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Manitowoc National Crane 900H Manuals
Manuals and User Guides for Manitowoc National Crane 900H. We have
2
Manitowoc National Crane 900H manuals available for free PDF download: Service Maintenance Manual, Operator's Manual
Manitowoc National Crane 900H Service Maintenance Manual (190 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 10.41 MB
Table of Contents
Table of Contents
5
General
11
Service and Repair
12
Supplemental Information
12
New Owner
12
Basic Nomenclature
12
Section 1
11
General Maintenance
14
Cleanliness
14
Removal and Installation
14
Disassembly and Assembly
14
Pressing Parts
14
Locks
14
Shims
14
Hoses and Tubes
15
Bearings
15
Gaskets
16
Batteries
16
Hydraulic Systems
17
Hydraulic Fittings
18
Electrical System
19
Dielectric Grease
19
Fatigue of Welded Structures
20
Loctite
21
Fasteners and Torque Values
21
Weld Studs
33
Wire Rope
33
General
33
Environmental Conditions
33
Dynamic Shock Loads
33
Lubrication
34
Recommendations for Servicing Wire Rope
34
Wire Rope Inspection
35
Boom Extension and Retraction Cables
35
Wire Rope Replacement (All Wire Rope)
35
Seizing Wire Rope
36
Section 2
38
Introduction
38
Hydraulic System General Overview
39
Introduction
41
Hydraulic Symbols
41
Maintenance
43
Preparation
43
Hydraulic System Maintenance Precautions
43
Label Parts When Disassembling
43
Hydraulic Oil Recommendations
43
Parts Replacement
43
Visual Inspection of Hoses and Fittings
43
Troubleshooting Aids
44
Troubleshooting Procedures
44
General Hydraulic System Troubleshooting
45
Parts Replacement
47
Service
47
Hydraulic Oil Recommendations
47
Draining and Flushing
47
Removing Air from the Hydraulic System
48
Hydraulic Pump
49
Load Sense Control
49
System Circuit Flow
49
Valves
50
General
50
Directional Control Valve
52
Description
52
Relief Pressures
52
Maintenance
53
Checking Relief Pressure
53
Preparation
53
Hoist and Boom Lift
53
Telescope in and Telescope out Reliefs
53
Swing
54
Outriggers Maximum Pressure
54
Outriggers Beam Extend
55
Single Front Outrigger (SFO)
55
Hydraulic Remote Control Pressure Setting
56
Supply Circuit
57
Description
57
Hydraulic Reservoir and Filter
57
Hydraulic Filter Replacement
57
Hydraulic Oil Cooler (Option)
57
Hydraulic Valves
58
Directional Control Valve Manifold
58
Hydraulic Remote Controllers
59
Outrigger Manifolds
59
Holding Valves
59
Swing Gearbox
59
Crane Function Power Switch
59
Hydraulic Pump Service
60
Description
60
Removal
60
Installation
60
Pump Startup
60
Trouble Diagnosis
61
Section 3
67
Maintenance
67
General Electrical Understanding
67
Maintenance
68
Comparing Electrical System to a Hydraulic System
68
General Maintenance Introduction
68
General Troubleshooting
68
Connector Troubleshooting
68
Comparing Electrical System to a Hydraulic
68
System
68
Troubleshooting Electrical System
69
Ignition Switch
70
Easyreach Proximity Switch
70
Description
68
RCL System Description
70
Anti-Two-Block System Description
70
A2B Cable Repair
70
Micro Relay/Fuse Block
72
Directional Control Valve Solenoids
73
Hoist Jog Switch
73
Outrigger Manifolds
73
Front Outrigger Manifold
73
Rear Outrigger Manifold
75
Hydraulic Oil Cooler Option
75
RCL Communication Overview
76
900H Rcl Canbus
76
Troubleshooting
78
RCL Sensor Calibration (Legacy RCL Version)
78
Slew Potentiometer Calibration
78
Boom Angle Calibration
79
Boom Length Calibration
79
Rod Side Pressure Sensor Calibration
79
Base Side Pressure Sensor Calibration
80
Outrigger Span/Length
80
Load Chart and Calibration Chart Download
80
System Configuration (Current RCL Version)
81
Accessing the System Configuration Menu
81
Entering the System Configuration Pass Code
81
Uploading Charts
82
Downloading the RCL Display Software
82
Setting System Date and Time
83
RCL Sensor Calibration (Current RCL Version)
