TABLE OF CONTENTS

TEREX
OP.
CRANES Manuals

RT400 SERIES

OPERATOR AND MAINTENANCE

MANUAL

Revised: December 1999 12261-202

 TABLE OF CONTENTS
CONSTUCTION AND INDUSTRIAL EQUIPMENT
PRODUCT SAFETY

It is the responsibility of the owner of the construction and in- vent accidents, reduce downtime and keep the equipment
dustrial equipment products to be knowledgeable about fed- working efficiently. These inspection programs should be de-
eral, state and local regulations that effect the total usage of signed to discover worn, cracked, broken or deteriorated parts
his equipment, and responsibility to working personal and the and loose or missing fasteners before they result in a problem.
public. Since regulations are subject to change, and also differ
from one local to another, this manual makes no attempt to
provide such information. Proper training and inspection programs are essential to
avoiding injury to persons, damage to property and excessive
Terex Cranes provides appropriate operation and mainte- maintenance costs.
nance manuals for various construction and industrial equip-
ment products that it manufactures and sells. In addition,
where applicable, appropriate national consensus standards, Read and understand the manuals provided with this equip-
industry standards and safety related manuals are included ment. Assistance is available from the distributors of your
with the Terex manuals in the shipment of each product. It is Terex product and from the Terex manufacturing facility.
company policy to provide this information for the owner or
user of the equipment. It is expected that the owner or user
will utilize these manuals and standards to provide the appro-
priate information and training to those people who are to op-
erate, maintain and supervise the use of equipment in a proper
and safe manner.
Construction and industrial equipment is designed and man-
ufactured to perform heavy-duty work. Under normal usage,
the equipment will wear. For this reason it is essential that the
owner/user establish and perform a periodic inspection of the
equipment. The objective of inspection programs is to pre-

When operating a hydraulic crane, the operator should realize that hydraulic and
structural competence, NOT TIPPING LOAD, is often the determinant of lifting ca-
pacity.

Therefore, THE OPERATOR MUST BE GUIDED SOLELY BY THE APPROPRI-

ATE MANUFACTURER’S LOAD RATING CHART when considering load
weights. The manufacturers rated loads must never be exceeded.

Follow the recommended operating and maintenance proce- various types of equipment, we ask that you include your ma-
dures and keep your machine operating at MAXIMUM EF- chine model and serial number in all correspondence so that
FICIENCY. Use the Suggested Crane Periodic Inspection we can provide the correct information.
Check List provided. In addition, we STRONGLY URGE
that a MAINTENANCE LOG be kept in conjunction with all The information, specifications, and illustrations in this pub-
maintenance performed on the machine. lication are based on the information in effect at the time of
approval for printing. We reserve the right to make changes
If you desire any special information regarding the care and at any time without obligation.
operation of the machine, we will gladly furnish it upon re-
quest. Because we build

Issued: December 1999

 SUGGESTED ROUGH TERAIN CRANE INSPECTION CHECKTABLE
LIST OF CONTENTS
This check list is to be used in addition to the information provided in this manual to properly operate and maintain
the machine.

