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Manitowoc 999, Service And Maintenance Manual

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Manitowoc 999 Service And Maintenance Manual Download Page 11

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Manitowoc

Published 05-16-17, Control # 233-03

1-i

1

SECTION 1

INTRODUCTION

TABLE OF CONTENTS

Continuous Innovation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Messages  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safety Alert Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Safe Maintenance Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maintenance Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safe Maintenance Practices  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Operating System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Hydraulic Components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Hydraulic Tank  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Shut-off Valve   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Supercharge Filter Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Return Manifolds  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Thermal Bypass Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic Pumps  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Charge Pressure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hydraulic Motors   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Main Pressure Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Accessory System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

EPIC

 Programmable Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 1-9

Standard Mode  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Other Crane Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Electrical Power to 999 Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Pressure Senders and Encoders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
System Faults  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Operating Faults and Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Brake and Drum Pawl Application/Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Swing System Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Swing Brake and Swing Lock  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Swing Right or Left  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Swing Holding Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

Travel System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

Travel Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Travel Forward and Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 1-18
Travel Speed-High/Low Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Travel Detent Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Boom Hoist System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Boom Hoist Brake and Pawl Switch  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Boom Hoist Raise  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Boom Stop Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Boom Hoist Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Front/Rear Drum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Load Drum Brake and Pawl Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Load Drum Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Load Drum Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Luffing Jib Operation (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

Free fall Mode (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

Summary of Contents for 999

Page 1: ...R e f e r e n c e O n l y Service Maintenance Manual Manitowoc 999 ...

Page 2: ...R e f e r e n c e O n l y ...

Page 3: ...or the exact location of the crane identification plate Always furnish serial number of crane and its attachments when ordering parts or discussing service problems with your Manitowoc dealer or the Manitowoc Crane Care Lattice Team To prevent death or serious injury Avoid unsafe operation and maintenance Crane and attachments must be operated and maintained by trained and experienced personnel Ma...

Page 4: ...R e f e r e n c e O n l y THE ORIGINAL LANGUAGE OF THIS PUBLICATION IS ENGLISH ...

Page 5: ...es 1 14 Brake and Drum Pawl Application Release 1 14 Swing System Operation 1 16 Swing Brake and Swing Lock 1 16 Swing Right or Left 1 16 Swing Holding Brake Switch 1 17 Travel System Operation 1 18 Travel Brakes 1 18 Travel Forward and Reverse 1 18 Travel Speed High Low Operation 1 18 Travel Detent Selector 1 19 Boom Hoist System Operation 1 21 Boom Hoist Brake and Pawl Switch 1 21 Boom Hoist Rai...

Page 6: ...eplacement 2 18 Disc Brake Operational Test 2 23 Operational Test 2 23 Shop Procedures 2 23 Initial Oil Fill 2 24 Accessory System Checks and Adjustments 2 26 Travel Handle and Speed Check 2 27 Operating Drum Speed Checks 2 27 SECTION 3 Electric System Inspect Electrical Components 3 1 Every Month or 200 Hours 3 1 Degradation Due to Severe Environment 3 1 Circuit Breaker and Fuse ID 3 2 Test Volta...

Page 7: ... Identifying Straps 4 11 Replacement Specifications 4 12 Storing Straps 4 16 Removing Straps from Service 4 16 Inspection Checklist 4 16 Lattice Section Inspection and Lacing Replacement 4 16 SECTION 5 Hoists Hoist Drawings 5 1 Wire Rope Removal 5 1 Free Fall Clutch Brake 5 1 Inspection 5 1 Overhaul 5 2 Minimum Bail Limit Pressure Roller 5 3 Minimum Bail Limit 5 3 Drum Pressure Roller 5 5 Block up...

Page 8: ...ing Diagram 7 9 Engine Enclosure 7 11 Engine Belt Routing 7 11 Engine Cooling System 7 13 Checking Coolant Level 7 13 Draining Cooling System 7 13 Filling and Bleeding Cooling System 7 13 Exhaust Aftertreatment System 7 15 DEF Tank 7 15 Coolant Solenoid Valve 7 16 Coolant Manifold 7 16 Air Bleed Valves 7 16 DEF Supply Module 7 16 SCR Module 7 16 DRT Module 7 16 DEF Dosing Module 7 17 DOC Module 7 ...

Page 9: ...est 9 Checking Voltage at the Pressure Senders 10 41 Test 10 Checking Voltage at the Speed Encoders 10 42 Test 11 Checking Voltage at the Hydraulic Brake Valve 10 43 Test 12 Checking Voltage at the Hydraulic Valve Assemblies 10 44 Test 13 Testing the Pump EDC and Motor PCP 10 45 Test 14 Location of Pump Ports 10 46 Test 15 Location of Motor Ports 10 47 Test 16 Manually Stroking the Pump 10 48 Test...

Page 10: ...R e f e r e n c e O n l y TABLE OF CONTENTS 999 SERVICE MAINTENANCE MANUAL TOC vi Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 11: ...ne Controls 1 8 EPIC Programmable Controller 1 9 Standard Mode 1 10 Other Crane Modes 1 10 Electrical Power to 999 Operator Cab 1 11 Pressure Senders and Encoders 1 12 System Faults 1 13 Operating Faults and Limit Switches 1 14 Brake and Drum Pawl Application Release 1 14 Swing System Operation 1 16 Swing Brake and Swing Lock 1 16 Swing Right or Left 1 16 Swing Holding Brake Switch 1 17 Travel Sys...

Page 12: ...iary Drum Lower 1 39 Crane Setup Systems 1 42 Gantry System 1 43 Gantry Cylinders Raise 1 43 Gantry Cylinders Lower 1 47 Mast System 1 50 Mast Cylinders Raise 1 52 Mast Cylinders Lower 1 53 Boom Hinge Pins 1 56 Carbody Jacking System 1 58 Carbody Jacking Cylinder Raise 1 59 Carbody Jacking Cylinder Lower 1 59 Left and Right Crawler Pin Pusher Cylinders 1 61 Right Crawler Pin Pusher Cylinders Engag...

Page 13: ...ve harm Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exhaust system Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel Battery posts terminals and related accessories contain chemical lead and lead compounds chemicals known to the State of Califo...

Page 14: ...oved hard hat 5 Never climb onto or off a moving crane Climb onto and off crane only when it is parked and only with 999 Operator permission Use both hands and handrails steps and ladders provided to climb onto and off crane NOTE Safety harness and tether line must be worn when working on top of enclosure Lift tools and other equipment which cannot be carried in pockets or tool belts onto and off ...

Page 15: ...d with or without support of boom rigging pendants or straps securely block each section to provide adequate support and alignment Do not go under boom jib or mast sections while connecting bolts or pins are being removed 28 Unless authorized in writing by Manitowoc do not alter crane in any way that affects crane s performance to include welding cutting or burning of structural members or changin...

Page 16: ...umber The HS numbers identify actual hydraulic solenoid valves on the crane for training proposes only Hydraulic Components See Hydraulic Schematic drawing at end of Section 2 Hydraulic Tank Hydraulic tank has a fill cap separate breather suction filter diffuser filter high and low level sight gauges vacuum temperature and level sensors The tank has two sections a suction section and a return sect...

Page 17: ...raulic fluid from supercharge filter manifold as needed Auxiliary drum system draws hydraulic fluid directly from suction manifold Variable displacement axial piston pumps are used in all closed loop systems Each pump operates in a bi directional closed loop system Each pump has a charge pump EDC Electrical Displacement Control cylinder block where pistons are positioned axially around a drive sha...

Page 18: ... maintained at or greater than preset value depending on engine RPM System pressure can also be checked at pressure sender diagnostic gauge coupler with a 10 000 psi 689 bar high pressure gauge when pump is stroked Accessory System Pressure Diagnostics monitor the accessory system pressure The rear drum pump is the source of pressure for the accessory system items When an accessory valve is enable...

Page 19: ...cement depends on engine driven pump speed through pump drive and swashplate tilt angle The engine provides power for work while the swashplate tilt angle provides speed control Engine speed is set and controlled with hand or foot engine throttle Each variable displacement motor except travel begins operation at maximum displacement high torque low speed and shifts to minimum displacement low torq...

Page 20: ...l valve 29 and relief valve 30 Loop flushing allows 6 GPM 23 L min of fluid at 350 psi 24 bar to be removed from main hydraulic circuit for added cooling and purification Engine Controls See engine manufacturer s manual for instructions The engine is started and stopped with engine key switch Use engine stop push button to stop engine in an emergency only as all brakes spring apply and any functio...

Page 21: ...s selectors or control handles send input voltage command signals to the PC The PC compares these input voltages with feedback voltages received from system monitoring sensors memory information and directives entered into programming Monitoring sensors includes limit switches pressure senders speed encoders engine RPM indicator hydraulic fluid and temperature probes and boom mast jib angle sensor...

Page 22: ...ram provides precise pump control needed for initial control handle movement Fluid then flows from pump to motor The higher the command voltage the more the pump EDC tilts swashplate As selected control handle is moved back to neutral position the PC sends an output signal to pump EDC to decrease pump output flow When control handle is moved to neutral position and motion is stopped the PC sends a...

Page 23: ...ing relay ACR power relay K1 engine control module relay ECM and start relay MS1 When power relay K1 is enabled power is available to operate crane controls and accessory controls see Electrical Schematic drawings in Section 3 FIGURE 1 5 K1 HORN 6A 20A 5H 45 5A TRANSIENT SUPPRESSOR 5A 0 0 24 VDC STARTER MOTOR 6A 6A1 SS MS1 SOL 5A 6B ALT 12 VDC DOME LIGHT 5A 5B 90 AMP 5 CB1 5 SOLENOID 6A1 ES SS M S...

Page 24: ... WB 09 SELECT CONFIRM CRANE MODE 8T 0 0 8 WB 26 WB 33 DOWN SCROLL UP SCROLL WA 24 WA 29 WA 25 WA 20 WA 26 WA 21 WA 22 WA 23 K1 F4 WD 02 WD 01 8E 0 FRONT DRUM SPEED ENCODER F A B D F8 SWING LEFT SWING RIGHT LEFT TRAVEL RIGHT TRAVEL BOOM HOIST ACCESSORY REAR DRUM PRESSURE TRANSDUCER FRONT DRUM SYSTEM FAULT BUZZER 25A 25 OPERATING LIMIT BEEPER WD 04 WD 03 8E 0 REAR DRUM SPEED ENCODER F A B D WD 06 WD...

Page 25: ...DRUM CHRG FILTER Auxiliary drum charge filter is plugged replace filter HYD SUCTION FILTER Remove blockage from suction side of hydraulic tank or pumps will be damaged BOOM ANGLE SENDER Boom angle sender output voltage is 0 volts or above 9 7 volts LUFF JIB SENDER Luffing jib angle sender output voltage is 0 volts or above 9 7 volts MAST SYSTEM Stop operating mast system and find cause of fault an...

Page 26: ... JIB BELOW HORIZONTAL Luffing jib operable See Capacity Chart Manual for luffing jib minimum operating angles RATED CAPACITY All load drums stop hoisting and boom luffing jib stop lowering MAST TOO FAR FWD Boom hoist inoperable in lowering direction occurs if mast is below 175 MAST SYSTEM Boom hoist inoperable in both directions FUNCTION IS PARKED Function inoperable because it is parked NOTE The ...

Page 27: ...NIVERSAL BOOM TOP JUNCTION BOX F8 SYSTEM FAULT BUZZER 25A 25 OPERATING LIMIT BEEPER PROGRAMMABLE CONTROLLER DIGITAL DISPLAY 5A 5A _ ENGINE 10A 5D 5A F15 STOP STOP 3 ENGINE RUN START 7 MS1 K1 5DA 8 8P1 50 AMP CB7 SEAT SWITCH WB 34 999CSM1 107 LIMIT BYPASS WB 25 LUFFING JIB WB 05 LIMIT BYPASS WB 03 FRONT DRUM MINIMUM BAIL LIMIT WB 02 FRONT DRUM MAXIMUM BAIL LIMIT WB 12 MAXIMUM BOOM ANGLE LIMIT WB 22...

Page 28: ...ngage solenoid HS 10 closes disengaging locking pins from slots in shaft locking flange Swing brake release solenoid HS 8 shifts to block tank port and supplies hydraulic charge pressure from rear drum pump to hydraulically release brake If brake pressure or electrical power is lost when operating brakes spring apply Before shutdown place swing brake switch in on park position Swing brake release ...

Page 29: ... Holding Brake Switch Swing holding brake switch 10 on side of swing handle holds rotating bed in position applies swing park brake for short periods when operating To prevent damage to swing system swing holding brake switch must only be applied when crane is at a standstill When swing holding brake switch is pressed in and held circuit to swing brake release solenoid HS 8 is opened allowing flui...

Page 30: ...or port B When left or right travel handle or pedal is moved in forward direction an input voltage of 5 volts or more is sent to the PC The PC sends a positive output signal to selected travel pump EDC and enables travel brake release solenoid HS 11 Travel brake release solenoid HS 11 shifts to release left and right travel brake with charge pressure from rear drum pump before selected travel pump...

Page 31: ...el information When travel handle is moved back to neutral position travel speed and direction is maintained Lifting travel detent selector again or moving either travel handle or pedal in opposite direction from neutral opens travel detent circuit and returns control of travel system to the operator Travel detent selector also serves as a brake function Lift the travel detent selector when travel...

Page 32: ...ALVES SHUTTLE VALVE LEFT TRAVEL MOTORS LEFT TRAVEL PUMP RIGHT TRAVEL PUMP HS 11 RIGHT PRESSURE SENDER FORWARD TRAVEL 2 SPEED HS 12 TRAVEL BRAKE SUCTION MANIFOLD A 350 PSI 24 BAR B 350 PSI 24 BAR B A REVERSE FORWARD 340 PSI 23 BAR B A 350 PSI 24 BAR B A TRAVEL BRAKE LEFT PRESSURE SENDER REVERSE FORWARD PILOT CHARGE PRESSURE FROM REAR DRUM PUMP 999CSM1 111 PILOT PRESSURE FOR MOTOR SERVOS 3 3 3 10 3 ...

Page 33: ...ence flow valve 9 Sequence flow valve opens at 200 psi 14 bar and removes 6 GPM 23 L min of hot fluid from system by dumping the fluid into the motor case where fluid returns to tank through tank cooler An orifice 10 across motor ports A and B allows for smoother fluid flow Boom Hoist Brake and Pawl Switch When boom hoist brake switch 2 is in on park position boom hoist brake release solenoid HS 1...

Page 34: ...essure to value stored in pressure memory When system pressure is high enough the PC sends a positive output signal to enable brake release solenoid HS 13 Brake release solenoid HS 13 shifts to block tank port and open port from low pressure side of closed loop system to release spring applied brake The PC sends a positive output voltage to enable boom hoist pump EDC that tilts pump swashplate to ...

Page 35: ...m is raised to maximum boom up stop angle of 83 above horizontal or 88 above horizontal with luffing jib the boom up limit switch 12 opens the circuit Boom hoist pump de strokes and boom hoist brake spring applies Operating limit MAX UP 1 is displayed as limit switch is tripped Lower the boom to correct problem Boom Hoist Lower See Figures 1 15 and 1 16 When boom hoist handle 1 is moved forward to...