84
RCL Sensor Calibration
84
Accessing the Sensor Calibration Menu
85
Calibrating the Boom Angle
85
Calibrating the Slew Sensor
85
Calibrating the Boom Length
86
Calibrating the Rod and Base Side Pressure
86
Calibrating the Rod and Base Side Pressure Transducers
86
Transducers
86
Calibrating the Outrigger Span/Length
88
Section 4
89
Theory of Operation
89
Theory of Operation
91
Boom Removal from Truck
91
Lift Cylinder Removal
91
Boom Disassembly
91
Nd , 3 Rd , 4 Th Boom Section Removal
92
Disassembly of 2
92
Nd Rd Th
92
Additional Maintenance, Disassembled Boom
93
Boom Assembly
93
Extend/Retract Cable Installation
95
Telescope Cylinder Installation
96
Nd /3 Rd /4 Th Boom Section Installation
97
Cable Tensioning
98
Tensioning Setup Procedure
98
Cable Tension Sequence
99
4- Section Boom W/ 2 Stage Cylinder Cable Positioning
99
4- Section Boom W/ 1 Stage Cylinder Cable Positioning
101
Cable Retention
102
Boom Installation on the Truck
103
Lift Cylinder Installation
103
Section 5
105
Description
105
Description
106
Maintenance
106
Warm-Up Procedure
106
Removal
106
Hydraulic Hoses
106
Hoist Installation
106
Drum Rotation Indicator
107
Removal
107
Installation
107
Programming the 3Rd Wrap Indicator (Optional)
108
Hoist Repair
108
Disassembly
108
Reassembly
109
Hoist Service
110
Brake
110
Planetary Set
113
Motor
113
Troubleshooting
113
Section 6
115
Description
115
Theory of Operation
115
Swing Drive
115
Swing Brake
115
Theory of Operation
118
Swing Gearbox and Brake
118
Disassembly and Assembly Instructions
118
Tools Required
118
Gearbox Disassembly
118
Input Planetary Repair
118
Output Planetary Repair
118
Pinion Shaft Repair
119
Case Assembly Repair
119
Gearbox Assembly
119
Swing Brake
120
Disassembly
120
Assembly
121
Swing Bearing
122
Description
122
Maintenance
122
General
122
Torquing Swing Bearing Bolts
122
Swing Bearing Bolts
122
Torque Values
124
Bearing Clearance
124
Bearing Replacement
125
Removal
125
Installation
126
Slew Potentiometer Calibration
127
Section 7
129
Description
129
Front Outrigger Assembly
129
Front Outrigger Assembly
130
Outrigger Beam Removal
130
Inspection
131
Installation
131
Extension Cylinder
132
Stabilizer Cylinder
133
Wear Pad Adjustment
133
Description
130
Rear Outriggers (RSOD)
134
RSOD Assembly
134
Extension Cylinder
135
RSOD Stabilizers
135
Outrigger Monitoring System (OMS) (Optional-Standard in North America)
136
Description
136
Removal
136
Outrigger Monitoring System (OMS)
136
Installation
137
Calibration
137
Section 8
139
General
139
Environmental Protection
139
Lubricants
139
Environmental Protection
140
Arctic Conditions below -9°C (15°F)
140
Chassis Grease
140
Low Temperature Grease
140
Extreme Pressure Multipurpose Gear Lubricant (EPGL)
140
Open Gear Lubricant
140
Antifreeze/Coolant (for Cab Heater)
140
Anti-Wear Additives
140
Hydraulic Oil
140
Standard Hydraulic Oil
140
Lubricants
140
Arctic Hydraulic Oil
141
Hydraulic Oil Inspection
141
Surface Protection for Cylinder Rods
141
General
140
Lubrication
141
Lubrication Points
143
Internal Cable Sheave Lubrication
144
Inner Boom Wear Pad Lubrication
144
Side and Bottom Boom Wear Pad Lubrication
144
Outrigger Beam Lubrication
145
Hoist Brake Oil
145
Hoist Gearbox Oil Level Check
146
Hoist Gearbox Oil Change
146
900H Hydraulic Oil Reservoir Level
147
Wire Rope Lubrication
147
Carwell© Rust Inhibitor
148
Protecting Cranes from Corrosion
148
Cleaning Procedures
148
Inspection and Repair
149
Application
149
Areas of Application
150
Section 9
153
Minimum Truck Requirements
153
Extension Protection Schematic
156
Minimum Truck Requirements
156
Mounting Configuration
156
PTO and Hydraulic Pump
158
Horsepower
158
Direct PTO Mount
158
PTO Ratio
158
Pump Rotation
158
Truck Frame Strength
159
Truck Preparation
163
Welding Precautions
163
Positioning the Crane on the Truck
