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PRODUCT SAFETY
It is the responsibility of the owner of the construction essential that the owner/user establish and perform a
and industrial equipment products to be knowledgeable periodic inspection of the equipment. The objective of
about federal, state and local regulations that effect the inspection programs is to prevent accidents, reduce
total usage of his equipment, and responsibility to work- downtime and keep the equipment working efficiently.
ing personal and the public. Since regulations are sub- These inspection programs should be designed to dis-
ject to change, and also differ from one local to another, cover worn, cracked, broken or deteriorated parts and
this manual makes no attempt to provide such informa- loose or missing fasteners before they result in a prob-
tion. lem.
When operating a hydraulic crane, the operator should realize that hydrau-
lic and structural competence, NOT TIPPING LOAD, is often the determi-
nant of lifting capacity.
Follow the recommended operating and maintenance various types of equipment, we ask that you include
procedures and keep your machine operating at MAX- your machine model and serial number in all corre-
IMUM EFFICIENCY. Use the Suggested Crane Period- spondence so that we can provide the correct informa-
ic Inspection Check List provided. In addition, we tion.
STRONGLY URGE that a MAINTENANCE LOG be
kept in conjunction with all maintenance performed on The information, specifications, and illustrations in this
the machine. publication are based on the information in effect at the
time of approval for printing. We reserve the right to
If you desire any special information regarding the care make changes at any time without obligation.
and operation of the machine, we will gladly furnish it
upon request. Because we build
SATISFACTORY
SATISFACTORY
INSPECTION
INSPECTION
ADJUST
ADJUST
REPAIR
REPAIR
ITEMS TO BE ITEMS TO BE
CODE
CODE
INSPECTED INSPECTED
& CHECKED & CHECKED
OVERALL HORN
CLEANLINESS D D
RADIATOR AIR
FLUID LEVEL D REGULATORS W
BOOM ANGLE
INDICATOR D
H Inspect OVERALL machine (including carrier) for cracks, weld separation, leaks, damage, vandalism.
INSPECTION CODE INTERVALS NOTES:
D - DAILY M - MONTHLY 1. Indicate inspection result by checking in the satisfactory, adjust, or repair boxes provided.
W - WEEKLY P - PERIODIC 2. When appropriate, enter your diagnosis on back of page for repairs or adjustments made.
This manual contains instructions and information on understanding of the material presented in the follow-
the operation, maintenance, lubrication and adjust- ing pages.
ments of the Rough Terrain Crane. The operator To aid in understanding the contents of this manual,
should not attempt to operate the machine before he the following terms will always have themeanings giv-
has gained a thorough en whenever they are used.
2. BOOM ATTACHMENT The telescopic crane boom with hydraulic winch, lift
cylinder, hook block assembly, jib arrangement.
2 1
4 3 4
SAFETY
1
CONTROLS AND INSTRUMENT 2
OPERATING INSTRUCTIONS 3
PERIODIC MAINTENANCE AND LUBRICATION 4
TROUBLESHOOTING
5
SERVICE AND ADJUSTMENTS 6
MACHINE STORAGE 7
GENERAL INFORMATION & SPECIFICATIONS 8
WIRE ROPE USERS MANUAL 9
WORK PLATFORMS 10
INDEX
SECTION 1
SUBJECT PAGE
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Handling Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Operators Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Management Responsibilty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Operation Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Terex Cranes appreciates your choice of our machine for your application. Our
number one priority is user safety, which is best achieved by our joint efforts. We
feel that you make a major contribution to safety if you as the equipment users
and operators:
If there is anything in this manual that is not clear or which you believe should be
added, please send your comments to Technical Publications Coordinator, Terex
Cranes, 106 12th St SE, Waverly, Iowa 50677; or contact us by telephone at (319)
352-3920.
Thank you!
Many aspects of crane operation and testing are discussed in standards published
by the American National Standards Institute. These Standards are updated on
an annual basis with addendas, which are sent by ASME to the original purchas-
ers of the standard. Terex recommends that you purchase and refer to the follow-
ing standards.
SYMBOLS
The symbols below are used to inform the operator of important information con-
cerning the operation of this unit.
!
These are general safety rules, which must be followed.
You are also required to read and understand the Operators
Manual as there are instructions, which are more detailed
specific to this machine.
! HANDLING PERSONNEL
1. Cranes can only be used to lift people when it is the least hazardous
way to do the job. (See OSHA 1926.550g, and ASME / ANSI B30.23.)
2. Do not operate this crane until you have been trained in its operation.
This crane must only be operated by trained personnel, who have
demonstrated their ability to do so safely.
6. Know that the crane can safely lift each load before attempting to lift.
! OPERATORS RESPONSIBILITIES
2. Make sure the machine is in proper order and that all operational aids
and warning signals are functional before operating.
4. Remove all oil, grease, mud, ice and snow from walking surfaces.
8. Be alert, physically fit and free from the influences of alcohol, drugs or
medications that might affect the operators eyesight, hearing, or
reactions.
10. Signal person must be used when the operators vision is blocked or
working in hazardous areas such as power lines or people.
11. Keep a fully charged fire extinguisher and first aid kit in the cab at all
times, and be familiar with how to use these items.
13. Never permit people on the machine platform while the machine is
working.
15. Start and stop movements smoothly and swing at speeds that will keep
the load under control.
16. Keep at least two full wraps of wire rope on drum when operating.
17. Feet must be kept on the pedals while foot pedal brake locks are in use.
4. Signal people must place themselves where they can be clearly seen
and where they can safely observe the entire operation.
! MANAGEMENT RESPONSIBILITY
7. Verify that all crew members are familiar with OSHA, ANSI B30.5
requirements as well as instructions in manuals.
4. Assign responsibilities.
6. Determine lift radius, boom angle, and the rated lifting capacity of
crane.
10. Determine where gas lines, power lines, or structures are which must
be moved.
11. Ensure that surface is strong enough to support machine and load.
15. Keep unnecessary people and equipment away from work place.
8. After starting engine, check all gauges and indicators for proper
readings.
11. Check load brakes by lifting a load a few inches off the ground and
holding it.
3. Backup Alarms.
2. Load radius will increase when the load is lifted. Reduce radius at start
of lift to allow for this.
4. Know boom length, jib length, parts of line and operating area.
5. Use next lower rated capacity when working at boom lengths or radius
between the figures on the rated lifting capacity chart.
6. Never lift a load without knowing whether it is within the rated capacity.
8. Do not lift loads if winds create a hazard. Lower the boom if necessary.
See the Rating Chart Manual for possible restrictions.
10. Never let the load or any other object strike the boom.
11. Release load slowly, be sure boom never tightens against back stops.
(Lattice Boom).
12. Place the boom point directly above the load when lifting.
2. Be sure cranes are level, check frequently and relevel when necessary.
3. Stay away from rotating cranes, erect barricades to keep people away.
Make sure these area's are clear before swinging.
1. Determine whether there are power lines in the area before starting any
job. Only operate around power lines in accordance with Federal, State
and Local Regulations as well as ANSI B30.5 latest edition.
2. Never remove materials from under powerlines with a crane if the boom
or machine is capable of contacting them.
4. Should contact occur stay on crane until the boom is cleared or until the
current is turned off.
5. If in contact keep all personnel off the crane. If you must leave the
crane, JUMP, DO NOT STEP OFF, leave area by jumping with feet
together.
! TRAVEL
1. Care must be taken when cranes are driven (traveled) whether on or off
the job site.
2. Watch for people, power lines, low or narrow clearance, bridge or road
load limits, steep hills or uneven terrain.
6. It is recommended that the seat belt be used during transit and travel.
7. Make sure travel surface can support weight of machine and load.
EMERGENCY PROCEDURES
When operational aids are inoperative or malfunctioning, the following requirements shall apply
for continued use or shutdown of the crane.
1. Steps shall be taken to schedule repairs immediately. The operational aids shall be put
back into service as soon as replacement parts, if required, are available and the repairs
and calibration can be carried out. Can be carried out does not mean, when convenient.
Every effort must be made to expedite the repairs and recalibration.
2. When a load indicator, rated capacity indicator, or rated capacity limiter is inoperative or
malfunctioning, the designated person responsible for supervising the lifting operations
shall establish procedures for determining load weights. Unknown loads shall not be lifted
without a properly functioning load indicating device.
6. When a level indicator is inoperative or malfunctioning, other means shall be used to level
the crane within the level requirements specified by the manufacturer.
In certain situations, it may be necessary to override the automatic motion limiter of the LMI / ATB
unit in order to safely operate the crane. These include but are not limited to:
The load block may lift the ATB weight before the load line can be tensioned while stowing the
boom. This will cause a motion cutout. Overriding the system, in this situation is acceptable in
order to continue to winch in slack line, securing the boom. Boom must be in the lowered
position.
If the Boom Up/Down control lever is pulled back after the boom is fully raised pressure will be
trapped in the base of the main cylinder. This will cause a motion cutout. Overriding the system is
acceptable in order to boom down enough to release the trapped pressure.
INDEX
SUBJECT PAGE
This section is intended to familiarize the operator with Diagrams of the various carrier and upper controls are
the controls and instruments provided for the operation illustrated on the following pages. A list of these con-
of this machine. It should be emphasized, however, trols and instruments are shown opposite each illustra-
that merely knowing the controls is inadequate prepa- tion. More detailed explanations of each control or
ration for operating hydraulic cranes. Do not attempt to instrument follow in the same order as they appear in
operate the machine until the other sections of this the number key.
manual have been covered. Sections 1 and 3 are es-
pecially important with respect to machine operation.
ELECTRICAL WASHER
SYSTEM ON HEADLIGHTS
IGNITION ON FAST
IGNITION
SLOW
T300-1 Page 2 - 1
CONTROLS AND INSTRUMENTS
AIR SUSPEN.
FILL KEY - ACC DIAGNOSTIC
STOP
LOW SPEED ENGINE
REAR AXLE KEY - START STOP
DIFF LOCK
ON PTO IN
DIFF LOCK
OFF PTO OUT
ENGINE
KEYSWITCH WARN
T300-1 Page 2 - 2
CONTROLS AND INSTRUMENTS
T300-1 Page 2 - 3
CONTROLS AND INSTRUMENTS
18 19 25 27
4 5 3 2 1 16 17 20 21 22 23 24 26 28
45
29
30
31
32
8 33
9
34
35
38 10 11 12 13 14 47 15 37 39 36 40
6 5 4 3 2 1
18
7 17
16
8 9 10 11 12 13 14 15
1. TACHOMETER/HOURMETER - Indicates engine 10. CRUISE [On/Off] - Press to toggle cruise on and off.
speed to 3000 RPM and total running time of engine (Option)
to 99999.9 hours.
11. CRUISE [Set/Resume] - Press to set or resume cruise
2. ENGINE COOLANT TEMPERATURE GAUGE - speed. Hold Set to coast. Hold Resume to accelerate.
Measures engine coolant temperature. Registers Minimum cruise set speed is 40 MPH.
from 100 to 280 F (40 to 130C.
12. ENGINE BRAKE [On/Off] - Press to activate engine
3. ENGINE OIL PRESSURE GAUGE - Measures brake.
engine oil pressure. Graduated from 0 to 100 psi
and 0 to 700 kPa. 13. ENGINE BRAKE [Hi/Med/Lo] - Center for medium, up
for high, down for low.
4. FUEL GAUGE - Graduated in quarters of full tank.
14. AC/FAN [Hi/Lo] - Press down for fan low, up for fan
5. VOLTMETER - Registers 9 to 12 volts, indicates high. Also turns on AC with AC also in On position. AC
condition of battery, alternator, etc. control switch located on AC unit behind seat.
6. GAUGE LIGHT DIMMER SWITCH - Turn to adjust 15. TEMP ADJUST - Adjusts heat temperature.
brightness of gauge lights.
7. HEADLIGHT SWITCH - Pull to turn parking lights 16. ENGINE BRAKE LIGHT - Indicates engine brake acti-
on, pull to second position for headlights. vated.
8. WASHER SWITCH - Press for windshield wash. 17. LOW COOLANT LIGHT - Indicates engine coolant level
is too low.
9. WIPER SWITCH - Press for windshield wiper.
24 26
25 27
21 22 23 28
20
19
19. TRANSMISSION LIGHT - Flashes trouble codes if 27. DIFF LOCK LIGHT - Indicates differential lock is activated.
there are issues with the transmission.
28. INTER AXLE LOCKOUT VALVE - Locks out inter-axle dif-
20. IGNITION ON LIGHT - Illuminates when ignition cir- ferential. Should the machine become stuck, a spinning
cuit is on. wheel will receive all power transmitted by the drivetrain
causing that wheel to spin faster and worsen the condition.
21. SPEEDOMETER - Incorporates odometer. Reads 0 to Use of the lockout divides the available power between the
80 m.p.h. and 0 to 130 km/h. two axles of the rear tandem. With the lockout engaged,
the stuck wheel may continue to spin but the other axle of
22. AIR GAUGE (FRONT) - Indicates air pressure in front the tandem will begin driving, thus helping to extricate the
air tank. Maintain 110 to 115 psi normal system air machine.
pressure.
24
29
30
B
A C
37 36 35 34 32 31
33
29. PTO AIR VALVE TOGGLE SWITCH - Push up to 33. WARNING LAMP - Lights and then flashes to indicate
engage pumps, push down to disengage. coolant temperature high, intake manifold temperature
high, oil pressure low, or coolant low condition. Lights to
indicate a fault code is present in diagnostic mode.
41 42 44
43
46
45
38
39 40
38. HEADLIGHT DIMMER SWITCH - Depress to 44. STEERING WHEEL - Turn clockwise to steer the
switch between high and low beams. machine right; turn counter-clockwise to steer the
machine left.
39. BRAKE PEDAL - Depress to actuate.
45. CIRCUIT BREAKERS - Electrical circuit breakers are
40. ACCELERATOR PEDAL - Depress to accelerate. under this panel.
41. TURN SIGNAL CONTROL - Lift up to activate 46. SHIFT LEVER (EATON) - Move to select transmission
right turn signals; press down to activate left turn gear.
signals.
20
15 16
1 14 2 3 4
25 24
19 19 21 22
5 6 7 8
19 19 23
9 10 11 12
17
18
27 13
27
30
31
32
26 28 29
1 14 2 15 3 16
4
5 6 7 8
9 10 11 12
13
27
20
25 21
19 19 24 22
17 19 19 23
18
17. ENGINE STOP - Shuts off fuel to the engine. Push 24. BOOM FAULT INDICATOR - Indicates that the
to activate. Pull to deactivate. boom is out of synch and must be overridden to
function. The boom sequence override switch is
18. IGNITION SWITCH - Turns ON and OFF behind the operators right shoulder on the forward
electrical circuits and stops the engine. surface of the control box.
19. OUTRIGGER SWITCHES - Four switches, used in 25. OK TO CHANGE MODE LIGHT - Indicates boom
conduction with switch (8), to extend and retract cylinders are either fully extended or retracted and
outrigger jacks and beams. in appropriate position for operator selected mode
change.
20. BUBBLE LEVEL - The machine must be leveled
prior to lifting loads.
27
30
31
32
26 29
28
26. SWING BRAKE - Apply to prohibit boom from 30. HAND THROTTLE - Holds engine throttle at an
swinging operator settable position. Place the accelerator
(27) at approximate RPM. Push in button on hand
27. SWING BRAKE RELEASE - Pull to disengage throttle. Pull throttle up and release button to lock.
swing brake. Make fine adjustments to engine RPM by rotating
the hand throttle clockwise to decrease RPM and
28. BOOM EXTEND RETRACT PEDAL - Tilt the counter-clockwise to increase RPM.
pedal halfway forward to power-extend the boom.
Tilt the pedal all the way forward for high speed 31. SWING BEARING GREASE FITTING
(regenerative) extend. The boom extend will stop
at the transition between power extend and high 32. SWING GEAR GREASE FITTING
speed. In high speed extend the boom extend has
minimal extend force. Tilt backward to retract
boom.
B B C
C
33
34
A A
33. SWING/AUX WINCH CONTROL - Move rope. Move joystick backward to take in main
joystick forward to pay out aux winch rope. winch rope. Move joystick left to raise boom.
Move joystick backward to take in aux winch Move joystick right to lower boom.
rope. Move joystick left to swing boom left. 34A Main Winch Rotation Indicator -
Move joystick right to swing boom right. Thumps to signal that rope is moving.
(Located internally in handle)
33A Aux Winch Rotation Indicator - 34B Horn - Press to sound horn. (Located
Thumps to signal that rope is moving. on underside of handle)
(Located internally in handle) 34C Hi-Speed Winch Switch - Press to
33B Horn - Press to sound horn. (Located toggle high speed winch.
on underside of handle)
33C Hi-Speed Winch Switch - Press to
toggle high speed winch.
35 37 38
36
Push lever forward and down to engage either 38. AUX WINCH DISABLE SWITCH
lock. Always engage lock before traveling the Move switch down to disable the aux winch
crane. NEVER ENGAGE THE LOCK WHILE function when it is not being utilized. This pre-
SWINGING THE MACHINE. vents damage to the cable when it is on the
winch, but not rigged over the boom head.
(Tied off to winch drum, etc.)
INDEX
SECTION 3
SUBJECT PAGE
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Vehicular Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Transmission Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
On Tires Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 30
Removable Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32
SEAT BELTS
4. Hand wash webbing with warm water and mild soap. Rinse thor-
oughly and dry in the shade.
7. For a non-locking retractor belt, completely extend the lap belt from
the retractor(s). After adjusting the belt snugly (see # 2 above),
attempt to pull additional webbing from the retractor. If no additional
webbing can be pulled from the retractor after adjustment, then the
seat belt is adjusted properly.
PRE-START INSPECTION
The following items should be checked each day FUEL FILTER Water and sediment should be drained
before start-up and the start of operations. Also see from the two fuel filters by opening the drain cock at the
Section 4, Daily Check. bottom of each. See Section 4, daily Check.
ENGINE OIL The level should be at the full mark. ANTI TWO-BLOCK SYSTEM Inspect all anti-two block
switches found on boom, jib, and auxiliary sheave heads
COOLANT The level should be near the top of the for damage. Check the freedom of counterweight
radiator tank. attached to these switches; and also, that counterweight
is attached around correct line of hoisting cable in the
LEAKAGE Make a ground check below the machine proper manner. Inspect all electrical connections and
for signs of leaks. wires as well as the entire length of cable attached to the
cable reel and its connections for evidence of excessive
FUEL Fuel for the engine and for upper unit heater wear, damage, or improper installation. Check spring
should be adequate for sustained operations. loaded cable reel for proper tension and to insure that
reel is free to rotate. Verify visual and audible warning
LUBRICATION Perform the daily lubrication as devices by lifting each of the counter weights.
required in the Lubrication Recommendations. Lubri-
cate cylinder mounting bushings, and pins. This crane is equipped with a disconnect system on the
control linkages. A check of this system should be made
LINES AND BLOCKS Inspect the hoist lines, hoist prior to lifting. Hoist the hook block to the boom point so
block and ball hook, and the crane attachment in that actual contact between block and anti-two block
general for readiness. counterweight is made. If all functions are operating
properly, winch hoisting will cease and the boom cannot
SAFETY EQUIPMENT Check the safety equipment, be extended or lowered. Should any of these functions
including all lights, brakes, and hazard warning continue, disconnect system is functioning improperly
devices. and a complete system check must be made. Boom
raise, boom retract, and winch down-functions remain
TIRES The tires should be checked for proper pres- active and will be unaffected by anti-two block system.
sure before traveling the machine. The tires should
only be checked when cold. Refer to the Tire Pres-
sure Chart in the operators cab.
When performing disconnect test, care should
WHEEL NUTS Torque all lug nuts to 400-500ft. lbs.
be taken as damage may result if disconnect
Check tightness daily during the first 50 miles of ser-
system malfunctions and the hook block is
vice on new units and any time the wheels have been
drawn into the boom point.
removed. Ensure proper alignment of tire and rim
assemblies by following the Torque Procedure
given on page 6-34.
If the engine has an emergency manual or automatic 1. Press the starter switch firmly.
shutdown system, make sure the control is set in the
open position before starting. The turbocharger may be
seriously damaged if the engine is cranked with the air
shutdown in the closed position. To prevent serious starting motor damage, do not
press the starter switch again after the engine has
The engine may require the use of a cold weather start- started.
ing aid if the ambient temperature is below 40F (4C).
2. If the engine fails to start within 15 seconds, release
the starter switch and allow the starting motor to cool
for 15 seconds before trying again. If the engine fails
Starting fluid used in capsules is highly flammable, to start after four attempts, an inspection should be
toxic, and possesses sleep-inducing properties. made to determine the cause.
To start a Series 60 DDEC engine be sure the trans- AIR STARTER - Because of the limited volume of most
mission is in neutral or park and turn the ignition key storage tanks and the relatively short duration of the
on. cranking cycle, it is important to make sure the engine
is ready to start before activating the air starter.
You will notice that both the Check Engine and Stop Start an engine equipped with an air starter as follows:
Engine lights will come on. This is a result of the
DDEC computer diagnosing the system to ensure 1. Check the pressure in the air storage tank. If neces-
everything is functional, including the light bulbs for the sary, add air to bring the pressure up to at least the
Check Engine and Stop Engine warning lights. If recommended minimum for starting.
everything is okay, both lights will go out in approxi-
mately five seconds. 2. With foot OFF the foot pedal, press the starter but-
ton firmly and hold until the engine starts.
Observe the oil pressure gauge immediately after start- Crankcase - If the engine oil was replaced, stop the
ing the engine. A good indicator that all of the moving engine after normal operating temperature has been
parts are getting lubrication is when the oil pressure reached. Allow the oil to drain back into the crankcase
gauge registers pressure (5 psi - 34.5 kPa at idle for approximately 20 minutes, and check the oil level. If
speed). If there is no oil pressure indicated within 10 to necessary, add oil to bring the level to the proper mark
15 seconds, stop the engine and check the lubricating on the dipstick.
system. The pressure should not fall below 28 psi (193
kPa) at 1800 rpm, and normal operating pressure Turbocharger - Make a visual inspection of the turbo-
should be higher. If pressure does not fall within these charger for oil leaks, exhaust leaks, excessive noise or
guidelines, it should be checked with a manual gauge. vibration. Stop the engine immediately if a leak or
unusual noise or vibration is noted. Do not restart the
engine until the cause of the concern has been
investigated and corrected.
To avoid personal injury from the hot oil, do not operate
a Series 60 engine with rocker cover removed for any Avoid unnecessary Idling
reason.
During long engine idling periods with the transmission
Warm-up in neutral, the engine coolant temperature may fall
below the normal operating range. The incomplete
Run the engine at part throttle for about five minutes to combustion of fuel in a cold engine will cause crank-
allow it to warm up before applying a load. case dilution, formation of lacquer or gummy deposits
on the valves, pistons, and rings, and rapid accumula-
Inspection tion of sludge in the engine. When prolonged idling is
necessary, maintain at least 850 rpm spring/summer
Transmission - While the engine is idling, check the and 1200 rpm fall/winter.
transmission for proper oil level and add oil as
required. Look for coolant, fuel, or lubricating oil leaks
at this time. If any are found, shut down the engine
immediately and have leaks repaired after the engine
Normal Stopping
Position the vehicle with the booster battery adjacent to discharged battery.
the vehicle with the discharged battery so that booster
cables can be connected easily to the batteries in both 7. Make certain that all cables are clear of fan blades,
vehicles. Make certain vehicles do not touch each belts, and other moving parts of both engines and be
other. sure everyone is standing away from vehicles. Then
start the engine with the booster battery. Wait a few
1. On both vehicles, turn off all electrical loads. Set the minutes, then attempt to start the engine of the vehi-
parking brake. Place transmission in PARK or cle with the discharged battery.
NEUTRAL.
8. After starting, allow the engine to return to idle speed
2. Determine whether the discharged battery has the and remove the cable connection at the engine
negative (-) or positive (+) terminal connected to block or good metallic ground. Then remove the
ground. The ground lead is connected to the engine other end of the same cable from the booster bat-
block, frame, or some other good metallic ground. tery.
The battery terminal connected to the starter relay is
the one which is not grounded.
5. Connect one end of the other cable to negative (-) Both batteries should be of the same voltage.
terminal of the booster battery.
VEHICULAR OPERATION
The Hydraulic Crane is capable of both on-road and bypass the two block system disconnects. Failure to
limited off-road travel. The kind of travel undertaken pull the hook block up to the head when traveling, or to
determines how the carrier is operated. secure it to the bumper ring, will result in excessive
swinging of the hook block and possible damage to
Before moving the crane, either around the work site or machine.
between sites, carefully consider the terrain type, road
conditions, and any hazards likely to be encountered
en route. Think the move through in advance and carry
it out safely.
Continuing to pull the block up after contact
has been made may result in damage to the
CARRIER BREAK-IN Refer to special break in
boom head and sheaves.
requirements for new cranes on page 4-3.
VEHICULAR OPERATION
1. Be seated in the drivers seat with the seat belt fas- pressures for tires used as duals.
tened low and snug.
The inflation pressures shown below are for those
2. Thoroughly review the shift pattern of the transmis- taken with the tires at the prevailing atmospheric tem-
sion. peratures and do not include any inflation pressure
build-up due to vehicle operation.
3. Start the engine, following the procedure in the topic
Starting the Engine.
Tire Size 11R22.5 425/65R22.5
VEHICULAR OPERATION
Neutral UPSHIFTING
START WITH RANGE SELECTOR DOWN
SHIFT LO-1-2-3-4 RAISE RANGE SELECTOR
SHIFT 5-6-7-8
LO 6 8 DOWNSHIFTING
SHIFT 8-7-6-5 MOVE SELECTOR DOWN
SHIFT 4-3-2-1-LO
PUT TRANSMISSION IN
NEUTRAL
The transmission provides eight highway ratios, plus a 3. Release pedal to engage clutch.
LO gear and a LL1 and LL2 gear for extra pulling
power. There are three reverse ratios. A. Upshifts - decelerate engine until engine RPM and
road speed match.
B. Downshifts - accelerate engine until engine RPM
The transmission has a five speed front section and a
and road speed match.
three speed auxiliary section which has an extra deep
reduction gear. The LO ratio in the front section is used 4. Quickly depress pedal to disengage clutch and move
only as a starting gear. The other four ratios are used gear shift lever to next gear speed position.
once in Low Range and one again in High Range.
5. Release pedal to engage clutch.
Always preselect the range shift. After preselection and
moving the shift lever, the transmission will automati- NOTE: By engaging the clutch with the gear shift lever
cally make the synchronized range shift as the lever in the neutral position, the operator is able to
passes through neutral. control the RPM of the main shaft gears since
they are regulated by engine RPM. This
LL1 is selected by the Deep Reduction Button mounted procedure enables the operator to match the
on the shift lever. When operation in ratios from LO to RPM of the main shaft gears with those of the
8th the Deep Reduction Button should be in the REAR- main shaft driven by the cranes rear wheels.
WARD position. Move the Deep Reduction Button into
the FORWARD position to select LL1. This shift should UPSHIFTING:
only be made with the transmission in Low Range and 1. Move the gear shift lever into neutral.
the shift lever in the LO speed gear position.
2. Start the engine and wait for the vehicles air system
to reach normal line pressure.
DOUBLE - CLUTCHING Always double-clutch when
making lever shifts. Use the following double - clutch- 3. Make sure the Range Selector Lever is DOWN in the
Low Range position.
ing procedure when upshifting and downshifting:
4. Make sure the Deep Reduction Button is in the
1. Depress pedal to disengage clutch. REARWARD position. Or, in the FORWARD position
if you want to start in LL1 under adverse conditions.
