volts CPU J3-49 (AI) A-20 Right Track Hydraulic Pressure 1.2 Volts at 300 psi; 1 Volt at 0 psi...
Page 132 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Board Test Voltage Wire Description (Signal Type) (DC unless otherwise specified) 7.5 Volts or 0 Volts Not Moving I/O 1 J6-04 (DI) D-04 81MB Rear Drum Flange Encoder CH B 3.5 Volts Moving 7.5 Volts or 0 Volts Not Moving...
Page 133 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Board Test Voltage Wire Description (Signal Type) (DC unless otherwise specified) 0 Volts Neutral; 1.4 to 5 Volts Lower; I/O 2 J7-64 (AI) A-19 80EP Front Drum Brake Pedal 5 to 8.6 Volts Raise 7.5 Volts or 0 Volts Not Moving...
Page 134 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Board Test Voltage Wire Description (Signal Type) (DC unless otherwise specified) I/O 3 J9-52 (AI) A-32 Spare I/O 3 J9-54 (AI) A-33 Spare Above 7.5 Volts or 0 Volts Not Moving; I/O 3 J10-01 (DI)
Page 135 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Board Test Voltage Wire Description (Signal Type) (DC unless otherwise specified) I/O 4 J12-09 (DI) E-13 Spare I/O 4 J12-10 (DI) E-14 89E4 Main Charge Filter Pressure Switch 12 Volts Nominal I/O 4 J12-11 (DI)
Page 136: Master Node Pin Identification
ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Master Node Pin Identification Master Node installed on Cranestar equipped and Tier 4. Test Voltage Pin # Function Type Description (DC unless otherwise specified) Receptacle – Front Console Master Node (Unused Terminals are Omitted) P11-01...
Page 137 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Test Voltage Pin # Function Type Description (DC unless otherwise specified) P12-34 DI-21 DPF Regen Switch OFF (disable) 0 Volts Off; 24 Volts On Data Download/Upload Receptacle – Front Console Master Node P2-1 Data TX1...
Page 138: Display Readings
ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL DISPLAY READINGS Operating Limits The display allows the operator to monitor three groups of Table 3-3 lists operating limits which can be displayed. crane information: operating conditions (normal and When one or more operating limits is reached, the operating diagnostic), operating limits, and system faults.
Page 139: System Faults
Selecting Display Language Table 3-4 lists system faults which can be displayed. Software for the Model 999 contains English and several foreign-language display readings. When a new computer When one or more system faults occur, the system fault alert chip is installed, any one of the languages could appear on (red light and beeper in cab) turns on to warn the operator.
Page 140 See Freefall Drum Slip Adjustment in Operator Manual. HYD SYSTEM CHECK — See Hydraulic System Calibration in Section 2. Computer Program Version and Crane Configuration Code. The Manitowoc PROGRAM M000001.0JP — Crane Care Lattice Team will request these numbers when troubleshooting CON 00000000000 crane problems.
Page 141 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-3 Operating Limits Listed below are the limits which turn on the operating limit alert (yellow light and continuous buzzer). When the alert comes on, the OPERATING LIMIT group of the display will indicate which limit has been reached. Take corrective action.
Page 142 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Table 3-4 System Faults Listed below are the faults which turn on the system fault alert (red light and beeper). When the alert comes on, the SYSTEM FAULT group of the digital display will indicate which fault has occurred. Take corrective action. The beeper sounds intermittently.
Page 143 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-5 Display Abbreviations Table 3-6 Drum and Pump Identification Abbreviation Definition Drum Plus Drum Number – Minus Front Load Drum Percent Handle Inputs Rear Load Drum Pump Control Outputs Boom Hoist Programmer’s Screen Angle...
Page 144: Crane Diagnostics
ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL CRANE DIAGNOSTICS Drum 4 (Boom Hoist) To activate the diagnostic display screens, turn the limit bypass key clockwise and scroll up at least one screen. To deactivate the diagnostic screens, turn the limit bypass DRUM key clockwise and scroll down at least one screen.
Page 145: Swing
999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Drum 2 pedal command is in percent (0% applied, 100% Parking brake command (1 release, 0 engage). fully released). Drum 2 PC output to proportional valve in percent of Depending on the crane configuration, RIN computers are pressure (0% to 100%).
Page 146: Accessory System
ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Accessory System Bank 7 indicates the RIN digital inputs. For example, if Bank 7 displays the number 72, see Table 3-9 and the shaded boxes in row 72. This indicates that Jib Maximum Up Working Limit (8) and Block-Up Limit – Luffing Jib Point (64) inputs (8 + 64 = 72) are active.
Page 147: A1 (Handles)
999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM A1 (Handles) For identification of the digital outputs and inputs (and the crane components connected to them) see Tables The variable control handle output voltage is represented in the controller by a number between 0 (0 Volts) and 255 (10 To determine the state of the individual inputs/outputs in a Volts).
Page 148 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Table 3-7 D1 (Crane Digital Outputs) Table 3-8 D2 (Crane Digital Inputs) Identifier* Component Identifier* Component Bank 1 Bank 1 Auxiliary Drum Pawl Enabled Travel Detent Set/Cancel Auxiliary Drum Pawl Disabled Front Drum Maximum Bail Limit...
Page 149 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-8 D2 (Crane Digital Inputs) Identifier* Component Bank 9** Block Up Limit (Boom Top) Block Up Limit (Boom Top) Jib Minimum Down Working Limit Jib Maximum Up Working Limit Jib Maximum Up Stop Block Up Limit (Luffing Jib/Fixed Jib Top)
Page 150 ELECTRIC SYSTEM 999 SERVICE/MAINTENANCE MANUAL Table 3-9 8-Bit Binary System Dark shaded boxes indicate ON; white boxes OFF. 3-40 Published 05-16-17, Control # 233-03...
