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Manitowoc 3900W Service Manual

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This manual has been prepared for and is considered part of -

The crane serial number is the only method your distributor or the factory

has of providing correct parts and answers to service problems.

The crane serial number is located on a decal attached to the operator's

cab. Always furnish crane serial number when ordering parts or

communicating service problems with your distributor or the factory.

TH

2401 SO. 30

08/29/05

SERVICE MANUAL

3900W

Crane Model No.

395143

Crane Serial No.

This manual is divided into the following sections:

SECTION 1

General

SECTION 2

Attachment

SECTION 3

Maintenance

SECTION 4

Lubrication

SECTION 5

Capacities

SECTION 6

Operating Controls

SECTION 7

Adjustments

SECTION 8

Troubleshooting

NOTICE

To prevent death or serious injury:

• Avoid unsafe operation and maintenance.

• This crane must be operated and maintained by trained and

experienced personnel. Manitowoc Cranes is not responsible for

qualifying these personnel.

• Do not operate or work on this crane without first reading and

understanding Operator's Manual and Capacity Charts supplied with

crane.

• Store Operator's Manual supplied with crane in holder in operator's

cab.

• Attach laminated Capacity Charts supplied with crane to chain in

operator's cab.

• If Operator's Manual or Capacity Charts are missing from cab,

contact your distributor for new ones.

MANITOWOC CRANES, INC.

STREET

PO BOX 70

MANITOWOC, WI 54221-0070 USA

PHONE 920-684-6621

FAX 920-683-6338

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Table of Contents

Troubleshooting

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Summary of Contents for Manitowoc 3900W

