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Manitowoc 999 Manuals
Manuals and User Guides for Manitowoc 999. We have
2
Manitowoc 999 manuals available for free PDF download: Service And Maintenance Manual, Operator's Manual
Manitowoc 999 Service And Maintenance Manual (298 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 25.75 MB
Table of Contents
Table of Contents
5
Continuous Innovation
13
Safety Messages
13
Safety Alert Symbol
13
Signal Words
13
Safe Maintenance Practices
14
Maintenance Instructions
14
Environmental Protection
15
Crane Operation
16
Operating System
16
Hydraulic Components
16
Hydraulic Tank
16
Shut-Off Valve
17
Supercharge Filter Manifold
17
Return Manifolds
17
Thermal Bypass Valve
17
Hydraulic Pumps
17
Main Pressure Monitoring
18
Accessory System Pressure
18
Basic Operation
18
Charge Pressure
18
Hydraulic Motors
18
Engine Controls
20
Epic Programmable Controller
21
Standard Mode
22
Other Crane Modes
22
Electrical Power to 999 Operator Cab
23
Pressure Senders and Encoders
24
System Faults
25
Operating Faults and Limit Switches
26
Brake and Drum Pawl Application/Release
26
Swing System Operation
28
Swing Brake and Swing Lock
28
Swing Right or Left
28
Swing Holding Brake Switch
29
Travel System Operation
30
Travel Brakes
30
Travel Forward and Reverse
30
Travel Speed-High/Low Operation
30
Travel Detent Selector
31
Boom Hoist System Operation
33
Boom Hoist Brake and Pawl Switch
33
Boom Hoist Raise
34
Boom Stop Cylinders
35
Boom Hoist Lower
35
Front/Rear Drum System
38
Load Drum Brake and Pawl Switch
39
Load Drum Hoisting
39
Load Drum Lowering
40
Luffing Jib Operation (Optional)
42
Free Fall Mode (Optional)
43
Drum Brake and Pawl Switch
43
Free Fall Brake/Clutch Operation
43
Free Fall Hoisting
44
Free Fall Lowering
45
Auxiliary Drum System (Optional)
49
Auxiliary Drum Brake and Pawl Switch
50
Auxiliary Drum Raise
50
Auxiliary Drum Lower
51
Crane Setup Systems
54
Gantry System
55
Gantry Cylinders Raise
55
Gantry Cylinders Lower
59
Mast System
62
Mast Cylinders Raise
64
Mast Cylinders Lower
65
Boom Hinge Pins
68
Carbody Jacking System
70
Carbody Jacking Cylinder Raise
71
Carbody Jacking Cylinder Lower
71
Left and Right Crawler Pin-Pusher Cylinders
73
Right Crawler Pin-Pusher Cylinders Engage
73
Right Crawler Pin-Pusher Cylinders Disengage
73
Counterweight Pins
75
Hydraulic Solenoid Valve Identification
77
Inspecting Hydraulic Hoses
81
Every Month or 200 Hours
81
Degradation Due to Extreme Environment
81
Hydraulic System Maintenance
82
Safety
82
Storing and Handling Oil
82
Storing and Handling Parts
82
Inspecting System
82
Replacing Filter Elements
86
Changing Oil
86
Tightening Hydraulic Connections
87
Pipe Thread Connection
87
SAE Straight Thread Connection
88
ORS Connection
89
Split Flange Connection
90
SAE Flare Connection
91
Hydraulic System Calibration
92
Accessing Calibration Screens
92
Calibration Procedures
92
Pressure Sender
92
Charge Pressure
93
Control System
94
Pump Pressure
95
Pressure Sender Replacement
98
Pump Components
100
Pump Identification
100
Pump and Motor Port Identification
101
Disc Brake Operational Test
103
Operational Test
103
Shop Procedures
103
Initial Oil Fill
104
Accessory System Checks and Adjustments
106
High Pressure Accessory Systems
106
Low Pressure Accessory Manifold
106
Travel Handle and Speed Check
107
Operating Drum Speed Checks
107
Inspect Electrical Components
111
Every Month or 200 Hours
111
Degradation Due to Severe Environment
111
Circuit Breaker and Fuse ID
112
Test Voltages
118
Controller Board Layout
118
Test Voltage Abbreviations
118
Pin Identification
119
Wire Identification
123
Description Identification
127
Controller Board Identification
131
Master Node Pin Identification
136
Display Readings
138
Operating Conditions
138
Operating Limits
138
System Faults
139
Selecting Display Language
139