VEHICULAR OPERATION
5. With clutch disengaged, move the gear shift lever to 3. Continue downshifting from 4th through 3rd, 2nd,
the LO speed gear position. Release clutch pedal to and 1st to LO while in Low Range.
start moving. If Deep Reduction was selected, the
crane will be moving in LL1. 4. DO NOT down shift into LL1 from LO unless operat-
ing conditions make it necessary. LL1 can be
6. To upshift from LL1 to LO in the same gear shift lever
obtained with the transmission in Low Range and
position, move the Deep Reduction Button to the
the shift lever in the LO speed gear position by mov-
REARWARD position and IMMEDIATELY release
ing the Deep Reduction Button to the FORWARD
accelerator. Depress the clutch pedal ONCE to
position. Then IMMEDIATELY release accelerator,
break torque and reengage the clutch. The transmis-
depress clutch pedal ONCE to break torque, reen-
sion will shift from /Deep Reduction to Low Range
gage clutch and accelerate. The transmission will
when synchronous is reached. Then accelerate.
shift from LO to LL1 when synchronous is reached.
7. To upshift form LO upshift from LO through 1st, 2nd
and 3rd to 4th while in Low Range. DOWN HILL DRIVING - The engine provides most effi-
cient braking when run at or near top RPM in the oper-
8. While in 4th and ready for the next upshift, PULL UP ating range - but remember, the governor has no
the Range Preselection Lever and move the shift control over the engine speed when it its being pushed
lever to the 5th speed gear position. As the shift by a load.
lever passes through neutral, the transmission will
automatically shift from Low Range to High Range.
VEHICULAR OPERATION
NOTE: When PROPERLY ADJUSTED THE PARKING NOTE: See the ON TIRES LIFTS instructions found
BRAKE WILL HOLD THIS MACHINE ON a later in this section for instructions on moving
30% grade, if the tires have adequate traction. the crane with a load.
It is recommended that when parked on a
grade that the wheels be chocked.
- Lock the swing brake and swing lock. NOTE: This machine can travel on 15 side slopes
which have a firm level prepared surface. Due
- Secure the hook block or ball to the bumper loop to variations in surface, tire pressure, bumps,
or raise the hook block or ball close to the boom potholes, etc., we recommend that travel on
head sheaves before moving. side slopes be limited to 5 and that the boom
be horizontal or below.
- Make sure all outriggers are completely retracted
before moving the crane.
- Stow the boom in the boom rack.
enable leveling of the crane. drum as specified in all applicable crane oper-
ating safety standards.
Proper positioning of the outriggers is critically impor-
tant to both the safety and effectiveness of craning The intent of this caution is to prevent any possibility of
operations. either reverse winding of the rope on the winch drum,
which could cause breakage of the winch rope, or of
3. Use the load rating chart attached to the crane to in- unseating the rope wedge in the winch drum, which
terpret the conditions and limitations that exist when could result in the uncontrolled fall of the hook block
making a lift with the crane. The determining factors and load. Use of more parts of line than required for the
are lifted load, radius, boom angle, working position, lift increases likelihood of rope damage.
hoist line reeving, tire pressure, travel data, and use
of a jib. 4. Raise the boom to the required angle, consulting the
boom angle indicator which indicates boom angle
The examples given in this section are given for your relative to upper structure.
interpretation of the terminology used on the chart (see
The boom elevation is controlled by foot pedals or
hand lever. To RAISE the boom, slowly depress the
LEFT boom control pedal or pull the lever back. To
LOWER the boom, slowly depress the RIGHT boom
page 3.28). control pedal or push the lever forward. Improved con-
The load rating chart values used in the exam- trol is obtained by operating the engine at low speed
ples may not be the same as those on your while metering the controls. Always operate and
load rating chart. Use the numbers from the release the controls slowly to minimize dynamic effects
chart attached to your crane whenever making of the load. During a lift where precise control of the
lift calculation. load is required, do not attempt to use more than one
function at a time.
The increased possibility for inadequate wraps remain-
ing on the winch drum occurs when operating with a
higher number of parts of line than are required for the
load being lifted, particularly at longer boom lengths
and high boom angles. Always consider possible obstructions when
varying boom height or length; not only those
Sufficient wire rope is initially provided to allow the to the front of the cab at the time of the adjust-
hook block to reach ground level when reeved for the ment, but those which may be encountered
required parts of line indicated on the capacity chart for during swings.
all given loads. Reeving with more parts of line than Play the swing through, considering all obstacles,
required may result in all of the wire rope being payed prior to using swing function.
off the winch drum.
5. Swing the boom over the load. tion as required to slow the swing.
Apply the swing brake, with the foot pedal, when the
Upper structure swing is controlled by the swing lever. swing is stopped or when emergency situations dictate
To swing the upper structure to the RIGHT, PUSH the that the swing be terminated abruptly.
lever forward. To swing LEFT, PULL the lever back-
wards. Swing speed increases as the lever is moved If properly executed, the load will hang motionless
further forward or back. Swing speed also varies with when the swing is terminated. If the load is oscillating,
the engine speed. the swing was made too rapidly and/or stopped too
abruptly.
Before attempting to swing the upper structure, make
sure the swing brake is not set and the swing lock is
not engaged. Be certain that no obstructions will block
the swing.
Stopping the swing too abruptly will cause the 6. Extend the boom to the desired length. Do not extend
load to oscillate and impose side loads on the the boom further than necessary to per- form the lift.
boom. Because side loading can damage the
boom, ALWAYS START AND STOP SWINGS
GRADUALLY.
tions and two speeds. When the lever is all the way for- to an operating condition, either lower the hook or ball,
ward, the regenerative mode provides increased retract or raise the boom.
speed. With the lever approximately one half of the
way forward, increased PUSH is available at reduced The operator may need to raise the hook block beyond
speed. the point at which the anti two block system is activated
during rigging or travel. The operator may override the
7. Lower the hook block to the load and fasten the hook. system. (shown in control and instrument sections).
Hoisting or lowering of the load with the winch is con- 9. Swing and spot the load over the location where it is
trolled by the winch lever. LOWER the load by pushing to be deposited.
the lever FORWARD and RAISE the load by pulling the
lever BACK. Improved control is obtained by operating
the engine at low speed while metering the control.
Always actuate and release this lever slowly to mini- 2nd
mize dynamic effects of the load and to prevent bird
nesting of the cable on the winch drum.
HOIST. With forearm vertical LOWER. With arm extended USE MAIN HOIST. Tap fist on USE WHIPLINE. (Auxiliary RAISE BOOM. Arm extended,
fore finger pointing up, move downward forefinger pointing head; then use regular signals. Hoist) Tap elbow with one fingers closed, thumb pointing
hand in small horizontal.circle. down, move hand in small circle. hand, then use regular signals. upward.
MOVE SLOWLY. Use one hand to RAISE THE BOOM AN LOWER THE BOOM AND
give any motion signal and place LOWER THE LOAD. With arm RAISE, THE LOAD With arm
LOWER BOOM. Arm other hand motionless in front of extended, thumb pointing up, extended, thumb pointing down,
hand giving the motion signal. SWING. Arm extended, point with
extended fingers closed, flex fingers in and out as load flex fingers in and out as long as finger in direction of swing of
thumb pointing downward. (Hoist slowly shown as example.) movement is desired. load movement is desired. boom.
IDLER
SHEAVE
WINCH 4 SHEAVE
DEAD END
1 1 D
2 1D 3
CABLE SOCKET 3 15 3D
4 14D 14
9 12345 1234D
10 12345D 12345
These patterns represent some, though not all, of the options for
reeving patterns for hookblocks. Always use a reeving pattern that
allows the block to hang level.
DESCRIPTION
Anti Two-block
Switch T - Handle
to jib.
Guide Rope
10. With the engine at idle, slowly boom down to mini-
1. Extend and set the outriggers.
mum boom angle while another operator uses the
guide rope to control the speed of the jib rotation.
2. Rotate the upper structure to the over rear position.
The jib will swing around until the left side mount-
ing holes line up.
3. Retract the boom completely.
11. If cable from main boom is to be used on jib,
4. Boom down to minimum boom angle to allow ease of remove cable from boom head load sheaves and
installation of the jib pins. If necessary raise rear out- swing over top left jib cord before pinning jib to
riggers till boom head can be reached from ground boom. Install the left upper and lower jib mounting
level. pins.
5. Install the upper and lower jib mounting pins in the 12. Remove the guide rope.
right side of the boom head.
13. Disconnect the anti two-block plug from the jib anti
6. Attach a guide rope to the eye on the bottom tip of two-block socket and connect it to the socket on
the jib. the boom head. Move the dummy plug from the
boom head socket to the anti two-block socket on
7. Extend outriggers if retracted, to bring crane back to the jib.
level. Raise the boom to horizontal.
14. Reeve the hoist line over the jib sheave.
8. Pull down and rotate the T - handle to unlock the jib
from the storage bracket. 15. Test the anti two-block system by lifting the anti
two-block weight. The light and audible alarms
9. With the engine at idle, slowly extend the boom 2-3 should be actuated in the cab and the boom down,
feet (.6-1 m). As the jib clears the storage brackets, boom extend, and winch up controls should dis-
the jib will swing out approximately 45. connect.
0 15 30
Jib Offset
Pin Holes
Sheave Shaft
Cap Screws
1. Retract the boom and set the outriggers. 7. With the engine at idle, slowly winch down to pay out
hoist cable. This will lower the tip of the jib until the
2. Boom down to minimum boom angle. jib comes in contact with the jib offset pins.
3. Loosen the two (2) cap screws on the left side of the NOTE: While lowering the tip of the jib, it may be
upper and lower sheave shafts. This will require a 3/ necessary to raise the boom to prevent the tip
4 inch hex wrench. of the jib from touching the ground.
4. Reeve the hoist line over the top center sheave on 8. Remove the hoist line from the tip of the jib and
the boom head, around the jib sheave, and attach to reeve the hoist line as needed.
the eye on the bottom of the jib tip.
DECREASING OFFSET
5. Winch up to take the slack out of the hoist line and to
take the weight of the jib off of the jib offset pins. 1. Reverse above procedure to return jib to 0 offset
position.
NOTE: To prevent damaging the jib, do not winch up
any more than is necessary to loosen the jib
offset pins.
6. Remove the jib offset pins from the 0 offset hole and
place in the 15 hole or if you are using 30 offset
Anti Two-block
Extended Socket
Anti Two-block
Retracted Socket
NOTE: The jib must be erected before extending the 1. Retract the boom completely and boom down to
pullout section. Do not attempt to extend the minimum boom angle.
pullout section while the jib is stowed.
2. Unplug the anti two-block plug from the anti two-
1. Retract the boom completely and boom down to block Extended socket. Move the dummy plug from
minimum boom angle. the retracted socket to the extended socket.
2. Attach the dead end of the wire rope to the eye on
3. Attach the dead end of the wire rope to the eye on
the bottom of the jib tip. This is done to prevent the
the bottom of the jib tip.
pullout from extending uncontrollably.
3. Unplug the pull out anti two-block plug from the anti 4. Remove pullout retaining pin from the erected retain-
two-block Retracted socket. Move the dummy plug ing pin hole.
from the extended socket to the retracted socket.
5. Winch up slowly to retract the pullout until the
4. Remove pullout retaining pin from the retaining pin retracted retaining pin holes line up and install
hole. retaining pin.
5. Pay out cable and extend the pullout until the retain- 6. Plug the anti two-block plug into the anti two-block
ing pin holes line up. Install retaining pin. Retracted socket.
6. Plug the anti two-block plug into the anti two-block
7. Test the anti two-block system by lifting the anti two-
Extended socket.
block weight. The light and audible alarms should be
7. Test the anti two-block system by lifting the anti two- actuated in the cab and the boom down, boom
block weight. The light and audible alarms should be extend, and winch up controls should disconnect.
actuated in the cab and the boom down, boom
extend, and winch up controls should disconnect.
Wear Pad
T - Handle
Anti Two-block
Switch
Guide Rope
2. Rotate the upper structure to the over rear position. 10. With the engine at idle, slowly boom up while a sec-
ond operator holds the guide rope to control the
3. Make sure the stinger is in the stowed position and rotating speed of the jib.
the jib offset is at 0 offset.
11. Boom up to approximately 30. Allow the jib to
4. Boom down to minimum boom angle. swing around until the jib contacts the wear pad on
the boom. As the jib gets close to the side of the
5. Remove the hoist line from jib sheave and lay to left boom, make sure the jib does not strike the side of
side. the boom.
13. Remove the guide rope from the tip of the jib.
Bracket mounted
to boom
Bracket mounted
to jib
Special problems in maintenance and operation are and block the fuel flow to the engine. To minimize
caused by unusual conditions such as extremes in this possibility, keep the tank as full as is practical
heat, cold and humidity, high altitude, salt water, and during cold weather. This may entail refilling the tank
dusty or sandy work sites. When operating under such more frequently than usual, but the inconvenience is
conditions, special precautions must be taken to pre- small compared to clearing a blocked fuel line.
vent damage, minimize wear, and avoid component
deterioration. If water should be noticed in the fuel supply, drain the
tank and refill it with uncontaminated fuel.
EXTREME COLD In periods of extreme cold, the prob-
lems of freeze damage, adequate lubrication and bat- 3. Lubricate the crane with the lubricants recom-
tery failure may become particularly troublesome. With mended for cold weather operation on the Lubrica-
the onset of very cold weather, it is advisable to winter- tion Chart. If necessary, change the engine oil and
ize the crane by servicing the cooling system and other lubricants in order to con- form to the recom-
switching to the lubricants recommended for cold mendations.
weather usage. Follow the recommendations in this
manual when the crane must be operated in very cold 4. The battery is more likely to sustain freeze damage if
conditions. not kept fully charged because its electrolyte will
freeze at a higher temperature than that in a fully
1. To prevent freeze damage to the cooling system charged battery. Be certain the battery is charging
and cracking of the engine block or head, drain and when the engine is running and use an external
flush the cooling system. Clean the radiator exterior, charger to restore full charge when the crane is not
making certain the air passages through the core being operated.
and the cooling fins are free of foreign matter.
The battery can discharge if snow or ice short circuits
Refill the cooling system, adding an antifreeze solution the terminals. Keep the battery posts and cable con-
recommended by the engine manufacturer in an nectors clean and dry. Remove any corrosion with a
amount and strength appropriate to the anticipated solution of soda and water.
temperatures. A corrosion inhibitor is recom-
mended.Consult engine manufactures recommenda- During extremely cold weather, it is advisable to
tion. remove and store the battery in a heated area when
the crane is to remain idle for any extended period.
The hydraulic oil may be run over relief to aid in the Allow the engine to cool before draining and
warm-up process. To do this, actuate a function, allow flushing the cooling system.
the cylinders involved to reach the limits of their travel
and hold the control in the engaged position for a few Water containing more than small concentrations of
seconds. salt or minerals should not be used in the cooling sys-
tem. Salt facilitates corrosion and minerals deposited
When running hydraulic oil over relief to warm it, be on the coolant passage walls. Both processes inhibit
sure to restrict the flow to as slow a speed as possible proper cooling.
by moderating pressure on the controls being engaged
and running the engine at low speed. 3. Air circulation around the engine and battery must
not be restricted. Keep air intake and exhaust open-
Continue warming the oil and slowly cycle all crane ings clear of leaves, paper or other foreign matter
functions, actuating all cylinders in turn, swinging the which may restrict air flow.
upper and operating the winches in both directions. 4. Keep the engine clean of dirt, grease and other sub-
stances which inhibit heat dissipation.
6. At the end of the work period, or whenever the crane
is to be left idle for extended periods, prevent it from 5. Use sound judgment in operating the engine. Avoid
being frozen to the ground by parking it on a wood, the two extremes of racing and lugging.
concrete, asphalt or mat surface.
load at the rated radius. The boom angle before loading OVE
should be greater to account for deflections. The loaded SIDE
boom angle combined with the boom length give only THESE LINES DETERMINE THE LIMITS
an approximation of the operating radius. OF WORKING POSITIONS WHICH COR-
RESPOND TO THOSE SHOWN ON THE
Freely Suspended Load: Load hanging free with no di- Cut - Offs: Rated chart values of less than approxi-
rect external force applied except by the hoist rope. mately 1,000 lbs for on outriggers and side-stow jib are
not shown. This is done because the effects of wind,
Side Load: Horizontal force applied to the lifted load ei- pendulum action, jerking, etc., can cause a tip over.
ther on the ground or in the air.
Example:
Hook Block 660 lbs.
Slings 215 lbs. 63.0
Object Lifted 18,700 lbs.
Lifted Load = 19,575 lbs. 19,575
ON TIRES LIFTS
REMOVABLE COUNTERWEIGHT
INSTALLATION
NOTE: The counterweight slabs are an integral part of this crane. When the crane is to be traveled at highway
speeds, a portion of these slabs are intended to be moved to and carried on the counterweight supports
on the deck of the crane in order to equalize the axle loading.
REMOVAL
NOTE: The counterweight slabs are an integral part of this crane. When the crane is to be traveled at highway
speeds, a portion of these slabs are intended to be moved to and carried on the counterweight supports
on the deck of the crane in order to equalize the axle loading.
This machine is equipped with an air suspension on the front axles. Operation of the suspension is very simple. As
explained in Group 2, air is added or released from the air bags by depressing the switch in the carrier cab.
To adjust the ride height, begin by loosening clamp (A). This will allow the bar to slide so that the trailing arm can
be rotated relative to the frame. Adjust the suspension member so that its surface (B) is parallel to the frame sur-
face (C). Pass a small rod through the holes in the air yoke and the switch. The rod should pass through both out-
side holes (D) and between the two small bosses (E) on the switch. Tighten the clamp (A). Remove the small rod,
by moving arm (D) up to add air, pushing the trailing arm away from the frame, or down to bring it closer.
E
D
BOOM OPERATION
This machine is equipped with a dual mode boom. It is important that the load chart being used corresponds to the
boom mode that is selected.
BOOM MODE A
Boom Mode A is designed to maximize the structural load ratings. In Boom Mode A, Section II fully extends, then
Sections III, IV, and V extend synchronously.
BOOM MODE B
Boom Mode B is designed to maximize machine stability. In Boom Mode B, Sections III, IV, and V extend synchro-
nously, then Section II extends.
5 4
2 1
If there is an error in the boom sequencing, the Boom Sequence Fault Indicator (4) will be lit and the boom will
stop functioning. Use the boom override switch (located on the front vertical panel of the control box) to let the sys-
tem allow you to retract the boom. When the switch is activated , both Boom Mode (A & B) indicators will light and
allow you to RETRACT ONLY the cylinder you select. When both cylinders are fully retracted, the Boom
Sequence Fault Indicator will reset. When the boom is fully extended or fully retracted, the OK to Change Mode
Indicator (5) will light. When the Mode Indicator is lit you may press the mode switch and the appropriate Mode
Indicator (1 or 2) will light.
INDEX
SECTION 4
SUBJECT PAGE
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Operator Observation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Engine Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 7
Transmission Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 8
Koehring Spec 805 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 10
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15
Drive Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
Slider Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
Boom Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 19
INTRODUCTION
T700
T300-1 Page 4 - 3 Issued:
Issued:
September
March 2002
2004
PERIODIC MAINTENANCE AND LUBRICATION
Check Hydraulic Reservoir Fluid Level Check Wire Rope And Related Components
Check Transmission Oil Level Check Engine Manufacturers Manual For Addi-
tional Maintenance Requirements
Drain Fuel Filters or Water Separator
Ensure Swing Brake Is Able To Hold Against Full
Check Boom Front Slider Pads Torque Of Swing Motor
Check Swing Reducer Oil Level Visually Inspect All Structural Members And
Welds For Cracks, Alignment and Wear
Check Axle Oil Level (after initial change)
Check Boom For Wear Cracked Welds, Align-
Check Battery Condition ment And Missing Or Illegible Decals
Check Tire Pressure And Condition Check Engine Manufacturers Manual For Addi-
tional Maintenance Requirements
Check Air System Safety Valve
Clean Machine Weekly If Salt Covered To Pre-
Check Torque On Wheel Lug Nuts vent Rust And Corrosion
Check Hydraulic Reservoir For Moisture Check Engine Manufacturers Manual For Addi-
tional Maintenance Requirements
DESCRIPTION OF CRANE
RESULTS OF INSPECTION
INSPECTOR:
A good lubrication program requires that all nor- mal should any discrepancy occur. If there is any doubt
wear points be lubricated according to a set schedule about the proper lubricants, intervals or lubrication pro-
with specific types of lubricants. Refer to the lubrication cedures, refer to the original manufacturers manual.
chart and the special items covered in this section for
the recommended lubricants, time intervals and lubrica- The lubrication intervals recommended in this section
tion procedures. assume normal operating conditions. Where dust, dirt,
high humidity or extreme heat
Where components such as the engine, transmission are encountered, lubrication intervals should be short-
and axles are not manufactured by Koehring, the origi- ened accordingly.
nal manufacturers recommendations take precedence
MIXING: Mixing different brands of oil is not recom- neutralization number. The oxidation process is typical-
mended. Various companies use different additive ly slow at first and then increases sharply in the final
packages, which when mixed together, may cause stages of complete oxidation. A sharp increase (by fac-
problems in a hydraulic system. This type of problem is tor of 2 - 3) in a neutralization number is a good indica-
rare but can cause sludge which can plug the filters or tion that the fluid is reaching the limit of its oxidation life
acid which will etch the pump plates. In either case, the and should be replaced.
warranty would be voided. If, knowing all this, you still
choose to add oil different from the initial fill, stay with a Water Contamination - All hydraulic oils in the follow-
single brand as this will minimize the likelihood of prob- ing charts will readily separate water which will settle to
lems occurring. Then at the first complete oil change the bottom of the reservoir. This water should be
you may switch to the brand you prefer to use. drained off. The water that is measured in the oil sample
will be dissolved water. This should be less than .05%.
PRE-FILTER: Oil should be filtered through a 10 micron If it is greater than .05%, the oil in the system should be
nominal filter before it enters the hydraulic system. New drained and replaced.
hydraulic fluid as received by the user is generally not in
a satisfactory cleanliness condition for long component Particle Contamination - Excess contamination in a
life. hydraulic system will greatly shorten the life of pumps
and motors. Your oil sample analysis will show the num-
OIL MAINTENANCE: Optimum life from hydraulic ber of particles per milliliter greater than a given micron
equipment can only be obtained with proper hydraulic size. The number of particles in your sample should be
oil maintenance. This includes checking the oil every less than the following:
three to six months. An oil should be checked for viscos-
ity, oxidation, water content, contamination and copper Particle Size No. of Particles/Milliliter
particles. A record should be kept of each check to de-
tect signs of progressive deterioration. Oil samples 10 micron or larger 3,000
should be taken with the system running at normal op-
erating temperature. It is important to use good tech- 20 micron or larger 300
nique in obtaining an oil sample. The exact same
30 micron or larger 100
procedure should be followed each time an oil sample
is taken. Most fluid suppliers will provide assistance in 40 micron or larger 30
analyzing your oil sample. The following are some
guidelines to use in this analysis. 50 micron or larger 10
Viscosity - Many hydraulic fluids will shear or thin out 100 micron or larger 1
with use. The viscosity at each check should be com- If your oil sample shows numbers greater than in the
pared to the viscosity when new. At no time should the chart, your hydraulic system is contaminated. The sys-
viscosity be less than 45 SSU at 210 F. If viscosity is tem should be checked for broken or torn filters,
less than 45 SSU at 210 F, the oil must be replaced im- plugged filters, stuck filter bypass valves and so forth.
mediately. Continued operation with particle counts greater than
those shown in the chart will result in short pump and
Oxidation - Oil oxidation will occur with age and use motor life.
and is evidenced by a change in color and/or odor, in-
creased acidity, and possible formation of sludge, gum Copper Particle Counts - The oil sample analysis
or varnish in the system. The rate of oxidation increases should include a copper particle count in parts/million.
significantly with operations at temperatures over 140 This number should normally be less than 100. A high
F (60C). The oil should be checked more often if oper- copper particle count indicates that a gear pump or mo-
ation is a high temperature. The oxidation process in- tor is rapidly deteriorating. A count of 200 or more would
creases the acidity of the fluid and is measured by a be cause for concern. The most important thing to look
PHYSICAL
PROPERTIES TEST METHOD REQUIRMENT
Maximum life of pumps, motors, hoses, and seals will be obtained by selecting an oil as far down the chart as pos-
sible.
Viscosity Minimum Ideal Cont. Maximum
Grade Start-UP Operating Operating Selection Guide
I.S.O. A.S.L.E. Temp. Hyd. Oil Hyd. Oil Lines
* Temp.
(New) (Old)
* Temp.
Extreme cold start can be
-30F 160F 195F
used year round in most
Synthetic (-8C) (71C) (91C)
machines in temperature
climates
* Minimum temperature for starting without extended warm-up. For lower temperatures, follow warm up proce-
dure in the operators manual.
OIL COMPANY ISO BRAND NAME OIL COMPANY ISO BRAND NAME
D-A Lubricant Co. Inc 32 D-A Hydra Shield 32 Shell Co. 23 Tellus 23
(USA) 46 D-A Hydra Shield 46 (USA) 32 Tellus 32
68 D-A Hydra Shield 68 46 Tellus 46 (XSL 9101)
100 D-A Hydra Shield 100 68 Tellus 68
100 Tellus 100
Dryden Oil Co. 32 Paradene Anti-Wear 32 AW
(USA) 46 Paradene Anti-Wear 46 AW Sun Oil Co. 32 Sunvis 816 WR
68 Paradene Anti-Wear 68 AW (USA) 46 Sunvis 821 WR
100 Paradene Anti-Wear 100 AW 68 Sunvis 831 WR
100 Sunvis 851 WR
Exxon Co. 32 Nuto-H 32
(USA) 46 Nuto-H 46 Texaco Inc. Rando Oil HD A2 (5w-20)
68 Nuto-H 68 (USA) 32 Rando Oil HD 32
100 Nuto-H 100 46 Rando Oil HD 46
68 Rando Oil HD 68
Gulf Oil Co. 32 Gulf Harmony AW 32
(USA) 46 Gulf Harmony AW 46
68
100
Gulf Harmony AW 68
Gulf Harmony AW 100
** Factory
alent.
filled with Northland Talamar 215 or equiv-
Aerosol Spraying
Standard lubrication frequencies are shown on lube grease. Under less severe conditions, add grease until
chart. it appears at the bottom seal.
RACE LUBRICATION - Inject grease as recommend- GEAR LUBRICATION - While swinging the machine,
ed through fitting located to rear of console in opera- apply gear grease through the second grease fitting lo-
tors cab just behind the shift lever, as the machine is cated to the rear of the console to the internal ring gear
rotated at least two complete revolutions. When com- with sufficient frequency to insure that the teeth remain
plete rotation is impractical, inject grease through fit- coated.
ting and rotate machine back and forth as far as
possible. Some lubricants recommended by the manufacturer
are:
Under extremely dirty or dusty conditions, sufficient
grease should be added to flush out contaminated
POWER STEERING
LUBRICATION - STEERING GEARS The lubricant wheel from left to right and continue filling until proper
used in the power steering system is the medium by level is maintained. (See final adjustments section for
which hydraulic pressures are applied and relieved, un- system bleeding procedures).
der control, to effect steering assist.
A replaceable type filter element is located in the reser-
In addition the lubricant also lubricates moving parts voir. Carefully clean any build-up of dirt and grease form
and dissipates heat which reduces efficiency and accel- the reservoir cover. Remove the reservoir cover and fil-
erates wear. It is of the utmost importance to use a lu- ter element. Clean inside of reservoir with a lint free
bricant specified and approved by R.H. Sheppard Co., cloth. Install a new filter element refill with oil and re-
Inc. in the Sheppard Steering Gear. place cover.