Page 1 • Avoid unsafe operation and maintenance. • This crane must be operated and maintained by trained and experienced personnel. Manitowoc Cranes is not responsible for qualifying these personnel. • Do not operate or work on this crane without first reading and understanding Operator’s Manual and Capacity Charts supplied with...
Page 3 DIESEL ENGINE EXHAUST CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. © 1997 Manitowoc Cranes, Inc. Rev. 07-08-97 Folio 1537-1...
Page 5 SERVICE MANUAL INDEX MODEL 3900W - SERIAL 395143 PUBLICATION DATE TITLE FRONT OF MANUAL Folio 1537 07/08/97 Diesel Engine Exhaust SECTION 1 - GENERAL Basic Specification Basic Specification Sheet Form 1-8506 08/18/97 New Parts Warranty Folio 953 01/05/02 Safety Messages...
Page 6 SERVICE MANUAL INDEX MODEL 3900W - SERIAL 395143 PUBLICATION DATE TITLE SECTION 3 - MAINTENANCE Folio 445 2-HA-1 Pilotair Valve Folio 451 2-HA-2 Pilotair Valve Folio 452 A Pilotair Valve Folio 503 06/14/96 Shuttle Valve Folio 525 06/14/96 Air System Deicer...
Page 7 SERVICE MANUAL INDEX MODEL 3900W - SERIAL 395143 PUBLICATION DATE TITLE SECTION 6 - OPERATING CONTROLS Folio 34-15.4 10/15/73 Independent Boom Hoist Auxiliary Brake Folio 34-16.1 03/01/67 Slide Pinion Control Folio 34-19.1 09/01/67 Travel Control Folio 34-20.1 01/16/84 Drum Rotation Indicator Folio 34-21.1...
Page 9 SECTION 1 - General...
Page 11 SEE ATTACHED CAPACITY CHART SHEET...
Page 12 Capacity Chart Sheet Model: 3900W Serial Number: 395143 Boom #: Jib #: #123 Signature/Date: BE 08-23-2005 CHARTS Number Date Drum and Lagging: 4867 1/29/1971 Barge Charts: 6896-A 12/17/2001 Lift Charts: 6705-A 5/5/1992 6705-C 5/5/1992 Jib Chart: 6706-A 5/5/1992 Range Diagram:...
Page 13 “boom and jib sections, strut, mast, backhitch, gantry, rotating bed, car- body and crawler side frames” is three (3) years from date of shipment by Manitowoc; provided, however, that the machine is used solely for liftcrane applications. No claims...
Page 15: General
Identifies potential hazards that could result in minor or moderate injury if the message is ignored. CAUTION Without the safety alert symbol, identifies potential hazards that could result in prop- erty damage if the message is ignored. NOTE: Highlights operation or maintenance procedures. © 2002 Manitowoc Cranes, Inc. Rev. 01-05-2002 Folio 953-1...
Page 17: Table Of Contents
Because of a program of continuing improvement in product job site personnel can result in their death or injury and costly design, Manitowoc r eser ves the rig ht to change the damage to the crane or property. information and specifications contained in the Crane The safety information in this publication is intended only as Instruction Manual at any time without notice.
Page 18: Operator Qualifications
Capacity charts furnished by Manitowoc are stamped with applicable crane’s serial number and laminated with If there is a warning sign at the start controls, the plastic.
Page 19: Handling Load
Apply the travel and swing brakes or locking the crane. devices. NOTE: The capacity charts for Manitowoc cranes show the Land any attached load. total weight of freely suspended loads for various boom lengths and operating radii. d. Lower the boom onto blocking at ground level or onto a boom rest if possible;...
Page 20 SAFE OPERATING PRACTICES b. The load is secured and properly balanced in the Before lifting a load which requires use of outriggers slings or lifting device before lifting the load more (or anytime outriggers are used), fully extend the than 3 – 6 in. (76 – 152 mm). outrigger beams and jacks so the truck tires do not bear any load.
Page 21: Holding Load
SAFE OPERATING PRACTICES d. Lock the upperworks against rotation except when it d. Keep unnecessary personnel out of the crane’s is necessary to negotiate a turn, and then only when operating area. the operator is seated at the controls or the boom is When moving the crane, the following audible signals supported on a dolly.
Page 22: Pedestal Mounting
PERSONNEL HANDLING straps, and tag lines as conductors. Manitowoc cranes are neither designed for nor intended to Most overhead power lines ARE NOT insulated. Treat all be used as personnel hoists. Refer to Folio 1295 in Crane...
Page 23: Electrocution Hazard Devices
SAFE OPERATING PRACTICES magnitude, can arc or jump to any part of the load, load line, Boom cages and boom guards afford limited protection from or crane boom if it comes too close to an electrical power electrocution hazards. They are designed to cover only the source.
Page 24: Refueling
OF CRANE. DO NOT STEP OFF. Hop away with both feet together. DO NOT walk or run. Following any contact with an energized electrical source, the local, author ized, Manitowoc distr ibutor must be immediately advised of the incident and consulted on necessary inspections and repairs. Thoroughly inspect the wire rope and all points of contact on the crane.
