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Manitowoc NATIONAL CRANE 900A User Manual

Manitowoc NATIONAL CRANE 900A
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Supplement to Service Manual
Boom Cable Tensioning
© 2017 Manitowoc
Published 03-23-2017, Control# 641-01
Reference Only
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Manitowoc NATIONAL CRANE 900A Specifications

General IconGeneral
BrandManitowoc
ModelNATIONAL CRANE 900A
CategoryConstruction Equipment
LanguageEnglish

Summary

GENERAL

Cable Tensioning

Tensioning Setup Procedure

Steps for preparing the boom for cable tensioning.

Cable Tension Sequence

Five section boom with two stage cylinder.

Lists tensioning order for a five-section boom with a two-stage cylinder.

321 and 123 cable balancing

Balances cables for a five-section boom, covering extension and retraction.

234 and 432 cable balancing

Balances cables for sections 2-3 and 3-4 of the boom.

345 and 543 cable balancing

Balances cables for sections 3-4 and 4-5 of the boom.

4- Section Boom w/ 2 Stage Cylinder Cable Positioning

Cable Tightening Sequence 4 Section Boom with Two Stage Extend Cylinder

Details the sequence for a 4-section boom with a 2-stage cylinder.

321 and 123 cable balancing

Balances cables for sections 1-2 and 2-3 of a 4-section boom.

234 and 432 cable balancing

Balances cables for sections 2-3 and 3-4 of a 4-section boom.

4- Section Boom w/ 1 Stage Cylinder Cable Positioning

Cable Tightening Sequence 4 Section Boom with (1) Stage Extend Cylinder

Details the sequence for a 4-section boom with a 1-stage cylinder.

321 and 123 cable balancing

Balances cables for sections 1-2 and 2-3 of a 4-section boom.

234 and 432 cable balancing

Balances cables for sections 2-3 and 3-4 of a 4-section boom.

3- Section Boom w/ 1 Stage Cylinder Cable Positioning

Cable Tightening Sequence 3 Section Boom with (1) Stage Extend Cylinder

Details the sequence for a 3-section boom with a 1-stage cylinder.

321 and 123 cable balancing

Balances cables for sections 1-2 and 2-3 of a 3-section boom.

234 and 432 cable balancing

Balances cables for sections 2-3 and 3-4 of a 3-section boom.

Cable Retention

OPERATOR MANUAL Supplement

Crane Warm-up Procedures

Procedures for warming up crane components in cold weather.

CRANE WARM-UP PROCEDURES

Engine

Warm-up procedures for the engine in various temperatures.

Transmission

Operating limitations and warm-up for the transmission.

Hoist

Warm-up procedure for the hoist system.

Swing Drive and Turntable Bearing

Warm-up procedures for swing drive and turntable bearing.

Axles

Warm-up procedures for axles.

Hydraulic Oil System

Operating limits and warm-up procedures for the hydraulic oil system.

OPERATOR AND SERVICE MANUAL

OWNER’S MANUAL Supplement

OUTRIGGER MONITORING SYSTEM (OMS) (OPTIONAL—STANDARD IN NORTH AMERICA)

Operation

How the Outrigger Monitoring System (OMS) operates.

Maintenance

Outrigger Cylinder Length Sensor

Procedures for removing, installing, and calibrating the sensor.

Stabilizer Proximity Switch (version 1)

Procedures for removing, installing, and testing the switch.

Stabilizer Proximity Switch (version 2)

Procedures for removing, installing, and testing the switch.

SIDE FOLDING SWING-AROUND JIB OPERATION

Note regarding jib deployment and stowing procedures.

Safety Information

SAFETY MESSAGES

Importance of safe operation and maintenance.

General

Basic principles for daily operation and safety.

Accidents

Procedures following equipment accidents or damage.

OPERATOR’S INFORMATION

Requirements for reading and understanding the operator's manual.

OPERATOR’S QUALIFICATIONS

Definition of a qualified person for crane operations.

OPERATIONAL AIDS

Information on operational aids and their proper use.

CRANE STABILITY/STRUCTURAL STRENGTH

Load Charts

Information on understanding and using load charts.

Work Site

Inspection of the work site and ground conditions.