Page 36: ...m motor port B returns to boom hoist pump port A The PC controls lowering speed by varying the voltage to pump EDC and motor PCP in relation to handle movement As boom hoist handle is pushed forward the PC sends a signal to increase the boom hoist pump swashplate angle The PC also sends a signal to reduce the displacement of the motor The PC is continuously balancing the system pressure and the mo...

Page 37: ...s a slightly positive signal This shifts the swashplate in the positive direction and builds pressure on high pressure side of closed loop The PC stores load holding pressure in pressure memory After control handle neutral switch opens the PC sends an output signal to disable brake release solenoid HS 13 to spring apply brake before boom hoist pump de strokes FIGURE 1 16 HS 14 06 X X 6 GPM B A A B...

Page 38: ...tor 9 in selected load drum control handle Rotation indicator on top of each control handle pulsates with a varying frequency that indicates rotational speed of load drum As drum rotates faster the indicator pulsates faster FIGURE 1 17 WA 01 8D 8 WB 10 WB 09 SELECT CONFIRM CRANE MODE 8T 0 0 8 WB 26 WB 33 DOWN SCROLL UP SCROLL WA 22 WA 23 K1 F4 F8 REAR DRUM PRESSURE TRANSDUCER FRONT DRUM SYSTEM FAU...

Page 39: ...14 are closed with no hydraulic system faults present The PC requires that front drum pump strokes in hoist direction to satisfy pressure memory The PC compares front drum holding pressure to value stored in pressure memory When system pressure is high enough the PC sends a positive output signal to enable brake release solenoid HS 16 Brake release solenoid HS 16 shifts to block tank port and open...

Page 40: ...rake release solenoid HS 16 Front drum brake release solenoid HS 16 shifts to block tank port and open port from low pressure side of closed loop to brake cylinder spring releasing brake The PC sends a negative output signal to enable front drum pump EDC that tilts pump swashplate to stroke pump in the down direction Hydraulic fluid flows from front drum pump port B to port B of front drum motor F...

Page 41: ...t for slower output speed to slow the drum rotation The PC shifts the pump swashplate through neutral until the EDC has a slightly positive signal This shifts the swashplate in the positive direction and builds pressure on high pressure side of closed loop The PC stores load holding pressure in pressure memory After control handle neutral switch opens the PC sends an output signal to disable brake...

Page 42: ...ch is placed in off park position drum pawl out solenoid HS 25 is enabled and pawl is disengaged Rear drum brake remains spring applied to drum and is controlled automatically by the PC with movement of control handle If a block up limit or LMI operating fault occurs while luffing the PC sends a command to stop the rear drum Corrective action for these operating faults is to raise the jib In full ...

Page 43: ...ables rotation indicator 7 in on top of control handle As drum rotates faster rotation indicator pulsates faster indicating rotational speed of drum Drum Brake and Pawl Switch When front drum 8 brake switch is in on park position front drum hoist brake release solenoid HS 16 is disabled so brake is spring applied to drum Front drum pawl in solenoid HS 19 is enabled and pawl is engaged Front drum p...

Page 44: ...PC sends an output signal to disable brake release solenoid HS 16 to spring apply drum brake before front drum pump de strokes WARNING Falling Load Hazard When operating in free fall load will lower uncontrolled if front drum brake clutch pedal is not applied Be ready to apply front drum brake clutch pedal so lowering speed can be controlled and load can be stopped immediately when necessary FIGUR...

Page 45: ...ERATING LIMIT BEEPER 5A 5A _ ENGINE 10A 5D 5A F15 STOP STOP 3 RUN START 7 MS1 K1 5DA 8 8P1 50 AMP CB7 PRESSURE TRANSDUCER SEAT SWITCH WB 34 999CSM1 122 F12 3A REGULATED 10V DC OUTPUT RAISE OFF LOWER FRONT DRUM WA 03 WD 18 WD 19 DIGITAL DISPLAY WC 05 FRONT DRUM B A EDC RAISE OFF LOWER REAR DRUM WA 04 REAR DRUM WC 06 B A EDC 3 9 3 4 3 7 RIN BLOCK UP LIMITS HS 16 FRONT DRUM WD 33 HS 20 FRONT DRUM WD ...

Page 46: ...d tank depending on PC command or back pressure Moving brake clutch pedal fully applies brake clutch without slipping CAUTION Brake Clutch Motor Damage Do not move a drum handle in either direction from neutral while a load is free falling Damage to brake clutch and or motor drive system could occur Stop the load with drum brake clutch pedal before moving drum control handle in either direction Do...

Page 47: ...TAL DISPLAY WC 05 FRONT DRUM RAISE OFF LOWER REAR DRUM WA 04 REAR DRUM WC 06 B A EDC 3 9 3 4 3 7 RIN BLOCK UP LIMITS FRONT DRUM WD 33 HS 20 FRONT DRUM WD 08 WC 18 WD 27 ROTATION INDICATOR FRONT DRUM 19 HS FRONT DRUM PAWL IN WD 32 BRAKE WD 24 FRONT DRUM WD 25 RD PCP REAR DRUM PUMP CONTROL PUMP CONTROL MOTOR CONTROL MOTOR CONTROL WD 28 ROTATION INDICATOR REAR DRUM WD 35 REAR DRUM 24 HS REAR DRUM PAW...

Page 48: ...HS18 HS23 5 GPM MOTOR MANIFOLD PUMPS HS19 HS16 FRONT LOAD DRUM BRAKE COOLING INLET BRAKE COOLING OUTLET PLUG PRESSURE PRESSURE SENDER BRAKE CLUTCH LOW SIDE HIGH SIDE 350 PSI 24 BAR LOW PRESSURE PILOT BRAKE PAWL A B HS20 X FRONT LOAD DRUM PUMP PUMP DRIVE 06 X B A ENGINE MANIFOLD SUPERCHARGE GEARBOX SENDER 3 11 3 14 3 15 3 12 3 13 3 15 3 16 3 3 3 5 3 1 3 2 3 4 999CSM1 125 ...

Page 49: ...ke 7 remains spring applied to prevent the auxiliary drum from turning When auxiliary drum rotates speed encoder 8 sends an input signal to the PC The PC sends an output signal that enables rotation indicator 9 in auxiliary drum handle Rotation indicator on top of control handle pulsates with a varying frequency that indicates rotational speed of load drum As drum rotates faster the indicator puls...

Page 50: ...vement of auxiliary drum handle Release of auxiliary drum brake is from 350 psi 25 bar charge pressure supplied from auxiliary charge pump If charge pressure drops below 200 psi 14 bar brakes spring apply Auxiliary Drum Raise See Figures 1 26 and 1 27 When auxiliary drum handle 1 is moved back for drum hoist handle neutral switch closes sending an input voltage of 5 volts or more to PC The PC send...

Page 51: ...ad holding pressure in pressure memory After control handle neutral switch opens the PC sends an output signal to disable brake release solenoid HS 26 to spring apply brake before auxiliary drum pump de strokes Auxiliary Drum Lower See Figures 1 28 and 1 29 When auxiliary drum handle 1 is moved forward to lower handle neutral switch closes sending an input voltage of 5 volts or less to PC The PC s...

Page 52: ...in the positive direction and builds pressure on high pressure side of closed loop The PC stores load holding pressure in pressure memory After control handle neutral switch opens the PC sends an output signal to disable brake release solenoid HS 26 to spring apply brake before auxiliary drum pump de strokes FIGURE 1 28 WA 01 8D 8 WB 10 WB 09 SELECT CONFIRM CRANE MODE 8T 0 0 8 WB 26 WB 33 DOWN SCR...

Page 53: ...99 SERVICE MAINTENANCE MANUAL INTRODUCTION 1 FIGURE 1 29 HS 28 B A A B LOW PRESSURE SIDE HIGH PRESSURE SIDE 350 PSI 24 BAR AUXILIARY DRUM LOW PRESSURE HS 27 BRAKE PAWL SUPERCHARGE MANIFOLD CHARGE PUMP PILOT AUXILIARY DRUM PUMP 3 4 3 10 3 7 3 3 3 13 3 5 06 HS 26 3 11 999CSM1 129 ...

Page 54: ...sory system safety delta pressure across the pump of 3770 260 BAR The lowerworks accessory valve system includes crawler pin pusher cylinders 10 and carbody jack cylinders 11 that are enabled by return to center hand levers Output flow from the lowerworks accessory system passes through control levers when all of the levers are centered An orifice 13 restricts the flow building pressure in the lin...

Page 55: ...mpletes power supply circuit to setup remote control switches A gantry operating limit message GANTRY DOWN appears on the digital display screen when gantry and the mast angle is 22 or more The PC detects this fault when the mast angle sensor 4 monitors the mast position at 22 and gantry up limit switch 5 circuit to the PC is closed The operator should raise gantry with the gantry switch in raise ...

Page 56: ...EL HIGH UPPERWORKS ACCESSORY MANIFOLD REAR DRUM PUMP DRIVE GEARBOX HS 4 A A A B B B BOOM HINGE PIN CYLINDER LOAD EQUALIZING VALVE 4 000 PSI 275 BAR MAST RAISING CYLINDERS 3 500 PSI 240 BAR LOW 999CSM1 130 HS 3 HS 2 HS 1 HS 6 HS 5 3 8 3 10 A A A B B B LOAD EQUALIZING VALVE 4 000 PSI 275 BAR GANTRY CYLINDERS 3 500 PSI 240 BAR HIGH FRONT DRUM PUMP DRIVE GEARBOX LOW LOW PRESSURE ACCESSORIES 3 10 3 11 ...

Page 57: ... BOOM HOIST SYSTEM FAULT BUZZER 25A 25 OPERATING LIMIT BEEPER 5A 5A _ ENGINE 10A 5D 5A F1 STOP STOP 3 RUN START 7 MS1 K1 5DA 8 8P1 50 AMP CB7 SEAT SWITCH WB 34 F12 3A REGULATED 10V DC OUTPUT RAISE OFF LOWER BOOM HOIST HANDLE WA 05 WD 18 WD 19 DIGITAL DISPLAY HS 13 BOOM HOIST 3 11 3 1 3 4 WC 14 BOOM HOIST B A EDC WD 37 HS 15 BOOM HOIST PAWL OUT WD 10 WC 09 3 10 3 9 3 5 3 3 GANTRY UP LIMIT WB 22 WE ...

Page 58: ...n restrictive portion of load equalizing valve before entering accessory system valve Hydraulic fluid exits the accessory system valve and returns to tank The free flow check valve sections on side B of load equalizing valve block the flow Hydraulic fluid then passes through flow restrain section of valve that is preset at 4 000 psi 275 bar Load equalizing valve operates with a 1 5 1 pilot ratio o...

Page 59: ...3 Brake release solenoid valve shifts to block tank port and open port from low pressure side of closed loop to boom hoist brake cylinder spring releasing brake The PC sends a negative output signal to enable boom hoist pump EDC that tilts pump swashplate to stroke boom hoist pump in the raise direction The PC sends a negative output voltage to rear drum pump EDC 13 that tilts rear drum pump swash...

Page 60: ...E 1 34 999CSM1 133 87F 8D 8 WB 10 WB 09 SELECT CONFIRM CRANE MODE 8T 0 0 8 WB 26 WB 33 DOWN SCROLL UP SCROLL WA 24 K1 F4 F8 PRESSURE TRANSDUCER BOOM HOIST SYSTEM FAULT BUZZER 25A 25 OPERATING LIMIT BEEPER 5A 5A _ ENGINE 10A 5D 5A F1 STOP STOP 3 RUN START 7 MS1 K1 5DA 8 8P1 50 AMP CB7 SEAT SWITCH WB 34 F12 3A REGULATED 10V DC OUTPUT RAISE OFF LOWER BOOM HOIST HANDLE WA 05 WD 18 WD 19 DIGITAL DISPLA...

Page 61: ... sends an output signal to disable brake release solenoid HS 13 to spring apply brake before hoist pump de strokes The PC sends an output signal to de stroke rear drum pump and boom hoist pump The PC also sends an output signal to shift gantry lower cylinder solenoid HS 4 back to center position FIGURE 1 35 HIGH UPPERWORKS ACCESSORY MANIFOLD REAR DRUM PUMP DRIVE GEARBOX HS 4 A A A B B B BOOM HINGE...

Page 62: ...nnected in center position This type of spool prevents premature opening of equalizing valves 8 Hydraulic pressure for mast cylinder solenoids HS 1 and HS 2 is from rear drum low pressure side closed loop system When raising the mast the PC monitors boom hoist drum speed with the boom hoist drum encoder 3 The PC maintains a speed that is proportional to accessory system hydraulic pressure applied ...

Page 63: ... 1 3 4 WC 14 BOOM HOIST B A EDC WD 37 HS 15 BOOM HOIST PAWL OUT WD 10 WC 09 3 10 3 9 WE 29 BH PCP BOOM HOIST MOTOR CONTROL PUMP CONTROL WD 29 ROTATION INDICATOR BOOM HOIST 14 HS BOOM HOIST PAWL IN WD 36 DRUM BRAKE BOOM HOIST SPEED ENCODER F A B D DRUM SHAFT WD 05 WD 06 WA 35 SENSOR MAST ANGLE WA 21 PRESSURE TRANSDUCER ACCESSORY 3 12 PRESSURE SWITCH WB 36 ACCESSORY 3 2 WC 06 REAR DRUM B A EDC 3 13 ...

Page 64: ...ow pressure side direction Low pressure side hydraulic fluid flows to mast extend cylinder solenoid HS 1 of accessory valve and through free flow check valve sections on side A of load equalizing valve 8 From equalizing valve fluid enters counterbalance valves 7 and piston end of mast raising cylinders 6 extending cylinder rods to raise the mast assembly As mast raises boom hoist drum pays out wir...

Page 65: ... restrictive portion of flow control valve and enters accessory system valve Hydraulic fluid exits the accessory system valve through control valve section before returning to tank When mast raises over 90 and starts to move away from mast assist arms the PC sends an output signal to de stroke rear drum pump The PC also sends an output signal to shift mast extend cylinder solenoid HS 1 back to cen...

Page 66: ...UP SCROLL WA 24 K1 F4 F8 PRESSURE TRANSDUCER BOOM HOIST SYSTEM FAULT BUZZER 25A 25 OPERATING LIMIT BEEPER 5A 5A _ ENGINE 10A 5D 5A F1 STOP STOP 3 RUN START 7 MS1 K1 5DA 8 8P1 50 AMP CB7 SEAT SWITCH WB 34 F12 3A REGULATED 10V DC OUTPUT RAISE OFF LOWER BOOM HOIST HANDLE WA 05 WD 18 WD 19 DIGITAL DISPLAY HS 13 BOOM HOIST 3 11 3 1 3 4 WC 14 BOOM HOIST B A EDC WD 37 HS 15 BOOM HOIST PAWL OUT WD 10 WC 0...

Page 67: ...side B of counterbalance valves and enters into rod end of the mast lowering cylinders To continue lowering mast the gantry must be lowered When lowering gantry support cylinders to fully retracted position boom hoist hydraulic system is monitored by the PC through boom hoist system pressure sender 12 and controlled by the PC to maintain a minimum rope tension on the boom hoist drum The PC maintai...