SATISFACTORY

SATISFACTORY
INSPECTION

INSPECTION
ADJUST

ADJUST
REPAIR

REPAIR
ITEMS TO BE ITEMS TO BE

CODE

CODE
INSPECTED INSPECTED
& CHECKED & CHECKED

VISUAL INSPECTION ★ BOOM ANGLE

(Complete Machine) D INDICATOR D

OVERALL HEAD/TAIL/BRAKE LIGHTS

CLEANLINESS D & 4 - WAY FLASHERS D

HYDRAULIC SYSTEM HORN

(Leaks or Damage) D D

AIR SYSTEM CABLE SPOOLING

(Leaks or Damage) D PROPERLY D

HYDRAULIC WEDGE
FLUID D SOCKETS D

AXLE LOCKOUT AXLE FLUID

SYSTEM D LEVEL W

TRANSMISSION SWING REDUCER

FLUID LEVEL D FLUID LEVEL W

ENGINE CRANKCASE DRIVE SHAFTS

FLUID LEVEL D & U JOINTS W

FUEL TANK TIRE & WHEEL CONDITION &

FLUID LEVEL D INFLATION PRESSURE W

RADIATOR AIR
FLUID LEVEL D REGULATORS W

MACHINE AIR CLEANER

LUBRICATION D ELEMENT W

ATTACHMENT CLUTCH & BRAKE

PIN BOLTS D LINKAGE & PINS W

MUFFLER/EXHAUST WHEEL LUG

SYSTEM D NUT TORQUE W

ALL CONTROL FAN BELT

MECHANISMS D TENSION W

INSTRUMENT STRUCTURAL MEMBERS &

GAUGES D WELDS W

CLUTCHES BOOM INSPECTION

& BRAKES D W

WIRE ROPE, SHEAVES BATTERIES &

& GUARDS D STARTING SYSTEM M

TWO BLOCK DAMAGE ALCOHOL

PREVENTION SYSTEM D EVAPORATOR M

LOAD SUPPORTING SWING BEARING

COMPONENTS CONDITION D BOLT TORQUE P

FIRE EXTINGUISHER MACHINERY

D GUARDS P

BACKUP ALARM LOAD CHART &

D SAFETY WARNINGS P

★ 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.

Revised: December 2002

 TABLE OF CONTENTS
REPAIRS - ADJUSTMENTS - REMARKS

ITEM REQUIREMENT DATE

Issued: December 1999

 TABLE OF CONTENTS

NOMENCLATURE
understanding of the material presented in the following
This manual contains instructions and information on the pages.
operation, maintenance, lubrication and adjustments of the To aid in understanding the contents of this manual, the fol-
Rough Terrain Crane. The operator should not attempt to op- lowing terms will always have themeanings given whenever
erate the machine before he has gained a thorough they are used.

1. UPPERSTRUCTURE The upperstructure weldment, swing mechanism, counter-

weight, cab.

2. BOOM ATTACHMENT The telescopic crane boom with hydraulic winch, lift cylin-
der, hook block assembly, jib arrangement.

The chassis complete, power unit, swing bearing, transmis-

3. CARRIER sion, planetary axles, outrigger assemblies.

The beams, cylinders, floats, boxes, hydraulic control sys-

tem.
4. OUTRIGGERS

All references to right or left hand will correspond to the op-

erator’s right or left hand when he is facing forward from the
RIGHT HAND/LEFT HAND operator’s seat, with the rear mounted engine to his back.

2
1

Issued: December 1999

 TABLE OF CONTENTS
- TABLE OF CONTENTS -

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

Issued: December 1999

 TABLE OF CONTENTS

SAFETY

INDEX

SECTION 1

SUBJECT PAGE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2

Handling Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

Training and Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

Operator’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4

Signal Person’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Responsibilities of All Crew Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

Management Responsibilty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

Planning The Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7

Operator’s Safety Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8

Operator Aids Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8

Operation Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9

Operation Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10

Power Line Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10

Slip and Fall Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11

Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11

Issued: October 1999

 TABLE OF CONTENTS

INTRODUCTION

Owners, Users, and Operators:

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:

1. Comply with OSHA, Federal, State, and Local Regulations.

2. Read, Understand, and Follow the instructions in this and other manuals
supplied with this machine.

3. Use Good, Safe Work Practices in a common sense way.

4. Only have trained operators - directed by informed and knowledgeable

supervision - running the machine.

NOTE: OSHA prohibits the alteration or modification of this crane without written
manufacturers approval. Use only factory approved parts to service or
repair this unit.

If there is anything in this manual that is not clear or which you believe should be added,
please send your comments to Manager of Publication, Terex Cranes, P.O. Box 260002 /
Highway 501 East, Conway, South Carolina 29526; or contact us by telephone at (843)
349-6900.

Thank you!

THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED!

!
READ, UNDERSTAND, AND FOLLOW ALL DANGER,
WARNING, AND CAUTION DECALS ON YOUR
MACHINE.

Issued: August 1999 Page 1-1

 TABLE OF CONTENTS

INTRODUCTION

SYMBOLS

The symbols below are used to inform the operator of important information concerning
the operation of this unit.

DANGER - Indicates an imminently hazardous

situation which, if not avoided, will result in
death or serious injury.

WARNING - Indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.

CAUTION - Indicates a potentially hazardous

situation which, if not avoided, may result in
minor or moderate injury.