Page 25 MAINTENANCE INSTRUCTIONS Wear clothing that is relatively tight and belted. To ensure safe and proper operation of Manitowoc cranes, they must be maintained according to the instructions Wear appropriate eye protection and approved hard hat.
Page 26 SAFE MAINTENANCE PRACTICES 11. Do not remove radiator cap while coolant is hot or under 27. Unless authorized in writing by Manitowoc, do not alter pressure. Stop engine, wait until pressure drops and crane in any way that affects crane’s performance (to coolant cools, then slowly remove cap.
Page 27 PERSONNEL HANDLING OSHA Regulations* state: Manitowoc Cranes are Designed and Intended for Handling Material — NOT FOR HANDLING PERSONNEL. “The use of a crane or derrick to hoist employees on a personnel platfor m is prohibited, except when the Check local, state, and foreign countr y codes before erection, use, and dismantling of conventional means of handling personnel.
Page 29 Carbody on barge. Foundation Manitowoc does not permit use of a truckcrane on a barge, ship or floating platform. NOTE: bolting carbody foundation,...
Page 30: Definition
Front and Rear tie-downs to the foundation (Figure 3). Required Carbody When Parked Curbing Foundation A839 NOTE: Manitowoc does not permit traveling with load. FIGURE 4 ® Carbody RINGER (crawler mounted, carbody mounted) Tie-Downs supported on blocking, screw jacks or steel pedestals...
Page 31: Definition
NOTE: Manitowoc does not recommend crane operation under dynamic conditions. However, if operation Manitowoc Cranes provides two types of capacity charts for under dynamic conditions is required, Manitowoc a crane mounted on a barge or other supporting structure Cranes will consider issuing a capacity chart for under static conditions.
Page 32: Definitions
While hook roller inspection is of major importance, regular inspection for signs of overloading in the following load Machine List , as defined by Manitowoc Cranes, is the bearing components is equally important and must not be crane’s out-of-level condition — from side-to-side — as overlooked.
Page 33 Refer to the applicable folio or drawing in the Service/Operator’s Manual or the Parts Manual provided with the crane for installation locations of signs. ORDERING SIGNS Order replacement signs from your local Manitowoc Dealer or from the factory at the fol- lowing address: Parts Department Manitowoc Cranes, Inc.
Page 37 Group F MANITOWOC CRANES, INC. Bottom Butt Insert Chord MALE Bottom Male Chord CONNECTOR Connector 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 Box Section Angle Tubular...
Page 39 2.2046 TON (2000 LB) NEWTON 8896.4 TON (2000 LB) 907.18 OZ (Avoirdupois) 28.35 LB (Avoirdupois) 453.59 METER (M) .3048 2.54 MILE (STATUTE) 1.6093 2.54 x 10 To Convert From Divide By © 2002 Manitowoc Cranes, Inc. Rev. 04-08-2002 Folio 1076-1...
Page 40 ENGLISH AND METRIC CONVERSIONS To Convert From Multiply By To Convert From Multiply By LB (Avoirdupois) .45359 FT/MIN 1.1364 x 10 LB (Avoirdupois) 453.59 KM/HR 1.6093 OZ (Avoirdupois) 28.35 METER/SEC .44704 SLUG 14.594 FT/SEC METER/SEC .3048 TON (2000 LB) 907.18 RADIANS/SEC .10472 TON (Metric)
Page 57 MANITOWOC DISTRIBUTORS To locate the Manitowoc Approved Distributor nearest you: Go to www.manitowoccranes.com. Click on Manitowoc logo. Click on Dealers. Follow on-screen instructions to locate distributor. When calling a distributor with parts or service questions, you need to know the model and serial number of your crane.
Page 59 SECTION 2 - Attachment...
Page 61 If possible, secure the area to keep unauthorized personnel and vehicles away. GENERAL Boom as used in this folio applies to all lattice NOTE: attachments (jib, mast, tower, etc.) 147852 FIGURE 1 © 2003 Manitowoc Cranes, Inc. Rev. 03-26-2003 Folio 1474-1...
Page 62 BOOM DISASSEMBLY SAFETY CONSIDERATIONS DISASSEMBLY PROCEDURES If boom to be disassembled is not cantilevered, pay out boom hoist line so that line is slack. As long as all boom Always block boom sections on both sides of connections so sections are securely blocked, top and bottom connecting that sections are securely supported and cannot shift or pins can be safely removed.
Page 67 Universal anchor joint (3) located some distance behind lower boom point, provides movement in four directions. Forward, back and sideways for magnet, clamshell, grapple, liftcrane and other FIGURE 1 operations requiring a 2-part load line (duty-cycle work). © 2002 Manitowoc Cranes, Inc. Rev. 04-08-2002 Folio 1507-1...
Page 103 SECTION 3 - Maintenance...
Page 149 Wash all rubber parts with soap and water. Rinse all parts thoroughly and blow dry with a low-pressure air jet. Replace the diaphragm and the gasket if damaged or worn. Reassemble the valve and check for leaks during operation. No lubrication is required. © 1996 Manitowoc Engineering Co. Rev. 06-14-96 Folio 441-1...