Page 68: ...L UP SCROLL WA 24 K1 F4 F8 PRESSURE TRANSDUCER BOOM HOIST SYSTEM FAULT BUZZER 25A 25 OPERATING LIMIT BEEPER 5A 5A _ ENGINE 10A 5D 5A F1 STOP STOP 3 RUN START 7 MS1 K1 5DA 8 8P1 50 AMP CB7 SEAT SWITCH WB 34 F12 3A REGULATED 10V DC OUTPUT RAISE OFF LOWER BOOM HOIST HANDLE WA 05 WD 18 WD 19 DIGITAL DISPLAY BOOM HOIST WC 14 BOOM HOIST WD 37 BOOM HOIST PAWL OUT WD 10 WC 09 WE 29 BOOM HOIST MOTOR CONTRO...

Page 69: ...mp EDC 13 that tilts rear drum pump swashplate to stroke pump in the low pressure side direction Low pressure side hydraulic fluid flows to boom hinge pins disengage solenoid HS 6 of accessory valve Hydraulic fluid leaves the accessory valve and enters rod end of boom pin cylinder 6 retracting cylinder rod to disengage the hinge pins Exhaust fluid from piston end of boom pin cylinder leaves access...

Page 70: ... Collapsing Hazard Keep rotating frame as level as possible while jacking Operating jacking cylinder with rotating frame more than 3 out of level can cause structural damage to jacking cylinders and possible collapse of rotating frame FIGURE 1 42 PRESSURE SWITCH SW LEFT CRAWLER PINS RIGHT CRAWLER PINS RIGHT CARBODY JACKS LEFT CARBODY JACKS LOWERWORKS ACCESSORY MANIFOLD SWIVEL HIGH UPPERWORKS ACCES...

Page 71: ...atio of the relief pressure This permits the valve to open when the pressure in rod end of the cylinder is approximately 1 170 psi 81 bar Restraining section of counterbalance valve opens controlling the fluid out of the carbody jacking cylinder Hydraulic fluid then flows through free flow check valve 5 section of flow control valve before entering lower accessory valve Hydraulic fluid leaving the...

Page 72: ...PINS RIGHT CARBODY JACKS LEFT CARBODY JACKS LOWERWORKS ACCESSORY MANIFOLD SWIVEL HIGH UPPERWORKS ACCESSORY MANIFOLD REAR DRUM PUMP DRIVE GEARBOX HS 4 LOW HS 3 HS 2 HS 1 HS 6 HS 5 FRONT DRUM PUMP DRIVE GEARBOX LOW LOW PRESSURE ACCESSORIES 3 2 3 6 3 3 3 1 999CSM1 142 TO GANTRY CYLINDERS TO MAST CYLINDERS TO BOOM PIN CYLINDERS 3 4 3 5 TO REAR HOIST MOTOR LOOP FLUSHING VALVE ...

Page 73: ...system pressure is 3 000 psi 207 bar Hydraulic fluid enters piston end of both crawler pin pusher cylinders extending each cylinder rod rotating each assembly lever to secure crawler frame to carbody Hydraulic fluid exhausting from rod end of both crawler pin pusher cylinders returns to lower accessory valve and is returned to tank Right Crawler Pin Pusher Cylinders Disengage Move right crawler pi...

Page 74: ...S RIGHT UNDER CARRIAGE JACKS LEFT UNDER CARRIAGE JACKS LOWERWORKS ACCESSORY MANIFOLD SWIVEL 3 2 3 4 3 1 HIGH UPPERWORKS ACCESSORY MANIFOLD REAR DRUM PUMP DRIVE GEARBOX HS 4 LOW HS 3 HS 2 HS 1 HS 6 HS 5 FRONT DRUM PUMP DRIVE GEARBOX LOW ACCESSORIES 3 3 TO GANTRY CYLINDERS TO MAST CYLINDERS TO BOOM PIN CYLINDERS LOW PRESSURE 999CSM1 143 TO REAR HOIST MOTOR LOOP FLUSHING VALVE ...

Page 75: ...E 1 45 15 HS HS 14 B A EDC 999CSM1 144 87F 8D 8 WB 10 WB 09 SELECT CONFIRM CRANE MODE 8T 0 0 8 WB 26 WB 33 DOWN SCROLL UP SCROLL WA 24 K1 F4 F8 PRESSURE TRANSDUCER BOOM HOIST SYSTEM FAULT BUZZER 25A 25 OPERATING LIMIT BEEPER 5A 5A _ ENGINE 10A 5D 5A F1 STOP STOP 3 RUN START 7 MS1 K1 5DA 8 8P1 50 AMP CB7 SEAT SWITCH WB 34 F12 3A REGULATED 10V DC OUTPUT RAISE OFF LOWER BOOM HOIST HANDLE WA 05 WD 18 ...

Page 76: ...VICE MAINTENANCE MANUAL 1 64 Published 05 16 17 Control 233 03 FIGURE 1 46 06 B A LOW PRESSURE SIDE HIGH PRESSURE SIDE 350 PSI 24 BAR SUPERCHARGE MANIFOLD CHARGE PUMP REAR LOAD DRUM PUMP 999CSM1 145 ACCESSORIES LOW PRESSURE HS 7 COUNTERWEIGHT PINS ...

Page 77: ...wl In HS 20 Front Drum Pawl Out HS 21 Rear Drum Brake Release HS 22 Rear Drum Brake Proportional Valve HS 23 Rear Drum Free Fall Enable HS 24 Rear Drum Pawl In HS 25 Rear Drum Pawl Out HS 26 Auxiliary Drum Brake Release HS 27 Auxiliary Drum Pawl In HS 28 Auxiliary Drum Pawl Out A Amber Light ACR Air Conditioning Relay AH Auxiliary Hoist ALT Alternator AUX Auxiliary BH Boom Hoist EDC Electrical Dis...

Page 78: ...R e f e r e n c e O n l y INTRODUCTION 999 SERVICE MAINTENANCE MANUAL 1 66 Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 79: ...hread Connection 2 8 ORS Connection 2 9 Split Flange Connection 2 10 SAE Flare Connection 2 11 Hydraulic System Calibration 2 12 Accessing Calibration Screens 2 12 Calibration Procedures 2 12 Pressure Sender 2 12 Charge Pressure 2 13 Control System 2 14 Pump Pressure 2 15 Pressure Sender Replacement 2 18 Pump Components 2 20 Pump Identification 2 20 Pump and Motor Port Identification 2 21 Disc Bra...

Page 80: ...R e f e r e n c e O n l y 999 SERVICE MAINTENANCE MANUAL 2 ii Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 81: ...visually inspect all other hydraulic components and valves for the following Leaking ports Leaking valve sections or manifolds and valves installed into cylinders or onto motors Damaged or missing hose clamps guards or shields Excessive dirt and debris around hose assemblies If any of these conditions exist address them appropriately Degradation Due to Extreme Environment Table 2 1 Climate Zone Cl...

Page 82: ... container tightly covered Storing and Handling Parts Store new parts valves pumps motors hoses tubes in clean dry indoor location Do not unpack parts or remove port plugs until parts are needed Once unpacked carefully inspect each part for damage that may have occurred during shipping Remove all shipping material from ports of parts before installing them Fittings hoses and tubes that are not equ...

Page 83: ...ine or scream from the pump can also indicate cavitation pump being starved of oil This condition is caused by the following problems Plugged suction filter Collapsed or plugged suction line Wrong oil viscosity too high 6 Look for signs of overheating heat peeled parts burned and scorched oil odor and darkening and thickening of oil Maximum temperature of oil in tank must not exceed 180 F 82 C 7 H...

Page 84: ...er 1 or 2 8 Return Oil Diffuser 2 Thermal Bypass Valve 9 Hydraulic Tank 3 Hydraulic Tank Sight Gauge 10 Suction Filter 4 Hydraulic Tank Fill Cap 11 Hydraulic Tank Access Cover 3 5 Hydraulic Tank Breather 12 Suction Tube to pumps 6 Hydraulic Tank Level Switch 13 Oil Temperature Switch 7 Hydraulic Oil Return Manifold P1432 1 2 4 3 5 M102000 6 9 81014032 8 7 10 Left Enclosure Left Enclosure 13 6 11 1...

Page 85: ... OPEN CLOSE FIGURE 2 1 continued Item Description 14 Auxiliary Drum Hydraulic Oil Filter 15 Charge Filter Shut Off Valve 16 Hydraulic Tank Shut Off Valve suction tube 17 Hydraulic Oil Charge Filters 3 18 Hydraulic Tank Drain Valve 14 15 OPEN CLOSE 16 17 Bottom of Hydraulic Tank Accessible from Under Rear of Rotating Bed 18 ...

Page 86: ...d and filter element does not leak 12 Start engine and allow hydraulic system to return to operating pressure Check filter element for leaks Tighten element as required to stop leakage 13 For filters 1 14 and 17 open filter shut off valve 15 Changing Oil Drain and refill hydraulic system every 1 000 hours or semiannually whichever occurs first unless an alternate interval is established through an...

Page 87: ...irt Carefully inspect threads and sealing surfaces for nicks gouges and other damage Do not use damaged parts they will leak Carefully inspect O rings for cuts and other damage Do not use damaged O rings they will leak Always lubricate O rings when assembling them to fittings Be careful not to cut O rings when assembling them to fittings Use thimble as shown in Figure 2 2 when assembling O ring ov...

Page 88: ... face as shown in Figure 2 4 View B NOTE If an elbow is being used back it out as necessary to align it with hose 4 Tighten jam nut When fitting is properly installed O ring will completely fill seal cavity and washer will be tight against spot face as shown in Figure 2 4 View B Table 2 3 Straight Thread Leakage View B View A O Ring Washer Jam Nut FIGURE 2 3 Washer cannot seat properly on spot fac...

Page 89: ...RS Leakage Nut Size inch across flats Fitting Size Torque In Lb N m 5 8 04 120 145 14 16 13 16 06 203 245 23 28 15 16 08 380 470 43 53 1 1 8 10 550 680 62 77 1 3 8 12 763 945 86 107 1 5 8 16 1110 1260 125 142 1 7 8 20 1500 1680 170 190 Nut Adapter O Ring FIGURE 2 5 S105 Causes Cures Nut Loose Tighten to proper torque O ring cut Replace O ring wrong size Replace with proper size Sealing surfaces go...

Page 90: ...nsion inch Flange Size Torque in lb N m Standard Pressure Series 1 1 2 08 175 225 20 25 1 7 8 12 225 350 25 40 2 1 16 16 325 425 37 48 2 5 16 20 425 550 48 62 2 3 4 24 550 700 62 79 3 1 16 32 650 800 73 90 High Pressure Series 1 9 16 08 175 225 20 25 2 12 300 400 34 45 2 1 4 16 500 600 57 68 2 5 8 20 750 900 85 102 3 1 8 24 1400 1600 158 181 3 13 16 32 2400 2600 271 294 Causes Cures Flanges not ti...

Page 91: ...en tightened and that it has been tightened Table 2 8 SAE 37 Flare Tightening Table 2 9 SAE 37 Flare Leakage Turn connector nut required number of flats Table 2 8 S108 FIGURE 2 7 Connector Nut Adapter Line View A View B Connector Nut Size inch across flats Fitting Size Adapter Flats to Rotate 9 16 04 2 1 2 5 8 05 2 1 2 11 16 06 2 7 8 08 2 1 10 1 1 2 2 1 1 4 12 1 1 1 2 16 3 4 1 2 20 3 4 1 2 1 4 24 ...

Page 92: ...on Troubleshoot the particular system to determine the cause of the fault If the number displayed on the screen is 0 there are no active items all items passed calibration Calibration Procedures Pressure Sender The pressure sender screen Figure 2 9 indicates if each system s pressure sender null 0 is within 0 65 1 35 volts The pressure senders must be calibrated at the following intervals When a n...

Page 93: ...en Figure 2 10 indicates if each system s charge pressure is within 275 400 psi 19 27 bar as monitored by the computer Charge pressure should be checked at the following intervals When a new programmable controller is installed When a new CPU board is installed When a new controller chip is installed When a pump is replaced When a pump control EDC or PCP is replaced Every 6 months To check charge ...

Page 94: ...To check control system calibration proceed as follows 1 Access calibration screen see Accessing Calibration Screens 2 Turn PARK ON for all crane functions drums boom hoist swing travel 3 Start engine and run at high idle It is normal for yellow operating limits light to come on during this procedure Calibration will not start if engine is not running at high idle Calibration will stop if engine s...

Page 95: ...ing faster than 900 rpm NOTE Pump pressure test will not start if engine is not running Testing will stop if engine speed is decreased during procedure 4 When testing starts the percent of completion is displayed on screen 5 Check binary number in screen when calibration is done a If 0 appears all items have passed b If any number other then 0 appears use Table 2 10 to determine which items have f...

Page 96: ... 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 2 4 8 16 32 64 128 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 1 2 4 8 16 32 64 128 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 12...

Page 97: ...50 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 1 2 4 8 16 32 64 128 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 1 2 4 8 16 32 64 128 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239...

Page 98: ...TE Pressure senders have pipe threads Be sure to install thread sealant 9 Calibrate pressure senders see Hydraulic System Calibration in this Section WARNING High Pressure Oil Hazard Do not attempt to remove a pressure sender unless following steps are performed High pressure oil will exhaust from pressure sender port Item Description 1 Gauge Coupler typical 2 Electric Plug typical 3 Front Drum Ra...

Page 99: ...R e f e r e n c e O n l y Manitowoc Published 05 16 17 Control 233 03 2 19 999 SERVICE MAINTENANCE MANUAL HYDRAULIC SYSTEM 2 7 6 1 2 1 1 9 2 1 2 FIGURE 2 13 continued 11 2 2 8 10 1 2 ...

Page 100: ...ge Pressure Gauge Port 8 Charge Pump Inlet Port 9 Pump Port B 10 Pump Port B Gauge Port 11 Pump Port A 12 Pump Port A Gauge Port 13 Neutral Adjusting Screw NOTE 1 Both Sides of Pump NOTE 2 Auxiliary Drum Pump Only NOTE 3 Valve is Directly Opposite Port it Protects or 8 12 11 10 4 9 13 3 2 1 5 4 6 5 7 6 7 6 4 1 To Filter From Filter 2 5 1 4 0 3 10 Supercharge Pump A817 A1187 Pump Identification Ite...

Page 101: ...ng Right Left Right Left Left Crawler Forward Reverse Forward Reverse Right Crawler Forward Reverse Reverse Forward Auxiliary Load Drum Raise Lower Raise Lower A B B A A B B A B A B A Right Crawler Pump Left Crawler Pump Front of Carbody Swivel Travel Circuit Left Crawler Motor Motor Front Hoist Circuit Right Crawler Motor Pump Motor Motor Swing Circuit Pump Pump Boom Hoist Circuit Pump Aux Drum C...

Page 102: ...R e f e r e n c e O n l y HYDRAULIC SYSTEM 999 SERVICE MAINTENANCE MANUAL 2 22 Published 05 16 17 Control 233 03 FIGURE 2 16 1 2 3 4 5 7 4 6 8 9 10 4 11 12 14 15 13 ...

Page 103: ...c system shall perform the shop procedures These technicians shall read understand and comply with the instructions in this section Contact the Manitowoc Crane Care Lattice Team for a detailed explanation of any procedure not fully understood All adjustments identified in this section were made to the crane before it was shipped from the factory Adjustments by field personnel are required only whe...