Page 151 999 SERVICE/MAINTENANCE MANUAL ELECTRIC SYSTEM Table 3-9 8-Bit Binary System (continued) Dark shaded boxes indicate ON; white boxes OFF. Manitowoc 3-41 Published 05-16-17, Control # 233-03...
Page 152: Cpu Eprom Replacement
— to include cranes with a Tier 4 Final engine — no longer has eproms (computer chips). For information on updating crane software, contact your Manitowoc dealer or the Manitowoc Crane Lattice Team. DIELECTRIC GREASE The following figures show the proper application of dielectric grease on J-tech type connectors.
Page 153: Section 4
Lattice Section Inspection and Lacing Replacement ........4-16 Manitowoc...
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Page 155: Automatic Boom Stop
999 SERVICE/MAINTENANCE MANUAL BOOM SECTION 4 BOOM AUTOMATIC BOOM STOP Maintenance At least once weekly, check that the automatic boom stop Maximum Boom Angle stops the boom at the specified maximum angle. If not, B o o m s t o p l i m i t s w i t c h a s s e m b l y ( 5 ,...
Page 156: Bypass Limit Test
BOOM 999 SERVICE/MAINTENANCE MANUAL Bypass Limit Test Lower the boom onto blocking at ground level. Have an assistant push the adjusting rod (Figure 4-2) in Perform the following test to determine if the boom up limit to trip the boom stop limit switch open.
Page 157 999 SERVICE/MAINTENANCE MANUAL BOOM Centerline of Boom Table 4-1 Table 4-1 Horizontal Item Description Boom Butt Adjusting Rod Limit Switch FIGURE 4-1 Manitowoc Published 05-16-17, Control # 233-03...
Page 158 BOOM 999 SERVICE/MAINTENANCE MANUAL Roller Over-Travel Left Leg VIEW A 9 10 Switch Opened VIEW B Switch Stored Closed Limit Switch Wiring VIEW C Switch Wire Function Right Outboard Leg Terminals 1 (green) Max Angle 2 (black) 3 (white) 12 VDC Supply...
Page 159: Adjustment
999 SERVICE/MAINTENANCE MANUAL BOOM Adjustment Loosen jam nut (3, View B). b. Turn adjusting rod (2a, 2b, or 2c) out against boom Figure 4-2 for the following procedure. butt (1) until limit switch (5) “clicks” open (View A). Park the crane on a firm level surface or level the crane Tighten jam nut (3).
Page 160 BOOM 999 SERVICE/MAINTENANCE MANUAL • 81° - Start of Spring Cushioning • 90° - Physical Stop (springs solid) Telescopic Struts (Pinned in Working Position) Boom Butt Physical Boom Stops Outer Tube Inner Tube Boom Stop Boom Stops Just Boom at 81°...
Page 161: Physical Boom Stop
999 SERVICE/MAINTENANCE MANUAL BOOM PHYSICAL BOOM STOP See Crane Assembly/Disassembly in Section 4 of 999 Operator Manual for instructions on raising and lowering The physical boom stops (Figure 4-3) serve the following physical boom stops. purposes: • Assist in stopping the boom smoothly at any angle above 81°...
Page 162: Boom And Luffing Jib Angle Indicator
BOOM 999 SERVICE/MAINTENANCE MANUAL BOOM AND LUFFING JIB ANGLE Angle Sensor Mounted Inside INDICATOR P1518 Angle indicator sensors are located inside node controllers mounted on the boom top and on the luffing jib top. The boom and luffing jib angles are calibrated automatically by the crane’s programmable controller as part of the load...
Page 163: Adjusting Angle
999 SERVICE/MAINTENANCE MANUAL BOOM Adjusting Angle Place an electronic level on mast (Figure 4-5). Record angle indicated on level. Perform following adjustment steps at initial installation, after installing a new sending unit, and during assembly. Mast Scroll to angle on digital display in operator’s cab.
Page 164: Gantry Limit Switch
BOOM 999 SERVICE/MAINTENANCE MANUAL Gantry Limit Switch Hold switch in place and tighten limit switch mounting bolts. The crane has a limit switch (Figure 4-7) which alerts the Test switch for proper operation by lowering and then operator when the gantry is raised to its maximum angle.
Page 165: Strap Inspection And Maintenance
Manitowoc Crane Care Lattice Team. Before beginning inspection, thoroughly clean strap of all dirt, grease, oil, etc. so a thorough inspection can be made.
Page 166: Replacement Specifications
BOOM 999 SERVICE/MAINTENANCE MANUAL Replacement Specifications Dent Any strap not within specifications listed in Table 4-3 must be replaced. WARNING I f d a m a g e t o s t r a p e x c e e d s t h a t a l l o w e d w i t h i n...
Page 167 999 SERVICE/MAINTENANCE MANUAL BOOM Corrosion or Abrasion Straightness Figure 4-12 for the following procedure. Figure 4-13 for the following procedure. For quick identification by repair workers, clearly mark Stretch a line (string or wire) from pin storage hole at one damaged areas with brightly colored tape.
Page 168: Flatness
BOOM 999 SERVICE/MAINTENANCE MANUAL Flatness Figure 4-14 for the following procedure. Lay strap on a flat surface. Do not block; strap may sag! Stretch a line (string or wire) across top surface of strap from pin storage hole at one end of strap.
Page 169: Elongated Hole
999 SERVICE/MAINTENANCE MANUAL BOOM Elongated Hole Length Figure 4-15 for the following procedure. Maximum Deviation Allowed Strap Length Insert pin into hole. 1 to <2 in (25 to 2 to <4 in (51 to ft (m) <51 mm) Thick <102 mm) Thick Push pin tight against edge of hole along horizontal center line.
Page 170: Storing Straps
BOOM 999 SERVICE/MAINTENANCE MANUAL Storing Straps Inspection Checklist Straps should be stored in a protected area. If stored in open, A Strap Inspection Checklist is provided at the end of this a protective covering is recommended, especially in a section. The checklist can be reproduced as needed.
