User Manuals: Manitowoc National Crane 900H Boom Trucks

Manuals and User Guides for Manitowoc National Crane 900H Boom Trucks. We have 2 Manitowoc National Crane 900H Boom Trucks manuals available for free PDF download: Service Maintenance Manual, Operator's Manual

Manitowoc National Crane 900H Service Maintenance Manual

Manitowoc National Crane 900H Service Maintenance Manual (190 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 10 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
- Parts Replacement
  47
- Service
  47
- 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
Description

68
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
- Cable Tensioning
  98
- 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

Manitowoc National Crane 900H Operator's Manual (142 pages)

Brand: Manitowoc | Category: Construction Equipment | Size: 26 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
- 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
- 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
- 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
- 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

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