Page 104: ... 2 18 4 At engine check that engine clutch is engaged Figure 2 19 5 Open charge filter shut off valve Figure 2 20 6 Remove bleed cap from outlet fitting of auxiliary drum filter Figure 2 20 7 Remove bleed plug from top of tee in suction tube Figure 2 20 8 Remove pressure gauge fitting from top of charge filter manifold Figure 2 20 CAUTION Equipment Damage Filters and fittings incorrectly installed...

Page 105: ...Monitor pressure gauge port on top of charge filter manifold Figure 2 20 Oil will flow by gravity from hydraulic tank to filter manifold Install pressure gauge fitting when clear oil appears 13 Check for oil at auxiliary drum charge filter Observe open bleed port at outlet fitting while cranking engine momentarily do not start engine Continue to bump engine starter until oil appears at bleed port ...

Page 106: ...r is present when gantry is extended 3 Boom pin pusher cylinder a Access setup remote control in left side enclosure b Use boom hinge pins switch on remote control to engage and disengage cylinders several times to remove air from system c Verify that 3 000 psi 241 bar is present when cylinder is extended 4 Crawler pin pusher cylinder a With handle on lower accessory valve engage and disengage bot...

Page 107: ...is released d Travel 2 speed is checked in test area when travel speed is checked Travel Handle and Speed Check Verify that travel movement responds correctly to handle commands You must count number of revolutions crawler rotates in one minute to determine travel speed NOTE Final evaluation of travel system is completed in test area 1 Put a timing mark on either front roller Figure 2 24 2 Start e...

Page 108: ...R e f e r e n c e O n l y HYDRAULIC SYSTEM 999 SERVICE MAINTENANCE MANUAL 2 28 Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 109: ...ion 3 13 Description Identification 3 17 Controller Board Identification 3 21 Master Node Pin Identification 3 26 Display Readings 3 28 Operating Conditions 3 28 Operating Limits 3 28 System Faults 3 29 Selecting Display Language 3 29 Crane Diagnostics 3 34 Drum 1 and 2 Front and Rear Drum 3 34 Drum 4 Boom Hoist 3 34 Drum 8 Auxiliary 3 34 FFall 3 34 Swing 3 35 Swing Speed Torque 3 35 Drum Slip 3 3...

Page 110: ...R e f e r e n c e O n l y 999 SERVICE MAINTENANCE MANUAL 3 ii Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 111: ...ion boxes Loose junction box mounting hardware If any of these conditions exist address them appropriately Degradation Due to Severe Environment Table 3 1 Climate Zone Classification Zone A and B Replace harnesses and battery cables operating in climate zone A and B after 8 000 hours of service life Their electrical service life is reduced by 25 to 40 Zone C Replace harnesses and battery cables op...

Page 112: ... the location and identification of the fuses and circuit breakers on this crane FIGURE 3 1 Item Description See 1 Fuse Junction Box in Operator s Cab page 3 3 2 Cold Weather Circuit Breaker Load Center page 3 4 3 Battery and Alternator Fuses page 3 4 4 Engine Node page 3 5 5 CraneStar TCU Fuses page 3 6 6 Exhaust Aftertreatment Junction Box page 3 6 1 3 4 6 5 2 ...

Page 113: ...ppressor Diode F1 10 5D Cab Power F2 10 5H Horn F3 10 8A LMI Gauges F4 10 8D Computer Inputs F5 10 8F Defogger Fan F6 10 8B Boom Jib Top F7 15 8S Swing Lock Park F8 10 8T Pressure Transducers Encoders F9 10 8X Front Console F10 10 8W1 Front Wiper F11 10 8W2 Overhead Wiper F12 3 87FA 10VDC Regulated F13 10 8C Hydraulic Clutch Solenoid K1 70 8 Fuse Breaker Power Relay S1 50 8P Computer Power CB7 S2 ...

Page 114: ...ption of Items Protected 1 50 Main Load Center Circuit Breaker 2 15 Hydraulic Reservoir Heaters 2 Cab Console Heater 3 15 Engine Coolant Heater Engine Oil Heater 4 15 Battery Pad Heaters 2 81012573D 1 2 3 4 FIGURE 3 3 FIGURE 3 4 Battery and Alternator Fuses Fuse Amps Description of Item Protected F19 250 Air Intake Heater F20 150 Alternator 12V F21 50 Alternator 24V F19 F20 F21 ...

Page 115: ... Engine Diagnostics AL2 Auto Lube 2 CB 4 30 5C1 Engine ECM AL3 Auto Lube 3 CB 5 15 6A3 CAN Bus Power CAN PWR CANBUS Power CB 6 15 6A4 Auto Lube and Engine Start AC CLUTCH Air Conditioner Clutch CB 6 15 8H Heater and A C KEY SWITCH Engine Start CB 7 30 6A1 Starter Solenoid MS1 50 Start Solenoid CB 8 30 58 A C Clutch MS2 NOT USED Eng Clutch 10 Cylinder Direction Eng Clutch 10 Cylinder Speed ECM FIGU...

Page 116: ...Power Bus F18 10 6C System 24VDC Fused Power FIGURE 3 6 F17 F18 FIGURE 3 7 Engine Exhaust Aftertreatment Junction Box Fuse Amps Description of Item Protected F5 15 DEF Supply Module F6 10 Aftertreatment Sensors F7 15 DEF Heaters K1 10 DEF Pressure Hose Heater K2 10 DEF Return Hose Heater K3 10 DEF Suction Hose Heater K4 10 DEF Supply Module K5 10 Aftertreatment Sensors K1 K2 K3 K4 K5 F5 F6 F7 ...

Page 117: ...R e f e r e n c e O n l y Manitowoc Published 05 16 17 Control 233 03 3 7 999 SERVICE MAINTENANCE MANUAL ELECTRIC SYSTEM 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 118: ... connections are not shown Controller Board Layout The board locations in the programmable controller are shown below Test Voltage Abbreviations The following abbreviations are used in this section I O Input Output AI Analog Input AO Analog Output Press Pressure psi Pounds per Square Inch DI Digital Input DO Digital Output NC No Connection CHA or CHB Channel A or B COMM Communication CPU Central P...

Page 119: ... Volts Raise I O 2 J7 58 AI A 17 68K Engine Throttle Lever Power On 064 to 10 05 Engine Running 101 to 10 09 I O 2 J7 60 AI A 18 68KA Engine Throttle Pedal Power On 280 to 10 05 Engine Running 092 to 10 03 I O 2 J7 62 AI A 19 80EP Front Drum Brake Pedal 0 Volts Neutral 1 4 to 5 Volts Lower 5 to 8 6 Volts Raise I O 2 J7 64 AI A 20 83Q Right Track Hydraulic Pressure 1 2 Volts at 300 psi 1 Volt at 0 ...

Page 120: ...Seat Switch 12 Volts Nominal I O 3 J10 12 DI B 35 89L1 High Speed Travel Switch 12 Volts Nominal I O 3 J10 13 DI B 36 89G5 Accessory Pressure Switch 12 Volts Nominal I O 3 J10 14 DI C 01 8P1 Computer Bus 12 Volts DC C 02 0 Main System Ground Bus 0 Volts C 03 8P1 Computer Bus 12 Volts DC C 04 0 Main System Ground Bus 0 Volts C 05 80A Front Drum Pump Control Servo Driver 1 0 to 2 8 10 110 mA Volts D...

Page 121: ... 7 5 Volts or 0 Volts Not Moving 3 5 Volts Moving I O 1 J6 01 DI D 02 80MB Front Drum Flange Encoder CH B 7 5 Volts or 0 Volts Not Moving 3 5 Volts Moving I O 1 J6 02 DI D 03 81MA Rear Drum Flange Encoder CH A 7 5 Volts or 0 Volts Not Moving 3 5 Volts Moving I O 1 J6 03 DI D 04 81MB Rear Drum Flange Encoder CH B 7 5 Volts or 0 Volts Not Moving 3 5 Volts Moving I O 1 J6 04 DI D 05 82MA Boom Hoist S...

Page 122: ... DO D 37 82RA Boom Drum Pawl Disable Solenoid 12 Volts Nominal I O4 J12 23 24 DO E 01 86MA Auxiliary Drum Flange Encoder CH A Above 7 5 Volts or 0 Volts Not Moving 3 5 Volts Moving I O 2 J8 03 DI E 02 86MB Auxiliary Drum Flange Encoder CH B Above 7 5 Volts or 0 Volts Not Moving 3 5 Volts Moving I O 2 J8 04 DI E 14 89E4 Main Charge Filter Pressure Switch 12 Volts Nominal I O 4 J12 10 DI E 15 89N4 A...

Page 123: ...O 2 J8 39 40 DO 52B C 26 Boom Hinge Pins Retract Solenoid 12 Volts Nominal I O 2 J8 23 24 DO 55C C 35 Mast Cylinder Retract Solenoid 12 Volts Nominal I O 2 J8 37 38 DO 55D C 34 Mast Cylinder Extend Solenoid 12 Volts Nominal I O 2 J8 35 36 DO 56A D 26 Counterweight Pins Retract Solenoid 12 Volts Nominal I O 3 J10 23 DO 68CA C 11 Engine Clutch Cylinder Direction 0 Volts Off 12 Volts On I O 1 DO 68CB...

Page 124: ... 5 Volts Moving I O 1 J6 04 DI 81MC D 25 Rear Drum Motor Control 0 Volts to 1 3 Handle Motion 0 96 to 2 19 Volts 1 3 to Full Handle Motion I O 2 J8 06 AO 81N D 28 Rear Drum Rotation Indicator 12 Volts Nominal I O 3 J10 25 26 DO 81P A 04 Rear Drum Handle 0 Volts Neutral 1 4 to 5 Volts Lower 5 to 8 6 Volts Raise I O 1 J5 52 AI 81QA A 21 Accessory System Hydraulic Pressure 1 2 Volts at 300 psi 1 Volt...

Page 125: ...s at 300 psi 1 Volt at 0 psi CPU J3 61 AI 85QR A 25 Swing Right Hydraulic Pressure 1 2 Volts at 300 psi 1 Volt at 0 psi CPU J3 59 AI 86A E 36 Auxiliary Drum Pump Control Up 0 to 2 8 10 110 mA Volts I O 4 J12 31 32 DO 86B E 37 Auxiliary Drum Pump Control down 0 to 2 8 10 110 mA Volts I O 4 J12 33 34 DO 86E C 25 Auxiliary Drum Park Brake Solenoid 12 Volts Nominal I O 2 J8 21 22 DO 86MA E 01 Auxiliar...

Page 126: ... 12 Volts Nominal I O 3 J10 20 DI 89R3 B 16 Hydraulic Fluid Level 12 Volts Nominal I O 2 J8 08 DI 89S B 08 Rear Drum Minimum Bail Limit Switch 12 Volts Nominal I O 1 J6 14 DI 89S2 B 09 Crane Mode Select Switch 12 Volts Nominal I O 1 J6 15 DI 89S4 D 12 Auxiliary Drum Park Brake Switch 12 Volts Nominal I O 3 J10 19 DI 89T B 03 Front Drum Minimum Bail Limit Switch 12 Volts Nominal I O 1 J6 09 DI 89T2...

Page 127: ...2 33 34 DO Auxiliary Drum Pump Control Up E 36 86A 0 to 2 8 10 110 mA Volts I O 4 J12 31 32 DO Auxiliary Drum Rotation Indicator E 30 86N 12 Volts Nominal I O 3 J10 29 30 DO Backhitch Load Sensor A 30 90E 1 5 Volts at No Load 9 5 Volts at Maximum Load CPU J3 54 AI Boom Drum Park Brake Switch D 10 89T4 12 Volts Nominal I O 3 J10 17 DI Boom Drum Pawl Disable Solenoid D 37 82RA 12 Volts Nominal I O4 ...

Page 128: ...2 Volts Nominal I O 4 J12 13 DI Front Drum Brake Pedal A 19 80EP 0 Volts Neutral 1 4 to 5 Volts Lower 5 to 8 6 Volts Raise I O 2 J7 64 AI Front Drum Flange Encoder CH A D 01 80MA 7 5 Volts or 0 Volts Not Moving 3 5 Volts Moving I O 1 J6 01 DI Front Drum Flange Encoder CH B D 02 80MB 7 5 Volts or 0 Volts Not Moving 3 5 Volts Moving I O 1 J6 02 DI Front Drum Free Fall Brake Pressure A 15 80QF 1 2 Vo...

Page 129: ...02 0 0 Volts Main System Ground Bus C 04 0 0 Volts Main System Ground Bus C 13 0 0 Volts Main System Ground Bus C 22 0 0 Volts Main System Ground Bus C 31 0 0 Volts Mast Angle Sensor A 35 88MA 5 VDC Mast at Vertical CPU J3 58 AI Mast Cylinder Extend Solenoid C 34 55D 12 Volts Nominal I O 2 J8 35 36 DO Mast Cylinder Retract Solenoid C 35 55C 12 Volts Nominal I O 2 J8 37 38 DO Mast Lower Switch B 11...

Page 130: ...verse 0 to 2 8 10 110 mA Volts Forward I O 2 J8 42 AO Rotating Bed Auto Lube Relay E 33 80G 12 Volts Nominal I O 4 J12 25 26 DO RS232 Receive from Laptop D 16 37 CPU J4 02 COMM RS232 Receive from LMI D 21 35 CPU J4 10 COMM RS232 To Display Black Ground D 20 30 0 Volts CPU J4 07 08 COMM RS232 To Display White D 19 31 CPU J4 05 COMM RS232 Transmit to Laptop D 17 36 CPU J4 01 COMM RS232 Transmit to L...

Page 131: ...12 Volts Nominal CPU J3 63 AI A 27 86QS Auxiliary Drum Hydraulic Pressure 1 2 Volts at 300 psi 1 Volt at 0 psi CPU J3 64 AI A 02 Spare CPU J4 01 COMM D 17 36 RS232 Transmit to Laptop CPU J4 02 COMM D 16 37 RS232 Receive from Laptop CPU J4 03 04 COMM D 18 Spare CPU J4 05 COMM D 19 31 RS232 To Display White CPU J4 07 08 COMM D 20 30 RS232 To Display Black Ground 0 Volts CPU J4 09 COMM D 22 34 RS232 ...

Page 132: ... Volts Nominal I O 1 J6 25 26 DO C 09 82E Boom Hoist Park Brake Solenoid 12 Volts Nominal I O 1 J6 27 28 DO C 10 84E Travel Park Brake Solenoid 12 Volts Nominal I O 1 J6 29 30 DO C 11 38 Remote Output Node Communication I O 1 J6 31 32 DO C 16 80F Front Drum Hydraulic Clutch Solenoid 12 Volts Nominal I O 1 J6 33 34 DO C 17 81F Rear Drum Hydraulic Clutch Solenoid 12 Volts Nominal I O 1 J6 35 36 DO C...

Page 133: ...12 Volts Nominal I O 2 J8 18 DI B 26 89J Display Scroll Up Switch 12 Volts Nominal I O 2 J8 19 DI B 27 89A5 Gantry Raise Switch 12 Volts Nominal I O 2 J8 20 DI B 28 89B5 Gantry Lower Switch 12 Volts Nominal I O 2 J8 21 22 DO C 25 86E Auxiliary Drum Park Brake Solenoid 12 Volts Nominal I O 2 J8 23 24 DO C 26 52B Boom Hinge Pins Retract Solenoid 12 Volts Nominal I O 2 J8 25 26 DO C 27 25X Motion Ala...