Page 150 QUICK RELEASE VALVE Operation The quick release valve has 3 ports as shown in the illustrations. Air pressure entering the IN port forces the diaphragm to seal the EXHAUST port and open a direct passage between the IN and OUT (cylinder) ports. When air pressure at the IN port is reduced and pressure is slightly greater at the OUT port, the diaphragm is forced against the IN port.
Page 157: General
Wash all rubber parts with soap and water. Rinse thoroughly and blow dry with a low-pressure air jet. Replace diaphragm (4) and gasket (5) if damaged or worn. Reassemble the valve and check for leaks during operation. No lubricant is required. © 1996 Manitowoc Engineering Co. Rev. 06-14-96 Folio 503-1...
Page 159: Operation
When the fill plug is replaced, the reservoir re-pressurizes through the charge valve at a nominal rate. The charge valve opens fully when inlet pressure is reached. © 1996 Manitowoc Engineering Co. Rev. 06-14-96 Folio 525-1...
Page 160 AIR SYSTEM DEICER S115 FIGURE 1 Adjusting Turn adjusting knob (6) COUNTERCLOCKWISE to INCREASE the drip rate or CLOCKWISE to DECREASE the drip rate (1 to 3 drops per minute is (Figure 1) usually sufficient). Drip rate adjustments should only be made under a steady flow condition.
Page 161 AIR SYSTEM DEICER Maintenance To service the deicer, shut off the air pressure. Deicer may be disassembled (Figure 2) without removal from air line. If deicer has transparent reservoir, remove guard (15) by rotating guard around body (1) to 'wind out' retaining spring (14) through cutout in guard. Slide guard off body.
Page 162 AIR SYSTEM DEICER S116 4 Fill Plug Install Remove FIGURE 2 Filling Fill reservoir with a good quality deicant to level indicated by maximum fill line. Do not overfill. Folio 525-4...
Page 163 4. In case of major repair work, it is recommended that the unloader pilot valve be returned to the Gardner-Denver factory in Quincy, Illinois, due to the special tools and testing equipment required to lap and align the seating surfaces. © 1996 Manitowoc Engineering Co. Rev. 06-10-96 Folio 574-1...
Page 164 UNLOADER PILOT VALVE MAINTENANCE Typical Mounting Near Air Tanks or Compressor Unloader Pilot Valve P296 Exhaust To Air Compressor S109 From Air Tank Item Description Unloader Outlet Connection Adjusting Screw Lock Nut Unloader Cap Unloader Cap Shim Unloader Spring Unloader Body Unloader Valve Valve Ball Filter...
Page 167 Turn the handle all the way IN. Turn the handle to this position if the valve malfunctions; the crane can then be operated until repairs or replacement can be made at a convenient time. © 1996 Manitowoc Engineering Co. Rev. 06-10-96 Folio 1002-1...
Page 168 MOISTURE EJECTOR VALVE MAINTENANCE Operational Make the following checks after the engine is started at the beginning of each Checks work shift: 1. Check for air leaks. There must be no leaks in the pilot line to the valve or at any point on the valve.
Page 175 AIR SYSTEM FILTER SERVICE INFORMATION General Two styles of air filters are used on Manitowoc cranes: Watts and Balston. This folio describes maintenance of both filters. Daily 1. Open the manual drain valve at the end of each shift to drain water and dirt Maintenance from the filter.
Page 176 AIR SYSTEM FILTER Air Tank Air IN P307 P308 Air IN Filter Shut-Off Valve Filter Manual Shut-Off Drain Valve Valve Head Manual S129 Drain Valve S128 Gasket Element Gasket Bowl Ring Stud Gasket Deflector Element O-Ring Element Retainer Gasket Gasket Secondary Baffle Base O-Ring...
Page 177: Normally Closed
E = Exhaust. For NORMALLY-CLOSED operation the air lines must be connected to the valve ports as shown in Figure 1. “E” S126 (exhaust) “A” (cylinder) “P” (in) Normally Closed FIGURE 1 © 1996 Manitowoc Engineering Co. Rev. 06-14-96 Folio 1307-1...
Page 178: Electrical Connection
SOLENOID VALVE For NORMALLY-OPEN operation the air lines must be connected to the valve ports as shown in Figure 2. “P” (in) S125 “A” (cylinder) “E” (exhaust) Normally Open FIGURE 2 WARNING Improper connection of air lines will result in improper operation of system. Electrical If the coil housing is located in an inconvenient position, it may be oriented in 90 degree steps.
Page 179: Disassembly
SOLENOID VALVE Noise If the valve develops a loud buzzing noise, first check voltage and pressure to determine if they correspond to the nameplate rating. Examine the inside of the sleeve assembly and the upper portion of the plunger and remove all foreign matter imbedded in these parts.
Page 180 SOLENOID VALVE Name Plate S127 Retainer Name Plate Housing Coil Washer Coil Yoke Screw Housing Plate Sleeve Assembly O-Ring Plunger and Spring Assembly Body FIGURE 3 Folio 1307-4...