The Sheppard Gear requires the use of 10W-30 Motor LUBRICATION - BEARING CAPS To lubricate the dirt
Oil. Highway vehicles should have the oil changed twice and salt seals in the bearing cap, and flush out any con-
a year or every 50,000 miles. Off highway vehicles will taminants that have passed these seals, chassis grease
require more frequent change intervals. should be added with low pressure per the lube chart.
DRIVE SHAFTS
LUBE
LUBE
LUBE PRESSURE
RELIEF
HOLE
If all the seals do not pop when being lubed, move the
drive shaft laterally in all four directions and pull or push
DRIVE SHAFTS
Cover pressure relief hole with finger and continue to universal joints should be used. Lithium soap base
apply pressure until grease appears at sleeve yoke greases meeting National Lubricating Grease Institute
seal. This insures complete lubrication of spline. (NLGI) Grade 1 and Grade 2 specifications are pre-
ferred. The use of greases which tend to separate and
cake should be avoided.
RE-LUBE CYCLE
OPERATING CONDI-
TION Miles Hours
BRAKES
AIR DRYER
Desiccant cartridge life will vary depending on operating conditions, speeds, loads, air usage and compressor con-
dition. It is recommended that the desiccant cartridge be replaced approximately every 2 years. If system perfor-
mance is reduced, desiccant cartridge replacement is necessary. It is also recommended that the desiccant
cartridge be replaced if the compressor has been rebuilt.
SLIDER PADS
The front bottom slider pad should be checked daily for wear. The remainder of the slider pads should be checked
monthly for wear.
Chamfer
All the slider pads contain a chamfer on the wearing surface. When this chamfer is worn off, the slider pad must be
replaced.
With boom extended brush grease on areas of boom where wear pads contact is evident. he inside of the top plate
of all sections except the tip section also require grease. This can be applied through the holes in the side plates
and piled on top of the next section out just in front of the top rear pads on that section so that extending the boom
to the next hole smears the grease onto the inside of the top plate. Remember to do both sides.
Grease intervals vary and should be more frequent if noise or jerking of the boom is evident.
BOOM LUBRICATION
BOOM LUBRICATION
INDEX
SECTION 5
SUBJECT PAGE
General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Hydraulic - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
Engine Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
Air Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20
Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
Winch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 28
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 31
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 33
Fluid Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 34
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36
Cylinder Leakage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 37
Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39
Propane Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 40
Maintenance Free Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 43
As the operator, it is your responsibility to detect any un- If you cant answer YES to all three questions, rely on
usual, sounds, odors, or other signs of abnormal perfor- your Distributor Serviceman. He has the right tools, test-
mance that could indicate trouble ahead. ing equipment and service knowledge to pin-point the
problem in minutes instead of the hours consumed in
By detecting any problems in their early stages, you can hit-or-miss methods. TIME IS MONEY! He will save it for
save yourself unnecessary downtime and your employ- you.
er a lot of money! Therefore, it is also your responsibility
to use good judgment in detecting failures in quickly and If you decide to attempt an adjustment yourself, follow a
repairing them. If you dont, one failure can lead to an- logical TROUBLE SHOOTING PROCEDURE. Dont
other. simply replace parts until the trouble is found.
GENERAL PROCEDURE
I - KNOW THE SYSTEM Study this manual and learn 6 - TEST YOUR CONCLUSION Test your conclusions,
what makes the machine tick, how it should behave, in order of obviousness, until the source of the failure is
sound and smell. found. The machine can then be repaired at minimal
cost and downtime. Make the repair. Recheck to ensure
2 - OPERATE THE MACHINE Test operate all machine that nothing has been overlooked, functionally test the
functions. Note all abnormal sounds, odors and move- repaired part in the system.
ments. Always proceed in the most logical order to de-
termine the cause. 7 - REVIEW MAINTENANCE PROCEDURES Prevent
recurrences of all premature failures by regularly check-
3 - INSPECT THE MACHINE Look for leaks, listen for ing the filters, temperature, adjust- ments and lubrica-
the source of abnormal sounds, detect the origin of un- tion. Make daily inspections.
usual odors. Check the condition of the oil and filters.
NOTE: Your safety and that of others is always the
4 - LIST THE POSSIBLE CAUSES Use your best judg- number one consideration when working around
ment in listing all possible causes of the failure. cranes. Safety is a matter of thoroughly understanding
the job to be done and the application of good common
5 - REACH A CONCLUSION Review your list of possi- sense. It is not just a matter of dos and donts. Stay
ble causes and decide which are the most likely to clear of all moving parts.
cause the failure. Consider the most obvious first.
HYDRAULICS - GENERAL
Before any troubleshooting is attempted, become fully If, in spite of these precautions, improper opera- tion
acquainted with the following two (2) basic fundamental does occur, the cause can generally be traced to one of
facts of a hydraulic system: the following:
1 - SPEED The speed of a hydraulic function is directly 1. Use of the wrong viscosity or type of oil.
related to the system flow. A reduction in speed of a cyl-
inder or motor is caused by an insufficient quantity of oil 2. Insufficient fluid in the system.
being delivered to the component.
3. Presence of air in the system.
2 - POWER The power or force of a hydraulic function
is related to pressure. 4. Mechanical damage or structural failure.
7. Improper adjustments.
Hydraulic components are precision units and their con- Clean and inspect all parts. Be sure all passages and
tinued smooth operation depends on proper care. holes are open. Cover all parts to keep them clean. Be
Therefore, do not neglect hydraulic systems. Keep sure parts are clean when they are installed. Leave new
them clean and change the oil and oil filter at estab- parts in their containers until ready for assembly.
lished intervals.
Clean the preservative compound from all machined
surfaces of new parts before installing them.
OPERATOR - CONTROLS
POWER STEERING
FRONT AXLES
CAUSE REMEDY
HARD STEERING
CAUSE REMEDY
Inadequate or improper lubrication of knuckle pins ................... Consult lubrication chart for proper lubricant,
lubrication intervals and procedures.
CAUSE REMEDY
Inadequate or improper lubrication ............................................ Consult lubrication chart for proper lubricant,
lubrication intervals and procedures.
FRONT AXLES
CAUSE REMEDY
Excessive power steering pressure ........................................... Check steering pump relief setting, check
steering system relief setting; adjust as
required.
Misadjusted steering relief plungers .......................................... Adjust plungers to unload steering system
when wheels are turned to extreme positions.
CAUSE REMEDY
Inadequate or improper lubrication ............................................ Consult lubrication chart for proper lubricant,
lubrication intervals and procedures.
Spring and seat in drag link worn............................................... Replace spring and seat, replace ball stud.
CAUSE REMEDY
Inadequate or improper lubrication ............................................ Consult lubrication chart for proper lubricant,
lubrication intervals and procedures. Increase
lubrication frequency when operating in extrem
conditions.
CAUSE REMEDY
STEERING CIRCUIT
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
Loose or damaged bushing on pump drive shaft ....................... Repair pump per pump service instructions.
CAUSE REMEDY
CAUSE REMEDY
Water entry through reservoir venting system ........................... Clean vent system or replace cap assembly.
CAUSE REMEDY
Air in system .............................................................................. Bleed air from system. Check for air leak on
suction side of supply pump.
Faulty supply pump (Cavitation)................................................. Check supply pump following Hydraulic Sup-
ply-Diagnosis. Repair pump per pump service
instruction.
CAUSE REMEDY
Operating temperatures too high ............................................... Check and correct cause of overheating.
Incorrect lubricant used.............................................................. Drain, flush and refill with 10W-40 motor oil.
CAUSE REMEDY
Air leak in suction side of supply pump ...................................... Refer to pump servicing instructions.
CAUSE REMEDY
Pinched oil return line. High back pressure .............................. Relocate line.
CAUSE REMEDY
CAUSE REMEDY
HARD STEERING
CAUSE REMEDY
CAUSE REMEDY
Bent or damaged king pins and tie rods .................................... Repair or replace king pins and tie rods.
Refer to servicing instructions.
Front end load too great for rated axle capacity......................... Lighten load or install larger steering gear.
Fatigued by-pass valve spring in pump...................................... Replace with flow control valve assembly.
Refer to pump servicing instructions.
Low oil level in steering system ................................................. Fill oil reservoir as required.
See Lubrication.
Air in system .............................................................................. Bleed system and check for cause of air.
Metal or foreign material caught in actuating valve.................... Remove actuating valve. Clean and check
parts for damage.
Actuating valve worn or chipped by dirt ..................................... If damage is excessive replace damaged parts
as required.
CAUSE REMEDY
Broken reversing springs in steering gear ................................. Replace reversing springs and damaged parts.
Refer to repair procedures to check for addi-
tional damage.
CAUSE REMEDY
CAUSE REMEDY
Bent or damaged reversing springs ........................................... Check for impact or accident damage. Replace
damaged parts.
EXCESSIVE BACKLASH
CAUSE REMEDY
Low oil volume ........................................................................... Check flow divider and pump drive belts.
Pitman arm ball worn egg-shaped ........................................... Replace pitman arm assembly where riveted
ball is used or only where bolted ball is used
(vertical socket).
Loose bracket frame to bracket or bracket to gear .................... Remove bracket. Clean frame and bracket.
Check radius of frame making sure bracket is
not bearing on radius surface. Check bracket
for wear from working. Replace bracket and
tighten to recommended torque rating accord-
ing to size and grade of bolts. If necessary,
replace bracket with new one.
CAUSE REMEDY
Worn output shaft bushings ....................................................... Replace bushings and polish shaft to remove
bronze deposits.
Worn actuating shaft and valve threads..................................... Replace worn parts as required. Follow
Hydraulic Supply Diagnosis procedures to
locate cause of wear.
Universal joint yoke loose on actuating shaft ............................. Repair or replace damaged parts, check for
spline wear.
CAUSE REMEDY
Steering column bind ................................................................. Check and repair U-joints and support bear-
ings.
Steering gear mounting distorted ............................................... Shim mounting pads to correct piston to bore
interference.
REAR AXLE
CAUSE REMEDY
Improper or inadequate lubrication ............................................ Consult lubrication chart for proper lubricant,
lubrication interval, and procedure.
Bearing rollers worn ................................................................... Replace bearing. Always replace both cups
and cones.
EXCESSIVE VIBRATION
CAUSE REMEDY
Fractured axle shaft at flange .................................................... Replace axle shaft. Examine axle housing for
bent condition. Make certain wheel bearings
are correctly adjusted.
See page 6 - 12.
ALTERNATOR
OPERATION NOISY
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
ALTERNATOR OVERHEATS
CAUSE REMEDY
Loose or worn belt or pulley ....................................................... Adjust belt, or replace worn belt or pulleys.
STARTER
STARTER INOPERATIVE
CAUSE REMEDY
ENGINE CLUTCH
CLUTCH SLIPPAGE
CAUSE REMEDY
Insufficient clutch pedal free play ............................................... Adjust release bearing position, then adjust
linkage if necessary.
Release bearing locknut loose ................................................... Adjust release bearing length and tighten lock-
nut.
CAUSE REMEDY
Worn or damaged clutch pressure plate .................................... Replace pressure plate and cover assembly.
Grease or oil contamination on facings...................................... Clean facings and repair cause of contamina-
tion. If contaminant cannot be removed,
replace clutch disc.
CAUSE REMEDY
Clutch damaged
- damaged clutch disc hub splines
- bent clutch disc
- bent drive straps
- broken/warped pressure plate ................................................. Replace damaged component.
Contamination/grease in release bearing bore .......................... Clean release bearing bore and transmission
input shaft.
Excessive side loading on release bearing ................................ Eliminate source of excessive side loading
(worn/damaged cross shaft bushings, worn/
damaged cross shaft, worn/damaged or bent
release yoke tips, worn/damaged or uneven
release bearing yoke contact wear pads, exces-
sive release bearing travel during disengage-
ment, worn/damaged pilot bearing, excessive
flywheel runout, excessive engine to transmis-
sion misalignment, etc.).
CAUSE REMEDY
Failed pilot bearing..................................................................... Replace pilot bearing and input shaft if dam-
aged.
Tight or contaminated clutch disc splines .................................. Clean clutch disc and input shaft splines or
replace clutch disc as necessary.
Flywheel housing to clutch housing
excessive misalignment ............................................................. Replace faulty housing.
Grease or oil contamination on facings...................................... Clean facings and repair cause of contamina-
tion. If contaminant cannot be removed,
replace clutch disc.
BRAKES
CAUSE REMEDY
Worn brake linings ..................................................................... Adjust for lining wear or replace brake shoes.
Blocked, bent, or broken tubing or hose .................................... Remove obstructions in line or replace faulty
tubing.
Brake valve delivery pressure below normal.............................. Clean and replace worn parts if brake valve is
defective, replace unit.
Insufficient parking brake valve delivery pressure ..................... Clean and replace worn parts, or if valve is
defective, replace unit.
CAUSE REMEDY
Weak or broken valve diaphragm return spring ......................... Replace brake valve.
CAUSE REMEDY
Brake shoe binding on anchor pin ............................................. Remove shoe, clean and lubricate anchor pins.
Weak or broken brake shoe return springs ................................ Replace faulty spring
CAUSE REMEDY
Grease or oil on linings .............................................................. Clean linings or replace linings or shoe assem-
blies.
Brake chamber diaphragm leaking ............................................ Tighten all fittings; if caused by broken or
faulty unit, replace the unit.
PARKING BRAKE
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
Defective spring brake valve ...................................................... Repair or replace spring brake valve.
CAUSE REMEDY
Insufficient hold off pressure ...................................................... Check for system (or excessive valve) leaks.
Leaking brake actuator diaphragm ............................................ Replace brake actuator (spring pot).
Defective spring brake valve ...................................................... Repair or replace spring brake valve.
AIR PRESSURE
CAUSE REMEDY
SWING CIRCUIT
CAUSE REMEDY
Mechanical swing lock applied, if equipped ............................... Disengage the swing lock.
Spring brake stuck in applied position ....................................... Disassemble swing brake and free-up unit.
Swing valve main relief valve stuck in open position ................. See section on Relief Valves.
Swing motor leaks excessively internally ................................... See section of Fluid Motor.
CAUSE REMEDY
Excessive leakage around swing control valve spool ................ Replace or replace control valve.
CAUSE REMEDY
Brake not releasing completely .................................................. Check operation of swing brake and/or swing
lock.
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
Load too great ............................................................................ Move lever to first position, not high speed.
Reduce load or set boom length before lifting
load.
Both port relief valves sticking ................................................... See section on Relief Valves.
CAUSE REMEDY
Inadequate grease on boom pad surfaces................................. Lubricate boom where pads contact boom.
Wear pads shimmed to boom too tight ...................................... Reshim wear pads.
CAUSE REMEDY
CAUSE REMEDY
WINCH CIRCUIT
CAUSE REMEDY
Main relief valve is set too low ................................................... Readjust the main relief.
CAUSE REMEDY
The sprag clutch is assembled backwards ................................ Be certain that the winch is assembled prop-
erly.
Insufficient parts of line for the load being lifted ......................... See the reeving diagram on the capacity chart.
CAUSE REMEDY
The winch brake is not releasing ............................................... Be certain that the brake release line is open. If
necessary, disassemble and inspect the brake
components.
CAUSE REMEDY
System back pressure too high.................................................. Warm oil: check for restriction in down stream
flow.
The over-running sprag on the brake is broken ......................... Inspect and replace, if necessary.
The automatic brake is not applying .......................................... Be certain that the winch brake release line is
not plugged and no foreign objects are in the
brake assembly.
The winch brake friction plates are worn ................................... Replace friction plates.
CAUSE REMEDY
OUTRIGGER CIRCUIT
CAUSE REMEDY
CAUSE REMEDY
Beam wedged in extended position ........................................... Extend jack far enough to pick up end of beam
and retract. Replace slider pad block on top of
outrigger box to pick up end of beams.
CAUSE REMEDY
CAUSE REMEDY
Thermal relief cartridge mounted in wrong end ......................... Check for proper assembly.
SWING
PUMPS
CIRCUIT
CAUSE REMEDY
Low fluid level in reservoir.......................................................... Add recommended oil and check level.
Oil viscosity too heavy to pick up prime ..................................... Use lighter viscosity oil. Follow recommenda-
tion for temperatures encountered.
Broken pump shaft or parts broken inside pump ....................... Contact your local distributor; if necessary,
refer to the manufacturers manual for the cor-
rect instructions in pump disassembly and
repair.
NO PRESSURE IN SYSTEM
CAUSE REMEDY
Valve setting not high enough .................................................... Increase pressure setting of valves.
Valve leaking .............................................................................. Check seat for score marks and reseat.
Internal leakage in control valves or cylinders ........................... To determine location, progressively block off
various parts of circuit. When trouble is
located, repair. (Do not block between pump
and relief valve).
CAUSE REMEDY
CAUSE REMEDY
Pump disconnect notengaged ................................................... Shut engine off and engage pump disconnect.
Air leaks:
At pump intake pipe joints .......................................................... Test by pouring oil on joints while listening for
change in sound of operation. Tighten as
required.
Air drawn in through inlet opening ............................................. Check and add oil to reservoir if necessary.
Too high oil viscosity .................................................................. Work only with oil at recommended operation
temperature.
Rag, paper, etc., pulled into suction line or pump ...................... Remove.
CAUSE REMEDY
Loose fitting on pump intake or discharge ................................. Keep all joints tight.
EXCESSIVE WEAR
CAUSE REMEDY
Viscosity of oil too low at working conditions1 ........................... Check oil recommendation.
Air recirculation causing chatter in system................................. Check for air being drawn into system. Use
hydraulic oil with a foam depressant.
CAUSE REMEDY
Excessive pressure above maximum pump rating..................... Check relief valve setting.
Seizure due to lack of oil ............................................................ Check reservoir level, oil filter and possibility
of restriction in suction line more often.
Solid matter being wedged in pump........................................... Check suction line filter, drain and flush system
as necessary.
CONTROL
SWING CIRCUIT
VALVES
STICKING PLUNGERS
CAUSE REMEDY
Excessively high oil temperature ............................................... See section on Excessive Heating of Oil in
System.
Valve warped from mounting...................................................... Loosen valve mounting bolts and check.
Excessively high flow in valve .................................................... Check to see if hoses from pump are not
crossed or reversed.
Spring or detent cap binding ...................................................... Loosen cap, re-center and re-tighten.
LEAKING SEALS
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
Scored check valve poppet or seat ............................................ Replace poppet or lap poppet to seat.
CAUSE REMEDY
SWING
RELIEF CIRCUIT
VALVES
CAUSE REMEDY
Poppet stuck open or dirt under seal ......................................... Check for foreign matter between poppets and
their mating members. Members must slide
freely.
ERRATIC PRESSURE
CAUSE REMEDY
Poppet seal damaged ................................................................ Replace damaged parts. Clean dirt and remove
surface marks for free movement.
CAUSE REMEDY
Wear due to dirt. Lock nut adj. screw loose .............................. See section on Valve Adjustments.
LEAK
CAUSE REMEDY
FLUID MOTOR
Relief valve stuck open or set too low........................................ Clean and free relief valve spool and adjust to
proper setting.
Large contaminating foreign bodies in fluid................................ Flush hydraulic system completely. Use new
oil and install new filters.
SLOW OPERATION
CAUSE REMEDY
Relief setting too low .................................................................. Set relief valve for proper psi.
CAUSE REMEDY
CAUSE REMEDY
Relief valve pressure set too low ............................................... Adjust relief valve setting.
Air being sucked in on inlet side of pump ................................ Tighten fitting(s) on pump inlet side.
LEAK AT SHAFT
CAUSE REMEDY
CAUSE REMEDY
Motor housing bolts loose .......................................................... Clean mating surfaces and tighten nuts to
appropriate value.
CAUSE REMEDY
CAUSE REMEDY
CYLINDERS
CAUSE REMEDY
Loose parts ................................................................................ Tighten cylinder rod eyes, if loose. Check cyl-
inder heads and tighten, if loose.
CAUSE REMEDY
Air in system:
Main Relief pressure too low or valve sticking ........................... See section on Relief Valve.
CYLINDER LEAKAGE
Hydraulic cylinders may retract due to the cooling of the An alternate method to test the hold valve would be to
oil in cylinder. Oil shrinks approximately 1% per 100F disconnect the two hoses coming from the valve bank
of cooling, or as an example, if a cylinder is extended and then elevate the boom . If oil continues to flow
100 and it cools 100F, it would shorten approximately slowly from the extend line then it is a hold problem. If
1. oil continues to flow from retract, then it is faulty or leak-
ing by piston in cylinder.
TELESCOPE CYLINDER
Note: With hollow rod telescope cylinders you can drain
If excessive leak-down is encountered, check items in in excess of 40 gallons of oil from the rod. If the
the following sequence: boom comes in while doing this test, then the cyl-
inder is faulty or leaking by the piston in the cylin-
1 With boom offside and horizontal, extend the boom der.
approximately 6 ft. per section. Mark the first tele-
scoping section at the end of the base section. IF THE HOLD VALVE IS NOT FOUND DEFECTIVE,
the cylinder must be removed from the boom assembly
2 Elevate the boom to maximum angle and suspend for repacking and checking. Prior to reassembly of the
a load on the hook. (7 tons on a 2-part line would cylinder, conduct an air test on the piston rod by block-
approximate manufacturers inspection proce- ing the retract ports on the rod near the piston end. Slip
dures.) a plastic bag over piston end of rod and retain and seal
with rubber band. Apply and hold a slight amount of air
3 With engine shut off, hold or tie the telescope func- pressure at the retract port of the rod. (Port stamped
tion lever in the full extend position for approxi- with R.) Expansion of the plastic bag indicates a
mately 15 minutes. defective rod weldment or seals on the port tube in the
rod.
4 Return the telescope lever to neutral, start engine,
ground the load, and return the boom to horizontal. WHEN REASSEMBLING THE CYLINDER, care
Re-mark the boom section as in (1). Measure the should be taken to keep the piston rod assembly paral-
distance between marks to determine leak-down of lel in all planes with the cylinder barrel as the piston
the cylinder. enters and is pushed down the barrel prior to gland
engagement.
The manufacturers allowable drift specification for pro-
duction machines is as follows: NOTE: An external leak from telescope cylinders or
hydraulic line within the boom assembly does not
With 14,300 lb. hook load, 2-part hoist line, boom cause leak-down without also having one or more of
extended about 6 ft. per section at maximum boom the above conditions present.
angle, and 160 degree F. hydraulic oil temperature, the
leak-down per cylinder is not to exceed 3/4 inch in a BOOM LIFT CYLINDER
15-minute period.
The suggested procedure for identifying the specific
IDENTIFY A DEFECTIVE HOLD VALVE in the cylinder cause of leak-down should be performed in the follow-
which drifts excessively by interchanging the hold valve ing sequence:
cartridge with one removed from a cylinder that is not
drifting, or by replacement with a new cartridge. Before ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE,
installing the cartridge, visually inspect the external O not completely extended, with a boom length sufficient
rings and backup washers. Retest per the procedure to winch up a convenient payload approximately one
above to determine if hold was defective. (1) foot from ground level. Shut of engine.
DISCONNECT THE EXTEND HOSE, PILOT DRAIN ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE,
HOSE, AND THE SMALL PILOT LINE HOSE at the not completely extended, with a boom length sufficient
holding valve ports and cap the pilot line hose and drain to winch up a convenient payload approximately one
hose ends. (1) foot from ground level. Shut off engine and remove
pressure from the hydraulic reservoir by loosening the
IF HYDRAULIC OIL CONTINUES TO RUN after the ini- filler cap.
tial draining from either port of the hold valve as the
hoist cylinder continues to leak-down, the cause is with- DISCONNECT THE EXTEND HOSE FROM THE
in the hold valve. HOLD VALVE. This is a hose farthest away from the
port tube and should have an E stamped next to it.
IF CYLINDER LEAK-DOWN OCCURS with no oil leak
from the hold valve ports, the cause is within the cylin- IF HYDRAULIC OIL CONTINUES TO RUN after the
der. initial draining from the port of the hold valve as the jack
cylinder continues to leak-down, the cause is within the
OUTRIGGER JACK CYLINDER hold valve.
The suggested procedure for identifying the specific IF CYLINDER LEAK-DOWN OCCURS with no oil leak
cause of leak-down is similar to the boom lift cylinder from the hold valve port, the cause is within the cylin-
procedure: der.
CAUSE REMEDY
Internal oil leakage due to wear ................................................. Repair or replace faulty component.
Viscosity of oil too high or too low .............................................. Follow recommendations for correct viscosity
grade to be used.
CAUSE REMEDY
Improper functioning of oil cooler ............................................... Inspect cooler and see that it is working prop-
erly.
Improper machine operation ...................................................... Return control to neutral when stalled, cylinder
at end of stroke, etc.
CAUSE REMEDY
Low oil level ............................................................................... Check oil level and fill if necessary.
ELECTRICAL CONTROLS
ELECTRICAL FAILURE
CAUSE REMEDY
Rocker switch sticking................................................................ Remove switch, check if hole is too tight. Cut
out decal or file hole larger.
PROPANE
SWING CIRCUIT
HEATER
CAUSE REMEDY
Full voltage not available at heater ............................................ Check for power at the heater: at least 11 VDC
with heater turned on. Trace system to find any
fault(s).
CAUSE REMEDY
Fuel supply blocked ................................................................... Check fuel supply by loosening the fitting on
the outside of the heater and checking for pro-
pane odor. If propane odor is present, pull off
the igniter wire completely and remove the
igniter. Try to start the heater and listen for the
solenoid click. Check for the odor of propane
in the burner. If propane odor is present at
bulkhead fitting, but not the burner head, the
solenoid valve is defective or contaminated
with some foreign object. The solenoid valve
can become contaminated when a liquid take-
off bottle is used instead of the required vapor
take-off bottle. If the fuel system is contami-
nated, the lines and solenoid must be cleaned
with a degreasing solvent.
CAUSE REMEDY
Igniter defective or inoperative ................................................... Check the igniter. To check, shut off the fuel
tank and depress the start switch until the lines
are purged of fuel. Remove the burner head
and check the gap between the igniter and the
burner tube. It should be 1/16 to 1/8. With
the burner head grounded, move the START-
RUN-OFF switch to the START position and
check the gap for spark. If no spark is pro-
duced, the igniter may be dirty or defective.
Before removing the igniter from burner head,
check inside the burner head to determine if
any carbon threads or chips are present which
could short the plug.
Fuel not suitable for temperatures encountered ........................ Check with your propane supplier to be sure
your fuel is suitable for the temperatures
encountered. Around -10F, propane may not
produce enough pressure to pass through the
regulator.
CAUSE REMEDY
Bi-metal blade broken or linkage out of adjustment ................... Check bi-metal blade and linkage and adjust,
repair or replace as necessary.
Dirt on fuel solenoid valve lip ..................................................... Clean solenoid valve lip.
Full voltage not available at heater ............................................ Using voltmeter, check to be sure full voltage is
available for heater operation, at least 11 VDC
with heater turned on. Trace system to find
fault.
CAUSE REMEDY
Air inlet tube blocked.................................................................. Check for plugged or blocked air inlet tube and
clear if necessary.
Defective pressure regulator ...................................................... Check for defective pressure regulator. There
should be 11 inches water pressure in the pro-
pane supply line at the connector.
CAUSE REMEDY
VISUAL INSPECTION
CAUSE REMEDY
CAUSE REMEDY
CAUSE REMEDY
If there is an indicator and it shows low charge ......................... Charge, then turn on high-beam head lamps (or
15 amp load for 15 seconds). Proceed to load
test.