Wind Forces

Effects of wind on crane operations and load ratings.

Lifting Operations

Procedures for safe lifting operations.

Counterweight

Proper installation and use of counterweights.

Outrigger Lift Off

Explanation of outrigger lift-off during operation.

Multiple Crane Lifts

Safety precautions for multi-crane lifts.

ELECTROCUTION HAZARD

Set-Up and Operation

Precautions for setting up and operating the crane near power lines.

Electrocution Hazard Devices

Information on devices that help prevent electrocution.

Electrical Contact

Procedures to follow in case of electrical contact.

Special Operating Conditions and Equipment

Precautions for specific operating conditions like thunderstorms.

PERSONNEL HANDLING

Standards and regulations for lifting personnel.

MAINTENANCE

ENVIRONMENTAL PROTECTION

Proper disposal of waste and environmental regulations.

Service and Repairs

Procedures for service and repairs by qualified personnel.

Hydraulic Fluid

Precautions when working with hydraulic fluid.

Moving Parts

Safety precautions related to moving machine parts.

Lubrication

Lubrication schedule and points.

Tires

Inspection and maintenance of tires.

Wire Rope

Inspection, use, and retirement criteria for wire rope.

Sheaves

Inspection and maintenance of sheaves.

Batteries

Safety and maintenance procedures for batteries.

Engine

Safety precautions for fueling and maintaining the engine.

TRANSPORTING THE CRANE

Procedures and checks for transporting the crane.

TRAVEL OPERATION

Operational guidelines for traveling with the crane.

Slopes

Guidelines for operating the crane on slopes.

WORK PRACTICES

Personal Considerations

Personal safety and preparation before operating the crane.

Crane Access

Safe methods for accessing the crane.

Job Preparation

Steps for preparing the crane and work area before operation.

Working

Operator responsibilities during crane operation.

Lifting

Procedures for safe and proper lifting operations.

Hand Signals

Standard hand signals for crane operations.

BOOM EXTENSION

PARKING AND SECURING

Instructions for parking and securing the crane.

COLD WEATHER OPERATION

Additional precautions for cold weather operation.

TEMPERATURE EFFECTS ON HYDRAULIC CYLINDERS

OVERLOAD INSPECTION

Boom Inspection

Superstructure Inspection

Carrier Inspection

OPERATION

CONTROLS

Description of truck cab and crane controls.

Control Functions

Explains the function of various crane control levers and knobs.

OPTIONAL HCA SYSTEM

Information on the optional Hydraulic Capacity Alert system.

CRANE NOMENCLATURE

EQUIPMENT FAMILIARIZATION

EQUIPMENT CHECKS

Pre-operation checks for the crane and equipment.

WORK SITE POSITION

Operation

Procedures for operating the LMI system.

CRANE SET UP

Procedures for setting up the crane with outriggers and stabilizers.

Before Making the Lift

Pre-lift checks and procedures.

READING AND UNDERSTANDING THE LOAD CHARTS

Overloading a crane

Causes and consequences of overloading a crane.

General

General information about the machine and its manuals.

Set-Up

Procedures for setting up the crane.

Example

Illustrative example of using the capacity chart.

WINCH SYSTEM OPERATION

GENERAL RULES WHEN OPERATING WINCH

General rules for operating the winch safely.

LIFTING THE LOAD

Procedures for safely lifting loads with the winch.

SHUTTING DOWN AND PREPARING FOR ROAD TRAVEL

Steps for shutting down the crane and preparing for travel.

ANTI-TWO BLOCK SYSTEM

OPTIONAL HYDRAULIC CAPACITY ALERT SYSTEM

HYDRAULIC CAPACITY ALERT ANTI-TWO-BLOCK OVERRIDE

Information on overriding the system during overload or two-block conditions.

HYDRAULIC CAPACITY ALERT SYSTEM

How the system operates and its limitations.

HCAS SYSTEM ADJUSTMENT

Jib HCA Adjustment

Wireline Jib Min. Angle Switch

Adjustment

Procedures for adjusting the wireline jib min. angle switch.

SIDE FOLDING SWING-AROUND JIB OPERATION

SAFETY TIPS FOR JIB OPERATION

Safety tips for operating with a jib.