Page 171 999 SERVICE/MAINTENANCE MANUAL BOOM STRAP INSPECTION CHECKLIST Inspector’s Name Signature Date Length Part Number Corrosion Kinks Cracks Dents Breaks Straightness Elongated Holes Abrasion Bends Flatness Length Other Length Part Number Corrosion Dents Kinks Cracks Breaks Abrasion Bends Straightness Flatness Elongated Holes...
Page 172 BOOM 999 SERVICE/MAINTENANCE MANUAL NOTES DRAW SKETCHES OR ATTACH PHOTOGRAPHS TO FOLLOWING PAGES 4-18 Published 05-16-17, Control # 233-03...
Page 173 999 SERVICE/MAINTENANCE MANUAL BOOM Manitowoc 4-19 Published 05-16-17, Control # 233-03...
Page 174 BOOM 999 SERVICE/MAINTENANCE MANUAL 4-20 Published 05-16-17, Control # 233-03...
Page 175: Section 5
Load Block and Hook-and-Weight Ball Inspection ........5-20 Manitowoc...
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Page 177: Hoist Drawings
999 SERVICE/MAINTENANCE MANUAL HOISTS SECTION 5 HOISTS HOIST DRAWINGS Inspection Applicable hoist and load block drawings are attached at the Inspect wear indicator with brake applied. Note that wear end of this Section. indicator moves in as brake discs wear.
Page 178: Overhaul
HOISTS 999 SERVICE/MAINTENANCE MANUAL Overhaul Place clutch/brake assembly on a workbench and securely block it with shaft pointing down. To overhaul either clutch/brake assembly, proceed as Remove wire from hex head cap screws (1 – 6). follows: Loosen cap screws (1, 3, and 5) two full turns.
Page 179: Minimum Bail Limit/Pressure Roller
999 SERVICE/MAINTENANCE MANUAL HOISTS MINIMUM BAIL LIMIT/PRESSURE ROLLER not contact limit switch roller (3) when step 3 performed. Figure 5-2 Pay out wire rope until bail limit rollers (11) are against The minimum bail limit assembly is a protective device. It...
Page 180 HOISTS 999 SERVICE/MAINTENANCE MANUAL Item Description Item Description Front Load Drum Return Spring Rear Load Drum Return Spring Eyebolt Limit Switch Roller Cap Screw Actuator Bail Limit Rollers Actuator Adjusting Screws Bail Limit Lever Pins Drum Pressure Roller Lever Pressure Roller Spring...
Page 181: Drum Pressure Roller
999 SERVICE/MAINTENANCE MANUAL HOISTS A1081 Auxiliary Load Drum 3 to 4 Wraps of Lever Wire Rope Remaining Jam Nut on Load Drum Adjusting Screw Limit Switch Roller Return Spring Eyebolt Cap Screw Bail Limit Bail Limit Limit Bare 1-5/8 in...
Page 182: Block-Up Limit
NOTE: See wiring diagrams in Boom Wiring, Limits, and the load drum from hoisting and the boom from lowering Load Indicator Electrical Assembly drawing in 999 when a load is hoisted a predetermined distance. Operator Manual. Two-blocking is the unsafe condition in which the load block...
Page 183: Installation
Boom Wiring, Limits and Load Indicator Electrical Assembly to be wound. Engage the locking pin to lock the reel in drawing in the 999 Operator Manual. position. The power supply cable to the reel must be disconnected before the reel can be wound.
Page 184: Disconnecting Block-Up Limit Controls
HOISTS 999 SERVICE/MAINTENANCE MANUAL A848 Luffing Jib Butt Boom Butt (typical top view) (top view) Fixed Jib Butt Brackets (typical view) Cable Reel Cable Cable Cable Cable Reel FIGURE 5-5 Disconnecting Block-Up Limit Controls Removing Jib or Boom Point Shorting plug (SP1, View A,...
Page 185: Maintenance
999 SERVICE/MAINTENANCE MANUAL HOISTS P1471 Electric Cable From Crane Shorting View C Plug Universal Boom Top Junction Box (Junction Boxes on Jib Tops Similar) P1518 View A Left Front Corner of Rotating Bed View B Base of Boom Butt P1517...
Page 186 HOISTS 999 SERVICE/MAINTENANCE MANUAL Two Chains Prevent See Load Block Reeving drawing for Weight Weight from Turning Suggested Location of Weight Lift Block Chain Shackle Weight Dead-End Load Line or Slowest Live Line Connecting Multiple Part Reeving Dead Ended at Block...
Page 187: Adjustment
999 SERVICE/MAINTENANCE MANUAL HOISTS Adjustment Hold lever at Dimension A. Hold the roller on the limit switch lever against the Figure 5-8 for the following procedure. actuating lever while performing step 6 Lower the boom onto blocking at ground level and adjust...
Page 188: Wire Rope Inspection And Replacement
Maintain a Wire Rope Condition Report from Manitowoc. Do not build lengths from individual components. Always keep on file a signed and dated periodic inspection report of the wire rope’s condition.
Page 189: Daily Inspection
999 SERVICE/MAINTENANCE MANUAL HOISTS Daily Inspection 2. Throughout the day, observe wire rope during operation, particularly: Wire rope should be inspected in accordance with ANSI/ Pick-up Points—Sections of wire rope that are ASME B30.5 and OSHA 29 CFR 1926.1413. A running...
Page 190: Periodic Comprehensive Inspection
HOISTS 999 SERVICE/MAINTENANCE MANUAL Periodic Comprehensive Inspection • Size, nature, and frequency of lifts. • Rope maintenance practices. The comprehensive inspection must be done by a qualified person. The inspection must include pulling all the rope off • Severity of environment, such as: the drum and carefully inspecting the entire length.