LOAD TEST
CAUSE REMEDY
TWO
SWING
BLOCK
CIRCUIT
SYSTEM
PANEL LIGHT & HORN WILL NOT COME ON WITH BOOM SWITCH WEIGHT LIFTED
(IF EQUIPPED WITH DISCONNECTS, CONTROLS WILL NOT ENGAGE)
CAUSE REMEDY
CAUSE REMEDY
LIGHT AND HORN ARE ON WITH HOOK BLOCK NOT CONTACTING SWITCH WEIGHT
(IF EQUIPPED W/ DISCONNECTS, CONTROLS WILL NOT ENGAGE)
CAUSE REMEDY
Boom head weight wire rope broken or hung up ....................... Check that weight is attached to wire and hang-
ing freely. If rope is caught up on something,
correct.
Broken electrical cable or bad connection ................................. Check all cable for visible damage, then
remove wire from terminals #3 and #6 in control
panel and check for continuity. If circuit is
open, check the wires inside cable reel, and
wires from the reel to the boom head switch. If
the wires are OK, check the anti-two block
switch. If there is continuity between #3 and #6
check the relay in the panel.
CAUSE REMEDY
Defective two block switch ......................................................... Check for correct mechanical operation. If OK,
remove cover and wires from terminals #1 and
#2. With arm pulled down, there should be a
closed circuit between them. With the arm up,
the circuit should be open. If all conditions are
not met, replace switch.
Defective relay in panel.............................................................. Check for 12 volts between relay pins #30 (hot)
and #86 (ground). If voltage is 0, check for volt-
age between pin #87a and ground. If 12 volt,
replace relay (With no electrical power to the
relay, pins #30 and #87a should show continu-
ity. With 12 volts to either #85 or #86 and the
other grounded, there should be continuity
between pins #87 and #30.)
LIGHT AND HORN ARE ON, BUT CONTROLS WILL NOT DISENGAGE
CAUSE REMEDY
Defective override key switch .................................................... Check to insure that the switch is in the off
position and the key removed. Check for 12
volts in the control panel. If so, replace the
switch or control panel.
CAUSE REMEDY
Broken wire or bad connection .................................................. Check voltage across disconnect terminals. If
0 volts, check voltage across terminals in the
control panel. If 12 volts, replace wire. If 12
volts across disconnect, then disconnect is
defective.
Defective function disconnect .................................................... Check solenoid for function. Applying 12 volts
to disconnect, solenoid should engage with a
distinct snap. If not, the solenoid must be
replaced. If the solenoid engages, but the dis-
connect breaks under load, the spool, ball,
and case should be replaced.
Contaminated function disconnect ............................................. 1. Ensure that a drain hole is present in the end
of the rubber tube covering the solenoid.
INDEX
SECTION 6
SUBJECT PAGE
As the operator, it is your responsibility to detect any When performing maintenance on a vehicle
unusual sounds, odors or other signs of abnormal per-
ALWAYS PLACE THE SHIFT LEVER IN THE
formance that could indicate trouble ahead.
NEUTRAL POSITION, set the parkingbrakes,
By detecting any malfunctions in their early stages, you block the vehicles wheels, and NEVER work
can save yourself unnecessary downtime and your under, in front of, or in back of a vehicle when
employer a lot of money! Therefore, it is also your the engine is running.
responsibility to use good judgement in detecting
potential problems in the early stages and repairing
them quickly. If you dont, one problem may lead to The methods used to remove assemblies, guards, cab
another. panels, etc. is left to the discretion of the customer
dependent on the type of overhaul equipment and
Before attempting to make a repair, ask yourself IF you maintenance personnel at hand.
have the RIGHT TOOLS, IF you have the PROPER
TEST EQUIPMENT and IF you can accurately DIAG- Keep parts in order when large components are disas-
NOSE the cause of the malfunction. sembled, particularly so when it has a great number of
similar parts. Loosely reassemble assemblies when-
If you cant answer YES to all three questions, rely on ever possible to prevent small parts from being lost.
your distributor serviceman. He has the tools, testing Keep subassembly parts together, but be careful not to
equipment and service knowledge to pinpoint the prob- get right and left hand parts mixed up.
lem in minutes instead of the hours consumed in hit - or
- miss methods. TIME IS MONEY! He will save it for When an assembly is removed to correct only one diffi-
you. culty, it is good practice to recondition the whole
assembly at the time thus avoiding repetition of work at
If you decide to attempt a repair yourself, follow a logi- a later date.
cal TROUBLE-SHOOTING PROCEDURE. Dont sim-
ply replace parts until the trouble is found. Bolts and nuts should be placed into their respective
holes when removing guards, cases, etc. so that
Once the cause of a problem or malfunction has been proper bolt will be on hand when reassembling these
diagnosed, take the corrective action specified in this parts.
manual. Follow the procedures given for the specific
problem. If the difficulty is not covered, consult your
Distributor Serviceman.
WELDING INSTRUCTIONS
When doing repair welding on your unit take precaution Always have a fire extinguisher on hand in case of fire.
attaching your ground to the component being Adequate ventilation and dry area are necessary. Pro-
repaired. This will reduce the chance of arcing through tective clothing should be used and all persons in the
a bearing, cylinder, etc., damging the component. Paint welding area should have protection for their eyes. Fol-
should be removed from the surface to be used as the low instructions for welding and cutting on paint.
ground (earth).
AWS CLASS E7018 Low hydrogenrod for normal
repairs on low alloy to medium carbon steel. All position
welding, good penetration, and crack resisting up to
80,000 yield. Also suitable for repair of previous inter-
shield welds.
Use necessary precaution when welding around fuel
tanks, oil reservoir, batteries, tubing and pressure sys- AWS CLASS E11018G Low hydrogen rod for repair on
tems. high strength alloy steel such as T-1, 80,000 to 100,000
yield. All position welding, good penetration, and high
tensile stength up to 110,000.
When welding close to glass, cylinder rods, or any pol- Note: Low hydrogen rod E7018 must be used within
ished surface, provide adequate protection from splat- four (4) hours upon removal from a freshly
ter. opened container or from a storage oven.
OUTRIGGERS
Hose
Disconnects
Outrigger Extend
Cylinder Dead End
Wear Pad
OUTRIGGERS
Rod
BEAM EXTEND CYLINDER tain all rings, seals, spacers and setscrews required in
The outrigger beam must be removed from the crane one step are in place before proceeding to the next
and the extend cylinder removed from the outrigger step. See Group 3 of the parts book for a complete list-
beam before servicing. With the beam removed, dis- ing of cylinder parts.
connect the hydraulic hoses form the jack cylinder and
remove the extend cylinder live end pin. Remove the
cylinder from the back end of the beam.
DISASSEMBLY
Disassemble the extend cylinder by means of the fol-
lowing procedure:
ASSEMBLY
Reassemble the extend cylinder by reversing the dis-
assembly procedure. Torque the piston retaining nut to
100-150 ft. lbs.
OUTRIGGERS
JACK CYLINDERS NOTE: The hold valve cartridge does not contain any
The jack cylinders on this crane can be removed with- serviceable parts. If the hold valve cartridge is
out removing the outrigger beams. To remove the jack broken, replace the entire hold valve cartridge.
cylinders, extend the outrigger beam a few feet, dis-
connect the hydraulic hoses and remove the four bolts Replace O-rings, wear rings, seals or other compo-
retaining the jack cylinder to the outrigger beam. nents as required.
DISASSEMBLY ASSEMBLY
Disassemble the jack cylinders by means of the follow- Assemble the jack cylinder by reversing the disassem-
ing procedure: bly procedure.
1. Remove the jack cylinder from the outrigger beam. Apply Loctite to the threads of the piston retaining nut
before assembly. Torque piston retaining nut to 900 ft
2. Extend the cylinder rod far enough to allow the head lbs.
gland to be screwed out of the cylinder barrel.
As the cylinder components are reassembled, be cer-
3. Remove the head gland, piston rod and piston as a tain all rings, seals, spacers and setscrews required in
unit. Remove the lower port tube fitting before one step are in place before proceeding to the next
removing the piston from the barrel. step. See Group 3 of the parts book for a complete list-
ing of cylinder parts.
4. Remove the piston retaining nut.
5. Slide the piston and head gland off the piston rod.
OUTRIGGERS
Outrigger
Relief Valve
Test Port
Bottom This
Relief Valve
DIVERTER VALVE ADJUSTMENT NOTE: There are two relief valves shown in the
The diverter valve regulates the flow of hydraulic oil to illustration. The relief valve in the lower valve
the outrigger control and should maintain a pressure section is not used and should be deactivated
setting at 2500 psi. Check the diverter valve relief pres- by turning it in until it bottoms out. This should
sure using the following procedure: be checked prior to setting the outrigger relief
valve.
1. Operate the boom over relief to warm the oil if nec-
essary. Loosen the jam nut on the relief valve. Adjust the relief
with the adjusting screw while fully retracting and con-
2. Attach a calibrated pressure gauge in the test port. tinuing to hold an outrigger jack or beam with the
engine at full RPM. Screw in the adjustment to
NOTE: The test port is located on the outrigger diverter increase the pressure and out to decrease it. Set the
valve which is mounted on the inside of the left pressure at 2500 psi 50 psi.
frame rail just ahead of the swing bearing.
Recheck the pressure setting after tightening the jam
nut as the pressure may change due to tighten the nut.
3. Stall an outrigger function over relief by retracting
either a beam or jack and continuing to hold the
function at full engine RPM. The relief setting
should be 2500 psi 50 psi. If necessary, adjust the
relief valve.
FRONT SUSPENSION
FRONT SUSPENSION
REAR SUSPENSION
FRONT AXLE
3. Position a full-floating turning-radius gauge plate 6. Read toe-in (or toe-out) from scale. The recom-
under each wheel. Lower vehicle and remove lock mended loaded toe-in is 1/32 - 1/16.
pins from gauge plates. (If full-floating turning- NOTE: Set radial tires from 0 to 1/32.
radius gauge plates are not available, lower vehicle
and move backward and forward approximately six
feet).
REAR AXLE
1. STUD-PILOTED MOUNTING
Wheels with the stud-piloted mounting system are
called stud mount wheels. Stud mount wheels are
designed to be centered by the nuts on the studs. The
seating action of the chamfered nuts in the chamfered
bolt holes centers the wheels. (See Figure 1).
Not all nuts and studs can be used with all types of
wheels. The use of improper nuts and studs can
cause nut loosening, stud failure, or premature
wheel failure, which could cause an accident or
injury.
1. STUD-PILOTED MOUNTING (continued) - If air wrenches are used, they must be periodically
calibrated for proper torque output. Use a torque
a. Front Wheels wrench to check the air wrench output and adjust the
line pressure to give correct torque.
- Slide front wheel over studs, being careful not to dam-
age the stud threads. Snug up nuts in the sequence
shown in Figure 4. Do nut tighten them fully until all
have been seated. This procedure will permit the uni-
form seating of nuts and ensure the even, face-to-face
contact of wheels, hub, and drum. Tighten nuts to 450-
500 ft.-lbs. (dry) using the same criss-cross sequence. Nuts must be kept tight by retorquing nuts on a routine
basis and using the proper nut torque and tightening
b. Dual Rear Wheels sequence. Loose nuts could result in loose wheels or
premature wheel failure. This can result in an accident
- Slide the inner dual wheel over studs, being careful or injury.
not to damage the stud threads. Snug up the inner cap
nuts in sequence shown in Figure 4. Do not tighten
them fully until all have been seated. This procedure
will permit the uniform seating of nuts and ensure the
even face-to-face contact of wheels, hub, and drum.
Tighten to 450-500 ft.-lbs. (dry) using the same criss-
cross pattern.
- Slide the outer dual wheel over the inner cap nuts and
repeat the entire procedure except using the nut tight-
ening sequence in Figure 5. Tighten the outer cap nut
to 450-500 ft.-lbs.
Not all nuts and studs can be used with all types of
wheels. The use of improper nuts and studs can cause
nut loosening, stud failure, or premature wheel failure,
which could cause an accident or injury.
1. STUD-PILOTED MOUNTING
1. Front Wheels:
3.Tighten both inner and outer cap nuts to 450 to 500 ft.
lbs. (dry) using the sequences shown in Figures 4 & 5.
TIRES
MAINTENANCE CHECK As a part of the WEEKLY will take place as soon as driving is resumed and tire
MAINTENANCE CHECK inspect the tires and rims for failure will result.
damage. Cuts, bruises, snags, punctures, and abra-
sions should be repaired before they can cause tire fail- UNDERINFLATION Too little air pressure increases
ure. Bent, cracked, or loose rims should be repaired or deflection, causes the tread to wipe and scuff over the
replaced. road, results in extra strain on the tire, and increases
the chance for bruising.
Check tire valve condition and make sure each valve
has a cap. PROPER INFLATION Maintaining the proper air pres-
sure provides maximum road contact and results in
TIRE PRESSURES Always maintain the recom- increased tire life.
mended tire inflation pressures in all tires.
OVERINFLATION Overinflation reduces tire deflection
When driving, some increase in tire pressures can be and tire contact area, causing the tire to ride on the
expected due to heat generated by friction. Over- crown, and results in rapid wear in the center of the
speeds may also produce increased pressures. In such tread.
circumstances, NEVER BLEED THE TIRES. Instead,
slow down or stop until the tires cool. TIRE MATCHING Unmatched tires on tandem drive
units will cause tire wear and scuffing and possible
damage to the drive units. Consequently, we recom-
mend the tires be matched to within 1/8 of the same
rolling radius; 3/4 of the same rolling circumference.
HOW TO MATCH TIRES - TANDEM UNITS 4.Mount the two largest tires on one side of one axle
The vehicle should be on a level floor, carrying a cor- and mount the two smallest on the opposite side of the
rectly distributed rated capacity load. Be sure all tires same axle.
are the same tire size.
5.Mount the four other tires on the other axle in the
1.Inflate all tires to the same pressure. same manner.
2.Carefully measure the rolling circumference of each TIRE SWITCHING SEQUENCE Bias ply tires should
tire with a steel tape. be cross switched at regular intervals to attain maxi-
mum tire life.
3.Mark the size on each tire with chalk and arrange
them in order of size, largest to smallest. Refer to the tire inflation chart located in the operators
cab of the carrier.
DO DONT
1.Follow mounting and demounting procedures out- 1.Dont use mis-matched parts. Mis-matched parts are
lined in the manufacturers instruction manual or other dangerous. Make sure side ring and lock ring designa-
recognized industry instruction manual. tions match those on the base.
2.Deflate tires completely prior to demounting by 2.Do not use loads or cold inflation pressures exceed-
removing the valve core. ing rim manufacturers recommendations.
3.Replace bent, cracked, worn, corroded, or damaged 3.Dont re-inflate a tire that has been run flat or seri-
parts. ously underinflated without first demounting and
inspecting the tire and rim assembly.
4.Double check to see that removable rings are prop-
erly seated before inflating. 4.Never use tire and rim combinations that are not
approved by the Tire & Rim Association.
5.Check for excessive side ring play and ring butting.
Either one of these conditions is an indication of mis-
matched rim parts.
In warm climates a coolant based on water with corro- Refer to the topic, Corrosion Inhibitor, above, when
sion inhibitors is approved for use. Water only systems cleaning the cooling system and be certain the inhibitor
need to be treated with the proper dosage of corrosion used is compatible with the coolant.
inhibitors.
Clean any foreign matter from the radiator cooling fins
and through core cooling passages by directing com-
pressed air and flushing water over the total area of the
core in the reverse direction of normal flow.
MONTHLY:
RADIATOR EXTERIOR Clean any foreign matter from
the radiator cooling fins and through-core cooling pas-
sages by directing compressed air and flushing water
over the entire area of the core on the reverse direction
of the normal air flow.
QUARTERLY:
CORROSION INHIBITOR FILTER Replace the cooling
system corrosion inhibitor filter every 250 hours of
operation.
Proper adjustment of the L.R.C. is necessary for NOTE: Ideally, the shift arm should be adjusted 90 to
smooth shift linkage operation. Use the procedure the selection lever as described, but in some chassis
listed below to insure correct adjustment. The steps configurations, it may be necessary to index the shift
should be followed as listed to avoid confusion and pre- arm in the vertical position. This is done to prevent a
vent mistakes. shift lever jump out complaint. This type of adjustment
will cause an unequal amount of gear shift lever travel
MOVE THE INNER SHIFT FINGER between neutral and a forward lever position as com-
TO THE NEUTRAL POSITION pared to neutral and a rearward lever position.
Move gear shift lever forward or backward to the neu- Re-install the shift arm on the splines of the inner shift
tral position. shaft. You may have to move the shift arm 4 or 5
degrees to align the splines of the two parts. Disregard
Move the gear shift lever sideways, toward reverse, any movement of the gear shift lever at this point. You
until you feel resistance from the reverse plunger will adjust the gear shift lever later.
spring. DO NOT overcome the spring tension and shift
to reverse. The shift finger must remain in this position Tighten capscrew B
while you are making all the adjustments.
Re-connect pivot link assembly ball joint to selection
lever. Secure with castle nut and cotter pin.
Remove the cotter pin, castle nut, and ball joint A from
the selection lever. Do not remove the ball joint from the
pivot link.
ENGINE MAINTENANCE
As a part of each periodic check, refer to the engine FUEL FILTERS No drain cocks are provided on the
manufacturers manual for engine maintenance spin-on filters. Residue may be removed by turning off
requirements. When servicing the engine, the engine the filter and inverting it. Refill the filter with clean fuel
manufacturers recommendations take precedence oil before reinstalling or replacing with a new one.
over those in this manual, should any discrepancy be
noted. AIR CLEANER Inspect the air cleaner and it connec-
tions for leaks, dents, and damage.
DAILY:
FUEL LEVEL The fuel tank and filler pipe are located A clogged air filter restricts engine power output. Check
on the left side of the machine. The filler cap is found to see that the vacuator valve is working and is not
under an access hole on the edge of the lefthand deck- inverted, damaged, or plugged. Should dust accumu-
plate. Keep the tank as full as possible to minimize con- late in the dust cup, remove and empty it.
densation. This is extremely important in cold weather.
Should engine power output decline, check restriction
ENGINE OIL LEVEL The engine oil level is checked of the air cleaner at the restriction tap provided in the air
with the dipstick located on the right side of the engine. cleaner. Replace or clean the element only when the
Do not check the oil level while the engine is running restriction has reached the maximum allowed by the
nor immediately after stopping the engine. For accurate engine manufacturer.
readings, allow approximately 15 minutes for the oil to
drain into the sump before checking. Keep the oil level Maximum allowable restriction (in inches of water) at
as close to the full mark as possible. Do not overfill. maximum governed rpm is 25 in. (635 mm) H2O for all
engine options.
ENGINE MAINTENANCE
Do not remove the plastic fin assembly; backflowing ENGINE BELTS Check all engine belts for condition
with compressed air or washing will remove dust from and proper tension. Consult the engine manufacturers
beneath the fin assembly. manual for the recommended belt tension and tension-
ing procedures.
The primary element mat be cleaned by washing or
with compressed air. Compressed air is recommended 400 HOURS:
when the element will be re-used immediately. A FUEL FILTER ELEMENTS Remove the fuel filter cas-
washed element must be dried before re-use. However, ings and replace the filter elements every 400 hours or
washing produces better results and must be used when there is evidence of plugging.
when exhaust soot has lodged in the fine pores of the
filter media. Clean via one of the following procedures: QUARTERLY:
FUEL TANK Drain accumulated water and sediment
Washing - use Donaldson D-1400 detergent which con- from the fuel tank by removing the drain plug and allow-
tains a special additive for removing soot and carbon. ing the tank to drain until all water is removed and the
fuel flowing from the tank is free of sediment.
1. Soak the element for 15 minutes or more in a deter-
gent-water solution (see carton for instructions). If a large amount of sediment has accumulated, drain
the tank completely and flush liberally with kerosene
2. Rinse until water is clear (maximum water pressure until all the sediment has been removed. Allow the tank
40 psi). to drain completely before refilling with fuel.
SEMI ANNUALLY:
3. Air-dry or use warm flowing air (maximum 160F).
CRANKCASE BREATHER Service the crankcase
Never use compressed air or light bulbs.
breather following the procedures given in the manu-
facturers manual.
Compressed air - Direct air through the element in the
direction opposite to normal air flow through the ele-
ment. Move nozzle up and down while rotating the ele-
ment. Keep the nozzle at least one inch from the
pleated paper. To prevent damage to the element, max-
imum air pressure may not exceed 100 psi.
MONTHLY:
ENGINE OIL Change the engine oil and oil filter. Refer
to engine manufacturers manual for the type and
weight of oil recommended for the expected ambient
temperatures.
TRANSMISSION
2. Change oil and filters regularly. The operational level should always be within the limit
marks on the dipstick. The exact amount of oil depends
Use the correct grade and type of oil. on the transmission inclination and model. Insufficient
Buy oil from a reputable dealer. oil damages the pump and other components, and can
affect the function and reduce the life of the transmis-
Additives and friction modifiers are not recommended sion.
for use in Eaton Fuller Transmissions.
DO NOT OVERFILL! This causes overheating and loss
of fuel economy. When adding oil, types and brands of
1. Maintain Proper Oil Level oil should not be mixed because of possible incompati-
bility. When changing oil viscosity to Arctic oil or alter-
nate viscosity ranges, follow the recommended
transmission oil flush procedure. Use clean oil and
clean containers when filling transmission. Containers
that have been used for anti-freeze or water should not
be used for transmission oil.
Different Views of the Oil Dipstick 2. Place the transmission in the neutral position and
apply the parking brakes. Start the engine and let it
Make sure oil is within dipstick marks for the corre- idle for 5 minutes, (this allows oil to fill the converter,
sponding oil temperature. Oil should be checked at idle
main case, and cooling system), add oil as needed
speed in the neutral position using the corresponding
to obtain a level at the proper temperature range,
temperature band. Cold checks can be performed
when the oil temperature is 60-120F. The oil level (cold band under 120F, hot band between 180 and
should be within the dipstick "cold" band. Additional 220F). Total oil quantity needed at this time should
checks can be made with the transmission at operating be approximately 10 gallons this varies depending
temperature by using the "hot" band on the opposite on the cooling system.
side of the dipstick. The "hot" band temperature range
is 180-220F.
TRANSMISSION
4. Flush Procedure
5. Maintenance Interval Chart
1. Disconnect the transmission cooler supply line
between the transmission outlet and the oil cooler,
(not between the cooler and the transmission oil
pan).
2. With clean dry air from a hose and nozzle (20 psi),
use a rubber stopper or clean rag to seal the air hose
to the converter outlet hose.
TRANSMISSION
The drive train on this machine incorporates three drive the shaft to fall onto or rest on the hydraulic connec-
shafts and five universal joints: tions on the outrigger solenoid valve. If the second
shaft has been removed, remove the capscrews, lock
The front shaft extends from the transmission to a point plates, and bearing caps from the transmission end
just above and aft of the forward outrigger box. The yoke. If the second shaft is in place, remove these
shaft runs in a Hanger bearing at this point. same components from the front end yoke of the sec-
ond shaft also. Remove the front shaft with journal
The second shaft couples with the front shaft and cross(es) and remaining bearings as a unit.
extends rearward to the intermediate axle.
SLIP JOINT REMOVAL Before removing the slip joint,
The third shaft couples the two axles of the rear bogie, be certain there are arrow marks stamped on the shaft
transmitting drive from the forward driving axle to the and sleeve yoke. If the arrow marks are not readily
rear axle. seen, mark both members so that, when reassembling,
these marks can be placed in the same relative posi-
End yokes are used at all shaft ends and all couplings tion. This is extremely important because the sleeve
use bearing-cap type cross journal retainers. yoke lugs must be in the same place as the stub ball
yokes to prevent excessive vibration in operation.
UNIVERSAL JOINT DISASSEMBLY (Continued) LOCK STRAP AND CAPSCREWS - Assemble and
bend lugs of lockstrap up against the flat of capscrews.
If joint appears to bind, tap lugs lightly to relieve any
pressure on journal end bearings.
TO PREVENT DAMAGE TO THE BEARING, USE A DRIVE SHAFT INSTALLATION The installation of the
SOFT ROUND DRIFT WITH FLAT FACE AND DIAME- drive shaft into the carrier does not present any
TER ABOUT 1/32 SMALLER THAN YOKE HOLE. unusual mechanical difficulties. Before actual installa-
tion, the drive shaft should be checked for the following
items:
SLIP JOINT ASSEMBLY Lubricate the splines thor- UNIVERSAL JOINT PHASING When yokes are
oughly and assemble on the shaft. BE SURE that the assembled to their shafts in the same plane, they are in
arrows on the shaft and slip joint are in line. The sleeve phase. To obtain vibration-free operation, check the fol-
yoke must be in the same plane as the stub ball yoke lowing:
lugs to prevent excessive vibration.
1. The forward and second shafts, between the trans-
The cork washer should be replaced if necessary mission and the intermediate axle, must be assem-
before assembling with the dust cap and steel washer bled In Phase.
on the sleeve yoke.
2. The inter-axle drive shaft yokes, at the third shaft,
must be assembled In Phase.
MACHINE
REAR
MACHINE
FRONT
DAILY:
AIR TANKS Open the air tank drain cocks at least once
daily to blow out moisture and accumulated sediment.
There are five (5) tanks in the air system, all having
drain cocks on the bottom of the tank. The accessory
tank is located at the front of the machine, behind the
front outrigger. The wet tank is located just inside of the
fuel tank with the rear tank immediately behind it. The
front tank is located just inside of the hydraulic tank.
The park brake tank is located at the rear of the
machine in the center just ahead of the rear outriggers.
WEEKLY:
AIR SYSTEM SAFETY VALVE Manually actuate the
air system safety valve by pulling out the system. This
will ensure that the valve is not sticking. If the valve
cannot be actuated in this manner, it should be repaired
or replaced. The valve is located on the wet tank.
MAINTENANCE CHECK It is very important to perform SWING BEARING TORQUE PROCEDURE A number
periodic swing bearing bolt checks. The bolts MUST BE of causes can reduce tension in the bolts when torqu-
KEPT TORQUE TIGHTENED to a rating of 181 ft. lbs. ing and after use. These include rust on the threads,
dry, 137 ft. lbs. wet, using a 4 to 1 torque multiplier, or damaged or rough threads on bolts or nuts, shanks of
725 ft. lbs. dry, 550 ft. lbs. wet, without the torque multi- bolts which hang up on holes, etc. All of these causes
plier. After the first day, and again after the initial 40 have a tendency to absorb the torque when bolts are
hours of machine operation, check and tighten the being tightened.
bolts. If additional torque is required after the first 8 or
40 hours, then recheck each 8 or 40 hours until all bolts All the fasteners inside the upperstructure and the four
are found properly torqued. Thereafter, checks should outside must be checked. This includes a total of sixty-
be performed quarterly. four (64) capscrews to be checked. If ANY are found to
have loosened, ALL sixty-four (64) must be retorqued.
Bolt torques are checked by applying the stated torque
while observing to determine if the bolt breaks loose. Remember, it is important to perform periodic checks of
If it is tightened (turned) by this procedure then it has the swing bearing bolts. The bolt MUST BE KEPT
loosened and all (26) bolts must be retorqued. Refer to TORQUE TIGHTENED.
the sequence illustrated below.
RING GEAR BOLTING SEQUENCE The following equipment is required for checking swing
bearing bolt torque:
DESCRIPTION
(1) 3/4 drive ratchet head torque wrench with 200 lb.
capacity
(1) 16 extension - 3/4 drive.
(1) 8 extension - 3/4 drive.
(1) 7/8 12 pt. socket - 3/4 drive.
(1) special wrench pn. 706F8697.
(1) 4 to 1 torque multiplier.
In some applications, a standard torque wrench and When using an extension, it must be remembered that
socket cannot be fitted to the bolt(s) to be tightened the wrench torque (the actual torque reading or setting
because of restricted access. In other instances, the of the wrench) and the wrench force (the force applied
torque value specified cannot be obtained because suf- to the wrench) must be adjusted to compensate for the
ficient force cannot be applied to the standard length added length and produce the desired bolt torque.
wrench. Both of these problems may be solved ny the
use of appropriate torque wrench extensions - either Refer to the illustration and formula below when calcu-
commercially made or fabricated by the user. lating the proper adjusted values for wrench torque,
wrench force, and bolt torque.