ATTENTION - Indicates a situation which, if

not avoided, may result in property or equipment
damage.

Page 1-2 Issued: August 1999

 TABLE OF CONTENTS

SAFETY

!
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.)

! TRAINING AND KNOWLEDGE

1. Safety must always be the operators most important concern.

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.

3. Comply with the requirements of current Occupational Safety and Health

Administration (OSHA) standards, the current American National Standards
Institute (ANSI) B30.5 latest edition.

4. Read and Understand all Decals and Warnings.

5. Read and Understand the Rating Chart.

6. Know that the crane can safely lift each load before attempting to lift.

Issued: August 1999 Page 1-3

 TABLE OF CONTENTS

7. Operator must understand crane signals and take signals only from designated
signal people; except the operator must obey the stop signal from anyone.

! OPERATOR’S RESPONSIBILITIES

1. Read and understand the Operator's Manual.

2. Make sure the machine is in proper order and that all operational aids and
warning signals are functional before operating.

3. Keep the machine clean, including all instrumentation, windows, lights and
other glazed surfaces.

4. Remove all oil, grease, mud, ice and snow from walking surfaces.

5. Store tools and other necessary items in the tool box.

6. Never lift a load without a Rating Chart Manual in the cab.

7. Know the load to be lifted.

8. Be alert, physically fit and free from the influences of alcohol, drugs or
medications that might affect the operators eyesight, hearing, or reactions.

9. Keep people, equipment and material out of the work area.

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.

12. Know about movements of other machinery, trucks and personnel at the
jobsite.

13. Never permit people on the machine platform while the machine is working.

Page 1-4 Issued: August 1999

 TABLE OF CONTENTS

14. Make sure everyone is in a safe place before moving the hook, boom, load or
outriggers.

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.

18. Use tag lines to keep loads under control.

19. Keep load close to ground.

20. Use shortest boom possible.

21. Never leave a running machine unattended or load suspended.

22. Always use outriggers in accordance with requirements of Load Rating Chart
and operators manuals.

! SIGNAL PERSON’S RESPONSIBILITY

1. Standard crane signals must be used, and understood.

2. Assist the operator in safe and efficient operation, without endangering people
or property.

3. Have a clear understanding of the work to be done.

4. Signal people must place themselves where they can be clearly seen and where
they can safely observe the entire operation.

Issued: August 1999 Page 1-5

 TABLE OF CONTENTS

! RESPONSIBILITIES OF ALL CREW MEMBERS

1. Unsafe conditions or practices must be corrected.

2. Obey all warning signs.

3. Watch out for your safety and the safety of others.

4. Know and understand proper machine erection and rigging procedures.

5. Alert operator and signal person of dangers, such as power lines, unstable
ground etc.

! MANAGEMENT RESPONSIBILITY

1. Operator's must be competent, physically fit and if required licensed.

2. Operator, signal people and riggers must be trained in correct crane operation
and use.

3. Operator and Signal people must know standard crane signals.

4. Have a supervisor at job site to be responsible for job safety.

5. Crew members given specific safety responsibilities and instructed to report

any unsafe conditions to supervisor.

6. Supply the weight on the load to be lifted to the operator.

7. Verify that all crew members are familiar with OSHA, ANSI B30.5
requirements as well as instructions in manuals.

Page 1-6 Issued: August 1999

 TABLE OF CONTENTS

! PLANNING THE JOB

1. Have a clear understanding of work to be done.

2. Consider all dangers at jobsite.

3. Know what crew members are needed?

4. Assign responsibilities.

5. Know the weight of load to be lifted.

6. Determine lift radius, boom angle, and the rated lifting capacity of crane.

7. Establish how signal people will communicate with operator?

8. Utilize equipment which will do job safety.

9. Establish how equipment can be safety transported to job site?

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.