Page 191: Broken Rope Wires
999 SERVICE/MAINTENANCE MANUAL HOISTS New Wire Rope—After initial loading, measure and record • Rotation-resistant Rope—two randomly distributed the diameter of any new wire rope for comparison to future broken wires in six rope diameters or four randomly inspections. See “Maintain a Wire Rope Condition Report.”...
Page 192: Distributing Wire Rope Wear
If the wire rope is too short to allow cutting off a piece of it, NOTE: Wire rope may be purchased through the reverse the rope end for end and refasten it. Manitowoc Crane Care Lattice Team. 5-16 Published 05-16-17, Control # 233-03...
Page 193: Sheave, Roller, And Drum Inspection
999 SERVICE/MAINTENANCE MANUAL HOISTS SHEAVE, ROLLER, AND DRUM INSPECTION Observe groove to see if contour of gauge Perform the following inspections WEEKLY. matches contour at bottom of sheave groove. 1. Check the drum clutches and brakes for proper adjustment. 2. Check all sheaves, rollers, and drums for the following...
Page 194 HOISTS 999 SERVICE/MAINTENANCE MANUAL 8. Inspect nylon sheaves to verify they have not separated and “walked off” steel inserts or bearings as shown in Item Description Figure 5-15. Maximum sideways displacement is 1/8 in Nylon Sheave (3 mm). Replace worn or damaged sheaves.
Page 195 999 SERVICE/MAINTENANCE MANUAL HOISTS E = Replacement dimension PLASTIC SHEAVE DATA E = B – 3/16 in (5 mm) (maximum) If tread print exists in root of sheave Sheave Outside Tread Diameter Width Rope Diameter groove, measure to maximum tread Diameter Part No.
Page 196: Load Block And Hook-And-Weight Ball Inspection
Block Weight (lb and kg) Latch Block Serial Number Hook Block Part Number (OEM and Manitowoc) Design Factor FIGURE 5-17 The operating condition of the load block and the hook-and- weight ball can change daily with use; therefore, they must...
Page 197 Do not weld on any load bearing Check that Hook is Not Twisted component unless proper welding methods are used Check for Cracks and Twisting (contact the Manitowoc Crane Care Lattice Team for Check for Wear and Cracks FIGURE 5-20 material and welding specifications).
Page 198 HOISTS 999 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK 5-22 Published 05-16-17, Control # 233-03...
Page 199: Section 6
Manual Release Procedure ............6-1 Manitowoc...
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Page 201: Manual Release Of Swing Brake And Lock
999 SERVICE/MAINTENANCE MANUAL SWING SECTION 6 SWING MANUAL RELEASE OF SWING BRAKE AND Manual Release Procedure LOCK Figure 6-1 for the following procedure. The hydraulic swing brake and hydraulic swing lock must be Hydraulic hand pumps with pressure gauge are needed to released when the swing planetary is removed and manually release the swing brake and swing lock.
Page 202 SWING 999 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-16-17, Control # 233-03...
Page 203: Section 7
DEF Heating and Cooling System ..........7-17 Manitowoc...
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Page 205: Batteries
Carefully check the connections before turning on the charger. WARNING Jump-Starting a Battery Explosion Hazard! The 999 with Tier 4 Final Engine has remote battery Batteries can explode with great violence and spraying of terminals as shown in Figure 7-1.
Page 206 POWER TRAIN 999 SERVICE/MAINTENANCE MANUAL View in Right Side Enclosure Item Description Battery Disconnect Switch Rear Battery Front Battery Battery Cover with Quarter-Turn Screws Remote Battery Terminal (3) To Starter Motor Engine Wiring Harness FIGURE 7-2 Published 05-16-17, Control # 233-03...
Page 207: Causes Of Battery Failure
999 SERVICE/MAINTENANCE MANUAL POWER TRAIN Causes of Battery Failure Lack of Water The plates must be completely covered with electrolyte. If A battery should never be left in a discharged state. When the plates are exposed, the high acid concentration will char discharged, it rapidly sulfates and unless recharged within and disintegrate the separators.
Page 208: Maintenance
POWER TRAIN 999 SERVICE/MAINTENANCE MANUAL Maintenance Table 7-2. Open Circuit Voltage Approximate Open-Circuit WARNING State-of-Charge Specific Gravity Voltage Personal Injury Hazard! (24V System) Each battery weighs 59 lb (27 kg). Use proper lifting 100% 1.260 25.2 procedures. 1.230 24.8 Checking Battery State-of-Charge 1.200...
Page 209: Battery Disconnect Switch
999 SERVICE/MAINTENANCE MANUAL POWER TRAIN BATTERY DISCONNECT SWITCH • To prevent crane from being started by unauthorized personnel. CAUTION Engine Damage! DISCONNECT To avoid possible engine fault codes and undesirable operation, make sure engine ignition switch has been off five minutes before disconnecting batteries.
Page 210: Air Cleaner
POWER TRAIN 999 SERVICE/MAINTENANCE MANUAL M100786 Item Description Service Indicator Reset Button Air Cleaner Housing Pre-Cleaner Service Cover Clamp (7-1/4 in) Rubber Elbow Clamp (5-1/2 in) Steel Tube Rubber Reducing Elbow Access Ladder on Right Clamp (4-1/2 in) Side of Crane...
Page 211: Changing The Filters
999 SERVICE/MAINTENANCE MANUAL POWER TRAIN • Check for loose clamps (6, 8, and 11). Tighten loose parts as needed. • Inspect the pre-cleaner (4) for obstructions. Clean as WARNING required. Fall Hazard! Changing the Filters It is necessary to climb onto the engine enclosure to inspect and service the air cleaner.
Page 212: Engine Clutch
POWER TRAIN 999 SERVICE/MAINTENANCE MANUAL ENGINE CLUTCH Park all crane functions (brakes applied) before disengaging the clutch. A disc-type manually operated clutch (see Figure 7-6) is b. Disengage and engage the clutch several times with mounted between the engine and the pump drive. The clutch the engine running.