EXAMPLE
(Assuming B = 43)
(Assuming A = 10.25)
25.800
=
53.25
SWING REDUCER
MAINTENANCE CHECKS A regular program of peri- HYDRAULIC CYLINDERS Check the cylinder mount-
odic maintenance is an essential part of continued ing brackets, bushings, and pins for wear, alignment,
hydraulic system operation. Allowing accumulations of tightness, and damage. If misalignment or excessive
moisture and sediment to build up in the system will play or wear are detected, replace the defective pin or
damage hydraulic valves, pumps, and motors. The bushing. Check the rod eye welds for cracks and
presence of leaking connections or damaged compo- breaks and have damaged welds repaired.
nents effect the efficiency of operation and are danger-
ous. The materials presented here are listed in HYDRAULIC COMPONENTS Check the hydraulic
accordance with the MAINTENANCE CHECK LIST in valves, motors, pumps, hoses, tubes, and connections
Section 4. Consideration of severe working conditions for excess dirt, oil, and grease. Clean these items if
may dictate a revision in scheduling periodic checks. necessary and check for leaks and damage. Tighten
leaky connections and repair any damaged compo-
DAILY: nents.
HYDRAULIC FLUID LEVEL The hydraulic reservoir,
fluid level indicators, and filler cap are on the right side WEEKLY:
of the machine. RETURN LINE FILTER Change the hydraulic reservoir
return line filters after the first 40 hours of the break-in
period; thereafter, follow the quarterly check recom-
mendation.
MONTHLY:
HYDRAULIC RESERVOIR Drain any accumulated
moisture from the hydraulic reservoir by parking the
machine on a slight incline and removing the plug in
the bottom of the reservoir.
Do not overfill.
PUMPS
PUMPS
TEST PROCEDURE Be sure there is an adequate sup- Many repairmen measure the output at normal operat-
ply of oil for the pump, at least one gallon of oil for each ing speed and at zero pressure, then again at 1000 psi
GPM of pump capacity. (or the operating pressure of the equipment) and allow
a volume decrease approximating the listing below. It is
If one section of a tandem pump is being tested, make a suggested reference only which makes allowance for
sure that all other sections not being tested are ade- re-used parts.
quately supplied with oil. If any of the other sections run
dry, or if plugs are left in ports, serious and permanent
damage will result. GPM DELIVERY
at 1800 rpm
120F plus or minus 5F. 100 psi 1000 psi/70 bar 2000 psi/140 bar 3000 psi/210 bar
10-30 1 1/2 - 3 2 - 3 1/2 2 1/2 - 4
30-50 2-3 2 1/2 -4 3 -4 1/2
The feed line must be of adequate size with no more 50-70 2 1/2 - 3 1/2 3-5 3 1/2 - 5 1/2
than 5 mercury vacuum adjacent to the pump inlet. As
a rule, the feed line must provide a feed flow velocity Be sure to run the pump in the direction for which it was
not in excess of 8 feet per second. designed and built. Driving pump in the wrong direction
will build up pressure behind shaft seal, damaging it
Hot oil must not be fed into a cold pump. It may seize. and necessitating replacement.
Jogging may prevent seizure.
Since it is rarely feasible to test motors on dynamome-
Operate the pump at least two minutes at zero pressure ters, the practical procedure is to test them as pumps,
and at moderate speed (not over 1500 rpm). running complete testing procedures in each direction.
If pump becomes hot to touch, it is binding and may After completing testing procedures, pump is ready for
seize. This doesnt happen very often, but if it does, installation and immediate duty operation on equip-
pump will have to be disassembled and rebuilt, with ment. Again, it must be remembered that to prevent
extra care taken to remove burrs and to assure free- seizure, hot oil must not be fed into a cold pump.
dom from binding.
VALVE ADJUSTMENTS
VALVE ADJUSTMENTS
Adjust the boom hoist relief by loosening jam lock nut 1. Attach a pressure gauge to the main winch test
on relief valve. Adjust valve with adjusting screw while port which is also used to check auxiliary winch
booming up or down over relief withe engine at maxi- pressure.
mum governed rpm. Screw in to increase pressure set-
ting; out to decrease it. Retighten lock nut when proper 2. Disconnect and plug the brake line at the piston
setting is obtained. housing of the auxiliary winch.
VALVE ADJUSTMENTS
While stalling out the swing motor with swing brake b. Operate the control valve at its extreme position
applied at maximum rpm, adjust valve with screwdriver long enough to get a pressure reading on the
until proper pressure is obtained; screwing in adjust-
gauge.
ment screw to increase pressure setting and out to
decrease it.
c. Turn the adjusting screw clockwise to increase
Retighten lock nut and replace acorn nut. pressure or counterclockwise to decrease pressure
until desired setting is obtained.
VALVE ADJUSTMENTS
RELIEF VALVE REPAIR RECOMMENDATIONS The cap, insert an allen wrench. adjust to the proper setting
cartridge type service port reliefs used in the swing while holding the outrigger in the retract position. Turn
valve are of the pilot poppet type with external adjust- in to increase pressure, out to decrease. After complet-
ment. Any malfunctioning is usually the result of foreign ing adjustment, replace cap on the relief valve.
matter lodging between the piston, relief valve poppet,
and check valve.
ROTARY MANIFOLD
ROTARY MANIFOLD
INSPECTION AND SEAL REPLACEMENT ample air space should be allowed for the
(continued) expansion of oil due to temperature changes.
REASSEMBLY
The cable and mechanical controls used on this THROTTLE CONTROL The throttle control consists of
machine are designed to require little or no adjustment. cables and clevis ends. Adjustment is dependent on
The use of standardized cable-mechanical linkage cable travel and the adjusted length of the clevis rods.
means that one adjustment procedure may be applied Adjustment is not required as long as the full range of
to several control functions. Should adjustment become engine rpm is available in response to control input.
necessary, refer to Group 28 of the Parts Book when
making them. REAR AXLE DISENGAGE No adjustments are possi-
ble. In the event of malfunction, check for electrical
continuity and air supply.
MAINTENANCE When conducting the SEMI-ANNUAL 1. With the engine ignition key in the "off" position,
MAINTENANCE CHECK, lubricate the anti-two block check that free action (no self-centering) occurs on
disconnects with SAE 30 engine oil. the boom lowering pedal, the boom telescope
lever- extended direction, and the winch lever (S) -
raising direction.
HEATER
Refer to the illustrations below when repairing the pro- heater malfunctions. If excessive repair is required,
pane heater or tracing electrical faults. See Section 5 refer to the Hunter Manufacturing Co. manual covering
for troubleshooting related to common heater Model PH-20-15A Falconaire heater.
ELECTRICAL SYSTEM
BATTERY CHECK
MAINTENANCE CHECK Observe all instruments and connection where it is grounded to the engine and the
gauges while operating machine and carrying out your positive cable to the starter relay. If the "Visual Inspec-
DAILY MAINTENANCE CHECKS. Replace or repair tion" is satisfactory, proceed to Step 2.
any malfunctioning instruments or gauges.
Step 2 - Electrolyte Levels And State Of Charge
Check the electrolyte level in the cells if possible. The
BATTERY The maintenance-free batteries are located level can be seen through translucent plastic cases. It
under the battery cover on the left-hand side of can also be checked in batteries which are not sealed.
machine. Use maintenance-free battery charging infor- If the electrolyte level is below the tops of the plates in
mation. any cell, add water if the vents are removable. If the
battery is sealed, and water cannot be added to it,
A maintenance-free battery does not require the addi- replace the battery and check the charging system for
tion of water during its life in normal service. This is due a malfunction such as a high voltage regulator setting.
to the fact that maintenance-free batteries produce little Follow instructions of manufacturer if the battery has a
special indicating device.
gas at normal charging voltages.
If the level is O.K., unknown, or water can be added to
TESTING MAINTENANCE-FREE BATTERIES
the battery, and the stabilized open circuit voltage is
below 12.4 volts, charge the battery as described
under "Charging". The voltage is stabilized if the bat-
tery has stood overnight without being charged or dis-
charged. If the battery has been on charge, the voltage
can be stabilized by placing a 15 ampere load across
the terminals for 15 seconds. Another method of stabili-
zation is to turn on the headlamps for 15 seconds.
WHENEVER THE BATTERY IS PLACED ON Read the voltage at least three minutes after the dis-
CHARGE, WEAR SAFETY GLASSES. DO NOT charge load is removed. When a hydrometer reading
BREAK "LIVE" CIRCUITS AT THE BATTERY TERMI- can be taken, a value of 1.225 @ 80F (26.7C) can be
NALS. Maintenance-free batteries of the latest design used instead of the 12.4 voltage reading. If the battery
incorporate flame arrester vents to reduce the possibil- has a test indicator, follow the instructions of the manu-
ity of explosions caused by external sparks. Therefore, facturer. After the battery is recharged, stabilize the
during charging, the vents, if removable, should remain voltage as described above, then proceed to Step 3.
in place. A wet cloth should be placed over the vent
openings as an additional precaution. If the stabilized voltage of the battery was above 12.4
volts when it was first examined, or the test indicator
Step 1 - Visual Inspection indicated the battery is charged, proceed to Step 3
without charging the battery.
Visually inspect the outside of the battery for obvious
damage such as a cracked or broken case or cover
which would allow electrolyte loss. Check for terminal
damage. If obvious physical damage is found, replace
the battery. If possible, determine the cause of damage
and correct.
ELECTRICAL SYSTEM
BATTERY CHECK
Step 3 - Load Test Procedure procedures to use and the safety precautions to take.
The load test procedure is conducted to determine if It must be realized the maintenance-free batteries can-
the battery requires recharging or replacement. not be charged at ampere rates or periods of time
greater than specified in the 12 Volt Maintenance-free
A. Disconnect the battery cables (ground connection Battery Charging Guide. If the battery is charged more
first) and connect the voltmeter and load test leads than specified, it loses water which cannot be replaced
to the battery terminals, making sure the load in some constructions so the life of the battery is short-
switch on the tester is in the OFF position. ened.
B. Apply a test load equal to 1/2 the Cold Cranking Battery chargers for maintenance-free batteries should
Amperes @ 0F (-18C) Rating of the battery, for 15 include a charge duration control of some sort. The
seconds. (Example: a battery has a Cold Cranking simplest control is a timer which the operator sets. Volt-
Rating @ 0F (118C) of 350 amperes. Use a test age controls can limit the charge more consistently and
load of 175 amperes.) accurately. Such controls also may have a safety fea-
ture that prevents sparks and reverse charging when
C. Read the voltage at 15 seconds and remove the the clamps are connected in reverse, by mistake.
load. If the voltage is less than the minimum speci-
fied in the Voltage Chart (see Maintenance-Free
Battery Testing Chart, in Troubleshooting section)
replace the battery. If the voltage meets or exceeds
the specified minimum, clean and return battery to
service.
ELECTRICAL SYSTEM
BATTERY CHECK
Always turn the charger to the OFF position before NOTE:If a battery is to be charged overnight, (16
connecting the leads to the battery. If you have any hours) a timer or voltage controlled charger is
doubts that the charger is actually OFF, disconnect it recommended. If the charger does not have
from the power source. such controls, a 3 ampere rate should be used
for batteries of 80 minutes or less capacity and
The state-of-charge of maintenance-free batteries can
5 amperes for above 80 to 125 minutes
be determined with an accurate voltmeter. A voltmeter
reserve capacity batteries. Batteries over 125
should not be used unless it can be checked frequently
against one of known accuracy. If the stabilized voltage minutes should be charged at the specified
of a battery at room temperature is 12.2. volts, it should Slow Charge rate.
be charged for one half the time shown in the Slow
Charge column of the Charging Guide, at the applica- BOOST CHARGE If a battery requires a boost charge
ble rate in amperes. If the voltage is 12.4 volts, it should to get started, it should be charged at 45 amperes for
be charged for one fourth the time shown in the Slow 20 minutes. This cannot be used for a new battery
Charge column, at the applicable charging rate. Follow being prepared for installation.
manufacturers instructions on batteries equipped with
state-of-charge indicators. MODIFIED CONSTANT POTENTIAL TAPER CHARG-
ING It is recommended that maintenance-free batteries
Any battery which is known to be discharged or has a be recharged on modified constant potential taper
stabilized voltage below 12.2 volts should be charged chargers. The total charge must not exceed the
as shown below. ampere-hour equivalent of the values shown in the
Charging Guide. It is recommended that the initial
12-VOLT MAINTENANCE-FREE BATTERY CHARG- charging rate not exceed 30 amperes.
ING GUIDE
Battery Capacity
(Reserve Minutes) Slow Charge
Above 125 to 170 20Hours @ 5 Amps
Minutes 10 Hours @ 10 Amps
ELECTRICAL SYSTEM
COLLECTOR RING
ELECTRICAL COLLECTOR RING When trouble- size, they can be broken if forced up or down.
shooting the electrical system, always check the collec- In the correctly installed position, the possibility
tor ring first to see that spring loaded brushes are of breakage is minimal.
centered in the bands. Keep free of any foreign mate-
rial.
The collector ring has a nylon bearing in the base of the
Keep the setscrews on the collector ring frame tight. assembly, eliminating the need for lubrication.
Otherwise, the wire harness may wrap up as the
machine is swung. If it should become necessary to remove the collector
ring from the machine, do so by loosening the socket
The cover should allow for free operation of the collec- screws at the base of the ring. This will allow the ring to
tor ring and the brake. If linkages bind, erratic operation be lifted off the mounting tube. When replacing it, make
may result. Check for unrestricted operation. sure these set screw, are again tightened. (Recom-
mended torque 45-55 in.-lbs.) If the set screws are not
COLLECTOR RING MAINTENANCE AND SERVICE tight, the core can turn or be held by the brushes, and
If not revolved for some time, under some conditions, twist off the core leads or center harness.
the ring will have a tendency to collect fine silt, or a salt
atmosphere will cause corrosion. If this happens, the
crane should be rotated through several revolutions, if
possible. The cleaning action of the brushes should
clean ring surfaces. If it does not, or it is not practical to
revolve the machine, it may be necessary to use a
standard non-residue solvent to clean the ring. Then
lightly sand the brushes and rings with a fine grade of
sandpaper and dust off with compressed air.
ELECTRICAL SYSTEM
VOLTMETER DIAGNOSIS
This electrical system has a voltmeter installed in it. It is used as an aid to diagnose the condition of the battery and
electrical system. The following illustrations show how the voltmeter indicates the condition of the battery, alterna-
tor, and voltage regulator and what to so to correct the condition.
ELECTRICAL SYSTEM
VOLTMETER DIAGNOSIS
HYDRAULIC CYLINDERS
Back-Up
Wear Band T Seal Rod O Ring O Ring
Buffer Seal
U Cup
Head Gland
Wiper
Bead End
Extend Port
EXTEND CYLINDER
Thread Ring
Piston
U Cup
Set Screw
Wiper
HOIST CYLINDER
HYDRAULIC CYLINDER
MAINTENANCE
HYDRAULIC CYLINDER DISASSEMBLY BOOM LIFT CYLINDER Disassemble the boom lift cyl-
inder by the following procedure:
GENERAL Refer to pages 5-37 and 5-38 for removal of
cylinders from the boom. Do not disassemble a cylinder 1. Remove the locking socket head capscrew from
unless no other maintenance procedure can correct the the draw ring. CAUTION: Failure to remove the
problem. All overhaul or new cylinder installations
locking capscrew may result in serious thread dam-
should be done in a clean, dust-free atmosphere with
age. With an adjustable spanner wrench, remove
all ports plugged until hose connections are made.
the draw ring and head gland. N0TE: One turn off,
BOOM EXTEND CYLINDERS The outer case is the back 1/3 turn, alternately.
"moving" member of the cylinder. The hollow shaft is
"stationary". The hollow shaft ports the piston and case 2. Remove the head gland, shaft, and piston from the
end to retract the cylinder while a tube within the "shaft" case.
ports the piston and head gland to extend the cylinder.
3. Remove piston and gland by removing setscrews
Disassemble the boom extend cylinders by the follow- in retaining collar and removing retaining nut.
ing procedure: Remove piston and gland from rod. Access to all
seal units is now possible.
1. Using an adjustable spanner wrench, remove head
gland of cylinder. As head gland is loosened, it may
be necessary to begin to move rod out of cylinder HYDRAULIC CYLINDER INSPECTION
tube.
Wash the cylinder bore and all the components with
2. With head gland fully disengaged, remove as an solvent and make the following inspections:
assembly, piston rod, head gland, and piston
assembly. CYLINDER BORE For signs of scoring and deep
scratches. In the event of any defects, reassemble the
3. To remove piston, remove the setscrews which entire cylinder and contact your distributor.
secure the piston retaining ring to piston rod.
CYLINDER SHAFT For dents, deep scratches, or dam-
4. Remove piston and gland which allows access to aged chrome plating. File any sharp edges on ends of
all seal units of cylinder. shaft to protect the seals upon reassembly. Always pro-
tect the shaft finish when clamping in a vice or when
welding against weld splatter.
HYDRAULIC CYLINDER
MAINTENANCE
HYDRAULIC CYLINDER REASSEMBLY BOOM EXTEND CYLINDERS With the piston, piston
rod, head gland, and retaining ring assembled as a
GENERAL As cylinder components are reassembled, unit, slide the piston into the cylinder bore. Next, insert
be certain all rings, seals, spacers and setscrews the head gland. It may be necessary to tap the gland
required in one step are in place before proceeding to into place using a wood block and hammer. In this
the next step. See Group 39 of the Parts Book for a event, cover the rod with rags or a rubber tube to pre-
complete listing of cylinder parts. vent damage from a glancing hammer blow. The head
gland is then spun in and tightened.
A teflon ring must be installed before the piston ring or
wear ring is installed since the teflon ring must first be NOTE: Apply Loctite Gr. 242 to piston retaining rings at
"walked" into the piston ring groove and then onto its assembly. Also apply to locking setscrews.
own groove. Warm the teflon ring until reasonably flexi-
ble and oil the piston ring or wear ring to aid in the On cylinders P/N 706 8584 and 706 8585 preset nylon
installation. plug with a 25 ft. lb. torque, using a Grade 8 capscrew,
and install setscrew and torque to 15 ft. lbs., three (3)
places.
MAINTENANCE All wire ropes in active service should Replace or repair any items found to be in unsatisfac-
be inspected DAILY along with spooling, sheaves, tory condition.
wedge sockets, and any other wire rope fittings for
damage. Once WEEKLY a thorough wire rope inspec- In addition to damage such as kinking, crushing, and
tion should be made by a competent inspector. A broken wires, factors such as corrosion, abrasion, pit-
record should be kept of the inspections on page 4-5. ting, peening, and scrubbing of outside wires, reduction
of rope diameter, the condition of other components
Refer to ANSI Standard B30.5 for guidelines covering and proper lubrication are considered. Refer to Section
the inspection, maintenance, repair and replacement of 9 for wire rope lubricating procedures.
wire rope. Worn, kinked, birdcaged, fatigued or other-
wise damaged wire rope must be removed immedi- Before installing a new or replacement rope, make cer-
ately. Wire rope, when properly installed, lubricated and tain the rope to be used is the proper type and size.
employed, will give many hours of satisfactory use. The wrong rope will not function properly and may
Whereas, a new piece of wire rope can be immediately even be dangerous.
ruined if misused.
CABLE REEVING When reeving the machine for any This machine incorporates a "Quick Reeving" boom
job, remember that hoisting and lowering speeds head and block which do not require removal of the
decrease as the number of parts of line increases. For wedge and socket from the rope in order to change the
the most efficient use of the machine, it is desirable to reeving. Removal of two pins in the boom head and
use the minimum number of required parts for lifting the three in the hook block will allow the wedge and socket
anticipated loads. to pass through.
NEVER USE LESS THAN THE NUMBER OF PARTS NOTE: IF A SOCKET IS CHANGED OR REPLACED,
CALLED FOR BY THE LOAD RATING CHART. THE OR IF YOU ARE CHANGING HOOK BLOCK
MINIMUM REQUIRED NUMBER OF PARTS IS WEIGHTS; IT IS IMPORTANT TO USE THE COR-
DETERMINED BY REFERRING TO THE LOAD RAT- RECT SOCKET.
ING CHART.
Care must be exercised when installing wire rope on If cable is wound from the storage reel onto the drum,
the winch drum. Improper spooling can result in rope the reel should be rotated in the same direction as the
damage through crushing, kinking, doglegs, abrasion hoist.
and cutting. Poorly installed wire rope will also
adversely affect the operating characteristics of the
machine by causing uneven application of force and
motion. This, in turn, can cause premature fatiguing
and failure of the rope.
Install cable on the winch drum in accordance with the 4. Position the anchor wedge in the drum slot; pull
following procedure: firmly on the free end of the cable to secure the
wedge.
1. Position the cable over the boom nose sheave and
route back to the winch drum. 5. Slowly rotate the drum, ensuring the first layer of
cable is evenly wound onto the drum.
2. Position the winch drum with the cable anchor slot
on top. 6. Install the remainder of cable, as applicable. The
end of the cable should be even with the bottom of
3. Insert cable through slot and position around the the anchor wedge.
cable wedge. See chart below.
NOTE: If the wedge does not seat securely in the slot,
carefully tap the top of the wedge with a mallet.
CABLE SOCKETS
CABLE SOCKETS
BOOM ADJUSTMENT
W X
A Y Z
B
C
1. Fully retract boom. (Both cylinders) that approximately 3 3/4 of threads are
showing at the outer end of the link.
2. Release all jam nuts for extend and
retract chains. (Locations A,B,C,D) 7. Cycle the internal boom cylinder in and
out several times (approximately 4-5
3. Remove outer proximity sensor located feet), then fully retract it.
on left side of 1st boom section.
8. The distance between plates Y & Z
should be between 5/16 and 7/16.
BOOM ADJUSTMENTS
W X
A Y Z
B
C
BOOM CENTERING
INDEX
SECTION 7
SUBJECT PAGE
ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
TRANSMISSION STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
RESTORATION TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Machines being placed in storage must be ade- 2. Drain and refill the swing reducer, winch(es),
quately protected from deterioration during the axle differentials, planetary hubs and the hy-
period of idleness. This will ensure that they can draulic reservoir. Refer to page 4-19 when servic-
be restored to active service with a minimum ef- ing the reservoir.
fort.
3. Distribute the new hydraulic fluid to all parts
Before removing this hydraulic crane from ser- of the system by operating all function.
vice for extended periods, it should be prepared
for storage as prescribed in the following para- 4. Clean and tape the battery cables after remov-
graphs. In general, three (3) major components ing and storing the battery.
must undergo preparation. These are the Ma-
chine Proper, the Engine and the Transmission. 5. Coat the external ring gear of the swing bearing
The specific procedure to be followed depends with oper gear lubricant.
upon the expected period of storage.
6. Fill the hydraulic reservoir to the top AFTER
THE MACHINE IS PARKED IN ITS STORAGE SPOT.
SHORT TERM STORAGE - 30 DAYS OR LESS 7. Coat wire rope with lubricant.
Short term storage requires minimal preparation.
8. Coat exposed cylinder rods with grease.
The MACHINE should be thoroughly cleaned, lu-
bricated in accordance with Section 4, and paint- The ENGINE should be prepared as prescribed
ed surfaces retouched where the paint has on page 7-2, the topic Engine Storage.
deteriorated. exposed portions of all hydraulic
cylinders should be coated with multipurpose The TRANSMISSION should be prepared as
grease. Coat unpainted metal surfaces with mul- prescribed on page 7-4, the topic Transmis-
tipurpose grease after removing any rust accu- sion Storage.
mulations.
The engine should be stored in a building which EXTENDED STORAGE (30 DAYS OR MORE)
is dry and can be heated during the winter When An Engine Is To Be Removed From Opera-
months. Moisture absorbing chemicals are avail- tion For An Extended Period Of Time,prepare It
able commercially for use when excessive damp- as follows:
ness prevails in the storage area.
1. Drain and thoroughly flush the cooling sys-
temwith clean, soft water
TEMPORARY STORAGE (30 DAYS OR LESS)
To protect an engine for a temporary period of 2. Refill the cooling system with clean, soft water.
time proceed as follows:
3. Add a rust inhibitor to the cooling system (re
1. Drain the engine crankcase. fer to page 4-7, Corrsion Inhibitor).
2. Fill the crankcase to the proper level with the 4. Remove, check and reconditon the injectors, if
recommended viscosity and grade of oil. necessary, to make sure they will be readyt to op-
erate when the engine is restored to service.
3. Fill the fuel tank with the recommended grade
of fuel oil. Operate the engine for two minutes at 5. Reinstall the injectors in the engine, time
1200 rpm and no load. them, and adjust the valve clearance.
NOTE: Do not drain the fuel system or the crank- 6. Circulate the coolant through the entire sys-
case after this run. tem by operating the engine until normal operat-
ing temperature is reached (160F. to 185F).
4. Check the air cleaner and service it, if neces-
sary as outlined under Air System. 7. Stop the engine.
5. If freezing weather is expected furing the stor- 8. Remove the drain plug and completely drain
age period, add a high boiling point type anti- the engine crankcase. Reinstall and tighten the
freeze solution in accordance with the drain plug. Install new lubricating oil filter ele-
manufacturers recommendations. Drain the ments and gaskets.
raw water system and leave the drain cocks open.
9. Fill the crankcase to the proper level with a
6. Clean the entire exterior of the engine (except 30-weight preservative lubricating oil MIL-L-
the electrical system) with fuel oil and dry it with 21260, Grade 2 (P10), or equivalent.
air.
10. Drain the engine fuel tank.
7. Seal all of the engine openings. The material
used for this purpose must be waterproof, vapor- 11. Refill the fuel tank with enough rust preven-
proof and possess sufficient physical stength to tive fuel oil such as Americal Oil Diesel Run-In
resist puncture and damage fro m the expansion Fuel (LH 4089), Mobil 4Y17, or equivalent, to en-
of entrapped air. able the engine to operate 10 minutes.
An engine prepared in this manner can be re- 12. Drain the fuel filter and strainer. Remove the
turned to service in a short time by removing the retaining bolts, shells and elements. Discard the
seals at the engine openings, checking the engine used elements and gaskets. Wash the shells in
coolant, fuel oil, lubricating oil, transmission, clean fuel oil and insert new elements. Fill the
and priming the raw water pump, if used. cavity between the element and shell about two-
thirds full of the same rust preventive compound
as used in the fuel tank and reinstall the shell.
13. Operate the engine for 5 minutes to circulate 20. Remove and clean the battery and battery ca-
the rust preventive throughout the engine. bles with a baking soda solution and rinse them
with fresh water. Store the battery in a cool (nev-
14. Refer to page 4-6 and service the air cleaner. er below 32F.) dry place. Keep the battery fully
charged .
15. With an all-purpose grease such as Shell Al-
vania No. 2, or equivalent, lubricate the clutch 21. Insert heavy paper strips between the pulleys
throwout bearing, clutch pilot bearing, drive and belts to prevent sticking.
shaft main bearing, clutch release shaft, and the
outboard bearings (if so equipped). 22. Seal all of the openings in the engine, includ-
ing the exhaust outlet, with moisture resistant
16. Remove the inspection hole cover on the tape. Use cardboard, plywood or metal covers
clutch housing and lubricate the clutch release where practical.
lever and link pins with a hand oiler. Avoid get-
ting oil on the clutch facing. 23. Clean and dry the exterior painted surfaces of
the engine. Spray the surfaces with a suitable liq-
17. Apply a non-friction rust preventive com- uid automobile body wax, a synthetic resin var-
pound, to all exposed parts. If it is convenient, nish or a rust preventive compound.
apply the rust preventive compound to the engine
flywheel. If not, disengage the clutch mechanism 24. Cover the engine with a good weather-resis-
to prevent the clutch disc from sticking to the fly- tant tarpaulin or other cover if it must be stored
wheel. outdoors. A clear plastic cover is recommended
for indoor storage.