Crane Diagnostics
144
Drum 1 and 2 (Front and Rear Drum)
144
Drum 4 (Boom Hoist)
144
Drum 8 (Auxiliary)
144
Ffall
144
Swing
145
Swing Speed/Torque
145
Drum Slip
145
Track
145
Rin
145
Accessory System
146
Engine Throttle
146
A1 (Handles)
147
D1, D2, and D3 (Digital Outputs and Inputs)
147
CPU EPROM Replacement
152
Dielectric Grease
152
Section 4
153
Automatic Boom Stop
155
Maximum Boom Angle
155
Operation
155
Maintenance
155
Bypass Limit Test
156
Adjustment
159
Actuator Rod Replacement
159
Physical Boom Stop
161
Operation
161
Boom and Luffing Jib Angle Indicator
162
Mast and Gantry Sensor Adjustments
162
Mast Angle Indicator
162
Adjusting Angle
163
Gantry Limit Switch
164
Adjustment
164
Strap Inspection and Maintenance
165
Inspection
165
Identifying Straps
165
Daily Inspection
165
Monthly Inspection
165
Cranes Not in Regular Use
165
Replacement Specifications
166
Corrosion or Abrasion
166
Straightness
166
Flatness
168
Elongated Hole
169
Length
169
Storing Straps
170
Removing Straps from Service
170
Inspection Checklist
170
Lattice Section Inspection and Lacing Replacement
170
Section 5
175
Hoist Drawings
177
Wire Rope Removal
177
Free Fall Clutch/Brake
177
Inspection
177
Overhaul
178
Minimum Bail Limit/Pressure Roller
179
Minimum Bail Limit
179
Weekly Maintenance
179
Adjustment-Front or Rear Drum
179
Adjustment-Auxiliary Drum
179
Drum Pressure Roller
181
Adjustment
181
Block-Up Limit
182
Operation
182
Installation
183
Storing Electric Cable
183
Disconnecting Block-Up Limit Controls
184
Removing Jib or Boom Point
184
Maintenance
185
Adjustment
187
Wire Rope Inspection and Replacement
188
Maintain a Wire Rope Condition Report
188
Wire Rope Lubrication
188
Required Inspection Intervals
188
Wire Rope Care and Replacement Guidelines
188
Daily Inspection
189
Periodic Comprehensive Inspection
190
Replacement Criteria
190
Determining Frequency of Inspection
190
Reduction in Rope Diameter
190
Broken Rope Wires
191
Distributing Wire Rope Wear
192
Rope that Has Been Idle a Month or more
192
Sheave, Roller, and Drum Inspection
193
Load Block and Hook-And-Weight Ball Inspection
196
Section 6
199
Manual Release of Swing Brake and Lock
201
Manual Release Procedure
201
Section 7
203
Batteries
205
Safety
205
Jump-Starting a Battery
205
Causes of Battery Failure
207
Overcharging
207
Undercharging or Discharged
207
Lack of Water
207
Loose Hold-Downs
207
Overloads
207
Multiple Battery System
207
Maintenance
208
Checking Battery State-Of-Charge
208
Troubleshooting-Slow Cranking
208
Quarterly Battery Maintenance
208
Battery Disconnect Switch
209
Air Cleaner
210
Inspection
210
Changing the Filters
211
Daily
211
Monthly
211
Engine Clutch
212
Maintenance
212
Adjustment
212
Engine Throttle
213
Foot Throttle Linkage Adjustment
213
Engine Idle Speed
213
Wiring Diagram
213
Engine Enclosure
215
Engine Belt Routing
215
Engine Cooling System
217
Checking Coolant Level
217
Draining Cooling System
217
Filling and Bleeding Cooling System
217
Exhaust Aftertreatment System
219
DEF Tank
219
Coolant Solenoid Valve
220
Coolant Manifold
220
Air Bleed Valves
220
DEF Supply Module
220
SCR Module
220
DRT Module
220
Excessive Nox Warning System
220
Aftertreatment Protection System
220
DEF Dosing Module
221
DOC Module
221
DEF Heating and Cooling System
221
Section 8
223
Turntable Bearing
225
Installation
225
Torque Requirements
225
Lubrication
225
Torque Values
225
Torque Sequence
225
Torque Intervals
225
Bolt Replacement
225
Crawler
226
Tread Slack Adjustment
226
Maintenance
226
Adjustment Procedure
227
Hydraulic Hand Pump
228
Assembly
228
Maintenance
228
Air Removal
228
Operation
228
Section 9
231
Lubrication
231
Lube and Coolant Product Guide
233
Section 10
233
Introduction
237
Safety Summary
237
Guidelines
238
Test Equipment
238
Troubleshooting Charts
239
Testing
268
Test 1 - Battery Test (12 and 24 Volts DC)
268