Page 207 The sulfate condition can eventually be converted to metallic water. Seek first aid if discomfort continues. lead which can short the positive and negative plates. These small shorts can cause low cell voltage when the battery is charged. © 2002 Manitowoc Cranes, Inc. Rev. 04-08-2002 Folio 972-1...
Page 208 BATTERY MAINTENANCE Lack of Water Every 2 Months – Test Batteries The plates must be completely covered. If the plates are NOTE: Before testing a battery: determine that the exposed, the resultant high acid concentration will char and alternator is putting out current, that the current is disintegrate the separators.
Page 209 BATTERY MAINTENANCE Open-Circuit Voltage Test CHARGING A sensitive voltmeter can be used to determine a battery’s If at all possible, the battery should be at room temperature state-of-charge as depicted in Table 3. when recharging. Before a battery is recharged, it must be thoroughly cleaned.
Page 241 Manitowoc Distributor. For inspection or repair procedures not covered in this Refer to Folio 823 for information on ordering lacings.
Page 242: Dents
Line Refer to Table 1 for the wall thickness of tubular lacings and chords on various attachments. For attachments not listed, refer to Lacing Drawings in your Parts Manual or contact your Manitowoc Distributor. Bent Lacing Dents Refer to Figure 1.
Page 243 BOOM, JIB, TOWER, AND MAST Table 1 Tubular Lacing And Chord Wall Thickness Boom, Jib, Tower, or Lacing Wall Thickness Chord Wall Thickness Mast in. (mm) in. (mm) Number 0.095 (2.4) Angle (NOTE 1:) 0.095 (2.4) Angle (NOTE 1:) 0.109 (2.8) 0.340 (8.6) 0.25 (6.4) Butt 0.095 (2.4)
Page 244: Kinks
BOOM, JIB, TOWER, AND MAST Kinks Cracks and Breaks Refer to Figure 3. Refer to Figure 4. Kinked lacings must be replaced; do not bend kinked lacings Cracked and broken lacings must be replaced; do not back into alignment . attempt to repair cracked or broken lacings .
Page 245: Corrosion And Abrasion
BOOM, JIB, TOWER, AND MAST Corrosion and Abrasion Refer to Figure 5. Corrosion and abrasion must not be deeper than 10 percent of the wall thickness, the angle thickness, or the plate thickness. P325 Not Acceptable Not Acceptable Acceptable Abrasion from handling with Surface is badly pitted;...
Page 246: Chord Straightness
BOOM, JIB, TOWER, AND MAST Chord Straightness Take the first set of measurements, then roll the insert o v e r 9 0 d e g r e e s , a n d t a k e t h e s e c o n d s e t o f Refer to Figure 6.
Page 247: Welding Electrodes
BOOM, JIB, TOWER, AND MAST Welding Electrodes Unheated electrodes will absorb moisture over a period of time. Remove only the quantity of electrodes from the sealed The welding electrodes must be high quality low hydrogen container or the oven that can be used in 30 minutes. type .
Page 248: Replacing Lacings
The packing slip shipped with new lacings identifies the before welding. If necessary use emery cloth to polish lacing and chord material. This information is also recorded the surfaces. with the original parts order from your Manitowoc Distributor. lacings into position...
Page 249 Signed and dated copies of completed checklists must be pages 3 and 4 for drawing sketches or attaching kept on file at all times, as they may be required to verify photographs. warranty or product liability claims. © 2002 Manitowoc Cranes, Inc. 04-08-2002 Folio 1354-1...
Page 250 One of the connectors on the boom, jib, tower, and mast sections is marked as indicated in the below illustration. These numbers must be recorded in the checklist for each section inspected. A524 Manitowoc Part Number Boom, Jib, Tower, of Component or Mast Number...
Page 251 BOOM, JIB, TOWER, AND MAST Insert: Length Manufacturing Code Part Number Dents Bends Kinks Cracks Breaks Corrosion Abrasion Straightness Welds Other Insert: Length Manufacturing Code Part Number Dents Bends Kinks Cracks Breaks Corrosion Abrasion Straightness Welds Other Insert: Length Manufacturing Code Part Number Dents Bends...
Page 252 BOOM, JIB, TOWER, AND MAST NOTES DRAW SKETCHES OR ATTACH PHOTOGRAPHS HERE Folio 1354-4...
Page 253 BOOM, JIB, TOWER, AND MAST NOTES DRAW SKETCHES OR ATTACH PHOTOGRAPHS HERE Folio 1354-5...
Page 255 Number Component Component View B Part Number Part Number CURRENT PRODUCTION Manufacturing Boom or ZZZZZZ-Z XXXXXX Code Jib Number Z-ZZ-ZZ X-X-XX A524 View A Manufacturing PAST PRODUCTION Code Chord FIGURE 1 © 2002 Manitowoc Cranes, Inc. Rev. 04-08-2002 Folio 823-1...
Page 256 The parts order must contain the following information to lacings with circled letters in Figure2 are damaged. Your ensure that Manitowoc provides you with the correct lacings: parts order should be similar to the following example: Crane serial number (can be found on builders plate in Crane Serial Number: 00000 (from builders plate).