SIDE FOLDING-SWING AROUND JIB OPERATION

Detailed procedures for deploying and stowing the jib.

JIB JACK SERVICE & MAINTENANCE

TROUBLESHOOTING

Common symptoms and corrective actions for jib jack issues.

ADJUSTABLE SWING SPEED VALVE

STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS

HYDRAULIC CAPACITY ALERT SYSTEM ADJUSTMENT

MAINTENANCE

INSPECTION AND MAINTENANCE

General schedule and frequency of inspections.

MONTHLY INSPECTIONS

List of items for monthly crane inspections.

PERIODIC INSPECTIONS

Items for periodic crane inspections (3-monthly).

OTHER

Other inspection points for crane stability.

Wire Rope Inspection and Maintenance

Care of Wire Rope

How to care for wire rope to ensure longevity.

Rope Construction

Information on wire rope construction types.

ADJUSTMENTS AND REPAIRS

Precautions for adjustments and repairs to wire rope systems.

TIRE LOAD AND INFLATION TABLES

LUBRICATION PROCEDURES AND CHARTS

LUBRICANTS

Information on recommended lubricants for various components.

HYDRAULIC OIL

Viscosity and properties of hydraulic oil.

LUBRICATION POINTS

Location and frequency of lubrication points.

WIRE ROPE LUBRICATION

Procedures for lubricating wire rope.

LUBRICATION CHART

HYDRAULIC OIL RESERVOIR LEVEL

CARWELL© RUST INHIBITOR

Protecting Cranes From Corrosion

Methods to protect cranes from corrosion.

Cleaning Procedures

Guidelines for cleaning the crane to prevent corrosion.

Inspection and Repair

Procedures for inspecting and repairing paint damage.

SERVICE

CLEANLINESS

Importance of cleanliness in hydraulic systems and during service.

HYDRAULIC SYSTEMS

Procedures for servicing hydraulic system components.

LABEL PARTS WHEN DISASSEMBLING

Importance of tagging parts during disassembly.

WELDING PRECAUTIONS

Precautions to take when welding near computer systems.

Fatigue of Welded Structures

Loctite

Application procedures for Loctite adhesives.

Fasteners and Torque Values

Importance of using correct torque values for fasteners.

Torque Wrenches

Torque Values

USING TORQUE WRENCH EXTENSIONS

WINCH OIL LEVEL

BRAKE OIL LEVEL

TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS (continued)

TROUBLE DIAGNOSIS (continued)

ANTI-TWO BLOCK TROUBLE DIAGNOSIS - ELECTRICAL

ANTI-TWO BLOCK TROUBLE DIAGNOSIS - ELECTRICAL (CONTINUED)

ANTI-TWO BLOCK TROUBLE DIAGNOSIS - HYDRAULIC

ANTI-TWO BLOCK TROUBLE DIAGNOSIS - HYDRAULIC (CONTINUED)

CYLINDER DISASSEMBLY AND REPAIR

SINGLE-STAGE EXTEND CYLINDER DISASSEMBLY AND REPAIR

FOUR SECTION BOOM OPERATION

FOUR SECTION BOOM MAINTENANCE

INTERNAL CABLE SHEAVE LUBRICATION

Lubrication of internal cable sheaves.

FOUR SECTION CABLE TENSIONING

Procedure for tensioning cables on a four-section boom.

BOOM DISASSEMBLY

ADDITIONAL MAINTENANCE/DISASSEMBLED BOOM

Additional maintenance tasks for a disassembled boom.

FOUR SECTION BOOM ASSEMBLY

FOUR SECTION TOP/BOTTOM PAD REPLACEMENT, ASSEMBLED BOOM

TOP REAR PAD REPLACEMENT

Procedure to replace top rear wear pads.

FRONT BOTTOM PAD REPLACEMENT

Procedure to replace front bottom wear pads.

THREE SECTION BOOM OPERATION

BOOM ILLUSTRATIONS

THREE SECTION BOOM MAINTENANCE

THREE SECTION BOOM SERVICE

BOOM REMOVAL

Procedure for removing the boom from the crane.

