Manitowoc 999

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BOOM 999 SERVICE/MAINTENANCE MANUAL

4-18

Published 05-16-17, Control # 233-03

NOTES

DRAW SKETCHES OR ATTACH PHOTOGRAPHS TO FOLLOWING PAGES

Main Page

Table of Contents5
Continuous Innovation13
Safety Messages13
Safety Alert Symbol13
Signal Words13
Safe Maintenance Practices14
Maintenance Instructions14
Environmental Protection15
Crane Operation16
Operating System16
Hydraulic Components16
Hydraulic Tank16
Shut-Off Valve17
Supercharge Filter Manifold17
Return Manifolds17
Thermal Bypass Valve17
Hydraulic Pumps17
Main Pressure Monitoring18
Accessory System Pressure18
Basic Operation18
Charge Pressure18
Hydraulic Motors18
Engine Controls20
Epic Programmable Controller21
Standard Mode22
Other Crane Modes22
Electrical Power to 999 Operator Cab23
Pressure Senders and Encoders24
System Faults25
Operating Faults and Limit Switches26
Brake and Drum Pawl Application/Release26
Swing System Operation28
Swing Brake and Swing Lock28
Swing Right or Left28
Swing Holding Brake Switch29
Travel System Operation30
Travel Brakes30
Travel Forward and Reverse30
Travel Speed-High/Low Operation30
Travel Detent Selector31
Boom Hoist System Operation33
Boom Hoist Brake and Pawl Switch33
Boom Hoist Raise34
Boom Stop Cylinders35
Boom Hoist Lower35
Front/Rear Drum System38
Load Drum Brake and Pawl Switch39
Load Drum Hoisting39
Load Drum Lowering40
Luffing Jib Operation (Optional)42
Free Fall Mode (Optional)43
Drum Brake and Pawl Switch43
Free Fall Brake/Clutch Operation43
Free Fall Hoisting44
Free Fall Lowering45
Auxiliary Drum System (Optional)49
Auxiliary Drum Brake and Pawl Switch50
Auxiliary Drum Raise50
Auxiliary Drum Lower51
Crane Setup Systems54
Gantry System55
Gantry Cylinders Raise55
Gantry Cylinders Lower59
Mast System62
Mast Cylinders Raise64
Mast Cylinders Lower65
Boom Hinge Pins68
Carbody Jacking System70
Carbody Jacking Cylinder Raise71
Carbody Jacking Cylinder Lower71
Left and Right Crawler Pin-Pusher Cylinders73
Right Crawler Pin-Pusher Cylinders Engage73
Right Crawler Pin-Pusher Cylinders Disengage73
Counterweight Pins75
Hydraulic Solenoid Valve Identification77
Inspecting Hydraulic Hoses81
Every Month or 200 Hours81
Degradation Due to Extreme Environment81
Hydraulic System Maintenance82
Safety82
Storing and Handling Oil82
Storing and Handling Parts82
Inspecting System82
Replacing Filter Elements86
Changing Oil86
Tightening Hydraulic Connections87
Pipe Thread Connection87
SAE Straight Thread Connection88
ORS Connection89
Split Flange Connection90
SAE Flare Connection91
Hydraulic System Calibration92
Accessing Calibration Screens92
Calibration Procedures92
Pressure Sender92
Charge Pressure93
Control System94
Pump Pressure95
Pressure Sender Replacement98
Pump Components100
Pump Identification100
Pump and Motor Port Identification101
Disc Brake Operational Test103
Operational Test103
Shop Procedures103
Initial Oil Fill104
Accessory System Checks and Adjustments106
High Pressure Accessory Systems106
Low Pressure Accessory Manifold106
Travel Handle and Speed Check107
Operating Drum Speed Checks107
Inspect Electrical Components111
Every Month or 200 Hours111
Degradation Due to Severe Environment111
Circuit Breaker and Fuse ID112
Test Voltages118
Controller Board Layout118
Test Voltage Abbreviations118
Pin Identification119
Wire Identification123
Description Identification127
Controller Board Identification131
Master Node Pin Identification136
Display Readings138
Operating Conditions138
Operating Limits138
System Faults139
Selecting Display Language139
Crane Diagnostics144
Drum 1 and 2 (Front and Rear Drum)144
Drum 4 (Boom Hoist)144
Drum 8 (Auxiliary)144
Ffall144
Swing145
Swing Speed/Torque145
Drum Slip145
Track145
Rin145
Accessory System146
Engine Throttle146
A1 (Handles)147
D1, D2, and D3 (Digital Outputs and Inputs)147
CPU EPROM Replacement152
Dielectric Grease152
Section 4153
Automatic Boom Stop155
Maximum Boom Angle155
Operation155
Maintenance155
Bypass Limit Test156
Adjustment159
Actuator Rod Replacement159
Physical Boom Stop161
Operation161
Boom and Luffing Jib Angle Indicator162
Mast and Gantry Sensor Adjustments162
Mast Angle Indicator162
Adjusting Angle163
Gantry Limit Switch164
Adjustment164
Strap Inspection and Maintenance165
Inspection165
Identifying Straps165