Page 257 Figure 3 are damaged. The parts order must contain the following information to Your par ts order should be similar to the following ensure that Manitowoc provides you with the correct lacings: example: Crane serial number (can be found on builders plate in Crane Serial Number: 00000 (from builders plate).
Page 259 Before cutting wire rope, apply seizings on both sides of the point where the cut will be made. Then cut the wire rope with a torch, rope cutter, or abrasive cut-off wheel. FIGURE 1 A925 © 2004 Manitowoc Cranes, Inc. Rev. 03-31-2004 Folio 931-1...
Page 260: Wire Rope Storage
WIRE ROPE INSTALLATION AND MAINTENANCE Refer to Table 1 for the number of seizings to be applied to Anchoring Wire Rope to Drum the ends of wire rope and to both sides of the point where a Refer to Figure 4. cut will be made.
Page 261: Winding Wire Rope Onto Drum
WIRE ROPE INSTALLATION AND MAINTENANCE Refer to “Boom Rigging Drawing” in Service or Operator’s Don’t Allow Dead End to Manual for correct type, size, and amount of wire rope to be Extend Out of Socket installed on boom hoist drums. Opening.
Page 262: Anchoring Wire Rope To Wedge Socket
Only use a wedge and socket which are correct size wedge seats tight. Do not shock load socket and wedge . for wire rope being used. On current production cranes and attachments, Manitowoc • Attach wire rope clip to dead end of wire rope after Cranes uses the Crosby “Terminator”...
Page 263 WIRE ROPE INSTALLATION AND MAINTENANCE Right! Method A Seizing Rope Clip Dead Live Side in Straight Line with Socket Socket 6 to 9 Rope Diameters for Conventional Rope Do not reinstall any shipping material (bolt, plastic strap, or wire) in hole of 20 Rope Diameters for wedge or socket after assembling.
Page 264: Wire Rope Lubrication
WIRE ROPE INSTALLATION AND MAINTENANCE WIRE ROPE LUBRICATION The wire rope must be clean and dry before applying lubricant; an air jet, or wire brush are some cleaning Wire rope is a complicated piece of machinery, and its methods. lubrication is just as important as it is for the gears and Do not use grease to lubricate wire rope.
Page 265: Replacing Wire Rope
WIRE ROPE INSTALLATION AND MAINTENANCE Wire Rope Diameter Broken or cut strands. Broken wires (see Periodic Inspection for additional Measure and record the diameter of a new wire rope after information). initial loading for comparison with future inspections. A reduction in rope diameter is often the first outward sign that Core failure in rotation resistant rope (indicated by lay the wire rope core is damaged.
Page 266 WIRE ROPE INSTALLATION AND MAINTENANCE Broken Wires Thoroughly clean the wire rope so breaks can be seen. Relax the rope, move it off “pick-up points,” and flex it as WARNING much as possible. Use a sharp awl to pick and probe between wires and strands, lifting any wire which appears Replace wire rope when more than one loose or moves excessively.
Page 267: Steel Sheave, Roller, And Drum Inspection
WIRE ROPE INSTALLATION AND MAINTENANCE Observe groove to see if contour of gauge matches contour at bottom of sheave groove. Dog-Leg Kink WRONG S144 Drum Abrasion Groove Too Small Groove Too Large Proper fitting sheave groove should support S145 wire rope or 135–150° of rope circumference. Drum RIGHT Crushing...
Page 268: Nylon Sheave Inspection
WIRE ROPE INSTALLATION AND MAINTENANCE Replace worn or damaged bearings. Most of Manitowoc’s nylon sheaves have sealed bearings that do not require lubrication. Replace grooved drums that allow one wrap of wire rope to contact next wrap as rope spools onto drum.
Page 269 WIRE ROPE INSTALLATION AND MAINTENANCE SHEAVE DATA Outside Sheave Width Rope Diameter Tread Diameter Diameter Part No. inch inch inch inch 912738 631054 13.19 335.0 11.42 290.1 1.77 45.0 631056 631065 16.00 406.4 13.37 339.6 2.17 55.1 9/16 631071 16.00 406.4 13.88 352.6...
Page 271 11. Inspect each hook and shackle for damage as shown in Check the sheaves for uneven wear in the grooves and Figure 4. on the flanges. Check for loose or wobbly sheaves. These conditions indicate faulty bearings or bushings. © 2002 Manitowoc Cranes, Inc. Rev. 04-08-2002 Folio 997-1...
Page 272 LOAD BLOCK AND HOOK-AND-WEIGHT BALL NOTE: Check each hook and shackle at least yearly for cracks using a dye penetrant test, MAG particle A923 test, ultrasonic test, or by X-raying. Dead-End Socket and Wedge Side Plate WARNING Tie Bolt Falling Load Hazard! Sheaves Center Plates To prevent load from dropping due to hook or shackle...
Page 273 SECTION 4 - Lubrication...
Page 295 • Resists becoming so stiff that it chips or peels off at coldest operating temperature. This type oil requires heating or thinning for proper application to gear teeth. Apply a light film of oil to each gear tooth. Do not rely on gear rotation to distribute oil. © 2001 Manitowoc Cranes, Inc.