Page 134: ...4 Auxiliary Drum Park Brake Switch 12 Volts Nominal I O 3 J10 20 DI D 13 89R1 Auxiliary Drum Minimum Bail Limit Switch 12 Volts Nominal I O 3 J10 23 DO D 26 56A Counterweight Pins Retract Solenoid 12 Volts Nominal I O 3 J10 23 24 DO D 27 80N Front Drum Rotation Indicator 12 Volts Nominal I O 3 J10 25 26 DO D 28 81N Rear Drum Rotation Indicator 12 Volts Nominal I O 3 J10 27 28 DO D 29 82N Boom Drum...

Page 135: ...I O 4 J12 16 DI E 20 Spare I O 4 J12 17 DI E 21 Spare I O 4 J12 18 DI E 22 Spare I O 4 J12 19 DI E 23 Spare I O 4 J12 20 DI E 24 Spare I O 4 J12 21 22 DO D 36 82R Boom Drum Pawl Enable Solenoid 12 Volts Nominal I O 4 J12 23 24 DO D 37 82RA Boom Drum Pawl Disable Solenoid 12 Volts Nominal I O 4 J12 25 26 DO E 33 80G Rotating Bed Auto Lube Relay 12 Volts Nominal I O 4 J12 27 28 DO E 34 85G Swing Aut...

Page 136: ...AN System Ground Ground P11 30 DO 4 Grd CAN System Ground Ground P11 31 CANH CAN Hi Data Line N A P11 32 CANL CAN Low Data Line N A P11 37 DO 5 Grd CAN System Ground Ground P12 Receptacle Front Console Master Node Unused Terminals are Omitted P12 01 24 Volts 24VDC Power Bus 24 Volts Nominal P12 02 Display Screen Contrast Positive N A P12 06 DI 2 Data Logger Enable 0 Volts Off 24 Volts On P12 07 DO...

Page 137: ... disable 0 Volts Off 24 Volts On P2 Data Download Upload Receptacle Front Console Master Node P2 1 Data TX1 RX1 35 Receive Variable 6 to 7 Volts Nominal P2 2 Data RX1 TX1 34 Transmit Variable 6 to 7 Volts Nominal P2 3 Data X Load Indicator Data Download N A P2 4 Logic Grd Ground Ground Pin Function Type Description Test Voltage DC unless otherwise specified ...

Page 138: ...t status of the condition displays see Figure 3 9 Operating Limits Table 3 3 lists operating limits which can be displayed When one or more operating limits is reached the operating limit alert yellow light and buzzer in cab turns on to warn the operator At the same time the operating limit display immediately appears see Figure 3 10 and automatically scrolls through the names of the limits stoppi...

Page 139: ...ault group even when the system fault alert is off To erase the names of inactive faults scroll to the system fault group Wait until the display scrolls through the name of each fault The names of inactive faults will be erased automatically If the alert is on only the names of active faults will remain NO FAULT appears on the display see Figure 3 13 when there are no faults Selecting Display Lang...

Page 140: ...een that displays both angles at same time MAST ANGLE DEG Degrees mast is positioned above transport position 2 CRANE MODE name of mode See E1 Crane Mode Selector in Section 3 of the Operator Manual for procedure to select and confirm desired crane mode DIAGNOSTIC SCREENS HYD TANK FLUID TEMP DEG F Temperature of oil in hydraulic tank HYD TANK FLUID LEVEL 0 100 of oil remaining in tank A1 A2 A3 2 R...

Page 141: ... when boom to jib angle is 170 This limit can be bypassed only when boom is below 50 Lower luffing jib CONFIRM MODE Load drums and boom hoist inoperable until an operating mode is selected and confirmed Select and confirm the desired operating mode see instruction in this section MAX BAIL Drum stops hoisting Operate drum in lowering direction MIN BAIL Drum stops lowering Operate drum in hoisting d...

Page 142: ...heating as soon as possible to prevent engine damage Engine coolant temperature above 205 F 96 C HYD TANK FLUID TEMP Does not affect operation Reduce loads and or speeds to allow oil to cool Oil temperature in hydraulic tank above 180 F 82 C HYD TANK FLUID LEVEL Does not affect operation Fill tank as soon as possible Hydraulic oil at CAUTION LOW LEVEL indicated on tank gauge MAIN CHARGE FILTER All...

Page 143: ...tion Charge Configuration Digital On Off Inputs Digital Inputs Digital Inputs or Outputs Degrees angle Degrees Fahrenheit Forward Free Fall Hydraulic Luffing Minimum Maximum Pressure Pounds Per Square Inch Pounds Per Square Inch Absolute Revolution Per Minute Remote Input Node Sender System Temperature Pump Identification Pump Number Crane 0 Front Load Drum 1 Rear Load Drum or Luffing Hoist 2 Boom...

Page 144: ...in percent from neutral raise and lower 3 The motor command is in percent 0 is maximum displacement 100 is minimum displacement 4 Parking brake command 1 release 0 engage 5 Clutch command 1 release 0 engage applies only to drums with free fall otherwise has no meaning 6 Measured pump pressure port A in psi 7 Measured drum speed in rpm raise and lower X is where the corresponding drum number appear...

Page 145: ...le is not in neutral 4 Left pump command in percent from neutral forward backward 5 Measured system pressure right track in psi 6 Measured system pressure left track in psi 7 Parking brake command 1 release 0 engage RIN Depending on the crane configuration RIN computers are mounted in the universal boom top junction box luffing jib top junction box or fixed jib top junction box Figure 3 14 The jun...

Page 146: ...measured pump pressure hoist in psi 7 Accessory system switches 1 Raise Gantry Remote Switch 2 Lower Gantry Remote Switch 4 Mast Raise Switch 8 Mast Lower Switch 16 Boom Hinge Pins In Switch 32 Boom Hinge Pins Out Switch 64 Accessory System Enable Switch 128 Spare Engine Throttle 1 Throttle pedal is expressed in counts 0 to 25 low idle and up to 230 to 255 high idle 2 Throttle Lever is expressed i...

Page 147: ... them see Tables 3 7 and 3 8 To determine the state of the individual inputs outputs in a bank find the number displayed for the bank in the first column in Table 3 9 In the corresponding row the identifier numbers that are ON active in the bank are shaded Use Tables 3 7 and 3 8 to identify the crane components associated with the identifiers for the corresponding bank If number displayed for shor...

Page 148: ...both ports a digital ON is displayed when pulsing to prevent a flickering number for the corresponding bank Table 3 8 D2 Crane Digital Inputs Identifier Component Bank 1 1 2 4 8 16 32 64 128 Bank 2 1 2 4 8 16 32 Bank 3 1 2 4 8 16 32 64 128 Bank 4 1 2 4 8 16 32 Bank 5 1 2 4 8 16 32 64 128 Bank 6 1 2 4 8 16 32 Bank 7 1 2 4 8 16 32 64 128 Bank 8 1 2 4 8 16 32 Travel Detent Set Cancel Front Drum Maxim...

Page 149: ...on Luffing Jib Top Binary Bank 9 inputs are from RIN computer not system computer Table 3 8 D2 Crane Digital Inputs Identifier Component Handle Pedal Identification Activated only in luffing jib mode Special handle arrangement activated only in luffing jib mode Handle Number Crane All Modes 1 Front Load Drum 2 Rear Load Drum or Luffing Hoist 3 Boom Hoist or Luffing Hoist 4 Swing 5 Right Crawler 6 ...

Page 150: ...0 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 2 4 8 16 32 64 128 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 1 2 4 8 16 32 64 128 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 1...

Page 151: ...144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 1 2 4 8 16 32 64 128 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 1 2 4 8 16 32 64 128 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 23...

Page 152: ...en assembling J tech type connectors A bead of grease needs to be applied on O ring and face of the socket female connector and only on the O ring for a pin male connector The size of the grease bead on the O ring is as follows On a 3 pin connector a 1 16 inch 1 5 mm bead is required On a 24 pin connector a 1 8 inch 3 mm bead is required On a 37 pin connector a 3 16 inch 5 mm bead is required Plac...

Page 153: ...t and Gantry Sensor Adjustments 4 8 Mast Angle Indicator 4 8 Adjusting Angle 4 9 Gantry Limit Switch 4 10 Adjustment 4 10 Strap Inspection and Maintenance 4 11 Inspection 4 11 Daily Inspection 4 11 Monthly Inspection 4 11 Cranes Not in Regular Use 4 11 Identifying Straps 4 11 Replacement Specifications 4 12 Corrosion or Abrasion 4 13 Straightness 4 13 Flatness 4 14 Elongated Hole 4 15 Length 4 15 ...

Page 154: ...R e f e r e n c e O n l y 999 SERVICE MAINTENANCE MANUAL 4 ii Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 155: ...om stop Once the automatic boom stop is properly adjusted it should not require periodic adjustment Adjustment is required however when The luffing jib is installed or removed Parts are replaced Table 4 1 WARNING Falling Attachment Hazard If boom fails to stop for any reason stop engine immediately Troubleshoot system to determine problem Do not resume operation until problem has been corrected WA...

Page 156: ...p limit switch open 3 Rotate the limit bypass key in crane cab to the bypass position and hold 4 Try to boom up do not raise the boom any higher than necessary to perform the test a If the boom rises your boom up limit can be bypassed b If the boom does not rise your boom up limit cannot be bypassed 5 The test is complete Release the limit bypass key and the adjusting rod to the normal operating p...

Page 157: ...nitowoc Published 05 16 17 Control 233 03 4 3 999 SERVICE MAINTENANCE MANUAL BOOM 4 FIGURE 4 1 1 5 Centerline of Boom Horizontal A See Table 4 1 Item Description 1 Boom Butt 2 Adjusting Rod 5 Limit Switch 2a 2b or 2c See Table 4 1 ...

Page 158: ...djusting Rod 9 Spring Washer 2c Adjusting Rod 10 Dowel Pin 1 4 in 6 mm Diameter 3 Jam Nut 11 Actuator Rod 4 Coupling 12 Punch Marks 5 Limit Switch 13 Digital Level 6 Cover Roller Over Travel 7 8 9 10 11 4 2a 3 5 5 6 VIEW B Switch Closed 11 1 Left Leg VIEW C Right Outboard Leg 13 12 2b or 2c 2a 2b or 2c Stored Limit Switch Wiring Wire Switch Terminals Function 1 green 22 14 Max Angle 2 black 13 Gnd...

Page 159: ...il the boom reaches the specified angle d Turn adjusting rod 2a 2b or 2c out against boom butt 1 until limit switch 5 clicks open View A e Tighten jam nut 3 7 If the boom reaches the specified angle before it stops a Loosen jam nut 3 View B b Turn adjusting rod 2a 2b or 2c out against boom butt 1 until limit switch 5 clicks open View A c Tighten jam nut 3 8 Check that actuator rod 11 over travels ...

Page 160: ...3 03 FIGURE 4 3 81 Start of Spring Cushioning 90 Physical Stop springs solid Physical Boom Stops Telescopic Struts Pinned in Working Position Boom Butt Outer Tube Inner Tube Rod End Boom Stop Pin Boom Stops Just Contacting Pins Boom at 81 Start of Cushioning Boom at 90 Physical Stop springs solid ...

Page 161: ...t be in this position for all crane operations SHIPPING POSITION struts retracted This position provides maximum clearance for shipping the boom butt with the physical boom stops installed See Crane Assembly Disassembly in Section 4 of 999 Operator Manual for instructions on raising and lowering physical boom stops Operation See Figure 4 3 When boom is raised to 81 springs in boom stop tubes begin...

Page 162: ...angle which can be monitored on the digital display in the operator s cab and used to control mast operation within the limits given in Table 4 2 Table 4 2 Mast Operating Limits Operating Limit Alert Comes on When any Limit is Reached Typical Node Controller Installation on Boom or Luffing Jib Top Angle Sensor Mounted Inside P1518 FIGURE 4 4 Limit Display Reading1 1 Mast angles are measured from t...

Page 163: ...sport position when checking or adjusting angle indicator 1 Park crane on a level solid surface 2 Lower mast to transport position 3 Place an electronic level on mast Figure 4 5 4 Record angle indicated on level 5 Scroll to angle on digital display in operator s cab 6 Angle shown on digital display must match angle recorded in step 4 plus or minus one degree 7 If necessary loosen mounting screws a...

Page 164: ...justment The gantry limit switch was set at the factory and should not require periodic adjustment However it will need adjustment whenever parts are replaced 1 Travel crane onto firm level surface 2 Make sure mast is raised 3 Select Setup mode and confirm 4 Using gantry switch completely raise gantry until hydraulic cylinders are fully extended 5 Loosen mounting bolts securing limit switch to fra...

Page 165: ... damage is likely to occur Look for straps that are disconnected loose or sagging excessively and for distortion such as kinking or twisting If any strap looks like it is damaged strap must be checked to make sure it is within specifications given in this section Monthly Inspection Periodic inspection must be performed at least monthly During this inspection entire length of strap must be inspecte...

Page 166: ... Crack or Break Figure 4 11 None Remove strap from service Corrosion or Abrasion Figure 4 12 6 of strap thickness Sandblast and paint to maintain continuous protective coating 6 of strap thickness Remove strap from service Straightness gradual or sweeping bend Figure 4 13 Varies dependingon strap length Remove strap from service if deviation exceeds maximum allowed Flatness includes twisted straps...

Page 167: ...ible and tie it off at other end 3 Mark strap center line Do not use center punch 4 If string does not align with center line measure distance from center line to line If deviation from straight is greater than maximum allowed remove strap from service Not Acceptable Abrasion from handling with chain exceeds allowable limit Acceptable Surface is relatively smooth within allowable limit Not Accepta...

Page 168: ... pin storage hole at one end of strap 3 Stretch line as tight as possible and tie it off at other end 4 Check that line touches top surface of strap at all points along its length 5 If string does not touch strap measure distance from line to strap If deviation from straight is greater than maximum allowed remove strap from service 6 Remove line Turn strap over 7 Repeat steps 1 5 above FIGURE 4 14...

Page 169: ...rap B View A View B A A1086 FIGURE 4 15 Elongated Holes Strap Length L ft m Maximum Deviation Allowed 1 to 2 in 25 to 51 mm Thick 2 to 4 in 51 to 102 mm Thick 3 0 9 0 17 4 3 0 50 12 7 3 to 4 0 9 to 1 2 0 63 15 9 0 56 14 3 4 to 5 1 2 to 1 5 0 75 19 1 0 70 17 5 5 to 6 1 5 to 1 8 0 80 20 6 0 75 19 1 6 to 7 1 8 to 2 1 0 88 22 2 0 75 19 1 7 to 8 2 1 to 2 4 0 94 23 8 0 75 19 1 8 to 9 2 4 to 2 7 1 0 25 4...

Page 170: ...rvice should be clearly marked to prevent accidental future use Rendering the strap useless in some way such as cutting off an end is recommended Inspection Checklist A Strap Inspection Checklist is provided at the end of this section The checklist can be reproduced as needed Signed and dated copies of the Strap Inspection Checklist must be kept on file at all times for each strap as the checklist...