Daily Inspection165
Monthly Inspection165
Cranes Not in Regular Use165
Replacement Specifications166
Corrosion or Abrasion166
Straightness166
Flatness168
Elongated Hole169
Length169
Storing Straps170
Removing Straps from Service170
Inspection Checklist170
Lattice Section Inspection and Lacing Replacement170
Section 5175
Hoist Drawings177
Wire Rope Removal177
Free Fall Clutch/Brake177
Inspection177
Overhaul178
Minimum Bail Limit/Pressure Roller179
Minimum Bail Limit179
Weekly Maintenance179
Adjustment-Front or Rear Drum179
Adjustment-Auxiliary Drum179
Drum Pressure Roller181
Adjustment181
Block-Up Limit182
Operation182
Installation183
Storing Electric Cable183
Disconnecting Block-Up Limit Controls184
Removing Jib or Boom Point184
Maintenance185
Adjustment187
Wire Rope Inspection and Replacement188
Maintain a Wire Rope Condition Report188
Wire Rope Lubrication188
Required Inspection Intervals188
Wire Rope Care and Replacement Guidelines188
Daily Inspection189
Periodic Comprehensive Inspection190
Replacement Criteria190
Determining Frequency of Inspection190
Reduction in Rope Diameter190
Broken Rope Wires191
Distributing Wire Rope Wear192
Rope that Has Been Idle a Month or more192
Sheave, Roller, and Drum Inspection193
Load Block and Hook-And-Weight Ball Inspection196
Section 6199
Manual Release of Swing Brake and Lock201
Manual Release Procedure201
Section 7203
Batteries205
Safety205
Jump-Starting a Battery205
Causes of Battery Failure207
Overcharging207
Undercharging or Discharged207
Lack of Water207
Loose Hold-Downs207
Overloads207
Multiple Battery System207
Maintenance208
Checking Battery State-Of-Charge208
Troubleshooting-Slow Cranking208
Quarterly Battery Maintenance208
Battery Disconnect Switch209
Air Cleaner210
Inspection210
Changing the Filters211
Daily211
Monthly211
Engine Clutch212
Maintenance212
Adjustment212
Engine Throttle213
Foot Throttle Linkage Adjustment213
Engine Idle Speed213
Wiring Diagram213
Engine Enclosure215
Engine Belt Routing215
Engine Cooling System217
Checking Coolant Level217
Draining Cooling System217
Filling and Bleeding Cooling System217
Exhaust Aftertreatment System219
DEF Tank219
Coolant Solenoid Valve220
Coolant Manifold220
Air Bleed Valves220
DEF Supply Module220
SCR Module220
DRT Module220
Excessive Nox Warning System220
Aftertreatment Protection System220
DEF Dosing Module221
DOC Module221
DEF Heating and Cooling System221
Section 8223
Turntable Bearing225
Installation225
Torque Requirements225
Lubrication225
Torque Values225
Torque Sequence225
Torque Intervals225
Bolt Replacement225
Crawler226
Tread Slack Adjustment226
Maintenance226
Adjustment Procedure227
Hydraulic Hand Pump228
Assembly228
Maintenance228
Air Removal228
Operation228
Section 9231
Lubrication231
Lube and Coolant Product Guide233
Section 10233
Introduction237
Safety Summary237
Guidelines238
Test Equipment238
Troubleshooting Charts239
Testing268
Test 1 - Battery Test (12 and 24 Volts DC)268
Test 2- Checking Resistance at Engine Temperature Sender269
Test 3 - Checking Resistance at Engine Oil Pressure Sender270
Test 4 - Cleaning and Adjusting the Engine RPM Transducer271
Test 5 -Test Adapters for Checking Electrical Inputs/Outputs272
Test 5 - Continued273
Test 6 - Testing for Voltage at the Fuse Box274
Test 7 - Checking Voltage at the Control Handle275
Test 8 - Adjusting the Control Handle Potentiometer276
Test 9 - Checking Voltage at the Pressure Senders277
Test 10 - Checking Voltage at the Speed Encoders278
Test 11 - Checking Voltage at the Hydraulic Brake Valve279
Test 12 - Checking Voltage at the Hydraulic Valve Assemblies280
Test 13 - Testing the Pump EDC and Motor PCP281
Test 14 - Location of Pump Ports282
Test 15 - Location of Motor Ports283
Test 16 - Manually Stroking the Pump284
Test 17 - Checking Pump Charge Pressure285
Test 18 - Adjusting Pump Charge Pressure Relief286
Test 19 - Setting the Pump Pressure287
Test 20 - Setting Pump Neutral288
Test 21 - Testing for Pump and Motor Leakage289
Test 22 - Checking Hydraulic Brake Pressure290
Test 23 - Servicing the Motor Loop Flushing (Purge) Valves291
Test 24 - Actuating the Solenoid Valve Manual Overrides292
Test 25 - Adjusting Accessory Pressure Switch293
Test 26 - Adjusting the Counterbalance Valves294

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