Page 213: Engine Throttle
999 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE THROTTLE NOTE: Both controllers have internal stops at high and low idle. The throttle assembly for the Cummins engines consist of an Release foot pedal to low idle position. electronic control module (ECM) on the engine, a hand...
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Page 215: Engine Enclosure
999 SERVICE/MAINTENANCE MANUAL POWER TRAIN Item Description Ladder Radiator Enclosure Radiator Access Door with Latches Engine Covers (3) (with quarter-turn latches) Engine Cover (with screws) Exhaust System Enclosure Left-Side Enclosure Enclosure Door Not Shown for Clarity Right-Rear Corner of Crane...
Page 216 POWER TRAIN 999 SERVICE/MAINTENANCE MANUAL Item Description Level Sight Glass Fill Cap Coolant Level Sensor Air Bleed Valve Charge Air Cooler Radiator Drain Valve with Hose Hydraulic Oil Cooler Radiator Shown with Engine Enclosure Removed for Clarity (see Figure 7-8...
Page 217: Engine Cooling System
999 SERVICE/MAINTENANCE MANUAL POWER TRAIN ENGINE COOLING SYSTEM supplemental coolant additive. Refer to the engine manufacturer’s manual for specifications. Refer to the engine manufacturer’s manual for coolant filter When the coolant is visible in the sight glass (1), install replacement instructions.
Page 218 POWER TRAIN 999 SERVICE/MAINTENANCE MANUAL Item Description Components DEF Tank Coolant Flow Control Solenoid Valve Coolant Manifold Air Bleed Valves DEF Supply Module SCR Module DRT Module DEF Dosing Module DOC Module Coolant Hoses (BLUE) From Coolant Manifold to DEF Tank...
Page 219: Exhaust Aftertreatment System
999 SERVICE/MAINTENANCE MANUAL POWER TRAIN EXHAUST AFTERTREATMENT SYSTEM Figure 7-11 for the following procedures. Item Description DEF Tank Fill Cap Abbreviation Description DEF Return Port DEF Coolant OUT Port Aftertreatment Protection System DEF Coolant IN Port Diesel Exhaust Fluid DEF Suction Port...
Page 220: Coolant Solenoid Valve
(de-rated) by the ECM. If the damage. condition persists, engine shutdown may occur. Refer to Section 3 of the 999 Operator Manual for SCR Module identification and location of the engine and exhaust aftertreatment warning lights.
Page 221: Def Dosing Module
999 SERVICE/MAINTENANCE MANUAL POWER TRAIN DEF Dosing Module The coolant solenoid valve (2) adjusts coolant flow according to the temperature of the DEF in the DEF tank. If the tank The DEF dosing module (8) injects a liquid mixture of urea temperature drops below 25°F (–4°C), the ECM will open the...
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Page 223: Section 8
Operation ..............8-4 Manitowoc...
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Page 225: Turntable Bearing
999 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE SECTION 8 UNDER CARRIAGE TURNTABLE BEARING When new bolts are installed, torque the bolts in two steps: first to 600 ft-lb (814 Nm) and then to 2,100 ft-lb (2 848 Nm). Installation Torque Sequence The outer ring can be installed in any position with relation to Torque two bolts at a time in the numbered sequence given the carbody.
Page 226: Crawler
UNDER CARRIAGE 999 SERVICE/MAINTENANCE MANUAL A1185 Numbers Indicate Access Outer Ring Bolts Tightening Sequence From Outside Rotating Bed. A - Dowel Pin (2 places) B - Grade 8 Bolt: 1-1/2 6 UNC x 8 inch Long with SAE Flat Washers •...
Page 227: Adjustment Procedure
999 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE Travel forward or reverse on a firm level surface so all Remove jack cylinder (3). tread slack is in top of treads at tumbler end of crawler. Travel crane forward to tighten shims. Place straight edge on treads as shown in Figure 8-2.
Page 228: Hydraulic Hand Pump
Prevent Possible Death or Serious Injury Securely reinstall vent/fill cap to Maintenance Personnel For Enerpac pump: Manitowoc has provided hand pump and cylinder for crawler adjustment only. Any other use is neither intended Place pump in vertical position with hose end nor approved.
Page 229 999 SERVICE/MAINTENANCE MANUAL UNDER CARRIAGE S135 S137 S138 Cylinder Vent/Fill Cap (Simplex Pump) Close Valve Extend Cylinder Hose Pump Open Retract Valve Notch in Dipstick Cylinder (Enerpac Pump) FIGURE 8-4 Manitowoc Published 05-16-17, Control # 233-03...
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Page 231: Section 9
Lube and Coolant Product Guide ........... . . 9-1 Manitowoc...
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Page 233: Lube And Coolant Product Guide
999 SERVICE/MAINTENANCE MANUAL LUBRICATION SECTION 9 LUBRICATION LUBRICATION LUBE AND COOLANT PRODUCT GUIDE See F2277 in this section. See the publication in this section. Manitowoc Published 05-16-17, Control # 233-03...
Page 234 LUBRICATION 999 SERVICE/MAINTENANCE MANUAL THIS PAGE INTENTIONALLY LEFT BLANK Published 05-16-17, Control # 233-03...
Page 235 Test 16 – Manually Stroking the Pump ......... . . 10-48 Manitowoc...
Page 236 999 SERVICE/MAINTENANCE MANUAL Test 17 – Checking Pump Charge Pressure ........10-49 Test 18 –...
Page 237: Introduction
You must be familiar with the equipment, trained in testing normal operation of the Model 999. These charts contain methods, and use common sense while troubleshooting to instructions to assist in identifying and correcting problems.
Page 238: Guidelines
The test equipment shown or described is available for • Check all terminal points for cleanliness and tighten testing the Model 999 hydraulic or electrical systems. This connections. equipment can be purchased in kit form (with or without carrying case) or separately, by contacting the Manitowoc •...