Test 2- Checking Resistance at Engine Temperature Sender
269
Test 3 - Checking Resistance at Engine Oil Pressure Sender
270
Test 4 - Cleaning and Adjusting the Engine RPM Transducer
271
Test 5 -Test Adapters for Checking Electrical Inputs/Outputs
272
Test 5 - Continued
273
Test 6 - Testing for Voltage at the Fuse Box
274
Test 7 - Checking Voltage at the Control Handle
275
Test 8 - Adjusting the Control Handle Potentiometer
276
Test 9 - Checking Voltage at the Pressure Senders
277
Test 10 - Checking Voltage at the Speed Encoders
278
Test 11 - Checking Voltage at the Hydraulic Brake Valve
279
Test 12 - Checking Voltage at the Hydraulic Valve Assemblies
280
Test 13 - Testing the Pump EDC and Motor PCP
281
Test 14 - Location of Pump Ports
282
Test 15 - Location of Motor Ports
283
Test 16 - Manually Stroking the Pump
284
Test 17 - Checking Pump Charge Pressure
285
Test 18 - Adjusting Pump Charge Pressure Relief
286
Test 19 - Setting the Pump Pressure
287
Test 20 - Setting Pump Neutral
288
Test 21 - Testing for Pump and Motor Leakage
289
Test 22 - Checking Hydraulic Brake Pressure
290
Test 23 - Servicing the Motor Loop Flushing (Purge) Valves
291
Test 24 - Actuating the Solenoid Valve Manual Overrides
292
Test 25 - Adjusting Accessory Pressure Switch
293
Test 26 - Adjusting the Counterbalance Valves
294
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Manitowoc 999 Operator's Manual (156 pages)
Luffing Jib Attachment
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 14.29 MB
Table of Contents
Table of Contents
5
Section 1
11
Crane Data
11
Crane/Attachment Identification
11
Change of Ownership Registration
11
Manitowoc Dealer
11
Crane Orientation
11
Identification of Luffing Jib Components
12
Crane and Luffing Jib Weights
13
English and Metric Conversions
18
Direct Conversion
18
Inverse Conversion
18
Section 2
21
Continuous Innovation
23
Nameplates and Decals
23
Safety Messages
23
General
23
Safety Alert Symbol
23
Signal Words
23
Symbol Identification
23
Safety and Information Signs
25
Maintaining Signs
25
Ordering Signs
25
Crane Access Points
27
General
27
Getting on or off Crane
27
Operator Manual/Capacity Chart Storage
28
General
28
Storing Manuals
28
Safe Operating Practices
28
Read Operator Manual
29
Operator Qualifications
29
Operator Conduct
29
Handling Load
31
Size of Load
31
Attaching Load
31
Lifting/Moving Load
31
Multiple Load Line Operation
33
Signals
34
Safety Devices
34
Holding Load
34
Operational Aids
35
Category 1 Operational Aids
35
Category 2 Operational Aids
35
Assembling, Disassembling, or Operating Crane Near Electric Power and Transmission Lines
36
Electrocution Hazard
36
Set-Up and Operation
37
Electrocution Hazard Devices
37
Electrical Contact
38
Refueling
38
Fire Extinguishers
38
Accidents
38
Safe Maintenance
39
Maintenance Instructions
39
Safe Maintenance Practices
39
Environmental Protection
40
Boom Disassembly Safety
42
General
42
Location
42
Pin Removal
42
Disassembly Precaution - #82 Boom
42
Disassembly Precaution - #22E/22EL Boom
44
Personnel Handling Policy
46
Pedestal/Barge Mounted Cranes
48
Pedestal Mounted Crane
48
Barge Mounted Crane
48
Definition
48
Examples
48
Capacity Charts
50
Shock Loading
50
Operation on Barge
50
Definition
50
General
50
Definitions
50
Crane Inspection
51
Transporting Crane on Barge
51
Section 3
53
Standard Hand Signals for Controlling Crane Operations
56
Luffing Jib Operating Controls
59
Rated Capacity Indicator/Limiter (RCL)
59
Crane Mode Selector
59
Digital Display
59
Limit Bypass Switch
60
Luffing Jib Limit Bypass Switch
60
Rear Drum Park Switch
61
Boom Hoist Control
61
Luffing Hoist Control
61
Boom Angle Indicator
61
10 - Level
61
Automatic Jib Stops (Not Shown)
62
Automatic Boom Stop (Not Shown)
62
Luffing Jib up Limits
62
Luffing Jib down Limits
62
Operating Precautions
63
Wind Conditions
64
Section 4
65
Luffing Jib Attachment