BOOM DISASSEMBLY

Step-by-step procedure for disassembling the boom.

THREE SECTION BOOM ASSEMBLY

INNER WEAR PAD CALIBRATION

INNER SIDE PADS

Measuring inner side pad dimensions.

INNER BOOM PAD LUBRICATION

JIB INSTALLATION AND ADJUSTMENT

JIB JACK SERVICE & MAINTENANCE

TROUBLESHOOTING

Common symptoms and corrective actions for jib jack issues.

(OPTIONAL) OIL COOLER SERVICE & MAINTENANCE

ROTATION GEARBOX AND BRAKE

SWING DRIVE SERVICE

LUBRICATION AND MAINTENANCE

Lubrication and maintenance for the swing drive.

SERVICING THE CONTROL VALVES

DISASSEMBLY AND REASSEMBLY OF CONTROL VALVES TO REPLACE SEALS

Procedures for disassembling and reassembling control valves.

REPLACING SPOOL SEALS

Steps for replacing spool seals in control valves.

CONTROL VALVE RELIEF ADJUSTMENT

UNLOADER DUMP VALVE - AIR PURGING INSTRUCTIONS

HYDRAULIC SYSTEM DESCRIPTION

SPECIFICATIONS (DIMENSIONAL SPECIFICATIONS)

SPECIFICATIONS (DIMENSIONAL SPECIFICATIONS) TRACTOR MOUNT

SPECIFICATIONS

Hydraulic System Requirements

Specifications for the hydraulic system.

Winch System

Specifications for the winch system.

INSTALLATION

TYPICAL LOCATIONS / SERIAL NUMBER IDENTIFICATION

MINIMUM TRUCK REQUIREMENTS

MOUNTING CONFIGURATIONS

CONFIGURATION 1 - 9103A

Mounting configuration details for the 9103A model.

CONFIGURATION 2 - 9103A

Mounting configuration details for the 9103A model.

CONFIGURATION 3 - 990A/969A

Mounting configuration for 990A/969A models.

CONFIGURATION 4 - 990A/969A

Mounting configuration for 990A/969A models.

CONFIGURATION 5 – REAR MOUNT (69’, 90’, 103’ BOOMS)

Rear mount configuration for various boom lengths.

CONFIGURATION 6 – REAR MOUNT (125’ BOOM)

Rear mount configuration for a 125' boom.

CONFIGURATION 7 - 9103A NEW YORK CITY APPROVED

NYC approved mounting configuration for 9103A.

CONFIGURATION 8 - 9103A NEW YORK CITY APPROVED

NYC approved mounting configuration for 9103A.

PTO HORSEPOWER REQUIREMENTS

PTO SELECTION

TRUCK FRAME STRENGTH

SECTION MODULUS TABLES

SINGLE FRONT STABILIZER BUMPER INSTALLATION

SECTION MODULUS TABLES

TRUCK PREPARATION

WELDING PRECAUTIONS

Precautions for welding near sensitive electronic systems.

POSITIONING CRANE ON TRUCK

Guidelines for positioning the crane on the truck.

Overhang

Regulations regarding truck overhang.

Federal Bridge Law

Regulations related to truck weight and bridge limits.

PTO, PUMP, RESERVOIR

Information on PTO, pump, and reservoir requirements.

REINFORCING/AFTER FRAME EXTENSION

Procedures for reinforcing the truck frame.

CRANE INSTALLATION

Terminator Tool Type Minimum

PIN BEARING INSPECTION AND INSTALLATION PROCEDURE

PIN INSPECTION

Procedures for inspecting pins.

BEARING INSPECTION

Procedures for inspecting bearings.

TRUNNION INSPECTION

Procedures for inspecting trunnions.

INSTALLATION

Procedures for installing bearings.

COUNTERWEIGHTING

COUNTERWEIGHTING NEW YORK CITY APPROVED

COUNTERWEIGHTING METHODS FOR STABILITY AROUND THE REAR 180°

ANTI-TWO-BLOCK LOAD MOMENT INDICATOR INSTALLATION AND FUNCTION VERIFICATION

BOOM RESTS

STABILITY CHECK

STABILITY CHECK NEW YORK CITY APPROVED

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