163
Reinforcing after Frame Extension
164
Mounting the Crane
168
Mount the T-Box
168
Attach the RSOD
170
Mount the Frame Assembly
171
Install the Front Outriggers
171
Install the Boom Rest
172
Install the Rear Bumper
172
Mount the Operator Platforms and Install the Foot Throttles
173
Install the Boom, Lift Cylinder, and Hoist
174
Install the RCL Reel
174
Connect the Slew Potentiometer
175
Connect the Electrical Interface
175
Install the Hydraulic System
176
Front Outrigger Hydraulic Line Connections
178
RSOD Hydraulic Line Connections
179
CAN Bus System Setup
180
Initial Crane Run in Procedure
180
RCL Calibration
180
Stability Test
180
Specifications
182
Hydraulic Pump
182
Hydraulic System
182
Reservoir
182
Hoist System
182
Outrigger Speeds
183
Section 10
185
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Manitowoc National Crane 900H Operator's Manual (142 pages)
Brand:
Manitowoc
| Category:
Construction Equipment
| Size: 26.6 MB
Table of Contents
Table of Contents
5
Section 1
11
Supplemental Information
12
New Owner
12
Notice to Owner/User
12
Basic Nomenclature
12
Section 2
15
Safety Messages
15
General
16
Safety Alert Symbol
16
Signal Words
16
Accidents
16
Operator Information
16
Operator Qualifications
17
Operational Aids
18
Rated Capacity Limiter (RCL) Systems
18
Anti-Two-Blocking Device
19
Working Area Limiter (if Equipped)
19
Equipment Stability/Structural Strength
19
Load Charts
20
Work Site
20
Wind Forces
20
Wind Speeds
21
Lifting Operations
32
Counterweight
33
Outrigger Lift off
33
Multiple Equipment Lifts
33
Tilt-Up Panel Lifting
34
Pile Driving and Extracting
34
Equipment
35
Equipment Inspection
35
Electrocution Hazard
35
Set-Up and Operation
36
Electrocution Hazard Devices
37
Electrical Contact
37
Special Operating Conditions and Equipment
38
Grounding the Equipment
38
Personnel Handling
38
Environmental Protection
40
Maintenance
40
Service and Repairs
40
Lubrication
41
Tires
41
Hoist Rope
42
Synthetic Hoist Rope
42
Wire Rope
42
Sheaves
43
Batteries
44
Engine
44
Transporting the Equipment
44
Travel Operation
44
Work Practices
45
Personal Considerations
45
Equipment Access
45
Job Preparation
46
Working
46
Lifting
47
Hand Signals
48
Jib
48
Parking and Securing
50
Shut-Down
50
Cold Weather Operation
50
Temperature Effects on Hook Blocks
50
Temperature Effects on Hydraulic Cylinders
50
Overload Inspection
52
Boom Inspection
53
Superstructure Inspection
55
Carrier Inspection
57
Section 3
59
Truck Cab Controls
59
Truck Cab Ignition Switch
59
Power Take off
59
Park Brake
60
Engine Speed Governor
60
Neutral Start/Safety Switch
60
Easyreach Pedestal
60
Power Take off
60
Outrigger Control Box (Pendent)
62
Crane Level Indicators
62
Crane Controls
64
Operator Console
64
Easyreach Lock Lever
64
Pedestal Lock Pin
64
Crane Ignition Switch
64
Crane Function Power Switch
64
Boom Telescope Control Lever
64
Hoist Control Lever
64
Hoist Speed Switch
64
Hoist Rotation Indicator
64
Boom Lift Control Lever
65
Foot Throttle
65
Load Charts
65
Rated Capacity Limiter (RCL) Display Module
65
Remote Control Enable Switch (Optional)
65
Momentary RCL Override Switch
65
Hoist Jog Switch
65
Diagnostic Connector
65
Control Levers (Optional)
66
Operating Procedures
66
Equipment Familiarization
66
Equipment Checks
66
Jump Starting Hazard
66
Charging the Batteries
66
Cold Weather Operation
67
Crane Warm-Up Procedures
67
Engine
67
Transmission
67
Hoist
67
Swing Drive and Turntable Bearing
68
Axles
68
Hydraulic Oil System
68
Anti-Two Block Check
68
RCL Check
68
Hoist System Operation
69
Work Site Location
69
Before Leaving the Truck Cab
69
Before Making the Lift
69
Load Chart
69
Using the Load Chart
69
Lifting the Load
70
Shut down and Preparation for Road Travel
73
Unattended Crane
73
Crane Remote Control (Optional)
74
Section 4
77
Outrigger Setup