Page 296 You are urged to consult your oil supplier before using a boom hoist lubricant that is not approved by Manitowoc. If your oil supplier warrants that the lubricant is in fact equivalent to the our approved lubricant and will provide the required lubrication, then your crane warranty will not be affected.
Page 297 Fluids Model System Fluid All Models † Gantry Lifting Device Pump Hydraulic 3900 Power Lowering 10W-30 * Boom Hoist 3900W, 3950W Hydraulic † Power Lowering 3950W Tagline Hydraulic 3950D Drag/Clam Boom Positioning Hoist (one drum) 10W-30 * 4000W Power Lowering 10W-30 * Boom Hoist, Hyd.
Page 301 SECTION 5 - Capacities...
Page 303 CAPACITIES MODEL 3900W - SERIAL 395143 PUBLICATION DATE TITLE SECTION 5 - CAPACITIES Folio 2081 03/07/05 Capacity Chart Information Folio 1094 01/27/93 Load Block Data For lifting capacities, wire rope specifications, drum and lagging information, and other capacity information, refer to separate capacity chart manual provided with crane or to laminated capacity charts retained in operator's cab.
Page 305 Read capacity chart in use to determine what is considered part of total load. If Capacity charts for Manitowoc cranes show the total weight in doubt, contact your Manitowoc Distributor or the Service of freely-suspended loads for various boom/jib lengths and Department at the factory for assistance.
Page 306: Example - Determining Total Load And Maximum Working Radius From Lower Boom Point
CAPACITY CHART INFORMATION EXAMPLE – Determining Total Load and Maximum Working Radius From Lower Boom Point For this example, an M-250 equipped as follows has been used: • B30.5 Capacity Chart Boom Boom Oper. Boom Point Capacity • 130 ft of #44 Heavy Lift Boom Lgth.
Page 307: Worksheet A - Determining Total Load And Maximum Working Radius From Lower Boom Point
CAPACITY CHART INFORMATION Worksheet A – Determining Total Load and Maximum Working Radius From Lower Boom Point DESCRIPTION WEIGHT Component Weights (see Note 1:) __________ Fixed Jib (see Jib Deduct table in capacity chart) ..........__________ Load Block/Hook and Weight Ball (below fixed jib point) .
Page 308: Worksheet B - Determining Total Load And Maximum Working Radius From Upper Boom Point
CAPACITY CHART INFORMATION Worksheet B – Determining Total Load And Maximum Working Radius From Upper Boom Point DESCRIPTION WEIGHT Component Weights ___________ Load Block/Hook and Weight Ball (below upper boom point) ........___________ Upper Boom Point (from capacity chart if noted) .
Page 309: Worksheet C - Determining Total Load And Maximum Working Radius From Fixed Jib Point On Boom
CAPACITY CHART INFORMATION Worksheet C – Determining Total Load and Maximum Working Radius From Fixed Jib Point on Boom DESCRIPTION WEIGHT Component Weights __________ Load Block/Hook and Weight Ball (below fixed jib point) ........__________ Upper Boom Point (from capacity chart if noted) .
Page 310: Worksheet D - Determining Total Load And Maximum Working Radius From Lower Boom Point With Luffing Jib Attached
CAPACITY CHART INFORMATION Worksheet D – Determining Total Load and Maximum Working Radius From Lower Boom Point with Luffing Jib Attached (see Note 1:) DESCRIPTION WEIGHT Component Weights ___________ Load Block/Hook and Weight Ball Below Lower Boom Point (see Note 2:)......___________ Fixed Jib (see Jib Deduct Table in capacity chart) .
Page 311: Worksheet E - Determining Total Load And Maximum Working Radius From Lower Luffing Jib Point
CAPACITY CHART INFORMATION Worksheet E – Determining Total Load and Maximum Working Radius From Lower Luffing Jib Point DESCRIPTION WEIGHT Component Weights __________ Load Block/Hook and Weight Ball (below lower luffing jib point) ....... . __________ Fixed Jib (see Jib Deduct Table in capacity chart) .
Page 312: Worksheet F - Determining Total Load And Maximum Working Radius From Fixed Jib Point On Luffing Jib
CAPACITY CHART INFORMATION Worksheet F – Determining Total Load and Maximum Working Radius From Fixed Jib Point on Luffing Jib DESCRIPTION WEIGHT Component Weights ___________ Load Block/Hook and Weight Ball (below fixed jib point) ........___________ Upper Luffing Jib Point (from capacity chart if noted) .
Page 313: Worksheet G - Determining Total Load And Maximum Working Radius From Intermediate Fall Point On Luffing Jib
CAPACITY CHART INFORMATION Worksheet G – Determining Total Load and Maximum Working Radius From Intermediate Fall Point on Luffing Jib (see Note 1:) DESCRIPTION WEIGHT Component Weights __________ Load Block/Hook and Weight Ball (below intermediate fall point) ....... . __________ Fixed Jib (see Jib Deduct Table in capacity chart) see Note 2: .
Page 314: Worksheet H - Determining Total Load And Maximum Working Radius From Tower Boom Point