1. Remove the valve rocker cover(s) and pour at 14. After all of the preparations have been com-
least one-half gallon of oil, of the same grade as pleted, start the engine. The small amount of
used in the crankcase, over the rocker arms and rust preventive compound which remains in the
push rods. fuel system will cause a smoky exhaust for a few
minutes.
2. Reinstall the valve rocker cover(s).
NOTE: Before subjecting the engine to a load or
3. Remove the covers and tape from all of the high speed, it is advisable to check the engine
openings of the engine, fuel tank, and electrical tune-up.
equipment. Do not overlook the exhaust outlet.
4. Wash the exterior of the engine with fuel oil to TRANSMISSION STORAGE
remove the rust preventive.
8. Fill the fuel tank with the fuel specified under STORAGE NEW UNITS
Diesel Fuel Oil Specifications. New units contain preservative oil when shipped
for Funk and can be safely stored for 6 weeks
9. Close all of the drain cocks and fill the engine without further treatment. Refer to the Funk
cooling system with clean soft water and a rust Transmission manual for additional information.
inhibitor. If the engine is to be exposed to freezing
temperatures, add a high boiling point type anti-
freeze solution to the cooling system (the anti- STORAGE, 30 DAYS TO 1 YEAR - WITHOUT
freeze contains a rust inhibitor). OIL
11. Service the air cleaner as outlined under Air 2. Seal all openings and breathers, except oil
System. drain hole, with moisture-proof cover or tape.
12. Prepare the generator for starting. 3. Coat all exposed, unpainted surfaces with Nox
Rust X-110.
5. If additional storage time is required, (3) and Refer to page 7-4, Restoring Engine to Service,
(4) above should be repeated at yearly intervals. and page 7-5 and 7-6, Restoring Transmission
to Service, for the procedures required to restore
these components to service.
*Nox Rust is a preservative additive manufac-
tured by the Daubert Chemical Company, Chi- Remove the MACHINE from storage via the fol-
cage, Illinois. Motorstor is covered by US lowing procedure:
Military Specifications MIL-L-46002 (ORD)
and MIL-1-23310 (WEP). 1. Remove preservative lubricants from all sur-
faces.
RESTORING TRANSMISSION TO SERVICE 2. Check all fluid levels, adding or draining as re-
quired.
1. If Nox Rust, or equivalent, was used in prepar- 3. Lubricate the machine according to Section 9,
ing the transmission for storage, use the follow- making certain that all points with grease fittings
ing procedures to restore the unit to service. are lubricated.
2. Remove the tape from openings and breather. 4. Make a thorough visual inspection of the entire
machine, placing special emphasis on the condi-
3. Wash off all the external grease with solvent. tion of all hydraulic hoses.
8. Drain oil.
CHROME CYLINDER ROD STORAGE 4. Inspect the cylinder rod surfaces and reapply
at three to six month intervals.
INDEX
SECTION 8
SUBJECT PAGE
CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
CONVERSION TABLES
8-1
GENERAL INFORMATION
SURVEYORS MEASURE
8-2
GENERAL INFORMATION
Sand or Gravel 60
MASONRY Sand or Gravel & Clay 65
Clayt 80
Ashlar Masonry * 143-162 River Mud 90
Rubble Masonry * 137-156 Soil 70
Dry Rubble Masonry * 110-130 Stone Riprap 65
*Granite, Syenite, Gneiss, Marble,
Limestone, Sandstone, Bluestone
Brick Masonry 103-128 STONE, QUARRIED, PILED
Concrete Masonry 100-128
Portland Cement 196 Basalt, Granite, Gneiss 96
Portland Cement, Loose 94 Limestone, Marble, Quartz 95
Lime, Gypsum, Loose 53-64 Sandstone 82
Mortar, Lime, Set 103 Shale 92
Greenstone, Hornblend 107
WOOD
MISCELLANEOUS
Cedar 22
Fir, Douglas 32 Water, 4 C. 62.4
Oak 42-54 Water, 100 C. 59.8
Pine, Oregon 32 Paper 58
Pine, Southern 38-42 Glass, Common 162
Redwood 2 Petroleum 45-54
Spruce 28 Coal, Anthracite 47-5
Black Walnut 37 Coal, Bituminous 40-54
Coal, Coke 23-32
8-3
GENERAL INFORMATION
TORQUE RATINGS
ES - 100.0
TORQUE RATINGS
FOR
DRY - UNCOATED FASTENERS
8-4
GENERAL INFORMATION
TORQUE RATINGS
ES - 100.1
TORQUE RATINGS
FOR
LUBRICATED OR PLATED FASTENERS
5/16 9 -*5 14 20
3/8 16 - * 9 25 35
7/16 25 - * 15 40 55
1/2 40 - * 20 60 85
9/16 55 - * 30 85 120 GRADE 2
5/8 75 - * 45 120 170
3/4 135 - * 80 210 300
7/8 130 340 485
1 200 515 720 GRADE 5
1-1/8 280 635 1,030
1-1/4 400 890 1,450
1-3/8 520 1,175 1,900
1-1/2 695 1,560 2,530
GRADE 8
1-3/4 1,100 1,825 3,980
2 1,650 2,750 6,000
2-1/4 2,400 4,000 8,760
2-1/2 3,300 5,500 12,000
The above information was compiled for U.N.C. Threaded Fasteners.
8-6
GENERAL INFORMATION
8-7
GENERAL INFORMATION
8-8
GENERAL INFORMATION
8-9
WIRE ROPE USERS MANUAL
INDEX
SECTION 9
SUBJECT PAGE
The publication of the material contained herein is not intended as a warranty on the
part of American Iron and Steel Institute-or that of any person named herein-that these
data are suitable for any general or particular use, or of freedom from infringement of
any patent or patents. Any use of these data or suggested practices can only be made
with the understanding that American iron and Steel Institute makes no warranty of
any kind respecting such use and the user assumes all liability arising therefrom.
2
CONTENTS
1. INTRODUCTION / 5
2. BASIC COMPONENTS / 7
3. WIRE ROPE INDENTIFICATION AND CONSTRUCTION / 9
4. HANDLING WIRE ROPE / 17
3
3 Wire Rope Identification and Construction
Wire rope is identified not only by its component parts, but also by its construction,
i.e. by the way the wires have been laid to form strands, and by the way the strands
have been laid around the core.
In Figure 3, drawings a and c show strands as normally laid into the
rope to the right-in as fashion similar to the threading in a right-hand bolt. Con-
versely, the left lay rope strands (drawings b and d) are laid in the opposite
direction.
Again in Figure 3, the first two drawings (a and b) show regular lay
ropes. Following these are the types known as lang lay ropes. Note that the wires
in regular lay ropes appear to line up with the axis of the rope; in lang lay rope the
wires form an angle with the axis of the rope. This difference in appearance is a
result of variations in manufacturing techniques: regular lay ropes are made so that
the direction of the wire lay in the strand is opposite to the direction of the strand lay
in the rope; lang lay ropes (c and d) are made with both strand lay and rope lay
in the same direction. Finally, the type e called alternate lay consists of alternat-
ing regular and lang lay strands.
Figure 3. A comparison of typical wire rope lays: a) right regular lay, b) left regular lay,
c) right lang lay, d) left lang lay, e) right alternate lay.
9
Wire rope nomenclature also defines: length, size (i.e., diam.), type, direction
of lay, grade of rope, type of core and whether it is preformed (p/f) or non-preformed
(np/f.) If the direction and type of lay are omitted from the rope description, it is pre-
sumed to be right regular lay. In addition, if no mention is made as to preforming, this
will be presumed as a requirement for preforming. On the other hand, an order of ele-
vator rope requires an explicit statement since p/f and np/f ropes are used extensively.
An example of a complete description would appear thus:
Classification Description
13
WIRE ROPE INSTALLATION
CHECKING THE DIAMETER
It is most important to check the diameter of the delivered rope before installation.
This is to make certain that the rope diameter meets the specified requirements for
the given machine or equipment. With an undersize diameter rope, stresses be
increased; an oversize diameter rope will wear out prematurely. This happens
because of abuse to the rope caused by pinching in the grooves of the sheave and
drum.
In checking, however, the true rope diameter must be measure. And this
is defined as the diameter of the circumscribing circle, i.e., its largest cross-sectional
dimension. To insure accuracy this measurement should be made with a wire rope
caliper using the correct method (b) shown in Fig. 11. For measuring ropes with an
odd number of outer strands, special techniques must be employed.
Design specifications for wire rope are such that the diameter is slightly
larger than the nominal size, according to the allowable tolerances shown in Table 3.
TABLE 3
OVERSIZE LIMITS OF WIRE ROPE DIAMETERS*
UNREELING AND UNCOILING
Wire rope is shipped in cut lengths, either in coils or on reels. Great care should be taken
when the rope is removed from the shipping package since it can be permanently damaged
by improper unreeling or uncoiling. Looping the rope over the head of the reel or pulling
the rope off a coil while it is lying on the ground, will create loops in the line. Pulling on
a loop will, at the very least, produce imbalance in the rope and may result in open or
closed kinks (Fig. 12). Once a rope is kinked, the damage is permanent. To correct this
condition, the kinks must be cut out, and the shortened pieces use for some other purpose.
Unwinding wire rope from its reel also requires careful and proper procedure.
There are three methods to perform this step correctly:
1) The reel is mounted on a shaft supported by two jacks or a roller payoff (Fig.
13). Since the reel is free to rotate, the rope is pulled from the reel by a work-
man, holding the rope end and walking away from the reel as it unwinds. A
braking device should be employed so that the rope is kept taut and the reel is
restrained from over-running the rope. This is necessary particularly with
powered de-reeling equipment.
2) Another method involves mounting the reel on an unreeling stand (Fig.14). It
is then unwound in the same manner as described above (1). In this case,
however, greater care must be exercised to keep the rope under tension suffi-
cient to prevent the accumulation of slack-a condition that will case the rope
to drop below the lower reel head.
3) In another accepted method, the end of the rope is held while the reel itself is
rolled along the ground. With this procedure the will pay off properly; how-
ever, the end being held will travel in the direction the reel is being rolled. As
the difference between the diameter of the reel head and the diameter of the
bound rope increases, the speed of travel will increase.
When re-reeling wire rope from a horizontally supported reel to a drum, it is
preferable for the rope to travel from the top of the reel to the tope of the drum;
or, from the bottom of the reel to the bottom of the drum (Fig. 15). Re-reeling
in this manner will avoid putting a reverse bend into the tope as it is being
installed. If a rope is installed so that a reverse bend is induced, it may cause
the rope to become livelier and, consequently, harder to handle.
When unwinding wire rope from a coil, there are two suggested methods for
carrying out this procedure in a proper manner:
1) One method involves placing the coil on a vertical unreeling stand. The stand
consists of a base with a fixed vertical shaft. On this shaft here is a swift,
consisting of a plate with inclined pins positioned so that the coil may be place
over them. the whole swift and coil then rotate as the rope is pulled off. This
method is particularly effective when the rope is to be wound on a drum.
2) The most common as well as the easiest uncoiling method is merely to hold one
end of the rope while rolling the coil along the ground like a hoop (Fig. 16).
Figures 17 and 18 show unreeling and uncoiling methods that are most likely
to provide kinks. Such improper procedure should be strenuously avoided in
order to prevent the occurrence of loops. These loops, when pulled taut, will
inevitably result in kinks. No matter how a kink develops, it will damage
strands and wires, and the kinked section must be cut out. Proper and careful
handling will keep the wire rope free kinks.
SEIZING WIRE ROPE
While there are numerous ways to cut wire rope, in every case, certain precautions
must be observed. For one thin, proper seizings are always applied on both sides
of the place where the cut is to be made. In a wire rope, carelessly or inade-
quately seized, ends may become distorted and flattened, and the strands may
loose. Subsequently, when the rope is put to work, there may be an uneven distri-
bution of leads to the strands; a condition that will significantly shorten the life of
the rope.
There are two widely accepted methods of applying seizing (Figure 19). The
seizing itself should be a soft, or anncaled wire or strand. The seizing wire diam-
eter and the length of the seizing should never be less than the diameter of the
rope being seized. For preformed ropes, one seizing on each side of the cut is nor-
mally sufficient. But for those that are not preformed, a minimum of two seizings
is recommended (Fig 20). Seizings should be spaced 6 rope diameters apart.
Table 4 list seizing lengths and seizing wire diameters suggested for use with
some commonly use wire ropes.
TABLE 4 SEIZING
Suggested Diameters and Lengths
23
CUTTING WIRE ROPE
Wire rope is cut after being properly seized (Fig. 20). Cutting is a reasonably
simple operation provided appropriate tools are used. There are several types of
cutters and shears commercially available. There are specifically designed to cut
wire rope.
Portable hydraulic and mechanical rope cutters are available. In remote areas,
however, it may at times be necessary to use less desirable cutting methods. For
example, using an axe or hatchet must be recognized as dangerous.
TABLE 5 TERMINAL EFFIECIENCIES (APPROXIMATE)
Efficiencies are based on nominal strengths
SOCKETING
Improperly attached wire rope terminals lead to serious-possibly unsafe- condi-
tions. To perform properly, all wire rope elements must be held securely by the
terminal. If this is not accomplished, the strands will loaf on the job and there
is every likelihood that a strand will become high. A high strand condition is
illustrated in Figure 42. In the case shown, selective abrasive wear of the loose
strand will necessitate early removal of the rope.
Poured Sockets-Spelter or Resin
When preparing a wire rope for socketing, it is of extreme importance to follow
recommended procedures. (See Appendix D: SOCKETING PROCEDURES.)
Procedures other than those stipulated here, may develop the required strength but
this cannot be pre-determined without destructive test. It is far safer-and ulti-
mately less costly-to follow well-established practices.
There are many ways to go wrong in socketing procedures. Some of the more
common pitfalls that should be guarded against include:
1) Turning back the strands-inward or outward-before the broom is inserted
into the socket;
2) Turning back the strands and seizing them to the body of the rope:
3) Turing back the strands and tucking them into the body of the rope:
4) Tying the knot in the rope:
5) Driving nails, spikes, bolts, and similar objects into the socket after the rope is
in, so as to jam it tight; this is particularly dangerous-and ruinous.
To avoid these and many other dangerous practices, play it safe by following cor-
rect procedures.
28
4) NOTICE! Apply the initial load and retighten nuts to the recommended
torque. Rope will stretch and shrink in diameter when loads are applied. Inspect
periodically and retighten.
A termination made in accordance with the above instructions, and using the
number of clips shown has an approximate 80% efficiency rating. This rating is
based upon the catalog breaking strength of wire rope If a pulley is using in place
of a thimble for turning back the rope, add one additional clip.
The number of clips shown is based upon using right regular or lang lay wire
rope, 6 x 19 class or 6 x 37 class, fiber core or IWRC, IPS or XIPS. If Seale con-
struction or similar large outer wire type construction in the 6 x 19 class is to be
used for sizes 1 inch and larger, add one additional clip.
The number of clips shown also applies to right regular lay wire rope, 8 x 19
class, fibre core, IPS, sizes 1 1/2 inch and smaller; and right regular lay wire rope,
18 x 7 class, fibre core, IPS or XIPS, sizes 1 3/4 and smaller.
For other classes of wire rope not mentioned above, it may be necessary to
add additional clips to the number shown.
If a greater number of clips are used than shown in the table, the amount of
rope turnback should be increased proportionally. ABOVE BASED ON USE OF
CLIPS ON NEW ROPE
29
FIST GRIP CLIPS (Table 7, on the following page)
31
32
WEDGE SOCKETS
One of the more popular end attachments for wire rope is the wedge socket. For
field, or on the job attachment, it is easily installed and quickly dismantled. The
procedure is simple:
1) Inspect the wedge and socket; all rough edges or burrs, that might damage the
rope, should be removed.
2) If the end of the rope is welded, the welded end should be cut off. This will
allow the distortions of the rope strands, caused by the sharp bend around the
wedge, to adjust themselves at the end of the line. If the weld is not cut off,
the distortions will be forced up the working line. This may result in the
development of high strands and wavy rope.
3) Place the socket in an upright position and bring the rope around in a large,
easy to handle, loop. Care must be taken to make certain hat the live-loaded-
side of the rope is in line with the ears (Fig. 25).
4) The dead end of the rope should extend from the socket for a distance approx-
imately nine times the rope diameter. The wedge is now place in the socket,
and a wire rope clip is placed around the dead end by clamping a short, extra
piece of rope to the tail. (Do not clamp to the live part.) The U-bolt should
bear against the tail; the saddle of the clip should bear against the sort extra
piece.
5) Secure the ears of the socket to a sturdy support and carefully take a strain on
the live side of the rope. Pull the wedge and rope into position with tension
sufficiently right to hold them in place.
6) After final pin connections ar mad, increase the loads gradually until the
wedge is properly seated. Avoid sudden shock loads.
The foregoing is the recommended procedure. If variations are made to suit
special conditions, they should be carefully evaluated beforehand.
Paragraph 4, page 33, cites one method used to clamp the rope dead end. Two
other acceptable methods are shown below. Method 3 can be used if the length of
the thread on the U bolt legs will allow the saddle to firmly clamp one diameter of
rope.
The purpose of clamping the dead end close to the socket is to prevent the rope
and wedge from disengaging from the socket.
33R
DRUMS-GROOVED
Drums are the means by which power is transmitted to the rope and thence to the
object to be moved For the wire rope to pick up this power efficiently and to
transmit it properly to the working end, installation must be carefully controlled.
If the drum is grooved, the winding conditions should be closely supervised
to assure adherence to the following recommended procedures;
1) The end of the rope must be secured to the drum by such means as will give
the end attachment at least as much strength as is specified by the equipment
manufacturer.
2) Adequate tension must be maintained on the rope while it is being wound so
that the winding proceeds under continuous tension.
3) The rope must follow the groove.
4) There should be at least three dead turns remaining on the drum when the rope
is unwound during normal operation Two dead turns are a mandatory require-
ment in many codes and standards.
If the wire rope is carelessly wound and, as a result, jumps the grooves, it
will be crushed and cut where it crosses from one groove to the other. Another,
almost unavoidable problem is created at the drum flange; as the rope climbs to a
second layer there is further crushing and the wires receive excessive abrasion.
Riser and filler strips may help remedy this condition.
34
DRUMS-PLAIN (SMOOTH)
Installation of a wire rope on a plain (smooth) face drum requires a great deal
of care. The starting position should be at the drum end so that each turn of the
rope will wind tightly against the preceding turn (Fig.26). Here too, close
supervision should be maintained all during installation. This will help make
certain that:
1) the rope is properly attached to the drum,
2) appropriate tension on the rope is maintained as it is wound on the drum,
3) each turn is guided as close to the preceding turn as possible, so that there
are no gaps between turns,
4) and that there are at least two dead turns on the drum when the rope is fully
unwound during normal operating cycles.
The term flexibility is frequently thought of as being synonymous with resis-
tance to bending fatigue. This is not true. Flexibility refers to the capability of
flexing or bending. While a high degree of fatigue resistance may sometimes
accompany the flexibility characteristic, it does not necessarily follow that this is
so. A fiber core rope, for example, is more flexible than an IWRC rope. Yet,
when the IWRC rope is bent around undersize sheaves at relatively high loads, it
will usually perform better than the more flexible fiver core rope. The reason for
lies in the ability of IWRC rope to retain its roundness nd freedom of internal
movement. Under the same conditions, a fiber ore rope will flatten and inhibit
free internal adjustment, thereby leading to early failure.
As note earlier, a design choice is almost invariably the result of compromise.
Ultimately, what is sought is an efficient, economical solution, hence whatever the
compromise, it must help achieve this goal.
45
If the fleet angle (Fig. 34) is large, it may be necessary to accept a smaller arc
of contact at the throat; 130 for example instead of 150. This is done to avoid
scrubbing the rope on the flange of the sheave.
As previously noted, the groove size is evaluated on the basis of how the gage
leaf fits the groove. Daylight under the gage is not tolerable when using the worn
groove gage. If a full over-size gage is used, some daylight may be acceptable,
but really must be judged by relating the measurement to the actual size of the
rope.
For new rope, extra caution should be observed as to its fit in the groove.
Characteristically, ropes become smaller in diameter immediately after being
placed in service. As a result, they would operated satisfactorily in a worn
groove; one that was gage OK by the worn groove gage. Nonetheless, in some
cases, a rope may not pull down, and it this happens, abnormal wear may occur.
It is important to remember that a tight groove not only pinches and damages
the rope but that the inching prevents the necessary adjustment of the wires ann
strands. On the other hand, a groove that is too large will not provide sufficient
support; in this case, the rope will flatten and thereby restrict the free sliding
action of the wires and strands.
The size of the groove is not only critical item to be examined closely. The
condition of the groove is also an important factor of concern. Is it smooth or
imprinted? If the groove is imprinted then it must be re-machined or, if it is
imprinted too deeply, it means that sheave, roller or drum must be replaced. If
replacement is indicated, a larger sheave or drum should be installed if possible,
or a harder material should be specified for the replacement.
Groove examination should also concern itself with how the groove is wear-
ing. If it is worn off-center, thereby forcing the rope to undercut or to rub against
the flange, it then becomes necessary to correct the alignment of the reeving sys-
tem, and to specify a harder material.
When checking the grooves, the bearings of the sheaves and rollers should
also be examined. They should turn easily. If not, each bearing must be properly
lubricated. Wobble in the sheave-from broken or worn bearings-is not accept-
able. Bad bearings will set up vibrations in the wire rope that can cause rapid
deterioration unless the condition is remedied. Bad bearings also increase the
force on the rope that is needed to move a given load, since friction forces will e
greatly increase.
Sheaves with broken flanges may allow the rope to jump from the sheave and
become fouled in the machinery. When this happens, the rope is cut, curled, and
the crowns of the wires in the strands are burred. There is ample evidence to sup-
port the rule that sheaves with broken flanges must be replaced immediately.
A sheave or drum with a flat spot can induce a whip into the line. This
whip, or wave, travels until is stopped by the end terminal, at which point the rope
may bend severely. This condition helps to accelerate the fatigue breakage of
wires. Sometimes the reeving is such that the whip or wave is arrested by a
sheave, or the drum itself. In these circumstances, the whipping will cause wire
breaks along the crowns of the strands. Obviously sheaves or drums that excite
vibrations of this sort, must be repaired or replaced.
46
GUIDELINE TO INSPECTIONS AND REPORTS FOR EQUIPMENT,
WIRE ROPE AND WIRE ROPE SLINGS
1) Maintain all inspection records and reports for the length of time deemed
appropriate.
2) Prior to each daily use, the following procedure should be followed.
a. Check all equipment functions.
b. Lower load blocks and check hooks for deformation or cracks.
c. During lowering procedure and the following raising cycle, observe the
rope and the reeving. Particular notice should be paid to kinking twisting
or other deformities. Drumwinding conditions should also be noted.
d. Check wire rope and slings for visual signs of anything that can cause them
to be unsafe to use, i.e., broken wires, excessive wear, kinking or twisting,
and marked corrosion. Particular attention should be give to any new dam-
age during operation.
3) Monthly inspections are recommended with a signed report by an authorized
competent inspector. The Monthly Reports should include inspection of the
following:
a. All functional operating mechanisms for excessive wear of components,
brake system parts and lubrication.
b. Limit switches.
c. Crane hooks for excess throat opening or twisting along with a visual for
cracks.
d. Wire rope and reeving for conditions causing possible removal.
e. Wire rope slings for excessive wear, broken wings, kinking, twisting and
mechanical abuse.
f. All end connections such as hooks, shackles, turnbuckles, plate clamps,
sockets, etc. for excessive wear, and distortion.
4) An Annual Inspection with signed report must be made for the following:
a. Crane hook for cracks.
b. Hoist drum for wear or cracks.
c. Structural members for cracks, corrosion and distortion.
d. For loose structural connections such as bolts, rivets, and weldments.
52
2) Rope Stretch
All ropes will stretch when loads are initially applied. For an extended discus-
sion of stretch, see pp. 73 and following:
As rope deteriorates from wear, fatigue, etc. (excluding accidental dam-
age), continued application of a load of constant magnitude will produce vary-
ing amounts of rope stretch. A stretch curve plotted for stretch vs. time (Fig.
35) displays three discrete phases:
Phase 1. Initial stretch, during the early (beginning) period of rope service,
caused by the rope adjustments to operating conditions (constructional stretch).
Phase 2. Following break-in, there is long period-the greatest part of the ropes
service life-during which a slight increase in stretch takes place over an
extended time. This results from normal wear, fatigue, etc. On the plotted
curve-stretch vs. time-this portion would almost be horizontal straight line
inclined slightly upward from its initial level.
Phase 3. Thereafter, the stretch begins to increase at a quicker rate. This
means that the rope is reaching the point of rapid deterioration; as result of pro-
longed subjection to abrasive wear, fatigue, etc. This second upturn of the
curve is a warning indicating that the rope should soon be removed.
53
3) Reduction in rope diameter
Any marked reduction in rope diameter indicates degradation. Such reduction
may be attributed to:
excessive external abrasion
internal or external corrosion
loosening or tightening of rope lay
inner wire breakage
rope stretch
ironing or milking of strands
In the past, whether or not a rope was allowed to remain in service
depended to a great extent on the ropes diameter at the time of inspection.
Currently this practice has undergone significant modification.
Previously, a decrease in the ropes diameter was compared with pub-
lished standards of minimum diameters. The amount of change in diameter is,
of course, useful in assessing a ropes condition. But, comparing this figure
with a fixed set of values is for the most part useless. These long-accepted
minima are not, in themselves, of any serious significance wince they do not
take into account such factors as: 1) variations in compressibility between
IWRC and Fiber Core: 2) differences in the amount of reduction in diameter
from abrasive wear, or from core compression, or combination of both; and 3)
the actual original diameter of the rope rather than its nominal value.
As a matter of fact, all ropes will show a significant reduction in diame-
ter when a load is applied. Therefore, a rope manufactured close to tis nomi-
nal size may, when it is subjected to loading, undergo a greater reduction in
diameter than that stipulated in the minimum diameter table. Yet, understand
these circumstances, the rope would be declared unsafe although it may, in
actuality, be safe.
As an example of the possible error at the other extreme, we can take
the case of a rope manufactured near the upper limits of allowable size. If the
diameter has reached a reduction to nominal or slightly below that, the tables
would show this rope to be safe. But it should, perhaps, be removed.
Today, evaluations of the rope diameter are first predicated on a com-
parison of the original diameter-when new and subjected to a known load-
with the current reading under like circumstances. Periodically, throughout
the life of the rope, the actual diameter should be recorded when the rope is
under equivalent loading and in the same operating section. This procedure, if
followed carefully, reveals a common rope characteristic: after an initial
reduction, the diameter soon stabilizes. Later, there will be a continuous,
albeit small, decrease in diameter throughout its life.
Core deterioration, when it occurs, is revealed by a more rapid reduction
in diameter and when observed it is time for removal.
Deciding whether or not a rope is safe is not always a simple matter. A
number of different but interrelated conditions must be evaluated. It would be
54
dangerously unwise for an inspector to declare a rope safe for continued ser-
vice simply because its diameter had not reached the minimum arbitrarily
established in a table if, at the same time, other observations lead to an oppo-
site conclusion.
Because criteria for removal are varied, and because diameter, in itself, is
a vague criterion, the table of minimum diameters has been deliberately omit-
ted from this manual.
