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This device manual pertains to the Manitowoc 3900W crane, serial number 395143. The manual is divided into sections covering general information, attachment, maintenance, lubrication, capacities, operating controls, adjustments, and troubleshooting.
The manual emphasizes the importance of safe operation and maintenance to prevent serious injury or property damage. It highlights that all personnel involved with the crane must read and understand the Operator's Manual and Capacity Charts. The crane serial number (395143) is crucial for ordering parts and addressing service problems.
Safety messages are categorized by signal words:
Only designated, trained, and experienced personnel should operate and maintain the crane. Operators must not be distracted, physically or mentally unfit, and are responsible for all operations under their direct control. Daily inspections, control tests, and ensuring personnel are clear of moving parts are mandatory before starting the engine.
The crane must not be loaded beyond its static or dynamic ratings. Operators must deduct the weight of lifting equipment from the total chart weight. Verified weights and measured radii take priority over load indicator readings. Slings and rigging must be in safe operating condition with appropriate ratings. The crane should not be used to drag loads, and personnel must not be on the load or hook during hoisting.
A California Proposition 65 Warning indicates that diesel engine exhaust can cause cancer and reproductive harm. Operators must maintain a minimum distance of 20 ft (6 m) from all electrical power lines and equipment. The crane is not insulated, and all parts should be treated as conductors. In case of electrical contact, the operator must stay in the cab, warn others, attempt to move the crane away, and remain until the power is de-energized.
A pedestal-mounted crane is securely fastened to a foundation, barge, ship, or floating platform, preventing tipping. The manual warns of an overload hazard, as these cranes will not tip to indicate exceeding capacity; structural components may fail instead. Careful planning is required for barge operations to verify the barge's capability to limit crane list and dynamics.
A comprehensive checklist is provided for daily, weekly, monthly, quarterly, and yearly inspections. Items include checking for broken glass, damaged sheet metal, leaks, wire rope condition, fluid levels (rotating bed sump, drum gear case, converter output housings, chain case, transmission case, hydraulic reservoir), brakes, clutches, and various control systems.
The unloader pilot valve controls air system pressure. Cut-in pressure is when the compressor starts, and cut-out pressure is when it stops. For the 3900W model, the unloader pilot valve cut-in pressure is 125 psi (8.6 bar) and cut-out pressure is 137 psi (9.4 bar). The safety valve is set at 165 psi (11.4 bar) for all models.
Two types of air filters, Watts and Balston, are used. Daily maintenance involves draining water and dirt from the filter. Monthly maintenance requires replacing the filter element. The Watts filter has IN and OUT ports, while the Balston filter has an arrow indicating flow direction.
The solenoid valve has three ports (P: inlet from control valve, A: outlet to cylinder, E: exhaust). For normally-closed operation, air lines are connected as shown in Figure 1. Troubleshooting includes checking for buzzing noise, external leakage, and internal leakage.
The oil flow switch is wired to a warning alarm in the operator's cab. It indicates FAULTY OIL FLOW if the needle is below the red mark. Cleaning the spool and ensuring proper oil flow are key maintenance tasks.
Electric gauges indicate pressure, temperature, and fuel levels. They are wired in series with a resistor and sending unit. Troubleshooting involves checking fuses, wiring, and sending units.
Regular checks include cam and roller clearance, control linkage, bevel gear wear, oil seals, and the pawl mechanism. The boom hoist auxiliary brake linkage should be free and correctly adjusted.
Inspect the wear pattern between the worm gear and worm shaft. Proper wear is centered on the tooth surface, covering at least 80%. Improper wear, shifted to one side, can cause heat spots, cracks, and metal pulling.
Inspect pedal travel, tooth clearance, latch wear, and tooth engagement. Replace parts if the pedal latch wear exceeds 1/16 inch (2 mm) or if tooth engagement is less than 3/16 inch (5 mm).
Inspect clutch linkage, band shape, lining condition, and air components. Ensure all pins are free and lubricated, and that there is proper clearance between the lining and drum flange.
The manual drum brakes are external, contracting band-type brakes. Inspection covers brake lining thickness, brake linkage return spring tension, pedal return spring tension, and latch bar/notches.
These clutches are manually applied and spring released. Inspection involves checking clutch-disc thickness and ensuring proper lever movement.
Hook rollers must be adjusted to just touch the underside of the roller path, allowing for slight variations in thickness. This prevents overloading and limits clearance.
Nonasbestos riveted linings are used. Linings should be replaced when their thickness decreases to specified dimensions (1/4 inch for 19" discs, 3/16 inch for 28" discs).
The main drive shaft carries reversing clutches. Swing clutch adjustment involves compensating for lining wear and ensuring proper piston rod throw.
Adjustment procedures are provided for chain sag and tread sag. Chains and treads should not be too tight to prevent rapid wear and breakage.
The hand pump is used for crawler adjustment. It is crucial to ensure fittings are tight, oil is at the proper level, and air is removed from the system for smooth operation.
The swing lock is a mechanical lock that engages the swing gear to lock the upperworks. It prevents unintended rotation of upperworks when the crane is unattended.
The steering control uses crawlers for travel. It allows for left, right, and neutral steering. The neutral stop position prevents the crawler from idling.
The level indicates the machine's levelness. It is used to ensure the crane is level before a lift.
The instrument panel displays gauges for boom hoist hydraulic oil temperature, fuel, and ammeter. It also includes panel lights for various warnings.
The selector valve controls the type of converter control linkage desired (air or manual). It has positions for "Excavator" (dragline or clamshell) and "Liftcrane" (liftcrane or precision work).
Travel locks are mechanical dogs that prevent travel when dropped against the ratchet wheel. Air travel locks are also available.
This gauge shows the air pressure available at the manifold in the operator's cab.
This indicator is a mechanically-driven knob or button that rotates when the drum turns, signaling drum rotation.
The tower-boom latch holds the boom to the underside of the tower during erection or lowering.
This is an additional brake that can be manually applied for emergency stops or controlled lowering of the boom.
The slide pinion control transfers power from the reversing clutches to the travel or swing gears. It has positions for travel, swing, and neutral.
The travel control manages the reversing clutches on the main drive shaft for forward and reverse travel.
This indicator is a mechanically-driven knob or button that rotates when the drum turns.
This control rotates the upperworks independently of travel.
This control increases the rear converter power output for swing operation.
This control manages the right drum clutch for dragline, clamshell, and liftcrane operations.
This control manages the boom hoist clutch and applies the spring-applied brake for boom hoist operation.
This control manages the front converter power output for liftcrane operations.
This control manages the left drum clutch for dragline, clamshell, and liftcrane operations.
This control increases or decreases engine speed.
This control activates the air horn for warning signals.
This control applies the left drum brake.
This control applies the right drum brake.
This control increases or decreases engine speed.
This control applies the swing brake.
This control operates the cab heater fan.
This control is an electrically powered hydraulic unit that partially raises and lowers the gantry.
This control operates the windshield wiper motor.
This control manages the steering clutches for crawler travel.
This control manages engine start-up and shut-down procedures.
This control manages the travel locks for crawler movement.
This control manages the independent swing clutches.
This control manages the travel clutches for crawler movement.
This control manages the boom hoist operation.
This section covers general liftcrane operations.
This section provides guidelines for operating the crane in cold weather, including derating capacities, using specific lubricants, and cold weather starting aids.
General| Brand | Manitowoc |
|---|---|
| Model | 3900W |
| Category | Construction Equipment |
| Language | English |