12. Determine how load will be rigged.

13. Establish special safety precautions, if necessary.

14. Consider weather conditions.

15. Keep unnecessary people and equipment away from work place.

16. Position machine to use shortest boom and radius possible.

Issued: August 1999 Page 1-7

 TABLE OF CONTENTS

! OPERATOR’S SAFETY CHECK

1. Safety related items must be in place.

2. Check machine log book, to see if periodic maintenance and inspections have
been performed.

3. Ensure that necessary repairs have been completed.

4. Inspect wire rope for damage (kinks, broken wires etc.)

5. Be sure no unauthorized field modifications have been made.

6. Check for air and hydraulic oil leaks.

7. Check control positions before starting engine.

8. After starting engine, check all gauges and indicators for proper readings.

9. Test all controls.

10. Check brakes and clutches.

11. Check load brakes by lifting a load a few inches off the ground and holding it.

! OPERATOR AIDS CHECK

Ensure that the listed items are in place and operational.

1. Boom hoist upper angle limit switch. (Lattice Boom).

2. Boom angle indicator.

3. Backup Alarms.

4. Anti-Two Block devices.

5. Overload Protection, Load Indicators, Rated Capacity Limiters

Page 1-8 Issued: August 1999

 TABLE OF CONTENTS

! OPERATION OVERLOAD PREVENTION

1. Know the weight of the load.

2. Load radius will increase when the load is lifted. Reduce radius at start of lift
to allow for this.

3. Know the weight of hook, and rigging.

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.

7. Never operate with anything other than recommended counterweight.

Unauthorized reduction or additions of counterweight constitute a safety

hazard.

8. Do not lift loads if winds create a hazard. Lower the boom if necessary. See
the Rating Chart Manual for possible restrictions.

9. Avoid side loading.

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.

13. Be sure loads are freely suspended.

Issued: August 1999 Page 1-9

 TABLE OF CONTENTS

! OPERATION SETUP

1. Be sure the load bearing surface is strong enough to support the machine and
load.

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.

! POWER LINE SAFETY

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.

3. No part of crane or load must come in contact with, or violate the minimum
allowable clearance required for operation of crane dear electrical lines.

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.

6. Use a signal person when working around power lines.

Page 1-10 Issued: August 1999

 TABLE OF CONTENTS

1. Always wait until machine has stopped before getting on and off equipment.
Do not jump on or off.

2. Do not use controls and steering wheel as hand holds.

3. Keep the machine clean and dry.

4. Replace all broken ladders.

5. Keep non-slip surfaces in good condition.

! 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.

3. Position boom in line with the direction of travel.

4. Inflate tires to specified pressure.

5. Travel slowly and avoid sudden stops and starts.

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.

8. Always set parking brakes when parking machine.

Page 1-11 Issued: August 1999

 TABLE OF CONTENTS

INTRODUCTION

INDEX

SUBJECT PAGE

UNIVERSAL SYMBOL IDENTIFICATION 2-1

CONTROLS AND INSTRUMENTS 2-2

CONTROL AND INSTRUMENT KEY 2-3

ENGINE CONTROLS 2-4

TRANSMISSION CONTROLS 2-5

AIR BRAKE SYSTEM 2-5

STEERING CONTROLS 2-5

OUTRIGGER CONTROLS 2-5

SWING CONTROLS 2-6

ATTACHMENT CONTROLS 2-6

ACCESORIES 2-8

ANTI-TWO BLOCK SYSTEM 2-9

Issued: Sept 96
 TABLE OF CONTENTS
CONTROLS AND INSTRUMENTS

This section is intended to familiarize the operator with the Diagrams of the various carrier and upper controls are illus-
controls and instruments provided for the operation of this trated on the following pages. A list of these controls and in-
machine. It should be emphasized, however, that merely struments are shown opposite each illustration. More
knowing the controls is inadequate preparation for operating detailed explanations of each control or instrument follow in
hydraulic cranes. Do not attempt to operate the machine un- the same order as they appear in the number key.
til the other sections of this manual have been covered. Sec-
tions 1 and 3 are especially important with respect to
machine operation.