77
Proper Leveling of the Crane
77
Bubble Level Adjustment
77
Site Selection
78
Setting the Outriggers
78
Outrigger Monitoring System (OMS) (Optional-Standard in North America)
78
Bubble Level Adjustment
78
Extension Safety Information
79
Side Folding Swing Around Extension Operation
80
Deployment Procedure
80
Side Folding Swing Around Extension
80
Operation
80
Stowing Procedure
82
Extension Removal
83
Extension Maintenance
83
Anti-Two Block Weight Installation
84
Multipart Line Reeving
84
Using Multiple Part Lines
84
Lifting a 30 Ton (60,000 Lb) Load
84
Installing Cable on the Hoist
85
Wedge Sockets
85
Terminator Wedge Installation
85
Wedge Socket Installation
86
Section 5
87
General
87
Environmental Protection
87
Lubricants
87
Arctic Conditions below 0°F (-18°C)
87
Chassis Grease
88
Extreme Pressure Multipurpose Gear Lubricant (EPGL)
88
Open Gear Lubricant
88
Chassis Grease Low Temp
88
Anti-Wear Additives
88
Hydraulic Oil
88
Standard Hydraulic Oil
88
Intermediate Hydraulic Oil
88
Wide Range Intermediate Hydraulic Oil
88
Arctic Hydraulic Oil
88
Hydraulic Oil Inspection
89
Lubrication Points
89
Surface Protection for Cylinder Rods
89
Lubrication Points
90
Internal Cable Sheave Lubrication
91
Inner Boom Wear Pad Lubrication
92
Side and Bottom Boom Wear Pad Lubrication
92
Hoist Brake Oil
93
Hoist Gearbox Oil
93
Hydraulic Oil Reservoir Level
93
Wire Rope Lubrication
94
Carwell® Rust Inhibitor
94
Protecting Cranes from Rusting
94
Cleaning Procedures
95
Inspection and Repair
95
Application
96
Areas of Application
96
Section 6
99
Crane Inspection and Maintenance
99
Inspections
99
Inspections
100
Special Boom Inspection
101
Stability
101
Hoist Cable Inspection and Maintenance
101
Keeping Records
101
Environmental Conditions
101
Dynamic Shock Loads
101
Precautions and Recommendations During Inspection
102
Inspection
102
Wire Rope Replacement
103
Care of Wire Rope
103
Replacement Cable
103
Crane Adjustments and Repairs
104
Boom Extension Cable
104
Extension Jack Service and Maintenance
104
Lubrication
104
Rust Prevention
104
Hydraulic System
104
Oil Cooler
104
Tire Load and Inflation Table
104
Specifications
108
Hydraulic Pump
108
Hydraulic System
108
Reservoir
108
Hoist System
108
Outrigger Speeds
109
Section 7
112
RCL System Description
112
Legacy RCL System
112
Alert and Limit Symbols
114
RCL Override Warning
114
RCL Setup (Legacy RCL Version)
115
Outrigger Configuration
115
Reeving Configuration
115
Confirmation
115
TARE Function
116
Operating Mode (Legacy RCL Version)
116
RCL Operating Modes
117
Operational Limits (Legacy RCL Version)
118
Slew Angle Limit
118
WADS Limit
118
Boom Angle Limit
119
Tip Height Limit
119
Radius Limit
119
Delete All Limits
120
Tools (Legacy RCL Version)
120
Diagnostic (Legacy RCL Version)
121
Current RCL System
123
Alert and Limit Symbols
125
RCL and A2B Override Warnings
127
RCL Setup (Current RCL Version)
127
Step 1: Configuring a Personnel Platform
127
Step 2: Configuring the Boom
127
Step 3: Configuring Outriggers
128
Step 4: Configuring Reeving
128
Step 5: Confirming the Configuration
128
Operating Mode (Current RCL Version)
129
Accessing Operating Mode Screen
129
TARE Function
129
Overriding the RCL System
130
RCL Operating Modes
130
Operational Limits (Current RCL Version)
130
Slew Angle Limit
131
WADS Limit
131
Boom Angle Limit
132
Tip Height Limit
132
Radius Limit
132
Delete All Limits
133
Tools (Current RCL Version)
133
Accessing the Tools Menu
133
Setting Units of Measure
133
Setting up the Hydraulic Filter Reminder
133
Setting RCL Screen Brightness
134
System Configuration (Current RCL Version)
134
Diagnostics (Current RCL Version)
134
About the Diagnostics Screen
134
Accessing the Diagnostics Menu
135
About Faults and Real-Time I/O Diagnostics
136
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