Page 171: ...n Abrasion Elongated Holes Flatness Length m Straightness Other Dents Length Part Number Bends Kinks Cracks Breaks Corrosion Abrasion Elongated Holes Flatness Length m Straightness Other Dents Length Part Number Bends Kinks Cracks Breaks Corrosion Abrasion Elongated Holes Flatness Length m Straightness Other Dents Length Part Number Bends Kinks Cracks Breaks Corrosion Abrasion Elongated Holes Flat...

Page 172: ...R e f e r e n c e O n l y BOOM 999 SERVICE MAINTENANCE MANUAL 4 18 Published 05 16 17 Control 233 03 NOTES DRAW SKETCHES OR ATTACH PHOTOGRAPHS TO FOLLOWING PAGES ...

Page 173: ...R e f e r e n c e O n l y Manitowoc Published 05 16 17 Control 233 03 4 19 999 SERVICE MAINTENANCE MANUAL BOOM 4 ...

Page 174: ...R e f e r e n c e O n l y BOOM 999 SERVICE MAINTENANCE MANUAL 4 20 Published 05 16 17 Control 233 03 ...

Page 175: ...c Cable 5 7 Disconnecting Block Up Limit Controls 5 8 Removing Jib or Boom Point 5 8 Maintenance 5 9 Adjustment 5 11 Wire Rope Inspection and Replacement 5 12 Wire Rope Lubrication 5 12 Maintain a Wire Rope Condition Report 5 12 Required Inspection Intervals 5 12 Wire Rope Care and Replacement Guidelines 5 12 Daily Inspection 5 13 Periodic Comprehensive Inspection 5 14 Determining Frequency of Ins...

Page 176: ...R e f e r e n c e O n l y 999 SERVICE MAINTENANCE MANUAL 5 ii Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 177: ...n in Figure 5 1 Inspection Inspect wear indicator with brake applied Note that wear indicator moves in as brake discs wear Replace brake discs when indicated in Figure 5 1 DANGER Falling Load Hazard Free fall clutch brake will not hold load if brake discs are worn To prevent load from falling inspect each wear indicator weekly and replace discs when indicated P1579 FIGURE 5 1 Brake Release Hose P1...

Page 178: ... Assembly drawing at the end of this Section Reverse the assembly steps to disassemble the clutch brake assembly Read and perform all steps on the assembly drawing Replace all seals any time the unit is disassembled to replace brake discs 14 Reassemble clutch brake assembly as instructed in Free Fall Drum Brake Assembly drawing 15 Reinstall clutch brake assembly on crane Reverse steps 2 5 above Fo...

Page 179: ...rum with three full wraps of wire rope remaining on drum 4 Position actuator out against limit switch roller only enough to open limit switch light off 5 Securely tighten adjusting screws drill holes in actuator and lever and insert pins to lock adjustment 6 Adjust return spring eyebolt 9 to dimension shown in Figure 5 2 7 Spool six to seven wraps of wire rope onto load drum Pay out wire rope from...

Page 180: ...1 10 3 9 12 Item Description Item Description 1 Front Load Drum 8 Return Spring 2 Rear Load Drum 9 Return Spring Eyebolt 3 Limit Switch Roller 10 Cap Screw 4 Actuator 11 Bail Limit Rollers 5 Actuator Adjusting Screws 12 Bail Limit Lever 6 Pins 13 Drum Pressure Roller 7 Lever 14 Pressure Roller Spring 1 6 in 40mm 8 4 5 6 7 2 1 1 6 in 40mm 4 5 6 7 9 8 13 14 A17578e A17578d A17578 ...

Page 181: ...lowing steps 1 With either roller contacting drum barrel adjust spring 14 to an overall length of 13 in 330 mm This ensures correct initial tension on drum NOTE The drum pressure roller is intended to be used with one layer of rope only It is permissible to store up to three layers of rope on drums Spooling of more than three layers of rope on drum requires removal of roller 3 to 4 Wraps of Wire R...

Page 182: ...TE See wiring diagrams in Boom Wiring Limits and Load Indicator Electrical Assembly drawing in 999 Operator Manual Block Up Limit Control Deactivated During normal operation the weight overcomes the spring force and rotates the actuating lever away from the limit switch lever This action allows the limit switch to close the load drum up and boom luffing jib down electric circuits Therefore the loa...

Page 183: ...he excess cable for the boom and luffing jib on the reel mounted on either butt Figure 5 5 The reel is equipped with a locking pin Disengage the locking pin to allow the reel to be wound Engage the locking pin to lock the reel in position The power supply cable to the reel must be disconnected before the reel can be wound Store the excess electric cable for the fixed jib by winding it around the b...

Page 184: ...equipped with shorting plugs as shown in View C Figure 5 6 When an attachment is removed the electric cable from the corresponding limit switch must be disconnected from the junction box receptacle View C Figure 5 6 and the proper shorting plug connected to the receptacle Failing to perform this step will prevent the load drum from hoisting and the boom from lowering Also the operating limit alert...

Page 185: ... of movement on the load line c Inspect each weight each chain each shackle and each connecting pin for excessive or abnormal wear Make sure cotter pins for shackles are installed and spread d Inspect the entire length of electric cables for damage e Check that the electric cables are clear of all moving parts on the boom and jib and that the cables are securely fastened to the boom and jib with c...

Page 186: ...n of Weight Two Chains Prevent Weight from Turning Weight Chain Shackle Connecting Pin Weight Shackle Chain FIGURE 5 7 Lower Boom Point multiple part Lower Boom Point two lines over point Universal Anchor Joint Luffing Jib Point multiple part or Fixed Jib Point 2 part Fixed Jib Point 1 part Upper Boom Point Luffing Jib Point single part Lower Boom Point single part or Luffing Jib Intermediate Fall...

Page 187: ... the weight to allow the actuating lever to rotate upward 4 Hold lever at Dimension A 5 Hold the roller on the limit switch lever against the actuating lever while performing step 6 6 Turn the limit switch shaft clockwise only enough to click limit switch open and hold Then securely tighten the setscrew in the limit switch lever 7 Test the limit switch for proper operation see Maintenance Repeat t...

Page 188: ... condition at the time of its removal from service See Replacement Criteria on page 14 for inspection guidelines Required Inspection Intervals The frequency of wire rope inspection shall be Daily see Daily Inspection and at minimum Yearly see Periodic Comprehensive Inspection Wire Rope Care and Replacement Guidelines 1 When replacing fixed length wire rope assemblies e g pendants having permanentl...

Page 189: ... more rapidly such as flange points crossover points and repetitive pickup points on drums Take special care to observe boom hoist ropes and rotation resistant ropes for evidence of core failure or other deterioration remove from service Internal deterioration of rotation resistant ropes may not be readily observable 2 Throughout the day observe wire rope during operation particularly Pick up Poin...

Page 190: ...xcessive moisture levels Exposure to corrosive chemicals or vapors Subjecting the wire rope to abrasive material Powerline contact Exposure to abuse and shock loads such as High velocity movement such as hoisting or swinging of a load followed by abrupt stops Suspending loads while traveling over irregular surfaces such as railroad tracks potholes and rough terrain Moving a load that is beyond the...

Page 191: ...f service when it has the following number of broken wires See Figure 5 12 for an explanation of lay length Running Ropes six randomly broken wires in one lay length or three broken wires in one strand in one lay length Standing Ropes Pendants more than two broken wires in one lay length in sections beyond the end attachment or more than one broken wire at the end attachment see Figure 5 11 Rotati...

Page 192: ...oints This practice can also help correct spooling problems and rope vibration To move the wire rope cut off a piece of wire rope at the worn end and refasten The piece cut off should be long enough to move wire rope at least one full drum wrap If the wire rope is too short to allow cutting off a piece of it reverse the rope end for end and refasten it FIGURE 5 12 Item Description 1 Lay Length dis...

Page 193: ...sheaves check depth width and contour of each sheave using a groove gauge as shown in Figure 5 13 Replace sheaves that have over or under size grooves 4 Replace grooved drums that allow one wrap of wire rope to contact next wrap as rope spools onto drum 5 Inspect sheaves to verify they do not contact another sheave or structural plate work There should be uniform clearance between sheaves in a clu...

Page 194: ...sheave properties will be degraded in temperatures above 140 F 60 C 9 Make sure sheaves drums and rollers are properly lubricated according to the instructions in the lubrication guide provided with the crane see Section 9 NOTE Many current production sheaves are not equipped with grease fittings but are packed with grease at assembly Repack the bearings of these sheaves with CraneLUBE EP 2 grease...

Page 195: ...4 1 94 50 8 7 8 22 631527 19 25 489 0 16 63 422 4 1 94 50 8 5 8 16 631055 19 69 500 1 17 60 447 0 1 85 47 0 7 8 22 631067 19 69 500 1 17 75 450 9 1 97 50 0 3 4 19 631529 20 00 508 0 17 00 431 8 3 00 76 2 1 25 631519 23 00 584 2 20 13 511 0 2 25 57 2 7 8 22 631520 631084 23 00 584 2 20 13 511 0 2 50 63 5 7 8 22 A00083 631102 23 00 584 2 20 13 511 0 2 50 63 5 1 25 631082 27 00 685 8 23 00 584 2 3 00...

Page 196: ... Hazard To prevent load from dropping due to structural failure of load block or hook and weight ball Only use a load block or a hook and weight ball which has a capacity equal to or greater than load to be handled Do not remove or deface nameplate Figure 5 17 attached to load blocks and hook and weight balls See Duplex Hook topic in Section 4 of Operator Manual for recommended sling angles and ca...

Page 197: ... the dead end socket Check the socket for cracks Tighten the wire rope clips at the dead end of the wire rope 11 Check that each hook has a latch and that the hook latch operates properly The latch must not be wired open or removed 12 Check each hook and shackle at least yearly for cracks using a dye penetrant test MAG particle test ultrasonic test or by X ray 13 Inspect each hook and shackle for ...

Page 198: ...R e f e r e n c e O n l y HOISTS 999 SERVICE MAINTENANCE MANUAL 5 22 Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 199: ...R e f e r e n c e O n l y Manitowoc Published 05 16 17 Control 233 03 6 i 6 SECTION 6 SWING TABLE OF CONTENTS Manual Release of Swing Brake and Lock 6 1 Manual Release Procedure 6 1 ...

Page 200: ...R e f e r e n c e O n l y 999 SERVICE MAINTENANCE MANUAL 6 ii Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 201: ...e port and at the swing lock OUT port 2 Attach a hand pump to each port brake release and swing lock OUT 3 Pressurize the brake and the swing lock to 350 psi 24 bar 4 Proceed to remove or install the swing gearbox 5 Relieve the pressure and remove the hand pumps WARNING Unexpected Crane Movement Crane can swing suddenly when swing brake is released Before releasing swing brake secure crane by lowe...

Page 202: ...R e f e r e n c e O n l y SWING 999 SERVICE MAINTENANCE MANUAL 6 2 Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 203: ...pection 7 6 Daily 7 7 Monthly 7 7 Changing the Filters 7 7 Engine Clutch 7 8 Maintenance 7 8 Adjustment 7 8 Engine Throttle 7 9 Foot Throttle Linkage Adjustment 7 9 Engine Idle Speed 7 9 Wiring Diagram 7 9 Engine Enclosure 7 11 Engine Belt Routing 7 11 Engine Cooling System 7 13 Checking Coolant Level 7 13 Draining Cooling System 7 13 Filling and Bleeding Cooling System 7 13 Exhaust Aftertreatment...

Page 204: ...R e f e r e n c e O n l y 999 SERVICE MAINTENANCE MANUAL 7 ii Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 205: ...erminals on the crane to be started Do not allow cable ends to touch 2 Connect the positive cable to the positive terminal of the booster battery 3 Connect the remaining cable to the frame or block of the starting vehicle Never connect it to the grounded terminal of the starting vehicle WARNING Explosion Hazard Batteries can explode with great violence and spraying of acid if a spark or flame is b...

Page 206: ...ished 05 16 17 Control 233 03 Item Description 1 Battery Disconnect Switch 2 Rear Battery 3 Front Battery 4 Battery Cover with Quarter Turn Screws 5 Remote Battery Terminal 3 6 To Starter Motor 7 Engine Wiring Harness View in Right Side Enclosure 1 2 3 5 4 FIGURE 7 2 1 2 3 7 5 6 ...

Page 207: ...r but may freeze see Table 7 1 Table 7 1 Battery Freeze Points Lack of Water The plates must be completely covered with electrolyte If the plates are exposed the high acid concentration will char and disintegrate the separators The plates cannot take a full charge if not completely covered by electrolyte Loose Hold Downs Loose hold downs will allow the battery to vibrate in the holder This can cau...

Page 208: ...connections are good When cranking a voltage drop of more than 0 2 volts between the starting motor cable and ground can cause hard starting regardless of a battery s condition The voltage drop can be caused by a poor contact between the cable terminal and ground or between the clamp terminal and the battery post Poor start switch contacts and frayed broken or corroded cables can also be the cause...

Page 209: ... Following are reasons for using the disconnect switch When servicing crane s electrical control system To help prevent batteries from discharging when the crane is stored for extended periods of time To prevent crane from being started by unauthorized personnel CAUTION Engine Damage To avoid possible engine fault codes and undesirable operation make sure engine ignition switch has been off five m...

Page 210: ... cleaner can allow dirty air to be drawn directly into the engine Either condition can cause engine damage Inspection To maintain engine protection and filter service life inspect the filters at the specified intervals FIGURE 7 5 Item Description 1 Service Indicator 2 Reset Button 3 Air Cleaner Housing 4 Pre Cleaner 5 Service Cover 6 Clamp 7 1 4 in 7 Rubber Elbow 8 Clamp 5 1 2 in 9 Steel Tube 10 R...

Page 211: ...lean the sealing surfaces and the inside of the housing Dust on the sealing surfaces could render the seal ineffective and cause leakage Ensure all contamination is removed before the new filters are installed 5 Visually inspect the old filters for leaks A streak of dust on the clean side of filter is a telltale sign Remove any cause of leaks before installing the new filters 6 Inspect the new fil...

Page 212: ... clutch several times with the engine running This practice will clean the disc surfaces and prevent the discs from seizing c Disengaging the clutch with the handle while checking for proper free travel Free travel should be at least 3 4 in 19 mm as shown Figure 7 6 Readjust the clutch when free travel decreases to less than 3 4 in 19 mm Adjustment The clutch is adjusted internally through the han...

Page 213: ...controller lever is rotated fully to high idle position Securely tighten jam nuts 6 to lock adjustment NOTE Both controllers have internal stops at high and low idle 5 Release foot pedal to low idle position 6 Adjust return springs so there is sufficient force to raise pedal and rotate controller lever to low idle 7 Adjust pedal stop screw 7 Screw must be tight against cab floor and there must be ...

Page 214: ...R e f e r e n c e O n l y POWER TRAIN 999 SERVICE MAINTENANCE MANUAL 7 10 Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 215: ...or Enclosure 3 Radiator Access Door with Latches 4 Engine Covers 3 with quarter turn latches 5 Engine Cover with screws 6 Exhaust System Enclosure 7 Left Side Enclosure Right Rear Corner of Crane 1 2 5 4 3 Enclosure Door Not Shown for Clarity 6 7 FIGURE 7 9 Looking at Engine from Fan End Item Description 1 Belt 2 Crankshaft Pulley 3 Belt Tensioner 4 Water Pump 5 Alternator 6 Air Conditioner Compre...