Page 239: Troubleshooting Charts
999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING TROUBLESHOOTING CHARTS Problem 1 Engine will not turn over to start. POSSIBLE CAUSES Dead battery; Loose connection on battery; Starter, Start solenoid (MS1) relay, or Starter solenoid (SS) is faulty. CHECKS Check for voltage at battery terminals while attempting to turn over engine. (See Test 1.)
Page 240 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 2 Engine turns over, but will not start. POSSIBLE No fuel to or from injector pump; Water or algae in fuel; Air intake restricted or blocked; Engine load is too high; Low battery amperage to gain starting RPM; Fuel shut-off is not working correctly.
Page 241 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 3 Engine runs, but no hydraulic operation. POSSIBLE CAUSES Clutch not engaged; No hydraulic fluid in tank; Blocked charge inlet to pumps; Clogged tank vent; Drive train damaged from flywheel to pump mount. CHECKS Check hydraulic filter service shut-off valve.
Page 242 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 4 Engine runs, but battery is not charging. POSSIBLE CAUSES Belt loose or broken; No input to alternator terminals; Damaged alternator; Corroded or loose battery connection; Battery discharged. CHECKS Check drive belt for correct tension.
Page 243 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 5 Engine fault alerts enable during engine operation. POSSIBLE CAUSES High engine coolant temperature or low engine oil pressure. High Engine Temperature Low Oil Pressure Check engine oil level at dipstick. Check coolant level and quality.
Page 244 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 6 Crawler travels at slow speed. POSSIBLE CAUSES Partial control voltage from handle to PC; Partial control voltage from PC to pump EDC; Pump or motor damaged. CHECKS Check travel speed switch for high-speed selection.
Page 245 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 7 Crawlers will not travel in either direction (one or both tracks). POSSIBLE CAUSES Brake valve, control handle, or EDC faulty; No voltage from handle to PC controller; No voltage out of PC controller to pump EDC; Low brake pressure; Wiring or switch is faulty; Pump, motor or gearbox is damaged.
Page 246 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 8 No front or rear load drum operation. POSSIBLE CAUSES Load drum disc brake not releasing; Load drum pawl not released or hung up; No voltage through control handle to PC controller; No voltage out of PC controller to pump EDC; Wiring or switch is damaged.
Page 247 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 9 Front or rear load drum will not raise load, but will lower load. POSSIBLE CAUSES Block up limit is opened; Pump is faulty; Rated capacity indicator/limiter (RCL) circuit is open; Control handle is faulty; Maximum bail limit is opened; Speed sender is faulty.
Page 248 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 10 Front or rear load drum will not lower load, but will raise load. POSSIBLE CAUSES Pawl in; Control handle is defective; Minimum bail limit opened; Pump is defective; Speed sender is defective. CHECKS Check Diagnostic Screen D2 (see Diagnostic Display topic in section 3).
Page 249 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 11 Front or rear load drum will not reach load drum maximum speed. POSSIBLE CAUSES Partial control from handle to PC; Partial control voltage from PC to pump EDC; Pump or motor is damaged. CHECKS...
Page 250 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 12 No boom hoist operation. POSSIBLE CAUSES Boom hoist brake not releasing; Boom hoist pawl not released or hung up; No voltage through control handle to PC controller; No voltage out of PC controller to pump EDC; Wiring or switch is defective.
Page 251 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 13 Boom hoist will not reach maximum speed. POSSIBLE CAUSES Partial control voltage from handle to PC; Partial control voltage from PC to pump EDC; Pump or motor defective. CHECKS When moving boom hoist control handle fully in both directions, diagnostic...
Page 252 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 14 Boom will not boom up, but will boom down. POSSIBLE CAUSES Maximum bail limit opened; Pump is defective; Boom maximum up limit opened; Equalizer/boom stop limit opened; Control handle is defective. CHECKS Check Diagnostic Screen D2 (see Diagnostic Display topic in section 3).
Page 253 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 15 Boom will not boom down, but will boom up. POSSIBLE CAUSES Boom maximum down limit opened; Minimum bail limit open; Pawl engaged; Pump is defective; Block-up limit open; Control handle is defective; LMI circuit open; Speed sender is defective.
Page 254 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL PROBLEM 15 (Continued) Boom will not boom down, but will boom up. Does diagnostic DRUM 4 screen (bank 2) approach -100% pump control with handle moved forward? Use test plug adapter. (See Test 13.) Are +2.3 or more volts Consult dealer/factory.
Page 255 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 16 No swing operation, but engine loads. POSSIBLE CAUSES Mechanical hang-up; Solenoid failure; Wiring fault. CHECKS Check swing operation in both directions with brake and swing lock released. Slight swing movement No swing movement Check for 12 volts DC at swing Check swing lock for damage.
Page 256 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 17 No swing operation, engine does not load. POSSIBLE CAUSES No voltage through control handle to controller; No voltage out of controller to pump EDC; Wiring or switch is faulty; Damaged pump or motor; Swing holding brake switch actuated.
Page 257 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 18 Travel system response is sluggish. POSSIBLE CAUSES Pump or motor is faulty; Travel speed out of adjustment. CHECKS Use a gauge to check charge pressure at travel pressure senders. 300 psi or less 300 psi or more Adjust charge pressure relief for 350 psi.
Page 258 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 19 Closed-loop hydraulic system response is sluggish. POSSIBLE CAUSES Low hydraulic oil level in reservoir; Low hydraulic oil temperature; Reservoir shut-off is partially closed; Dirty charge filter; System multifunction valves are not set correctly; Pump or motor problem.
Page 259 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 20 Hydraulic system is operating hot. POSSIBLE CAUSES Low hydraulic oil level in reservoir; Heat exchanger problem; Dirty filter; System multifunction valves are not set correctly; Pump or motor problem. CHECKS Is hydraulic oil level in reservoir OK and shut-off valve fully open? Fill tank to full level or open shut-off valve.