4) Corrosion
Corrosion, while difficult to evaluate, is a more serious cause of degradation
than abrasion. Usually, it signifies a lack of lubrication. Corrosion will often
occur internally before there is any visible external evidence on the rope sur-
face. Pitting of wires is a cause for immediate rope removal. Not only does it
attack the metal wires, but it also prevents the ropes component parts from
moving smoothly as it is flexed. Usually, a slight discoloration because of
rusting merely indicates a need for lubrication.
Severe rusting, on the other hand, leads to premature fatigue failures in the
wires necessitating the ropes immediate rope removal from service. When a
rope shows more than one wire failure adjacent to a terminal fitting, it should
be removed immediately. To retard corrosive deterioration, the rope should be
kept well lubricated. In situations where extreme corrosion action can occur,
it may be necessary to use galvanized wire rope.
5) Kinks
Kinks are permanent distortions cause by loops drawn too tightly. Ropes with
kinks must be removed from service.
6) Bird Caging
Bird caging results from torsional imbalance that comes about because of
mistreatments such as sudden stops, the rope being pulled through tight
sheaves, or wound on too small a drum. This is cause for rope replacement
unless the affected portion can be removed.
7) Localized Conditions
Particular attention must be paid to wear at the equalizing sheaves. During
normal operations this wear is not visible. Excessive vibration, or whip can
cause abrasion and/or fatigue. Drum cross-over and flange point areas must
be carefully evaluated. All end fittings, including splices, should e examined
for worn or broken wires, loose or damaged strands, cracked fittings, worn or
distorted thimbles and tucks of strands.
8) Heated Damage
After a fire, or the presence of elevated temperatures, there may be metal dis-
coloration, or an apparent loss of internal lubrication; fiber core ropes are par-
ticularly vulnerable. Under these circumstances the rope should be replaced.
9) Protruding Core
If, for any cause, the rope core protrudes from an opening between the strands
the rope is unfit for service.
55
10) Damaged End Attachments
Cracked, bent, or broken end fittings must be eliminated. The cause should
be sought out and corrected. In the case of bent hooks, the throat openings-
measured at the narrowest point-should not exceed 15% over normal not
should twisting be greater than 10.
11) Peening
Continuous pounding is one of the causes of peening. The rope strikes
against an object such as some structural part of the machine, or it beats
between the rope and the object it is striking. Another common cause of
peening is continuous passage-under high tension-over a sheave or drum.
Where peening action cannot be controlled, it is necessary to have more fre-
quent inspections and to be ready for earlier rope replacement.
Figure 36 shows the external appearance of two ropes, one of which has
been abraded and the other peened. Also shown are the cross-section of both
wires in these conditions.
12 Scrubbing
Scrubbing refers to the displacement of wires and strands as a result of rub-
bing around or against an object. This, in turn, causes wear and displacement
of wires and strands along one side of the rope. Corrective measures should
be taken as soon as this condition is observed.
13) Fatigue Failure
Wires that break with square ends and show little surface wear, have usually
failed as a result of fatigue. Such failures can occur on the crown of the
strands, or in the valleys between the strands where adjacent strand contact
exists. In almost all cases, these failures are related to bending stresses or
vibration.
If the diameter of the sheaves, rollers or drum cannot be increased, a more
flexible rope should be used. But, if the rope in use is already of maximum
flexibility, the only remaining course that will help prolong its service life is
to move the rope through the system, the fatigued sections are moved to less
fatiguing areas of the reeving. This technique is most frequently used in
rotary drilling.
14) Broken Wings
The number of broken wires on the outside of a wire rope are 1) an index of its
general condition, and 2) whether or not it must be considered for replace-
ment. Frequent inspection will help determine the elapsed time between
breaks. Ropes should be replaced as soon as the wire breakage reaches the
numbers give in Table 13. Such action must be taken without regard to the
type of fracture.
On occasion, a single wire will break shortly after installation. However, if no
other wires break at that time, there is no need for concern. On the other hand,
should more wires break, the cause should be carefully investigated.
On any installation, valley breaks-i.e., where the wire ruptures between
strands-should be given serious attention. When two or more such conditions are
found, the rope should be replaced immediately.
It is well to remember that once broken wires appear-in normal rope operating
under normal conditions-a good many more will show up within a relatively short
period. Attempting to squeeze the last measure of service from a rope beyond the
allowable number of broken wires (Table 13), will create an intolerably hazardous
situation.
A diagnostic guide to some of the most prevalent rope abuses is given in Table
14. On the following pages these abuses are illustrated and described.
57
TABLE 14 DIAGNOSTIC GUIDE TO COMMON WIRE ROPE ABUSES
Fatigue Wire break is transverse-either straight across Check for rope bent around too small a radius;
or Z shape. Broken ends will appear grainy. vibration or whipping; wobbly sheaves; rollers too
small; reverse bends; bent shafts; tight grooves;
corrosion; small drums & sheaves; incorrect rope
construction; improper installation; poor end
attachments. All running rope if left in service
long enough will eventually fail by fatigue.
Tension Wire break reveals predominantly cup and Check for overloads; sticky, grabby clutches;
cone fracture with some 45 shear breaks. jerky conditions; loose bearing on drum; fast
starts, fast stops, broken sheave flange; wrong
rope size & grade; poor end attachments.
Check for too great a strain on rope after factors
of deterioration have weakened it.
Abrasion Wire break mainly displays outer wires Check for change in rope or sheave size; change
worn smooth to knife edge thinness. Wire in load; overburden change; frozen or stuck
broken by abrasion in combination with sheaves; soft rollers, sheaves or drums; excessive
another factor will show a combination break. fleet angle; misalignment of sheaves; kinks;
improperly attached fittings; grit & sand; objects
imbedded in rope; improper grooving.
Cut or Gouged Wire ends are pinched down, mashed and/or Check on all the above conditions for mechanical
or Rough Wire cut in a rough diagonal shear-like manner. abuse, or either abnormal or accidental forces
during installation.
Torsion or Wire ends show evidence of Check on all the above conditions for mechanical
Twisting twist and/or cork-screw effect. abuse, or either abnormal or accidental forces
during installation.
Mashing Wires are flattened and spread at broken ends. Check on all the above conditions for mechanical
abuse, or either abnormal or accidental forces
during installation.
Corrosion Wire surfaces are pitted with break showing Indicates improper lubrication or storage.
evidence either of fatigue tension or abrasion.
59
61
ROPE INSPECTION SUMMARY
Any wire rope that has broken wires, deformed strands, variations in diameter, or
any change from its normal appearance, must be considered for e replacement. It
is always better to replace a rope when there is any doubt concerning its condition
or its ability to perform the required task. The cost of wire rope replacement is
quite insignificant when considered in terms of human injuries, the cost of down
time, or the cost of replacing broken structures.
Wire rope inspection includes examination of basic items such as:
1) Rope diameter reduction
2) Rope lay
3) External wear
4) Internal wear
5) Peening
6) Scrubbing
7) Corrosion
8) Broken Wires
Some sections of rope can break up without any prior warning. Already
discussed in some detail as to cause and effect, sections where this occurs are
ordinarily found at the end fittings, and at the point where the rope enters or
leaves the sheave groove of boom hoist, suspension systems, or other semi-opera-
tional systems. Because of the working that takes place at these sections, no
appreciable wear or crown breaks will appear. Under such an operation, the core
fails thereby allowing the strands to notch adjacent strands. However, when this
happens, valley breaks will appear. As soon as the first valley break is detected,
the rope should be removed immediately.
If preventative maintenance, previously described, is diligently performed,
the rope life will be prolonged and the operation will be safer. Cutting off a given
length of rope at the end attachment before the core deteriorates and valley breaks
appear, effectively eliminates these sections as a source of danger.
EQUIPMENT INSPECTION
Any undetected fault on a sheave, roller, or drum-be it of relatively major or
minor significance-can cause a rope to wear out many times faster than the wear
resulting from normal operations. As a positive means of minimizing abuses and
other-than-normal wear, the procedures here set forth should be adhered to.
Every observation and measurement should be carefully recorded and kept in
some suitable and accessible file.
1) Give close examination to the method by which the rope is attached both to the
drum and to the load. Make certain that the proper means of attachment is
applied correctly, and that any safety devices in use are in satisfactory work-
ing order.
67
2) Carefully check the groove and working surface of every sheave, roller, and
drum, to determine whether each (groove and surface) is as near to the correct
diameter and contour as circumstances will permit, and whether all surfaces
that are in contact with the rope are smooth and free of corrugations or other
abrasive defects.
3) Check sheaves and rollers to determine whether each turns freely, and whether
they are properly aligned with the travel of the rope. All bearings must be in
good operating condition and furnish adequate support to the sheaves and
rollers. Sheaves that are permitted to wobble will create additional forces that
accelerate the deterioration rate of the rope.
4) If starter, filler, and riser strips on drums are used, check their condition and
location. Should these be worn, improperly located or badly designed, they
will cause poor winding, dog legs, and other line damage.
5) Wherever possible, follow the path that the rope will follow through a com-
plete operating cycle. Be on the lookout for spots on the equipment that have
been worn bright or cut into by the rope as it moves through the system.
Ordinarily, excessive abrasive wear on the rope can be eliminated at these
points by means of some type of protector or roller.
FIELD LUBRICATION
During fabrication, ropes receive lubrication; the kind and amount depending on
the ropes size, type, and anticipated use. This in-process treatment will provide
the finished rope with ample protection for a reasonable time if it is stored under
proper conditions. But, when the rope is put into service, the initial lubrication
may be less than needed for the full useful life of the rope. Because of this possi-
bility, periodic applications of a suitable rope lubricant are necessary.
Following, are the important characteristics of a good wire rope lubricant:
1) It should be free from acids and alkalis,
2) It should have sufficient adhesive strength to remain on the ropes,
3) It should be of a viscosity capable of penetrating the interstices between wires
and strands,
4) It should not be soluble in the medium surrounding it under the actual operat-
ing conditions,
5) It should have a high film strength, and
6) It should resist oxidation.
67
Before applying lubrication, accumulations of dirt or other abrasive mate-
rial should be removed from the rope. Cleaning is accomplished with a stiff wire
brush and solvent, and compressed air or live steam. Immediately after it is
cleaned, the rope should be lubricated. When it is normal for the rope to operate
in dirt, rock or other abrasive material, the lubricant should be selected with great
care to make certain that it will penetrate and, at the same time, will not pick up
any of the material through which the rope must be dragged.
As a general rule, the most efficient and most economical means to do field
lubrication/protection is by using some method or system that continuously
applies the lubricant while the rope is in operation. Many techniques are used;
these include the continuous bath, dripping, pouring, swabbing, painting, or
where circumstances dictate, automatic systems can be used to apply lubricants
either by a drip or pressure spray method (Fig. 56).
MINIMUM
SAFETY REQUIREMENTS
FOR
WORK PLATFORMS USED
ON TEREX LIFT CRANES
12261-80
MINIMUM SAFETY REQUIREMENTS and with automatic braking which is applied when
FOR WORK PLATFORMS SUSPENDED ON the applicable control is in neutral;
LOAD LINE OF A TEREX LIFT CRANE
(2)A control or device which will deactivate any free fall
Scope load line function during the hoisting of personnel;
When it is determined that use of a work platform sus- (3)An operable anti-two block warning device which
pended from the load line of a lift crane manufactured by automatically deactivates the control function bring-
Terex Cranes (hereinafter Terex) creates the least hazard ing about the two-blocking condition;
to personnel and is the only practical means of accom-
plishing a task, the following procedures and minimum (4)Crane controls which return to neutral when released
requirements shall apply: (unless a second operator is in the cab at all times);
Terex Lift Cranes and Their Equipment (5)A boom angle indicator having high and low set
points, a maximum boom angle kickout, and an
1.The requirements and procedures set forth herein are ap- audio/visual alarm;
plicable to hydraulic lift cranes, with or without a tele-
scopic boom, and mechanical/friction operated lattice (6)Appropriate load charts for the lift crane;
boom lift cranes manufactured by Terex.
(7) A winch drum rotation indicator.
2.Hydraulic lift cranes shall comply with PCSA Std. No. 2
and No. 4, and ANSI B30.5-1983 and mechanical/friction 4. Such cranes shall not be equipped with a free fall (live
operated lattice boom lift cranes shall comply with PCSA boom) boom hoist.
Std. No. 1 and No. 4, and ANSI B30.5-1983, as applicable.
Work Platform Minimum Requirements
3.The lift cranes referred to in A.1 shall include the follow-
ing equipment and/or controls when used to suspend Work platform manufacturers shall comply with the follow-
work platforms from the load line. ing minimum requirements. Users of work platforms shall
ensure that the following minimum requirements have
a)Hydraulic Lift Cranes been met before personnel are hoisted.
(1)A boom and load line with power lowering and raising 1.Work platforms suspended from the load line of a lift
and with automatic braking which is applied when crane shall comply with all applicable governmental
the applicable control is in neutral; and/or industry standards relating to design and manu-
facture including, but not limited to, ANSI A92.2-1979.
(2)A control or device which will deactivate any free fall Design considerations shall include,but not be limited to:
load line function during the hoisting of personnel;
a) the material and design safety factors;
(3)Crane controls which return to neutral when released
(unless a second operator is in the cab at all times); b) construction, including fasteners and welding;
(5)A boom angle indicator having high and low set e) toe boards;
points and having an audio/visual alarm;
f) safety lanyard attachment;
(6)Appropriate load charts for the lift crane;
g) gates;
(7)A boom extension indicator (when crane is equipped
with a telescopic boom); h) hoisting and tag line attachments; and
(8) A winch drum rotation indicator. i) load limit, occupant limit, and work platform weight
instructions, labels and warnings.
b)Mechanical/Friction Operated Lattice Boom Lift
Cranes 2.The specifications for the work platform shall be in writ-
ing and shall describe the platform weight, load and
(1)A boom and load line with power lowering and raising occupancy limit, platform inspection and maintenance
ii
procedures; procedures for attachment of the platform hydraulic or mechanical/friction lift crane.
to the loadline, and any appropriate precautionary infor-
mation applicable to the platform itself, and shall be g) With the boom at maximum elevation, the hoist drum
permanetly placed in the lift crane and in or on the work shall have at least three wraps of wire rope remaining
platform. on it when the work platform is resting on the ground,
or at its lowest operational level if working below the
Inspection and Rigging, Testing and Operation supporting surface of the crane.
The inspection, operation and safety requirements of PCSA h)The wire rope safety factor for the combined weight of
Standard No. 2 and ANSI B30.5-1983 for hydraulic lift the lifting attachments, plus platform, personnel and
cranes, PCSA Standard No. 1 and ANSI B30.5-1983 for tools shall be no less than 7:1 for manufacturers spec-
mechanical/friction lift cranes and PCSA Standard No. 4, ified construction wire rope and no less than 10:1 for
as applicable, shall be complied with at all times. Applica- rotation resistant wire rope.
ble governmental requlations shall also be adhered to. In
addition, the following limitations and minimum require- i) Boom hoist wire ropes, load line wire ropes, reeving,
ments shall apply: and boom support pendants shall be inspected daily.
1. Inspection and Rigging j) Wire rope ends shall be seized and ancored (attached)
to boom, fall balls, hook blocks, and drums as
a) The lift crane and work platform shall be inspected im- described in the Wire rope Users Manual published by
mediately prior to commencement of operation. In- the Wire Rope Producers, American Iron and Steel
spection shall include, but not be limited to, wire rope, Institute.
hook, brakes, boom and other mechanical and rigging
equipment vital to the safety of the operation. 2. Crane Test Procedures
b)The inspection shall be performed at least once daily The test procedures listed below shall be conducted at
when the machine is being used in work platform ser- the following intervals:
vice or each time the machine is converted from mate-
rial handling to personnel operation. In the event the (1) daily,
operator is replaced, a new inspection is required.
(2) when an operator is replaced, and
c) Any structural or functional defect which adversely af-
fects the safe operation of the lift crane shall be correct- (3) when, in the judgement of responsible jobsite man-
ed before any operation utilizing a work platform begins agemant, there has been a significant change in the
or continues. conditions of the personnel lifting operation.
d)The anti-two block device shall be calibrated to sound No personnel shall ride the work platform during any of
a warning and to deactivate the control function bring- the tests recommended in this Standard.
ing about the two-blocking condition whenever the ook
block assembly, platform, radius, fall ball assembly, or a) The work platform shall be loaded with ballast at two
other assembly is at the following minimum distance times the intended load.
from the boom tip:
b)This test load shall be raised and lowered at maximum
(1) Not less than three (3) feet for boom lengths of 100 power controlled line speed (NOT FREE FALL). The ac-
feet or less; celeration must be smooth and the deceleration capa-
bility of the control/braking system shall be confirmed
(2) Not less than six (6) feet for boom lengths between by bringing the work platform to a smooth stop. The
100 feet and 200 feet; and specific operation to be undertaken shall then be sim-
ulated in its entirety. The work platform shall then be
(3)Not less than ten (10) feet for boom lengths exceed- inspected for any evident sign of damage or defect.
ing 200 feet.
c) The boom shall be raised to test the set point limits of
e)Hooks on fall ball assemblies, sheave block assemblies the boom angle indicator and the audio/visual warning
or other assemblies shall be of a type that can be alarms. All limiting and warning devices shall be acti-
closed and locked, eliminating the hook throat open- vated by each control function which may create a two-
ing, and shall be full load-bearing, and contain a man- blocking condition.
ual trigger release. Alternatively, a shackle with bolt,
nut and retaining pin may be used. d)The operator shall have demonstrated his ability to op-
erate the lift crane prior to hoisting personnel in a work
f)No work platform shall be suspended from a load line platform suspended from a load line.
passing over the pendant supported jib of any Terex
iii
3. Operation and Safety telephone communication with the machine operator
and signal person at all times. In the event of failure of
a)Mobile lift cranes shall be erected to obtain maximum the communication system, personnel will immediately
machine stability and must be level and on firm be returned to ground level using hand signals until
ground. Rubber tired lift cranes shall have outriggers the communications system is operational.
fully extended and the tires clear of the ground before
beginning any operation utilizing a work platform sus- l) If other cranes or equipment may interfere with the lift-
pended from the load line. No operations utilizing a ing of personnel, signals or other means of communica-
work platform shall be conducted while any rubber tion between all crane or equipment operators shall be
tired lift crane is on rubber. maintained to avoid interference by other operations.
b)The operators experience and physical condition shall m)No lifts shall be made on another of the cranes load
meet all applicable industry standards and/or govern- lines while personnel are suspended in a work plat-
mental regulations. form.
c) The operator shall not leave the operators station when n)After position ing of the work platform, all brakes and
the work platform is occupied. He shall remain at his locks in the lift crane shall be set before personnel per-
work station with the engine running and the master form any work.
clutch engaged whenever the work platform is occu-
pied. o) Work platforms shall not be used in winds in excess of
10 m.p.h., electrical storms, snow, ice, sleet, or other
d)Unauthorized personnel shall not be in the operators adverse weather conditions which could affect the safe-
cab, on the lift crane, or near the lift crane while a work ty of personnel.
platform is suspended from the load line.
p)Movement of the work platform with personnel shall be
e) Any operation in which the work platform is to be sus- done in a slow, controlled, cautious manner with no
pended from the load line shall be carefully planned by sudden movements of the crane or work platform.
the operator, signal person, supervisory personnel, and
personnel to be lifted prior to commencement of such q) At no time shall personnel stand on or work from the
operation. top rail, midrail, or toe board of the work platform.
f) The operator shall make no sudden movements of the r) Personnel shall keep all parts of the body, tools, and
crane or the work platform while suspended from the equipment inside the work platform during raising,
load line and shall engage in no reckless operation or lowering, and positioning.
horseplay at any time.
s) If not resting on the ground, the work platform shall be
g) A distance no less than twice the minimum distance to secured to the structure by rope or other means before
power lines as specified in OSHA 29CFR, Part 1910 personnel enter or leave.
shall be maintained when a work platform is attached
to the load line of a Terex lift crane. Further, work on t) When working from a work platform, belting off or oth-
any energized power line or any other energized device erwise attaching a work platform to an adjacent pole,
used for electric power generation or transmission is structure, or other equipment shall not be permitted,
prohibited. except as specified in subsection s above.
h)The combined weight of the work platform plus any at- u)Employees on the work platform shall wear safety belts
tachment device, personnel, tools and other equipment with lanyards attached, preferably above the hook or
shall not exceed 50% of the lifting capacity specified by shackle.
the applicable lift crane load chart.
v) When welding is done by an employee on the platform,
i) A work platform stabilizing tag line shall be attached the electrode holders shall be protected from contact
when practical to a work platform corner and con- with metal components of the platform. If electrically
trolled so as to prevent rotation of the work platform connected electrode holders contact work platform,
and to minimize any swaying motion of the work plat- work platform could be dropped due to burning/melt-
form. ing of wire ropes suspending the work platform.
j) When lifting personnel in a work platform, no more w)Work platform lifts shall be a single crane operation. A
than one crane funtion shall be utilized at any time. work platform shall not be lifted using two cranes.
The lift crane shall not be travelled while the work plat-
form is occupied. x) Before positioning or repositioning the work platform,
the lift crane operator shall locate soa s toavoid all ob-
k)Personnel in the work platform shall have radio or structions and high voltage conductors in the area.
iv
y) Prior to any movement of the work platform, care shall
be taken to prevent ropes, electric cords, hoses, etc.
from becoming entangled in the work platform while
the work platform is being elevated, lowered, or moved.
NOTE:
The criteria and procedures set forth herein are mini-
mum requirements only to be used in the absence of
any more stringent applicable standard and/or regula-
tion. Applicable government and/or industry stan-
dards (e.g., federal or state OSHA, MESA, Industrial
OSHA, etc.) must be reviewed and adhered to in con-
junction with the contents hereof.
v
MINIMUM SAFETY REQUIREMENTS b) construction, including fasteners and welding;
FOR WORK PLATFORMS RIGIDLY MOUNTED ON THE
BOOM OF TEREX HYDRAULIC LIFT CRANE c) flooring;
1.The requirements and procedures set forth herein are ap- i) load limit, occupant limit, and work platform weight
plicable to all Terex hydraulic lift cranes with or without instructions, labels and warnings.
a telescopic boom.
2.The specifications for the work platform shall be in writ-
2.Hydraulic lift cranes shall comply with PCSA Std. No. 2 ing and shall describe the platform weight, load and
and No. 4 as applicable, and ANSI B30.5-1983. occupancy limit, platform inspection and maintenance
procedures; procedures for attachment of the platform
3.Such hydraulic lift cranes shall include the following to the boom, and any appropriate precautionary infor-
equipment and/or controls when used with rigidly mation applicable to the platform itself, and shall be
mounted work platforms on the boom. permanetly placed in the lift crane and in or on the work
platform.
(a)A boom with power lowering and raising and with
automatic braking which is applied when the applica- 3)Such cranes shall not be equipped with a free fall (live
ble control is in neutral; boom) boom hoist.
(b)Crane controls which return to neutral when released Inspection and Rigging, Testing and Operation
(unless a second operator is in the cab at all times);
The inspection, operation and safety requirements of PCSA
(c)A boom angle indicator having high and low set Standard No. 2 and No. 4, as applicable, and ANSI B30.5-
points and having an audio/visual alarm; 1983 for lift cranes shall be complied with at all times.
Applicable governmental requlations shall also be adhered
(d)Appropriate load charts for the lift crane; to. In addition, the following limitations and minimum
requirements shall apply:
(e)A boom extension indicator (when crane is equipped
with a telescopic boom); and 1. Inspection and Rigging
(f) A means to rigidly attach the basket to the boom tip a) The lift crane and work platform shall be inspected im-
which is supplied by or approved by Terex; mediately prior to commencement of operation. In-
spection shall include, but not be limited to, brakes,
Work Platform Minimum Requirements boom and other mechanical and rigging equipment vi-
tal to the safety of the operation.
Work platform manufacturers shall comply with the follow-
ing minimum requirements. Users of work platforms shall b)The inspection shall be performed at least once daily
ensure that the following minimum requirements have when the machine is being used in work platform ser-
been met before personnel are hoisted. vice or each time the machine is converted from mate-
rial handling to personnel operation. In the event the
1.Work platforms rigidly mounted on the boom of a Terex operator is replaced, a new inspection is required.
hydraulic lift crane shall comply with all applicable gov-
ernmental and/or industry standards relating to design c) Any structural or functional defect which adversely af-
and manufacture including, but not limited to, ANSI fects the safe operation of the lift crane shall be correct-
A92.2-1979. Design considerations shall include,but not ed before any operation utilizing a work platform begins
be limited to: or continues.
a) the material and design safety factors; d) No work platform shall be mounted to the jib of any hy-
draulic lift cranes.
vi
2. Crane Test Procedures mounted on the boom of a hydraulic lift crane shall be
carefully planned by the operator, signal person, super-
The test procedures listed below shall be conducted at visory personnel, and personnel to be lifted prior to
the following intervals: commencement of such operation.
(3) when, in the judgement of responsible jobsite man- g) A distance no less than twice the minimum distance to
agemant, there has been a significant change in the power lines as specified in OSHA 29CFR, Part 1910
conditions of the personnel lifting operation. shall be maintained when a work platform is mounted
on the boom of a Terex lift crane. Further, work on any
No personnel shall ride the work platform during any of energized power line or any other energized device used
the tests recommended in this Standard. for electric power generation or transmission is prohib-
ited.
a) The work platform shall be loaded with ballast at two
times the intended load. h)The combined weight of the work platform plus any at-
tachment device, personnel, tools and other equipment
b)The boom shall be raised to test the set point limits of shall not exceed 50% of the lifting capacity specified by
the boom angle indicator and the audio/visual warning the applicable lift crane load chart.
alarms.
i) When lifting personnel in a work platform, no more
c) This test load shall be raised and lowered between than one crane funtion shall be utilized at any time.
boom angle set points at maximum controlled hoist The lift crane shall not be travelled while the work plat-
speed. The acceleration must be smooth and con- form is occupied.
trolled. The specific operation to be undertaken shall
then be simulated in its entirety. The work platform j) Personnel in the work platform shall have radio or
shall then be inspected for any evident sign of damage telephone communication with the machine operator
or defect. and signal person at all times. In the event of failure of
the communication system, personnel will immediately
d)The operator shall have demonstrated his ability to op- be returned to ground level using hand signals until
erate the lift crane prior to hoisting personnel in a work the communications system is operational.
platform mounted on the boom.
k)If other cranes or equipment may interfere with the lift-
3. Operation and Safety ing of personnel, signals or other means of communica-
tion between all crane or equipment operators shall be
a)Mobile hydraulic lift cranes shall be expected to obtain maintained to avoid interference by other operations.
maximum machine stability and must be on firm
ground with the outriggers fully extended and the tires l) A hydraulic lift crane on which a work platform is
clear of the ground before beginning any operation uti- mounted shall not be used for any other function or op-
lizing a work platform. No operations utilizing a work eration during lifting of personnel.
platform shall be conducted while any rubber tired lift
crane is on rubber. m)After positioning of the work platform, all brakes and
locks in the lift crane shall be set before personnel per-
b)The operators experience and physical condition shall form any work.
meet all applicable industry standards and/or govern-
mental regulations. n)Work platforms shall not be used in winds in excess of
10 m.p.h., electrical storms, snow, ice, sleet, or other
c) The operator shall not leave the operators station when adverse weather conditions which could affect the safe-
the work platform is occupied. He shall remain at his ty of personnel.
work station with the engine running and the master
clutch engaged whenever the work platform is occu- o) Movement of the work platform with personnel shall be
pied. done in a slow, controlled, cautious manner with no
sudden movements of the crane or work platform.
d)Unauthorized personnel shall not be in the operators
cab, on the lift crane, or near the lift crane while a work p)At no time shall personnel stand on or work from the
platform is mounted on the boom. top rail, midrail, or toe board of the work platform.
vii
q) Personnel shall keep all parts of the body, tools, and
equipment inside the work platform during raising,
lowering, and positioning.