Page 216: ...3 03 FIGURE 7 10 Item Description 1 Level Sight Glass 2 Fill Cap 3 Coolant Level Sensor 4 Air Bleed Valve 5 Charge Air Cooler 6 Radiator Drain Valve with Hose 7 Hydraulic Oil Cooler 8 Radiator 81009399_a 2 1 4 5 6 8 1 2 3 7 Shown with Engine Enclosure Removed for Clarity see Figure 7 8 for access points ...

Page 217: ...en the radiator stops draining close the drain valve and store the drain hose on the crane 7 Fill and bleed the cooling system 8 Refer to the Lubrication Guide supplied with your crane for cooling system capacity Filling and Bleeding Cooling System Perform the following procedure to fill and bleed the cooling system Coolant added to the engine must be mixed with the correct proportions of antifree...

Page 218: ... SCR Module 7 DRT Module 8 DEF Dosing Module 9 DOC Module Coolant Hoses BLUE C1 From Coolant Manifold to DEF Tank C2 From DEF Tank to Coolant Manifold C3 From Engine C4 Return to Engine C5 From DRT Module to Coolant Manifold C6 From Coolant Manifold to DRT Module DEF Hoses GRAY D1 From Tank to DEF Supply Module D2 From DEF Supply Module to DEF Tank D3 From DEF Supply Module to DRT Module D1 1 4 5 ...

Page 219: ... DEF may require the tank to be drained and the system purged Abbreviation Description APS Aftertreatment Protection System DEF Diesel Exhaust Fluid DOC Diesel Oxidation Catalyst dP Dual Pressure DRT Decomposition Reactor Tube ECM Engine Control Module HEST Hugh Exhaust System Temperature SCR Selective Catalytic Reduction NH3 Ammonia NOx Generic term for the mono nitrogen oxides NO and NO2 nitric ...

Page 220: ...elevated NOx level such as Disconnected DEF tank level or quality sensor Blocked DEF hose or dosing module Disconnected dosing module Disconnected supply module Disconnected SCR wiring harness Disconnected NOx sensor EGR valve malfunction Aftertreatment Protection System The APS continually monitors exhaust gas temperatures In the event of excessive exhaust temperatures the APS will illuminate the...

Page 221: ...EF warm and the other path delivers coolant to the DEF dosing module 8 to keep it from overheating The coolant solenoid valve 2 adjusts coolant flow according to the temperature of the DEF in the DEF tank If the tank temperature drops below 25 F 4 C the ECM will open the solenoid valve and engine coolant will flow through the heat exchanger in the DEF tank To keep the DEF flowing during cold tempe...

Page 222: ...R e f e r e n c e O n l y POWER TRAIN 999 SERVICE MAINTENANCE MANUAL 7 18 Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 223: ...ng 8 1 Installation 8 1 Torque Requirements 8 1 Lubrication 8 1 Torque Values 8 1 Torque Sequence 8 1 Torque Intervals 8 1 Bolt Replacement 8 1 Crawler 8 2 Maintenance 8 2 Tread Slack Adjustment 8 2 Checking Tread Adjustment 8 2 Adjustment Procedure 8 3 Hydraulic Hand Pump 8 4 Assembly 8 4 Maintenance 8 4 Air Removal 8 4 Operation 8 4 ...

Page 224: ...R e f e r e n c e O n l y 999 SERVICE MAINTENANCE MANUAL 8 ii Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 225: ... Torque Sequence Torque two bolts at a time in the numbered sequence given in Figure 8 1 Torque Intervals INITIAL OPERATION torque all bolts to the specified value after the first 50 hours of operation YEARLY OR EVERY 2 000 HOURS OF OPERATION whichever comes first torque all bolts to the specified value Bolt Replacement If at the yearly inspection interval one or more bolts are found to be torqued...

Page 226: ...e that the treads are adjusted too tight Repair or replace damaged parts immediately to prevent further damage Tread Slack Adjustment Checking Tread Adjustment Check tread slack at the tumbler end of each crawler Maintain equal tread slack at both crawlers Y Y View Y Y View Z Z A1185 FIGURE 8 1 14 13 17 10 24 16 20 12 22 18 23 15 19 11 21 13 11 19 15 18 14 12 20 16 17 23 22 24 21 Front 5 6 4 8 1 9...

Page 227: ...n from center punch A in shaft to center punch line B in crawler frame is same on both sides of crawler to within 1 8 in 3 2 mm 10 Check for proper adjustment see Checking Tread Adjustment and readjust as required steps 4 through 9 11 Tighten nuts on bolts at primary roller to 2 000 ft lb 2 712 Nm lubricated with Never Seez or an equivalent oil and graphite mixture 12 Install cover 2 on both sides...

Page 228: ...igher than cylinder and position cylinder so rod is down 3 Operate pump to fully extend cylinder rod 4 Open valve and retract cylinder rod to force oil and trapped air back into pump 5 Repeat steps until cylinder operates smoothly Erratic operation indicates air in system Operation 1 Before using pump a Check that all fittings are tight and leak free b Check oil level 2 To pressurize cylinder and ...

Page 229: ...shed 05 16 17 Control 233 03 8 5 999 SERVICE MAINTENANCE MANUAL UNDER CARRIAGE 8 S135 S137 S138 Notch in Dipstick Enerpac Pump FIGURE 8 4 Hose Cylinder Vent Fill Cap Simplex Pump Extend Cylinder Close Valve Open Valve Retract Cylinder Pump OR ...

Page 230: ...R e f e r e n c e O n l y UNDER CARRIAGE 999 SERVICE MAINTENANCE MANUAL 8 6 Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 231: ...R e f e r e n c e O n l y Manitowoc Published 05 16 17 Control 233 03 9 i 9 SECTION 9 LUBRICATION TABLE OF CONTENTS Lubrication 9 1 Lube and Coolant Product Guide 9 1 ...

Page 232: ...R e f e r e n c e O n l y 999 SERVICE MAINTENANCE MANUAL 9 ii Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 233: ...l y Manitowoc Published 05 16 17 Control 233 03 9 1 999 SERVICE MAINTENANCE MANUAL LUBRICATION 9 SECTION 9 LUBRICATION LUBRICATION See F2277 in this section LUBE AND COOLANT PRODUCT GUIDE See the publication in this section ...

Page 234: ...R e f e r e n c e O n l y LUBRICATION 999 SERVICE MAINTENANCE MANUAL 9 2 Published 05 16 17 Control 233 03 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 235: ... loop hydraulic system response is sluggish 10 22 Problem 20 Hydraulic system is operating hot 10 23 Problem 21 Gantry cylinders will not raise or lower 10 24 Problem 22 Mast cylinders will not raise or lower 10 25 Problem 23 Boom hinge pin cylinders will not extend or retract 10 26 Problem 24 Jacking cylinder s will not extend or retract 10 27 Problem 25 Crawler pin cylinder s will not extend or ...

Page 236: ... Test 19 Setting the Pump Pressure 10 51 Test 20 Setting Pump Neutral 10 52 Test 21 Testing for Pump and Motor Leakage 10 53 Test 22 Checking Hydraulic Brake Pressure 10 54 Test 23 Servicing the Motor Loop Flushing Purge Valves 10 55 Test 24 Actuating the Solenoid Valve Manual Overrides 10 56 Test 25 Adjusting Accessory Pressure Switch 10 57 Test 26 Adjusting the Counterbalance Valves 10 58 ...

Page 237: ...owoc shall not be responsible for the training of personnel who might use this manual to perform the troubleshooting operations Whenever possible turn off the engine for your protection and keep unauthorized personnel away from the crane when troubleshooting Never troubleshoot the crane alone Always perform troubleshooting procedures with a qualified operator in the crane cab Maintain constant com...

Page 238: ...ck all terminal points for cleanliness and tighten connections Check pressures at the specified hydraulic component ports Check the motor pressure control pilot PCP valve on the motor under test Test the pump electric displacement controls EDC on the pump under test Check each pressure sender electric supply at the system sender Check the encoder electric supply at the test plug adapter of the enc...

Page 239: ... Test 1 12 Volts DC or more 12 Volts DC or less Replace circuit breaker Charge or replace battery Check fuse F1 If Good If Bad Check electrical connections in starter circuit from battery to starter Connections Good Connections Bad Check cab start switches and starter circuit connections Clean connections or replace starter Replace fuse Check start solenoid MS1 relay If Good If Bad Replace start s...

Page 240: ...e injector pump fuel shut off valve is fully open Fully Open Not Open Check for fuel in tank or line obstruction A fuel additive is recommended in cold weather Algae can occur in warm climates Make adjustments to solenoid shut off valve or check valve for correct operation Remove injector pump inlet line Turn over engine Look for momentary burst of fuel Fuel No Fuel Loosen fittings at filters Turn...

Page 241: ...gagement Open filter service shut off valve or replace filters if necessary Clutch Engaged Clutch not Engaged Engage clutch Remove tank cap and check vent fluid level and viscosity In extreme cold conditions oil may not flow freely to pump inlets causing pump cavitation Tank Vent Oil Level Viscosity Ok Not Ok Service hydraulic system Check manual override on two or more pumps Does engine load when...

Page 242: ... power on and engine running POSSIBLE CAUSES Belt loose or broken No input to alternator terminals Damaged alternator Corroded or loose battery connection Battery discharged Problem 4 Engine runs but battery is not charging CHECKS Check drive belt for correct tension See engine manual for drive belt deflection specifications Ok Not Ok Zero Volts DC 13 6 Volts DC or less 13 6 Volts DC or more Tight...

Page 243: ...ngine oil level at dipstick Ok Not Ok Check fan belt for excessive wear Check pressure sender See Test 3 Ok Not Ok Add or replace coolant Check for leaks before adding oil Ok See engine manual Check if radiator is plugged Check temperature sender See Test 2 Ok See engine manual Adjust or replace fan belt Ok Not Ok Clean or repair radiator Does Engine Oil Temperature gauge in overhead panel indicat...

Page 244: ...peed Obstruction No Obstruction Is throttle in maximum RPM position Yes No When moving applicable travel control handle fully in both directions TRACK diagnostic screen banks 1 or 3 obtains 100 handle control in each direction Yes No When moving travel handle fully in both directions TRACK diagnostic screen banks 2 or 4 obtains 100 pump control in each direction Repair or replace control handle wi...

Page 245: ...each direction No Yes Replace switch fuse or wiring Does track turn while moving handle and actuating manual override on brake valve No Yes When moving problem handle in both directions does TRACK diagnostic screen banks 3 and 4 obtain 100 pump control in each direction No Yes Voltage at handle 83P or 84P is greater than 0 with handle moved See Test 7 No Yes Replace solenoid Is pressure at brake m...

Page 246: ... while moving handle and actuating manual override on brake valve Replace valve Yes No When moving problem handle in both directions does DRUM 1 2 or 3 diagnostic screen bank 2 obtain 100 pump control in each direction Yes No Voltage at handle 80P or 81P is more than 0 with handle moved See Test 7 Yes No Is there an operating or system fault when handle is moved Correct problem Yes No Consult deal...

Page 247: ... replace pump Repair or replace wiring or consult dealer factory Yes No When moving problem handle fully in both directions does A1 diagnostic screen bank 1 and 2 read 38 to 120 in lower or 136 to 215 in raise Yes No Check jib shorting plug for continuity across pins A to C in boom top junction box Does RIN screen bank 7 read 255 Yes No Disconnect LMI boom cable at boom top Test cable for continui...

Page 248: ... Bank number not increased by number shown Does diagnostic DRUM 1 or 2 screen bank 1 approach 100 handle control with handle moved forward Check for problem Repair limit switch wiring or fuse Repair or replace control handle Does diagnostic DRUM 1or 2 screen bank 2 approach 100 pump control with handle moved forward Consult dealer factory Use test plug adapter See Test 11 Are 12 volts present at b...

Page 249: ...ons diagnostic display DRUM 1 or 2 screen bank 2 obtains 100 pump control in each direction Repair or replace control handle Check for control voltage of 2 3 volts or more and coil resistance of around 19 ohms at pump EDC See Test 13 Consult dealer factory Yes Voltage and Coil Ok Remove plug at motor port M5 and check orifice for obstruction See Test 15 Repair or replace coil or wiring Obstruction...

Page 250: ...00 handle control in each direction Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Does drum turn while moving handle and actuating manual override on brake valve When moving problem handle in both directions does DRUM 4 diagnostic screen bank 2 obtain 100 pump control in each direction Is voltage at handle 82P more than 0 with handle moved See Test 7 Replace v...

Page 251: ...and coil resistance at pump EDC and motor PCP See Test 13 Check for pump and motor leakage See Test 21 Repair or replace coil or wiring Clean or replace orifice Consult dealer factory When moving applicable handle fully in both directions does A1 diagnostic screen bank 3 read 38 to 120 in lower or 136 to 215 in raise Yes No Adjust handle center position see Test 8 Repair replace control handle wir...

Page 252: ...t increased by number shown Does diagnostic DRUM 4 screen bank 1 approach 100 handle control with handle moved back Check for problem Repair limit switch wiring or fuse Yes No Yes No Yes No Yes No Does diagnostic DRUM 4 screen bank 2 approach 100 pump control with handle moved back Repair or replace control handle Use test plug adapter See Test 13 Are 2 3 or more volts present at pump EDC when con...

Page 253: ...lem Repair switch or wiring Yes No Repair or replace switch or wiring to PC Does diagnostic screen D2 bank 7 boom pawl command change by 2 when moving brake park switch Check that D1 screen bank 1 changed by 4 to release pawl See Problem 28 Yes No Does diagnostic DRUM 4 screen bank 1 approach 100 handle control with handle moved forward Repair or replace control handle When moving applicable handl...

Page 254: ...o Yes No Use test plug adapter See Test 13 Are 2 3 or more volts present at pump EDC when control handle is moved forward Consult dealer factory Repair or replace wiring or consult dealer factory Replace pump EDC Repair or replace pump Can boom pump be manually stroked down See Test 16 Yes No Does diagnostic DRUM 4 screen bank 2 approach 100 pump control with handle moved forward ...

Page 255: ... Repair or replace switch fuse or wiring Repair or replace wiring Check for 12 volts DC to swing lock solenoid valve See Test 12 Replace valve Check charge pressure at swing lock with a 0 500 psi gauge Repair or replace swing lock 300 psi or more 300 psi or less Yes No Enable manual override on brake valve See Test 24 Does swing brake release Is swing lock or brake release pressure 350 psi or grea...

Page 256: ...PC See Test 7 Ok No Voltage Voltage Not Ok Yes No Ok Not Ok Yes No Yes No Does diagnostic display SWING screen bank 2 approach 100 pump control when handle is extended in either non swinging direction Repair or replace handle wiring Consult dealer factory Repair or replace swing holding brake switch and or wiring to PC Check wiring connector at pump EDC Consult dealer factory Connect or repair con...

Page 257: ... pump with brakes applied See Test 16 Is system pressure greater than 6 000 psi Adjust charge pressure relief for 350 psi See Test 18 Is 350 psi obtained Yes No No Yes No Yes No Adjust multifunction valve for 6 000 psi system pressure See Test 19 Retest with brakes applied Is pressure ok Adjust travel speed per Shop Procedure SP9 Is correct speed obtained Travel system response should be correct C...