UNIVERSAL SYMBOL IDENTIFICATION

FLOODLIGHTS ENGINE ENGINE OIL

RUNNING PRESSURE

PUMP COOLANT
HORN TEMPERATURE
DISENGAGE

TRANSMISSION
ELECTRICAL PARKING OIL
SYSTEM ON BRAKE TEMPERATURE

ELECTRICAL SERVICE
SYSTEM OFF FAST
BRAKE

IGNITION ON OUTRIGGERS
SLOW

ENGINE NOT AIR PRESSURE

SAFETY
RUNNING

Page 2 - 1 Issued: Sept. 96

 TABLE OF CONTENTS
CONTROLS AND INSTRUMENTS

CONTROLS & INSTRUMENTS

Page 2 - 2 Issued: Sept. 96

 TABLE OF CONTENTS
CONTROLS AND INSTRUMENTS

CARRIER CONTROL AND INSTRUMENT KEY

1 IGNITION SWITCH 28 SWING BRAKE PEDAL

2 DIESEL STOP 29 SWING BRAKE PEDAL RACHET RELEASE
3 COLD STARTING AID (OPT.) 30 SWING PIN LOCK
4 PUMP DISCONNECT (ON REAR DECK) 31 BOOM LOWER PEDAL AND LEVER
5 ACCELERATOR 32 BOOM ANGLE INDICATOR ON BOOM (NOT
6 HAND THROTTLE SHOWN)
7 INSTRUMENT WARNING LIGHT 33 BOOM RAISE PEDAL AND LEVER
8 LOW COOLANT WARNING LIGHT 34 BOOM TELESCOPE LEVER
9 OIL PRESSURE GAUGE 35 TWO MODE SWITCH
10 FUEL GAUGE 36 BOOM HOIST MOMENTARY SWITCH
11 ENGINE TEMPERATURE GAUGE 37 MAIN WINCH LEVER
12 HOUR METER (ENGINE COMPARTMENT) 38 AUXILIARY WINCH LEVER (OPT)
13 VOLTMETER 39 WINCH ROTATION INDICATOR(S) (ON LEVER
14 TRANSMISSION TEMP. GAUGE NOT SHOWN)
15 TRANSMISSION OIL PRESSURE GAUGE 40 LIGHT SWITCH
16 TRANSMISSION SHIFT LEVER 41 TURN SIGNALS
17 AIR PRESSURE GAUGE (FRONT) 42 DASH LIGHTS
18 AIR PRESSURE GAUGE (REAR) 43 WORK LIGHT SWITCH
19 LOW AIR WARNING LIGHT & BUZZER 44 WIPER
20 BRAKE PEDAL 45 DEFROSTER FAN
22 STEERING MODE SWITCH 46 HEATER CONTROLS
23 OUTRIGGER EXTEND-RETRACT MASTER 47 CIRCUIT BREAKERS
SWITCH 48 FIRE EXTINGUISHER
24 OUTRIGGER SWITCHES 49 TWO BLOCK WARNING LIGHT
25 BUBBLE LEVEL 50 ANTI-TWO BLOCK AUDIBLE WARNING
26 SWING LEVER SWITCH
27 HORN 51 ANTI-TWO BLOCK BYPASS KEY SWITCH

Page 2 - 3 Issued: Sept. 96

 TABLE OF CONTENTS
CONTROLS AND INSTRUMENTS

1. IGNITION KEY SWITCH - Turns “On” and “Off” elec- 6. HAND THROTTLE - Vernier control with adjustment
trical circuits. Stops engine. feature.
2. DIESEL STOP - Shuts off fuel to engine. Solenoid actu- 7. WARNING LIGHT - Indicates high engine temperature,
ates governor lever. high transmission temperature, low engine oil pres-
sure, low coolant. Stop engine and check gauges on
3. “QUICK START”’ - Recommended for ambient tempera-
instrument panel.
tures below 32 F. Follow the manufactures instruction
regarding its use and handling and storage of fluid 8. LOW COOLANT WARNING LIGHT
capsules.
9. OIL PRESSURE GAUGE
10. FUEL GAUGE
11. ENGINE TEMPERATURE GAUGE
12. HOUR METER (In engine compartment)
13. VOLTMETER - Indicates battery charging condition.
14. TRANSMISSION TEMPERATURE GAUGE

4. PUMP DISCONNECT - For cold weather starting or

extended travel. Pull up to engage pumps. The unit is
equipped with a mechanical type of disconnect.
Engine must be stopped to engage pumps (located on
rear deck).
5. ACCELERATOR - (Foot Throttle).

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 TABLE OF CONTENTS
CONTROLS AND INSTRUMENTS

15. TRANSMISSION OIL PRESSURE GAUGE - Indicates vice brakes while the ignition is switched on.
transmission charge pressure. Normal range is 240 to
260 psi. Optional centering indicator light located above the shift
quadrant
22 STEERING SWITCH - Provides the following:

Never drive the machine when the transmission charge pres-

sure is below 240 psi.