NOTE:
The criteria and procedures set forth herein are mini-
mum requirements only to be used in the absence of
any more stringent applicable standard and/or regula-
tion. Applicable government and/or industry stan-
dards (e.g., federal or state OSHA, MESA, Industrial
OSHA, etc.) must be reviewed and adhered to in con-
junction with the contents hereof.
viii
TELESCOPIC BOOM CRANES
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
1 of 35
Introduction
Outline of Operation..................................................................................................................... 4
The Pictograph............................................................................................................................. 5
Information Screen....................................................................................................................... 6
Overload Indicator........................................................................................................................ 6
Parts-of-Line ................................................................................................................................ 8
Point of Lift ................................................................................................................................... 8
Winch ........................................................................................................................................... 8
Counterweight.............................................................................................................................. 8
Tires ............................................................................................................................................. 8
Outriggers .................................................................................................................................... 8
Power Up Self-Test ................................................................................................................................. 9
Start-Up Screen..................................................................................................................................... 10
System Setup
Counterweight............................................................................................................................ 12
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
2 of 35
Outriggers .................................................................................................................................. 13
Stowed Jibs................................................................................................................................ 15
Auxiliary Head............................................................................................................................ 17
Notes.......................................................................................................................................... 21
Cancel Alarm
Glossary............................................................................................................................................ 32-35
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
3 of 35
MicroGuard Display Unit The extension sensor provides an increasing voltage
MicroGuard Computer Unit proportional to the extension of the boom. A cable
Pressure Transducers attached to the boom head provides a low current
electrical path for the A2B signal
Extension Reel with length and angle sensors
Anti 2-Block (ATB) switches
Cables Two pressure transducers measure the pressure in
Installation/Operator Manuals the boom hoist cylinder. The resultant Total Moment
signal is processed to provide a continuous display of
The MicroGuard TEREX RCI 510 System is intended
the load suspended below the point of lift.
to aid the crane operator by continuously monitoring
the load and warning of an approach to an overload
or Two-Block condition. Crane functions are
A switch monitors the approach of the hookblock or
monitored by means of high accuracy sensors. The
overhaul ball to the boom head. The switch is held in
system continuously compares the load suspended
the normal position until the hookblock or overhaul
below the boom head with the crane capacity chart
ball raises a weight that is mounted around the hoist
stored in the computer memory. At approach to
rope. When the weight is raised, it causes the switch
overload, the system warns by means of audible and
to operate. The resultant signal is sent to the
visual alarms. The system can be configured to cause
computer via the extension reel causing the A2B
function kick-out by sending a signal to function
alarm to operate and function kick-out to occur.
disconnect solenoids.
The operator is provided with a continuous display of: Electrically operated solenoids disconnect the control
lever functions for boom hoist lower, telescope out,
Rated Load
and winch up whenever an overload or an A2B
Actual Load condition occurs.
Bar Graph showing Percentage of Rated Load
Radius of the Load
These alarms, when properly set by the operator,
Boom Angle
define the operating range. This is achieved by
Main Boom Length means of minimum and maximum angle, maximum
Working Area height, and/or maximum length. These alarms can be
Crane Configuration programmed for each job site and allow the operator
to work in a defined area.
On-screen messages provide the operator with visual
warnings of conditions that occur during operation of
the system. When set, this alarm permits the operator to define
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
4 of 35
MANUAL SECTION
/ BOOM MODE STOWED JIB WINCH
JIBS
COUNTERWEIGHT
AUX HEAD
OUTRIGGERS
The PICTOGRAPH gives a pictorial representation of the current setup of the system. It does this by means of light
emitting diodes (LEDs). Each shaded area contains a group of one or more LEDs and a push button that is pressed
to change the setup selection. In the groups with more than one choice or option, LEDs illuminate one at a time to
indicate the selection. The groups are shown below.
OUTRIGGERS - contain 3 LEDs. These indicate the STOWED JIB - contains 1 LED. This will be
selection of either full outriggers, intermediate, or illuminated when the jib is stowed on the boom.
retracted outriggers.
MANUAL SECTION - contains 1 LED. It is
TIRES - contain 1 LED. When operation on tires is active on cranes that have pinned extensions or
selected, the outrigger LED will turn off and the tire active tip boom options.
LED will illuminate.
JIBS - contain 6 LEDs. These indicate the length
COUNTERWEIGHT - contains 1 LED. It is only active and offset of the jib in use.
on cranes that have counterweight options.
AUX HEAD - contains 1 LED that illuminates
WINCH - contains 2 LEDs. These indicate the when the AUX HEAD is fitted.
selection of FRONT or REAR winch.
POINT OF LIFT - contains 3 LEDs. One will
illuminate to show the point of lift.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
5 of 35
4 5 6
2 3
1
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
6 of 35
7 9 11 12
#$
$
!!!"
TEST
8 10
7. The BAR GRAPH indicates the ACTUAL 11. The LENGTH display shows the length of
LOAD as a PERCENTAGE OF RATED the main boom from the boom foot pin to the
CAPACITY. sheave pin of the main boom head
machinery.
8. The ACTUAL LOAD display shows total
load, including load, slings, etc. suspended 12. The ANGLE display indicates, in degrees,
below the lifting point. the angle of the main boom relative to
horizontal.
9. The RATED CAPACITY display shows the
RATED CAPACITY of the crane in the
current configuration.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
7 of 35
13 15 16 17 18 19
14 22
13. The number of PARTS-OF-LINE. 19. Indicates which WINCH will be used for the
pick.
14. POINT OF LIFT, e.g. main boom, auxiliary
head or jib. 20. Indicates which COUNTERWEIGHT is fitted
(if applicable).
15. AUXILIARY HEAD ON or OFF the crane.
21. TIRES creep, static, 2 1/2 MPH, and
16. Indicates JIB configuration in use.
RIGGING/TRAVEL mode.
17. MANUAL SECTION or ACTIVE TIP
22. OUTRIGGERS full extension, mid
extended (if applicable).
extension, or retracted.
18. JIB STOWED ON BOOM.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
8 of 35
TEST
26
Immediately following electrical power up or following operation of the TEST switch (item 26), the system
executes a self-test that last for 8 seconds. During this time, the numerical display segments and
bar graph segments are all turned on, the audible alarm will sound, and alarm indicator lights are
illuminated.
The information display shows the crane model and rating chart number.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
9 of 35
--- - -- -
- -- -
--- - -- -
TEST
27
Immediately following power up self-test, the display indications will show as above. During this time,
crane motions are disabled by the system function kickout. Operation of the bottom right information
display push button (item 27) will acknowledge the information display message and allow the system to
start normal operation.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
10 of 35
TEST
25 27
Immediately following self-test and the start up screen, the information display will display a 2 second
reminder of the brightness and contrast control functions.
Push buttons to the left of the information display (item 25) allow the brightness of all LEDs on the display
panel to be adjusted up or down at any time during operation of the system unless operator alarms are
being set.
Push buttons to the right of the information display (item 27) allow the contrast of the information display
to be adjusted up or down at any time during operation of the system unless operator alarms
are being set.
During adjustment of the contrast or brightness, the information window will automatically display the
reminder window shown.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
11 of 35
!"#$%&$'()#
TEST *+ !"#$%&$'()#
1
IF THE COUNTERWEIGHT PUSH BUTTON IS The available counterweight options will be
PRESSED ON A CRANE THAT DOES NOT displayed in the information screen (1). There
HAVE COUNTERWEIGHT OPTIONS, THE can be four options displayed at a time, one next
MESSAGE NO OTHER COUNTERWEIGHT to each selection key.
OPTIONS WILL APPEAR IN THE
If the required option is visible,
INFORMATION DISPLAY. REFER TO YOUR
select the option by pressing the
CRANE RATING MANUAL FOR DETAILS OF
button next to it.
THE OPTIONS ON YOUR CRANE
If more than 4 options are available,
On cranes that have counterweight options the
a second selection screen can be
operator must tell the MicroGuard System
viewed by pressing the button next
which counterweight is currently fitted. If there
to the "next" label.
are no options, continue on to selection of
outriggers. If only a single option is available, it
will automatically be selected.
Start the choice by pressing the counterweight
push button (item 20).
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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12 of 35
1 22
The operator must tell the system which The outrigger selection will automatically
outrigger position is in use. move on to the next selection.
EXAMPLE:
Start the choice by pressing the outrigger
From fully extended to half extended, or
push button (item 22).
from half-extended to fully retracted and
then back to fully extended with each push
of the button. If no other selections are
available, the message "No other chassis
options" will appear on the information
screen (item 1).
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
13 of 35
TEST
1 21
There can be four options displayed at a
IF THE TIRE PUSH BUTTON IS PRESSED ON
time, one next to each selection key.
A CRANE THAT DOES NOT HAVE TIRE
OPTIONS THE MESSAGE NO OTHER TIRE If the required option is visible,
OPTIONS WILL APPEAR IN THE select the option by pressing the
INFORMATION DISPLAY. REFER TO YOUR button next to it.
CRANE RATING MANUAL FOR DETAILS OF
If more than 4 options are available,
THE OPTIONS ON YOUR CRANE.
a second selection screen can be
On cranes that have more than one tire viewed by pressing the button next
option, e.g. static, creep etc., the operator to the "next" label.
must select the tire configuration that
If only a single option is available, it
corresponds to the tire chart to be used.
will automatically be selected.
Start the choice by pressing the tire push
RIGGING/TRAVEL MODE is selected when
button (item 21).
the crane is in the rigging process or is a
The available tire selection options will be rough terrain crane traveling between jobs.
displayed in the information screen (item 1).
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
14 of 35
18
TEST
1
IF THE STOWED JIB PUSH BUTTON IS The available stowed jib options will be
PRESSED ON A CRANE THAT DOES NOT displayed in the information screen (1).
HAVE JIB OPTIONS, THE MESSAGE NO There can be four options displayed at a
OTHER STOWED OPTIONS WILL APPEAR time, one next to each selection key.
IN THE INFORMATION DISPLAY. REFER TO
If the required option is visible,
YOUR CRANE RATING MANUAL FOR
select the option by pressing the
DETAILS OF THE OPTIONS ON YOUR
button next to it.
CRANE.
If more than 4 options are available,
On cranes that have more than one jib
a second selection screen can be
option (fixed, offset, or telejib etc.), the
viewed by pressing the button next
operator must select the jib to be used.
to the "next" label.
Start the choice by pressing the stowed jib
If only a single option is available, it
push button (item 18).
will automatically be selected.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
15 of 35
16
#%&'()* #%&
()*
TEST #%&#()* !+
1
IF THE ERECTED JIB PUSH BUTTON IS There can be four options displayed at a time,
PRESSED ON A CRANE THAT DOES NOT one next to each selection key.
HAVE JIB OPTIONS, THE MESSAGE NO If the required option is visible,
OTHER JIB OPTIONS WILL APPEAR IN THE select the option by pressing the
INFORMATION DISPLAY. REFER TO YOUR button next to it.
CRANE RATING MANUAL FOR DETAILS OF
If more than 4 options are available,
THE OPTIONS ON YOUR CRANE.
a second selection screen can be
To erect a JIB, it must first have been viewed by pressing the button next
selected and stowed as detailed on the to the "next" label.
previous page. If only a single option is available, it
Start the choice by pressing the erected jib will automatically be selected.
push button (item 16).
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
16 of 35
15
1
IF THE AUXILIARY HEAD PUSH BUTTON IS An auxiliary head fitted on a crane must be
PRESSED ON A CRANE THAT DOES NOT included in the crane setup.
HAVE AN AUXILIARY HEAD, THE MESSAGE
To set up the crane with an auxiliary head, press
NO OTHER AUXILIARY HEAD OPTIONS
the auxiliary head push button, (item 15).
WILL APPEAR IN THE INFORMATION
This will toggle the auxiliary head on and off
SCREEN (ITEM 1).
each time the button is pressed.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
17 of 35
19
#$
$
TEST
!!!"
1
For cranes with two winches, always select the winch to be used for the lift before selecting the point of lift
and parts of line. The system stores point of lift and parts of line selections for each winch.
Choose the winch to be used by pressing This toggles between the two available
the winch push button (item 19). winches each time the button is pressed.
If no other winch is available, the message
"No other winch options" will appear for
three seconds on the information screen
(item 1).
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18 of 35
14
#$
$
!!!"
TEST
1
Before choosing the point of lift, check that the correct winch has been selected.
Always check the point of lift selection following selection of the winch.
Choose the point of lift to be either from the If an option is not available, it will be
main boom, auxiliary head, or jib by pressing skipped over.
the point of lift push button (item 14).
If no other pick point options are
This action moves the selected lifting point
available, the message "No other pick
to the next available lifting point, i.e. from jib
point options" will be displayed on the
to aux head, from aux head to main boom,
information screen (item 1).
and from main boom back to jib again.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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19 of 35
13
Always check and select parts-of-line following selection of the winch and point of lift.
Set the PARTS-OF-LINE for the currently When another winch is selected, it may be
selected winch by pressing the UP or necessary to reset the parts-of-line for the
DOWN arrow, as appropriate. (item 13). other winch.
The number of parts-of-line will appear in When the number of parts in the parts-of-
the parts-of-line display (item 13). line on the crane is changed, it will be
necessary to reset the parts-of-line on the
display.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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20 of 35
The system has the capability of remembering all of the configuration data
previously set. After removing power to the system and then powering up again,
the settings remain intact until reset by the operator.
After the configuration has been set, the operation of the System
depends only upon setting which winch is in use. Changing the winch
will automatically change the lifting point and the parts-of-line to the
values previously set for the selected winch. Always check the point of
lift and parts-of-line following selection of the winch.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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21 of 35
$
!
TEST
23
The cancel alarm push button (item 23) is (such as overload) is removed and then
used to silence the audible alarm. Pressing this recurs, the new alarm condition will cause
button once will cancel an audible alarm that the audible alarm to sound again.
has occurred as a result of an:
The CANCEL ALARM push button is also used
Overload
to reset the function kick-out relay when it is
A2B Alarm necessary to bypass the function disconnects.
Operator Settable Alarm Examples of when it may be necessary to
override a function disconnect condition are:
The audible alarm remains canceled until the
condition that caused the alarm has been If the boom hoist cylinder is fully extended, the
removed. See page 23. pressure in it will rise. This will be seen by the
system as an overload and will not allow the
EXAMPLES:
operator to boom down. Using the bypass is
AFTER CANCELING AN AUDIBLE ALARM: necessary in this situation to move away from
If the audible alarm sounded because of an the fully extended boom hoist cylinder position.
overload condition, the alarm will remain
canceled until the condition is corrected.
If another alarm condition occurs that
normally causes an alarm to sound (such
as A2B) or if a previous condition
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
22 of 35
23,500 44.8
6 62.7
i2,300 26.4
TEST
23
Press and release and then press and hold WHEN THE FUNCTION DISCONNECT RELAY
the CANCEL ALARM push button (item 23)
IS RESET BY MEANS OF THE CANCEL
for approximately 5 seconds to reset the
ALARM PUSH BUTTON, THERE IS NO
relay. At this time a second beep is heard
confirming the bypass. When the condition LONGER PROTECTION AGAINST THE
that caused the alarm is no longer present, CONDITION THAT CAUSED THE FUNCTION
the function disconnect relay will reset to the KICK-OUT.
normal condition. Should a different alarm
condition occur while the relay is over-
ridden, the new alarm condition will cause
the controls to disconnect again.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
23 of 35
TEST
28 29 24
25 27
To access the Operator Alarms from the main Each push button operates as a toggle switch
working screen, press the operator alarms push turning the alarm "ON" or "OFF."
button (item 24). The Information Screen will
To activate or deactivate an alarm:
then show the current status of the alarms.
If the alarm is OFF, press the
The four operator alarms are shown below appropriate push button to turn the
followed by the number identity of the push alarm ON.
button that controls each alarm. These buttons If the alarm is ON, press the
are called out in the illustration above. appropriate push button to turn the
alarm OFF.
Minimum Boom Angle (item 28)
Maximum Boom Angle (item 29) Refer to page 25 for a discussion on minimum
Maximum Boom Length (item 25) and maximum boom angles and page 26 for
maximum boom length and maximum tip height.
Maximum Tip Height (item 27)
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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24 of 35
23,500 44.8
6 62.7
i2,300 26.4
28 29 24
Move the boom to the desired minimum angle
(in this example 32). Move the boom to the desired maximum
Press the operator alarm push button (item 24) angle (in this example 67).
to access the operator alarm screen. Press the operator alarm push button (item
Press the push button (item 28) pointing to Min 24) to access the operator alarm screen.
Angle. In this example the display will read Press the push button (item 29) pointing to
MIN ANGLE 32. Max Angle. In this example the display will
The red warning light (item 5) will flash and the read MAX ANGLE 67.
audible alarm will sound whenever the boom The red warning light (item 5) will flash and
angle is below 32. the audible alarm will sound whenever the
Pressing the MIN ANGLE push button again will boom angle is above 67.
cancel the alarm and the display will read Pressing the MAX ANGLE push button
MIN ANGLE OFF again will cancel the alarm and the display
will read MAX ANGLE OFF.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
25 of 35
24
25 27
Move the boom to the desired maximum Move the boom to the desired maximum
length, in this example 58 ft. height, in this example 78 ft.
Press the operator alarm push button (item Press the operator alarm push button (item
24) to access the operator alarm screen. 24) to access the operator alarm screen.
Press the push button (item 25) pointing to Press the push button (item 27) pointing to
Max Length. In this example the display will Max Height. In this example the display will
read MAX LENGTH 58 FT. read MAX HEIGHT 78 FT.
The red warning light (item 5) will flash and The red warning light (item 5) will flash and
the audible alarm will sound whenever the the audible alarm will sound whenever the
boom length exceeds 58 ft. boom tip height exceeds 78 ft.
Pressing the MAX LENGTH push button again
Pressing the MAX HEIGHT push button again
will cancel the alarm and the display will read
will cancel the alarm and the display will read
MAX LENGTH OFF.
MAX HEIGHT OFF.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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26 of 35
%& &
%&
TEST
&
29
28 24
25 27
Each push button operates as a toggle switch. If
To access the SWING AND WORK AREA the alarm to be set is OFF, pressing the push
ALARMS from the main working screen, press button will turn the alarm ON. If the alarm to be
the OPERATOR ALARM push button (item 24) set is ON pressing the push button will turn the
2 times. alarm OFF.
The Information Screen will show the current When Operator Alarms are set, the light in the
status of the Swing and Work Area Alarms. push button (item 24) will be illuminated.
There are 4 separate operator alarms, all Return to the main screen by pressing the
controlled by push buttons (items 25, 27, 28, OPERATOR ALARM push button (24).
and 29). Each one of these push buttons relates
to the alarm to which it points.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
27 of 35
Right Swing
WARNING
THE OPERATOR DEFINED SWING ALARM IS A WARNING DEVICE. ALL FUNCTIONS REMAIN OPERA-
TIONAL WHEN ENTERING THE OPERATOR DEFINED EXCLUSION ZONE. IT IS THE RESPONSIBILITY OF
THE OPERATOR TO SET SWING ALARMS THAT ENSURE THAT THE CRANES BOOM, ATTACHMENT,
LOAD, AND RIGGING ETC. MAINTAINS A SAFE WORKING DISTANCE FROM THE OBSTACLE. AVOID POSI-
TIONING THE BOOM, ATTACHMENT, LOAD, AND RIGGING ETC. IN THE EXCLUSION ZONE WHEN MOVING
TO THE LEFT AND RIGHT SWING POINTS. WHEN SELECTING LEFT AND RIGHT SWING POINTS ENSURE
THAT THE LOAD WILL MAINTAIN A SAFE DISTANCE FROM THE OBSTACLE. IF THE CRANE OR OBSTACLE
IS MOVED OR IF A DIFFERENT SIZE LOAD IS LIFTED THE SWING ALARMS MUST BE RESET.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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28 of 35
1 24
28 29
Swing the boom to the desired Left Swing Move the boom to the desired Right Swing
Limit, e.g. 325. Limit, e.g. 35.
Press the operator alarm push button (item
Press the Right Swing push button (item
24) 2 times to access the swing alarm
29). The information screen (item 1) will
screen.
read RIGHT SWING 35.
Press the push button (item 28) pointing to
The red warning light (item 5) will flash and the
Left Swing. The information screen (item 1)
audible alarm will sound whenever the boom
will read LEFT SWING 325.
swings past the preset limits.
Both Left and Right Swing Alarms must be set
Pressing the LEFT SWING and RIGHT SWING
for the system to operate correctly. The red
push buttons again will cancel the alarm and the
warning light (item 5) will flash and the audible
information screen (item 1) will read:
alarm will sound whenever only one of the
LEFT SWING OFF RIGHT SWING OFF.
left/right swing limits is set.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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29 of 35
This alarm, when set, permits the operator to define an Operating Zone by only two set points. The use of
this method results in a greatly enhanced work area and also clearly and simply defines the Exclusion
Zone area. The following diagram illustrates the Operating Zone and the Exclusion Zone.
Operating Zone
Safe
Working Set Point 1
Distance
EXCLUSION ZONE
OBSTACLE
Obstacle
EXCLUSION ZONE
The operator defined work area alarm, when set, will define an imaginary vertical plane between two set
points to optimize the working area. When passing the plane, the red warning lamp will illuminate, the
audio alarm will sound, and the message EXCLUSION ZONE will flash on the display.
WARNING
THE OPERATOR DEFINED WORK AREA ALARM IS A WARNING DEVICE. ALL FUNCTIONS REMAIN OPERATIONAL WHEN
ENTERING THE OPERATOR DEFINED EXCLUSION ZONE. SAFE WORKING DISTANCE IS THE TIME IT WOULD TAKE AN
OPERATOR TO REACT TO AN ALARM AND FOR THE CRANE MOTION TO BE HALTED BEFORE ENTERING THE EXCLU-
SION ZONE. IT IS THE RESPONSIBILITY OF THE OPERATOR TO SET POINTS THAT ENSURE THAT THE CRANE BOOM,
ATTACHMENT, LOAD, RIGGING, ETC. MAINTAINS A SAFE WORKING DISTANCE FROM THE OBSTACLE. AVOID
POSITIONING THE BOOM, ATTACHMENT, LOAD, RIGGING, ETC. IN THE EXCLUSION ZONE WHEN MOVING TO SET
POINTS 1 AND 2. WHEN SELECTING SET POINTS 1 AND 2, ENSURE THAT THE LOAD WILL MAINTAIN A SAFE DISTANCE
FROM THE OBSTACLE. IF THE CRANE OR OBSTACLE IS MOVED, OR IF A DIFFERENT SIZE LOAD IS LIFTED, THE WORK
AREA ALARM MUST BE RESET.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
30 of 35
23,500 44.8
6 62.7
i2,300 26.4
25 1 27 24
Press the operator alarm push button (item Move the boom, attachment, load, rigging
24) two times to access the Work Area etc. to the desired RIGHT SET POINT.
alarm screen.
Press the push button (27) pointing to Right
SETTING POINTS 1 AND 2 Point. The information screen (item 1) will
read RIGHT POINT SET.
Move the boom, attachment, load, rigging
etc. to the desired LEFT SET POINT. The red warning light (item 5) will flash and the
audible alarm will sound whenever the boom tip
Press the push button (item 25) pointing to
penetrates the exclusion zone.
Left Point. The information screen (item 1)
will read LEFT POINT SET. Pressing the LEFT POINT and RIGHT POINT
push buttons (25 & 27) again will cancel the
Both Left and Right Points must be set for the
alarm and the information screen (item 1)
system to operate correctly. The red warning
will read
light (item 5) will flash and the audible alarm will
sound whenever only one of the left/right swing LEFT POINT OFF RIGHT POINT OFF
limits is set.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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31 of 35
ALARM A signal that warns or alerts, such as a flashing light or loud noise.
ANTI TWO-BLOCK A device that, when activated, prevents movement that causes two-
blocking.
AUXILIARY HEAD A short jib fitted at the main boom head that is used to provide
(AUXHD) separation of the main and auxiliary ropes when both are reeved over the
main boom head.
AUXILIARY HOIST A separate hoist rope system other than the main hoist.
(AUX HOIST)
BOOM A member hinged to the upperstructure that supports the hoisting tackle.
BOOM ANGLE The angle of the longitudinal axis of the boom relative to horizontal.
BOOM LENGTH The length of the boom along its longitudinal axis from the foot pin to the
axle of the head machinery.
BOOM MOMENT The turning moment around the boom pivot caused by the moment of the
unladen boom.
CENTER LINE OF The vertical axis around which the crane upperstructure rotates.
ROTATION
CENTER OF GRAVITY The point at which the entire weight of a body may be considered as con-
centrated so that if supported at this point the body would remain in equilib-
rium in any position.
ERECTED ATTACH- An attachment on the main boom fitted in its working position.
MENT
EXTENSION SENSOR A device that measures the extension of the telescoping sections of a boom.
FUNCTION KICK-OUT A device that disengages certain crane functions whose movement could
cause overload or two-blocking.
HEIGHT The vertical distance from the ground to the tip of the boom or attachment.
INFORMATION SCREEN A display that gives information supplemental to the information on the
pictograph.
INTEGRATED CIRCUITS A tiny complex of electronic components and connections on a small slice of
material (such as silicon).
MANUAL SECTION The tip section of the main boom that can be telescoped independently of
the other sections.
OPERATOR ALARMS Alarms that can be set by the operator, which provide working limits
additional to the chart limits.
OUT OF DUTY A point which is either longer than the longest permitted radius or lower than
the lowest permitted angle on a capacity chart
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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OUTRIGGER (ORs) A support projecting from a main structure used to provide additional
stability.
OVERLOAD The point at which the actual load exceeds the rated capacity of the crane.
PARTS OF LINE The number of parts of hoist rope between the upper and lower blocks.
POINT OF LIFT The location of the hoist rope for the current lift e.g. main boom, auxiliary
head or jib.
PRE-ALARM The point at which the actual load is 90% of the rated capacity of the crane.
RADIUS The horizontal distance from the centerline of rotation to the center of the
hook.
RATED CAPACITY The lifting capacity of a crane, as determined by the published capacity
chart.
RATED CAPACITY The load that a crane can safely handle based on factors such as strength,
stability, and rating.
REEVING A rope system in which the rope travels around drums and sheaves.
ROPE LIMIT The maximum permitted single line pull determined by the construction and
diameter of a wire rope.
ROPE LIMIT A condition that occurs when the type of rope and the parts-of- line in use
restrict the capacity of the crane.
SLEW OFFSET The horizontal distance from the boom pivot to the center of rotation
STOWED ATTACHMENT An attachment usually stowed on the main boom when not in use.
UPPERSTRUCTURE The structural part of a crane above the carrier, usually rotating.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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SWING The rotation of a crane upper around its center line.
SWING ALARMS Audible alarms occurring when the upper structure swings into areas
defined by the operator with the use of Operator Alarms.
SWL (%SWL) Percentage of safe working load. The proportion of the crane capacity which
is being utilized at any one time expressed as a percentage of rated
capacity
TRANSDUCER A device that is actuated by energy from one system and converts this to
another form for use by a different system (as a loudspeaker, that is,
actuated by electrical signals and supplies acoustic power).
TWO-BLOCKING The condition when the lower load block or hook assembly comes in contact
with the upper load block or boom point.
UNLADEN A boom that has no additional stowed or erected attachments and that is not
supporting a load.
WINCH A hoist drum used in conjunction with a rope for raising and lowering loads.
WORK AREA ALARM Permits the operator to define an operating zone by the means of only two
set points.
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
35 of 35
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth defects,
and other reproductive harm.