Page 260 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 21 Gantry cylinders will not raise or lower. POSSIBLE CAUSES Not in setup mode; Faulty control valve section; Low pump pressure; Bad pump; Switch failure; Faulty counterbalance valve. CHECKS Does system pressurize to 3,500 psi when moving gantry switch...
Page 261 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 22 Mast cylinders will not raise or lower. POSSIBLE CAUSES Not in setup mode; Faulty control valve section; Low pump pressure; Bad pump; Switch failure; Faulty counterbalance valve. CHECKS Does system pressurize to 3,500 psi when moving mast switch to...
Page 262 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 23 Boom hinge pin cylinders will not extend or retract. POSSIBLE CAUSES Not in setup mode; Faulty control valve section; Low pump pressure; Bad pump; Switch failure; Mechanical problem. CHECKS Does system pressurize to 3,500 psi when moving boom hinge pins switch...
Page 263 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 24 Jacking cylinder(s) will not extend or retract. POSSIBLE CAUSES Not in setup mode; Faulty control valve section; Low pump pressure; Bad pump; Faulty counterbalance valve. CHECKS Check for 3,500 psi at rear drum flushing valve test port while manually enabling jacking cylinder on lower accessory valve.
Page 264 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 25 Crawler pin cylinder(s) will not extend or retract (left or right set). POSSIBLE CAUSES Not in setup mode; Faulty control valve section; Low pump pressure; Bad pump; Mechanical problem. CHECKS Check for 3,500 psi at rear drum flushing valve port while manually enabling crawler pin cylinder handle on lower accessory valve.
Page 265 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 26 System pump will not return to neutral. POSSIBLE CAUSES Pump system control handle is faulty or pump EDC is faulty or out of adjustment; System pump is damaged; Pump is not centered. CHECKS Diagnostic display screen A1 displays voltage for problem system handle in neutral position?
Page 266 TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Problem 27 Counterweight pins will not extend or retract. POSSIBLE CAUSES Remote controller or switch wiring failure; Solenoid valve failure; Cylinder failure; Mechanical problem. CHECKS Check for 12 volts at counterweight pins retract switch (pin number WB-30) at remote controller while enabling switch.
Page 267 999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Problem 28 Pawl on load drum or boom hoist is not operating correctly. POSSIBLE CAUSES Mechanical hang-up; No hydraulic pressure; No voltage to pawl solenoid; Fuse or wiring; Cylinder failure. CHECKS Check for damage to pawl linkage. Check for pawl or pawl actuator/cylinder for freedom of movement.
Page 268: Testing
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL TESTING Test 1 – Battery Test (12 and 24 volts DC) 12 VDC AA301 Description Description Item Item Positive Lead Negative Lead Test the 12-volt DC accessory system voltage with a digital A voltage reading of 12 volts or less before cranking engine multi-meter.
Page 269: Test 2- Checking Resistance At Engine Temperature Sender
999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 2– Checking Resistance at Engine Temperature Sender P1589 Description Item Temperature Sender Set digital multi-meter to test resistance. Make required connections to test lead adapter at the meter. Connect negative lead to a grounded component on the crane and the positive lead to engine temperature sender wire terminal.
Page 270: Test 3 - Checking Resistance At Engine Oil Pressure Sender
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 3 – Checking Resistance at Engine Oil Pressure Sender P1590 Description Item Oil Pressure Sender Set digital multi-meter to test resistance. Make required connections to test lead adapter at the meter. Connect negative lead to a grounded component on the crane and the positive lead to engine pressure sender wire terminal.
Page 271: Test 4 - Cleaning And Adjusting The Engine Rpm Transducer
999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 4 – Cleaning and Adjusting the Engine RPM Transducer P1591 Description Item Flywheel Housing RPM Transducer Lock Nut Resistance/AC Voltage Test With engine cold, check for a resistance of approximately 136 ohms. With engine running, check for AC voltage output.
Page 272: Test 5 -Test Adapters For Checking Electrical Inputs/Outputs
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 5 –Test Adapters for Checking Electrical Inputs/Outputs A1103 10-36 Published 05-16-17, Control # 233-03...
Page 273: Test 5 - Continued
In-line Testing Boards Set — Male and Female Pins (P/N 417350) Negative Lead Ground (black) Positive Lead (red) The above test adapters can be ordered from the Manitowoc cable connector A, B, C, D and E with pins numbered 1 Crane Care Lattice Team. The pressure sender, encoder, through 37.
Page 274: Test 6 - Testing For Voltage At The Fuse Box
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 6 – Testing for Voltage at the Fuse Box A1185 F1 - Cab Power (5D) F2 - Horn (5H) F3 - LMI & Gauges (8A) F4 - Computer Inputs (8D) F5 - Defogger Fan (8F) F6 - Boom &...
Page 275: Test 7 - Checking Voltage At The Control Handle
999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 7 – Checking Voltage at the Control Handle P1524 Description Item Load Drum Handle Boom/Swing Handle Crawler Handle Test Terminal Ground Terminal “R” Use following test points to determine the correct voltages at • The positive lead must be placed on the test terminal...
Page 276: Test 8 - Adjusting The Control Handle Potentiometer
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 8 – Adjusting the Control Handle Potentiometer Single Axis Controller P1525 Double Axis Controller P1526 Description Description Item Item Neutral (snap) Switch Center Terminal “C” Jumper Connection (N/O) Potentiometer Ground Terminal “R” Socket Set Screw...
Page 277: Test 9 - Checking Voltage At The Pressure Senders
Test voltage and resistance of a system pressure sender with To test voltage output from the pressure sender to the PC: a standard test adapter (can be ordered from the Manitowoc • Engine must be off and power on, with all brakes and Crane Care Lattice Team) and a digital multi-meter.