67
Accessing Parts
67
Assist Crane Requirements
67
Crane Weights
67
Operating Controls
67
Counterweight Requirement
68
Blocked Crawlers
68
Rigging Drawings
68
Luffing Jib Raising Procedure
68
Identifying Boom/Jib Components
68
Handling Components
68
Retaining Connecting Pins
68
Pin and Connecting Hole Cleanliness
68
Shipping Crane Components
68
Luffing Jib Rigging Guide - #149 Jib
71
Installing Jib
71
Lower Boom
71
Prepare Crane for Jib
71
Install Jib Stop Strut Assembly
71
Install Jib Butt Assembly
71
Install Jib Stop Pendants
71
Connect Main Strut to Boom Top
73
Raise Jib Strut to Assembly Position
73
Install Jib Inserts
73
Install Jib Top
75
Connect Jib Straps
75
Install Jib Backstay Pendants
75
Install Jib Stop Control Cable
77
Install Luffing Hoist Wire Rope
77
Raise Main Strut/Connect Backstay Pendants
79
Raise Main Strut/Connect Backstay Pendants (Continued)
81
Disconnect Jib Strut from Jib Butt
81
Install Load Lines
81
Connect Electric Cords/Adjust Electronic Devices
81
Installing Intermediate Suspension
83
Pre-Raising Checks
83
General
83
Option a
83
Option B
83
Raising Boom and Jib
85
General
85
Preliminary Raising Procedure
85
In-Line Raising Procedure
87
Jack-Knife Raising Procedure
89
Lowering Boom and Jib
91
In-Line Lowering Procedure
91
Jack-Knife Lowering Procedure
93
Final Lowering Procedure
94
Lowering Struts
94
Removing Jib
95
Assemble-In-Air Raising Procedure
96
Danger Tag
96
Signal Person
96
Counterweight Requirement
96
Outrigger
96
Boom-Luffing Jib Rigging
97
Lifting Slings
97
Assist Crane
97
Prepare Crane and Boom
99
Assemble Partial Luffing Jib
99
Raising Procedure
101
Raise Jib
101
Raise Boom
102
Attach Jib Top
104
Raise Boom and Luffing Jib
104
Raise Boom, Luffing Jib, and Fixed Jib
105
Lowering Procedure
106
Lower Boom and Luffing Jib
106
Lower Boom, Luffing Jib, and Fixed Jib
106
Remove Jib Top
106
Lower Boom
107
Fixed Jib Rigging Guide - #134 Fixed on #149 Luff
108
Preparing Boom and Luffing Jib
111
Installing Jib
111
Install Jib Butt
111
Install Jib Inserts
111
Install Jib Top
111
Install Jib Pendants
111
Install Backstay Pendants
111
Connect Jib Sections to Jib Butt
111
Installing Load Line
112
Connect Jib Stop Control Cable
112
Installing Electronic Devices
113
Pre-Raising Checks
113
Raising Boom and Jib
115
Raising Boom and Jib (Continued)
117
Lowering Boom and Jib
119
Removing Fixed Jib
120
Load Block Reeving
122
Load Blocks and Weight Ball
122
Guide Sheaves
122
Wire Rope Specifications
122
Wire Rope Installation
122
Reeving
122
Rigging Winch Operation
125
Operation
125
Selecting Rigging Mode
125
Operating Rigging Winch
126
Wire Rope Installation
127
Wire Rope Storage
127
Removing Wire Rope from Shipping Reel
127
Seizing and Cutting Wire Rope
127
Anchoring Wire Rope to Drum
128
Winding Wire Rope Onto Drum
128
Anchoring Wire Rope to Wedge Socket
129
Anchoring Wire Rope to Button Socket
131
Breaking in Wire Rope
131
Pad Eye Usage for Wire Rope Reeving
131
Safety
131
Section 5
133
Lubrication
133
Lube and Coolant Product Guide
135
Section 6
137
Maintenance and Adjustment
139
Jib Stop Adjustment
141
General
141
Maintenance
141
Adjustment
141
Preliminary Adjustment
141
Max up 1 Limit Adjustment
141
Max up 2 Limit Adjustment
141
Max down Limit Adjustment
141
Operational Checks
142
Final Adjustment Steps
142
Boom and Luffing Jib Angle Indicator Calibration
143
Automatic Boom Stop Adjustment
144
Maximum Boom Angle
144
Operation
144
Maintenance
144
Bypass Limit Test
144
Adjustment
147
Actuator Rod Replacement
147
Block-Up Limit Installation and Adjustment
148
Operation
148
Installation
148
Storing Electric Cable
148
Block-Up Limit Control Deactivated
148
Block-Up Limit Control Activated
148
Disconnecting Block-Up Limit Controls
150
Removing Jib or Boom Point
150
Maintenance
151
Adjustment
152
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