CAPACITY CHART INFORMATION Worksheet H – Determining Total Load and Maximum Working Radius From Tower Boom Point DESCRIPTION WEIGHT Component Weights ___________ Jib (see Jib Deduct Table in capacity chart) ..........___________ Load Block/Hook and Weight Ball (below jib point, if installed) .
Page 315: Worksheet J - Determining Total Load And Maximum Working Radius Tower Jib Point
CAPACITY CHART INFORMATION Worksheet J – Determining Total Load and Maximum Working Radius Tower Jib Point DESCRIPTION WEIGHT Component Weights __________ Load Block/Hook and Weight Ball (below jib point) ......... . __________ Load Block/Hook and Weight Ball (below boom point, if installed) .
Page 316: Worksheet K - Determining Total Load And Maximum Working Radius From Tower Intermediate Fall
CAPACITY CHART INFORMATION Worksheet K – Determining Total Load and Maximum Working Radius From Tower Intermediate Fall (see Note 1:) DESCRIPTION WEIGHT Component Weights ___________ Load Block/Hook and Weight Ball (below jib point, if installed) (see Note 1:) ..... . ___________ Load Block/Hook and Weight Ball (below boom point, if installed) .
Page 317 CAPACITY CHART INFORMATION THIS PAGE BLANK F2081-13...
Page 318: Crawler Blocking Diagram
CAPACITY CHART INFORMATION CRAWLER BLOCKING DIAGRAM • Raising and lowering booms, boom and fixed jibs, tower attachments, and luffing jib attachments which require increased stability as stated on the capacity chart. • Capacity chart ratings which require front of crawlers to WARNING be blocked (limited swing).
Page 319 6.35 22.22 2250 25.40 12.70 2900WC 19.05 19.05 2900WC 25.40 25.40 3000W 6.35 25.40 3900 6.35 12.70 4, 5 3900W 6.35 12.70 3950D 6.35 19.05 3950W 6.35 19.05 4000 12.70 19.05 4000W 6.35 12.70 4100W S1, S2 15.88 12.70 4600 15.88...
Page 320: Operating Radius
Ring Gear 3000W 0.96 C L Rotation 3600 A921 1.37 2900T 1.09 2900WC 3900 3900T 3900W or WT 3950D 1.35 Outside Edge 3950W or WT of Roller Path 4000 4000W C L Rotation 4100W 1.37 4600 S-1, 2, 3 1.68...
Page 321 CAPACITY CHART INFORMATION Radius – R Model Identification ft-in. meters M-250 1.85 C L Rotation 2250 Front Plate of Rotating Bed Adapter Frame Outside Edge of X-TENDER Beam 4100W S-2 C L Rotation 67-4 20.52 X-TENDER™ S-2 Front Plate of Rotating Bed 1.40 Front of Front...
Page 322 CAPACITY CHART INFORMATION Radius – R Model Identification ft-in. meters A043001 16000 1.85 C L Rotation 18000 Front Edge of Rotating Bed Adapter Frame C L Rotation 21000 1.42 Front Plate of Rotating Bed Adapter Frame F2081-18...
Page 323 CAPACITY CHART INFORMATION F2081-19...
Page 327 SECTION 6 - Operating Controls...
Page 329 OPERATING CONTROLS MODEL 3900W - SERIAL 395143 PUBLICATION DATE TITLE SECTION 6 - OPERATING CONTROLS Service Drawing 184679 04/09/97 Standard Hand Signals for Controlling Crane Operations Folio 1395 12/09/99 Converter Operation Controlled & Non-Controlled Converters Folio 34-1.1 01/16/84 Swing Lock Control Folio 34-4.1...
Page 331 © 1997 Manitowoc Cranes, Inc. Rev. 04-09-97 Dwg. 184679-1...
Page 332 STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS STOP. Arm extended, palm EMERGENCY STOP. Both TRAVEL. Arm extended for- DOG EVERYTHING. Clasp down, move arm back and arms extended, palms down, ward, hand open and slightly hand in front of body. forth horizontally.
Page 333 Doing any of the above will cause excessive converter output torque. This action will cause increased loadings on housing, turbine, impeller blades, and sleeve valve. DAMAGE WILL RESULT. © 1999 Manitowoc Cranes, Inc. Rev. 12-09-99 Folio 1395-1...
Page 409 The static load carrying limitations of the steels used in Engine startup at temperatures below 40°F (4°C) requires Manitowoc cranes is not affect ed by cold weather. the use of a cold weather starting aid. Therefore, Manitowoc’s standard capacity char ts are Ether acceptable for use in cold weather.
Page 410 FUEL OIL AIR SYSTEM Refer to the engine manual for recommendations. Install the optional air dryer available from Manitowoc. GEAR OIL Frequently inspect the moisture ejector at the air tanks for proper operation. The moisture ejector has a heater which...
Page 411 SECTION 7 - Adjustments...
Page 445 Prevent Possible Death or Serious Injury not overfill. to Maintenance Personnel Securely reinstall vent/fill cap. Manitowoc has provided hand pump and cylinder for For Enerpac pump: crawler adjustment only. Any other use is neither intended nor approved. Place pump in vertical position with hose end down.
Page 446 HYDRAULIC HAND PUMP S135 S137 S138 Close Extend Valve Cylinder Cylinder Open Retract Valve Cylinder Vent/Fill Cap (Simplex Pump) Hose Pump Notch in Dipstick (Enerpac Pump) FIGURE 1 Folio 999-2...
Page 453 SECTION 8 - Troubleshooting...

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