Page 258: ...e than 350 psi at diagnostic display screen Fill reservoir to correct level warm hydraulic oil to 60 F or open shut off valve Does tank filter read less than 7 psia on diagnostic display screen Check and replace suction filter if required Adjust charge pressure relief valve for 350 psi See Test 18 350 psi Obtained 350 psi not Obtained System multifunction valves operating at recommended system pre...

Page 259: ...hanger radiator clean Yes No Clean repair or replace heat exchanger radiator Yes No System charge pressure is 350 psi at pressure sensor station Yes No System multifunction valves are operating at the recommended system pressures Are suction filters clean Replace filters Yes No Adjust or replace problem valve See Test 19 Adjust charge pressure relief valve for 350 psi See Test 18 350 psi obtained ...

Page 260: ...when moving gantry switch from neutral to raise or lower Check for 12 volts at gantry power switch pin number WB 27 for raise or WB 28 for lower Voltage No Voltage Repair problem Adjust cylinder counterbalance valve See Test 26 Does cylinder operate correctly No Replace cylinder or consult dealer factory Are solenoids magnetized when switch position are enabled Check diagnostic display DRUM 2 scre...

Page 261: ...2 change by 4 for lower when moving mast switch from neutral to raise or lower Yes No Adjust cylinder counterbalance valve See Test 26 Does cylinder operate correctly Replace cylinder or consult dealer factory No Is crane setup mode selected and confirmed Yes No Consult dealer factory Select and confirm setup mode Check for 12 volts at mast power switch pin number WB 06 for raise or WB 11 for lowe...

Page 262: ...k 5 change by 4 for extend and by 8 for retract when moving boom hinge pin switch to extend or retract position Voltage No Voltage Yes No Is crane setup mode selected and confirmed Yes No Consult dealer factory Select and confirm setup mode Check for 12 volts at boom hinge pin switch pin number WB 31 for extend or WB 32 for retract Replace cylinder or consult dealer factory Repair problem Are sole...

Page 263: ... cylinder on lower accessory valve 3 500 psi or more 3 500 psi or less Is crane setup mode selected and confirmed Yes No Exchange both counterbalance valve cartridges on problem jacking cylinder Is cylinder enabled with handle movement Adjust rear drum system pressure to 3 500 psi when jacking handle is moved See Test 19 Repair or replace rear drum pump Consult dealer factory 3 500 psi or more Rep...

Page 264: ...more 3 500 psi or less Check for 3 500 psi at rear drum flushing valve port while enabling other crawler pin cylinder on lower accessory valve 3 500 psi or more Repair or replace problem crawler pin cylinder Is crane setup mode select and confirmed Yes No Select and confirm setup mode Does system develop any pressure Yes No Adjust rear drum system pressure to 3 500 psi when jacking handle is moved...

Page 265: ... handle is faulty or pump EDC is faulty or out of adjustment System pump is damaged Pump is not centered No Yes Repair or replace system control handle or wiring With system handle in neutral does diagnostic display screen FUNCTION display command activity for pump Consult dealer factory Does system pump EDC manually return to neutral See Test 13 Adjust pump neutral See Test 20 Repair or replace s...

Page 266: ...bank 5 change by 2 when enabling switch No Yes Does D2 screen bank 5 change by 1 when enabling switch Test for voltage to remote controller Yes No No Voltage Check for 12 volts at fuse F4 Yes No Replace fuse F4 Repair or replace wiring from PC to remote controller Consult dealer factor Is voltage present at counterweight pins solenoid Yes No Repair or replace wiring Is there hydraulic pressure at ...

Page 267: ...wl Enable Bank 7 changed by 1 Boom Hoist Pawl Disable Bank 7 changed by 2 Auxiliary Drum Pawl Enable Bank 1 changed by 1 Auxiliary Drum Pawl Disable Bank 1 changed by 2 Damage Repair damage Test and adjust Front Drum Bank 6 changed by 1 or Rear Drum Bank 6 changed by 2 or Boom Hoist Bank 6 changed by 4 or Auxiliary drum Bank 6 changed by 16 Yes No Check and or replace Fuse F4 switch or wiring Move...

Page 268: ...icate a charging system fault A drop of 4 volts or more indicates the battery is failing Test the 12 volt DC starting batteries in series for 24 volts using a digital multi meter Record the voltage before and during engine cranking A voltage reading of 24 volts or less before cranking engine may indicate a charging system fault A drop of 8 volts or more indicates the battery is failing Item Descri...

Page 269: ...ne Temperature Sender Set digital multi meter to test resistance Make required connections to test lead adapter at the meter Connect negative lead to a grounded component on the crane and the positive lead to engine temperature sender wire terminal With engine cold check for a resistance of approximately 0 70 ohms Item Description 1 Temperature Sender 1 P1589 ...

Page 270: ...l Pressure Sender Set digital multi meter to test resistance Make required connections to test lead adapter at the meter Connect negative lead to a grounded component on the crane and the positive lead to engine pressure sender wire terminal With engine cold check for a resistance of approximately 240 ohms Item Description 1 Oil Pressure Sender 1 P1590 ...

Page 271: ...ing check for AC voltage output To clean and adjust engine RPM transducer Loosen the lock nut and remove threaded transducer from flywheel housing Clean any metallic debris from the magnetic pickup on the transducer with a cleaning solvent Reinstall the transducer so magnetic pickup makes contact with flywheel Back off flywheel 1 2 turn and secure lock nut Item Description 1 Flywheel Housing 2 RPM...

Page 272: ...17 Control 233 03 Test 5 Test Adapters for Checking Electrical Inputs Outputs 1 20 3 2 21 22 37 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 24 25 26 27 28 29 30 31 32 33 34 35 36 4 23 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 37 5 3 4 1 2 A1103 ...

Page 273: ...est Voltages in Section 3 of this manual for circuit wires located on each cable connector A B C D and E with pins numbered 1 through 37 Connect meter negative lead 7 to ground and positive lead 8 to problem item terminal Check for 12 volts DC 10 volts DC for regulated supply items as shown at problem circuit wire terminal on in line testing board Item Description 1 Hydraulic Brake Valve Adapter C...

Page 274: ...etal Fuse Contact 3 Air Conditioner CB 15 amp 4 Controller CB 50 amp 5 Transient Suppressor Diode 6 Fuse Box Chassis 7 K1 Cab Power Relay A1185 F6 Boom Jib Top 8B K1 Fuse Breaker Power 8 70A Relay S1 Computer Power 8P1 50A Breaker S2 Heater A C 8H 15A Breaker F13 Hydraulic Clutch Solenoid 8C F12 10VDC Regulated 87FA F11 Overhead Wiper 8W2 F10 Front Wiper 8W1 F9 Front Console 8X F8 Press Transducer...

Page 275: ...handle electrical circuit or electrical components Item Description 1 Load Drum Handle 2 Boom Swing Handle 3 Crawler Handle 4 Test Terminal 5 Ground Terminal R P1524 4 3 5 1 2 Hand Controller Test Terminal Wire No Acceptable Voltage DC Hand Controller Test Terminal Wire No Acceptable Voltage DC Swing Left Right Center 3 4 87FA 0 WA 08 8S Brake WD 15 Brake 10 Ground 1 4 to 8 6 12 12 Left Travel Lef...

Page 276: ... terminal block Connect the positive lead of a digital multi meter to terminal C Connect the negative lead on a grounded crane component or on terminal R Loosen the slotted set screw item 4 and allow handle to return to neutral position Re tighten slotted set screw and move handle until a reading of 5 volts DC is obtained Holding the handle in the 5 volt position loosen the slotted set screw item ...

Page 277: ... from adapter cable to digital multi meter jacks Check for 12 volts DC If this reading is not obtained check for 5 amps at F8 fuse on fuse panel see Test 6 To test voltage output from the pressure sender to the PC Engine must be off and power on with all brakes and locks engaged Connect green positive and black negative wires to digital multi meter jacks Check for 1 00 to 1 04 volts DC The PC null...

Page 278: ...e test adapter red positive and black negative to digital multi meter jacks Start engine with all brakes and locks engaged The motor or drum should remain at rest Check for 12 volts DC If this reading is not obtained check the 5 amp F8 fuse at the fuse panel see Test 6 To test voltage output from the speed encoder to the PC Engine must be off and power on with all brakes and locks engaged Connect ...

Page 279: ...are Lattice Team and a digital multi meter To test brake valve Connect the test adapter between brake valve and DIN plug Connect white positive and black negative wires from adapter cable to digital multi meter jacks Check for 12 volts DC while releasing the brake for the system being tested Load current can be measured by connecting red and white wires from adapter cable to digital multi meter ja...

Page 280: ...s DC Connect white positive and black negative wires from adapter cable to digital multi meter jacks Install test adapter between solenoid valve electrical socket and DIN plug Enable valve under test Check for 12 volts DC at upper valve assembly Item Description Item Description 1 Counterweight Pin Solenoid Valve 8 Front Drum Pawl Solenoid Valve 2 Boom Hoist Pawl Solenoid Valve 9 Mast Arms Bypass ...

Page 281: ...sistance is between 17 and 19 ohms Leave test adapter installed at the pump EDC Set the digital multi meter for testing volts DC Connect the PC input cable to PC end of test adapter With engine running slowly enable test system control handle Check that the range of voltage change is between 0 and 2 35 volts DC Load current can be measured by connecting red and white wires from adapter cable to di...

Page 282: ... Luffing Hoist 2 Boom Hoist 3 Swing 4 Right Crawler 5 Left Crawler 10 Auxiliary Load Drum Item Description 1 EDC Electronic Displacement Control 2 Manual Override Control 3 Case Drain Port Note 1 4 Charge Pressure Relief Valve 5 Filter Adapter Note 2 6 Multi Function Valve Note 3 7 Charge Pressure Gauge Port 8 Charge Pump Inlet Port 9 Pump Port B 10 Pump Port B Gauge Port 11 Pump Port A 12 Pump Po...

Page 283: ...Case Pressure 14 X1 External PCP Supply Pressure 5 M1 Gauge Port A 15 Minimum Displacement Limiter 6 M2 Gauge Port B 16 Charge Pressure Relief valve 7 M3 Servo Pressure Gauge Port or Servo Pressure Supply 17 Pressure Compensator Adjuster 8 M4 Servo Pressure Gauge Port or Servo Pressure Supply 18 Manual Override 9 M5 Servo Pressure Supply 19 Control Start Setting 10 M6 Charge Pressure Gauge Port 20...

Page 284: ...ation of pump ports To stroke the pump Start with engine running and all brakes and locks engaged Rotate the pump manual override in the clockwise direction to load down and raise pressure in port A Rotate the pump manual override in the counter clockwise direction to load down and raise pressure in port B Item Description 1 Manual Stroke Override 2 Pump EDC 2 P966 1 ...

Page 285: ...eck pump charge pressure Install a 0 600 psi 0 42 bar gauge at the desired system diagnostic gauge coupler at pressure sender Start system and record charge pressure at engine idle speed No hydraulic systems should be enabled A reading of 350 psi 24 bar is system charge pressure A reading of less than 350 psi 24 bar indicates a charge pressure relief adjustment is necessary See Test 18 Item Descri...

Page 286: ...si 0 42 bar gauge at system diagnostic gauge coupler see Test 17 Start engine with all brakes and locks engaged Check gauge for approximately 350 psi 24 bar To adjust loosen and hold 1 1 16 inch adjusting lock nut for series 045 100 units or 1 5 8 inch adjusting lock nut for series 130 units Turn adjusting screw until 350 psi 24 bar is obtained Torque adjusting lock nut to 34 to 41 ft lbs 46 to 56...

Page 287: ...ressure NOTE The bypass hex nut is for special applications only and must not be rotated during setting of pump pressure without first consulting the pump manufacturer literature Item Description Item Description 1 Multifunction Valve Adjusting Screw for Port A 3 Lock Nut 2 Multifunction Valve Adjusting Screw for Port B 4 Bypass Hex Nut P1537 P1533 3 1 4 2 Pump Port Control Function Pump Port A Po...

Page 288: ...ges Note the handle position of the hex wrench and without moving wrench rotate the neutral adjusting screw counter clockwise until pressure increases in the other gauge Note the handle position of the hex wrench again and without moving wrench rotate the neutral adjusting screw clockwise halfway between the last position The control should now be in neutral with both gauges reading the same case ...

Page 289: ...m hoist motor before testing see Test 23 To test a motor Connect flow meter between the motor case drain hose and the highest motor case drain port With the engine running at 1 000 rpm measure the flow rate of the motor Case flow at neutral or very light loads should be approximately 5 gpm 19 L min Record all measurements at neutral At heavier loads normal case flow may go to 7 gpm 26 L min Motors...

Page 290: ... charge pressure line To check hydraulic brake pressure for front drum rear drum or boom hoist system Engine must be off and power off with all brakes engaged Connect a 0 1 000 psi 69 bar gauge at diagnostic gauge coupler on loop flushing valve Start engine and set throttle at high idle 2 000 rpm Enable test system brake and check that brake pressure is 325 375 psi 22 26 bar Charge pressure can al...

Page 291: ...e Engine must be off and power off with all brakes and locks engaged Drain motor by removing attached hydraulic lines After draining replace hydraulic hose Remove hoses from flushing valve and replace valve The hydraulic fluid flow through the valve is adjusted with valve flow control on top of valve set for 6 gpm The hydraulic sequence valve is adjusted with flow control on side of valve set for ...

Page 292: ...To check that a solenoid valve or system valve is operating correctly Start the engine and actuate the manual override Hydraulic brake valves have an override push button in center of black nut If the valve is operating correctly the valve shifts to perform the control function Item Description 1 Hydraulic Brake Valve 2 Valve Override under cap P1603 1 2 Brake Valve ...

Page 293: ... signal to the PC to stroke the low pressure side of rear drum pump to enable the selected valve component To test the pressure switch trip pressure Disconnect pressure switch item 4 at rotating frame swivel item 1 Install a manual hydraulic pump and a 0 600 psi 42 bar gauge Remove DIN connector and install hydraulic brake valve adapter cable with meter Switch should open at 120 psi 8 3 bar If an ...

Page 294: ...on To adjust a counterbalance valve 1 Loosen the adjusting lock nut 2 Rotate counterbalance adjusting screw 1 2 turn clockwise in to lower holding pressure 3 Rotate counterbalance adjusting screw 1 2 turn counter clockwise out to raise holding pressure 4 While holding counterbalance adjusting screw with hex wrench tighten lock nut 5 Recheck cylinder s for correct load support and uniform operation...

Page 295: ...ontroller 1 9 Exhaust Aftertreatment System 7 15 Free Fall Clutch Brake 5 1 Free fall Mode Optional 1 31 Front Rear Drum System 1 26 Guidelines 10 2 Hoist Drawings 5 1 Hydraulic Solenoid Valve Identification 1 65 Hydraulic System Calibration 2 12 Hydraulic System Maintenance 2 2 Inspect Electrical Components 3 1 Inspecting Hydraulic Hoses 2 1 Introduction 10 1 Lattice Section Inspection and Lacing...

Page 296: ...ublished 05 16 17 Control 233 03 999 SERVICE MAINTENANCE MANUAL Test Voltages 3 8 Testing 10 32 Travel System Operation 1 18 Troubleshooting Charts 10 3 Turntable Bearing 8 1 Wire Rope Inspection and Replacement 5 12 Wire Rope Removal 5 1 ...

Page 297: ...R e f e r e n c e O n l y ...

Page 298: ...R e f e r e n c e O n l y ...

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