Page 278: Test 10 - Checking Voltage At The Speed Encoders
(can be • If this reading is not obtained, check the 5 amp F8 fuse ordered from the Manitowoc Crane Care Lattice Team) and a at the fuse panel (see Test 6). digital multi-meter.
Page 279: Test 11 - Checking Voltage At The Hydraulic Brake Valve
DIN Plug Hydraulic/Brake Valve Adaptor Cable Testing for voltage at any hydraulic brake valve requires a standard test adapter (can be ordered from the Manitowoc Crane Care Lattice Team) and a digital multi-meter. To test brake valve: • Connect the test adapter between brake valve and DIN plug.
Page 280: Test 12 - Checking Voltage At The Hydraulic Valve Assemblies
The solenoid is enabled if screwdriver is magnetically pulled toward the solenoid coil. Measure system voltage at various locations with a standard test adapter (can be ordered from the Manitowoc Crane Care Lattice Team) and a digital multi-meter. To test a hydraulic valve: •...
Page 281: Test 13 - Testing The Pump Edc And Motor Pcp
Testing a pump EDC or motor PCP requires a standard test • Set the digital multi-meter for testing volts DC. adapter (can be ordered from the Manitowoc Crane Care • Connect the PC input cable to PC end of test adapter.
Page 282: Test 14 - Location Of Pump Ports
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 14 – Location of Pump Ports Pump Identification Pump Identification Number Front Load Drum Supercharge Pump Rear Load Drum or Luffing Hoist Boom Hoist Swing Right Crawler Left Crawler A817 Auxiliary Load Drum Pump Components...
Page 283: Test 15 - Location Of Motor Ports
999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 15 – Location of Motor Ports A1188 Swing Motor Boom Hoist, Load Drums, and Travel Motor Port Port Item Description Item Description Main System Pressure Control Pressure Main System Pressure Control Pressure Case Pressure Servo Pressure Supply...
Page 284: Test 16 - Manually Stroking The Pump
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 16 – Manually Stroking the Pump P966 Item Description Manual Stroke Override Pump EDC See Test 13 for location of pump ports. To stroke the pump: • Start with engine running and all brakes and locks engaged.
Page 285: Test 17 - Checking Pump Charge Pressure
999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 17 – Checking Pump Charge Pressure P1599 Item Description Pressure Sender Charge Pressure Test Port Text Gauge Component charge systems can be checked at the desired system diagnostic gauge coupler at pressure sender. To check pump charge pressure: •...
Page 286: Test 18 - Adjusting Pump Charge Pressure Relief
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 18 – Adjusting Pump Charge Pressure Relief P1600 Item Description Adjusting Screw Adjusting Lock Nut The pump charge pressure must be measured to accurately adjust the charge pressure relief valve. To adjust pump charge pressure: •...
Page 287: Test 19 - Setting The Pump Pressure
999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 19 – Setting the Pump Pressure P1537 P1533 Item Description Item Description Multifunction Valve Adjusting Screw for Port “A” Lock Nut Multifunction Valve Adjusting Screw for Port “B” Bypass Hex Nut To adjust multifunction valve: Turning adjusting screw counter-clockwise will decrease relief pressure.
Page 288: Test 20 - Setting Pump Neutral
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 20 – Setting Pump Neutral P1535 Item Description Neutral Adjusting Screw and Lock Nut Servo Gauge Ports To set pump neutral: • Note the handle position of the hex wrench and without moving wrench, rotate the neutral adjusting screw •...
Page 289: Test 21 - Testing For Pump And Motor Leakage
30 gpm (113 L/min). Flow meters can be ordered from the • Record all measurements at neutral. Manitowoc Crane Care Lattice Team. • At heavier loads, normal case flow may go to 7 gpm Acceptable leakage is based on the combined case flow of (26 L/min).
Page 290: Test 22 - Checking Hydraulic Brake Pressure
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 22 – Checking Hydraulic Brake Pressure P1603 Item Description Diagnostic Gauge Coupler Loop Flushing (purge) Valve Brake Solenoid Valve The swing brake, swing lock and travel brakes operate off • Connect a 0 – 1,000 psi (69 bar) gauge at diagnostic rear drum low-pressure charge pump pressure.
Page 291: Test 23 - Servicing The Motor Loop Flushing (Purge) Valves
999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 23 – Servicing the Motor Loop Flushing (Purge) Valves P1603 Item Description Motor Loop Flushing (purge) Valve Valve Flow Control Sequence Valve Problems with a faulty loop-flushing valve are best corrected by replacing the complete valve assembly. To service the loop flushing valve: •...
Page 292: Test 24 - Actuating The Solenoid Valve Manual Overrides
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 24 – Actuating the Solenoid Valve Manual Overrides Brake Valve P1603 Item Description Hydraulic Brake Valve Valve Override (under cap) To check that a solenoid valve or system valve is operating correctly: • Start the engine and actuate the manual override.
Page 293: Test 25 - Adjusting Accessory Pressure Switch
999 SERVICE/MAINTENANCE MANUAL TROUBLESHOOTING Test 25 – Adjusting Accessory Pressure Switch P1488 Item Description Rotating Frame Swivel Electrical DIN Connector Accessory Pressure Switch Adjusting Screw Accessory Pressure Switch In setup mode, when an accessory valve main spool shifts, the supply flow passages of other accessory valves are blocked, stopping fluid to accessory pressure switch.
Page 294: Test 26 - Adjusting The Counterbalance Valves
TROUBLESHOOTING 999 SERVICE/MAINTENANCE MANUAL Test 26 – Adjusting the Counterbalance Valves P1617 P1527 Item Description Counterbalance Valve Gantry Cylinder Jacking Cylinder Counterbalance valves are pre-adjusted at the factory, but are not calibrated. Adjust counterbalance valves with a closed-end wrench and hex wrench.
Page 295 Test Equipment ..............10-2 Manitowoc...
Page 296 999 SERVICE/MAINTENANCE MANUAL Test Voltages ..............3-8 Testing.

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