TRANSMISSION CONTROLS

16. TRANSMISSION SHIFT LEVER

Do not make directional shifts between forward and reverse

while the vehicle is in motion.
Switch to crab or 4-wheel steering only when axles are cen-
UPSHIFTING AND DOWNSHIFTING - Full power shifts tered. Otherwise, steering will be limited and may lock.
between ranges under load may be made without endanger-
ing the transmission or drive train components. There are 6 If wheels should become locked, switch to 2-wheel steer,
speeds forward. 3 reverse. 4 wheel drive F1 thru F3 and R1. turn front wheels, switch back to crab or 4-wheel steer and
2 wheel drive FK4 thru F6 and R2 and R3. center wheels.

Downshifting should not be made when the vehicle speed Exercise caution when the upper structure is not in the travel
exceeds the maximum speed of the next lower range. Down- position as the steering will appear to be reversed when
shifting at excessive speeds will over speed the drive train boom is over rear.
components with possible resultant damage to drive shafts.

OUTRIGGER CONTROLS
AIR BRAKE SYSTEM

17. AIR PRESSURE GAUGE (Front) - 105 - 125 psi opti- 23 OUTRIGGER EXTEND-RETRACT MASTER
mum operating pressure. SWITCH - Selects direction of movement of cylin-
ders (beams and jacks).
18. AIR PRESSURE GAUGE (Rear) - 105 - 125 psi opti-
mum operating pressure. 24 OUTRIGGER SWITCHES - Four (4) switches con-
trol vertical jacks and right and left beams. Select cyl-
19. LOW AIR WARNING LIGHT & BUZZER - Will warn inders (beams and jacks) to be operated.
when pressure falls below 65 psi.
25 BUBBLE LEVEL - The machine must be levelled
20. BRAKE PEDAL - Actuates the air brakes. Do not prior to lifting.
attempt to drive the machine until normal operating
air pressure has been reached on the air gauge. Then
the service brakes will release.

21. EMERGENCY / PARKING BRAKES - The parking

brake automatically engages when the ignition is
switched off. The dash switch is for engaging the ser-

Page 2 - 5 Issued: Sept. 96

 TABLE OF CONTENTS

CONTROLS & INSTRUMENTS

SWING CONTROLS 31. BOOM “LOWER” PEDAL AND BOOM “LOWER”

LEVER.

26. SWING LEVER - Push to swing right, pull to swing left. 32. BOOM ANGLE INDICATOR (PENDULUM TYPE
When the upperstructure is swung 10 degrees off center, LOCATED ON BOOM) - Indicates boom angle relative
the rear axle pivot cylinders are locked into position to to the upperstructure. (not shown). May be part of Rated
maintain stability for crane work. Load Indicator, if equipped).

27. HORN 33. BOOM “RAISE” PEDAL AND BOOM RAISE LEVER

28. SWING BRAKE PEDAL 34. BOOM TELESCOPE LEVER - Push to extend boom.
Pull to retract boom.
29. SWING BRAKE PEDAL RATCHET RELEASE - Pull
and lock to permit operation of the pedal. Release to al-
low pedal to be locked in applied position.

30. SWING LOCK - Positive mechanism engages in carrier

structure or swing gear teeth. Raise lever to engage, low-
er to disengage. Never engage while swinging machine.

ATTACHMENT CONTROLS

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 TABLE OF CONTENTS

CONTROLS & INSTRUMENTS

38. AUXILIARY WINCH LEVER (OPTIONAL)

39. WINCH ROTATION INDICATORS (OPTIONAL) -

Mounted on winch control levers.

40. LIGHT SWITCH

41. TURN SIGNAL SWITCH

TWO MODE SWITCH
42. DASH LIGHTS
35.TWO MODE SWITCH - Depress to left for high speed
boom hoist, or telescope functions. Depress to right for 43. WORK LIGHT SWITCH
simultaneous independant normal speed boom hoist
and telescope functions. 44. TWO SPEED WINCH SWITCH

TELESCOPE
LEVER

BUTTON

36.BOOM HOIST MOMENTARY BUTTON - Use when

the Two Mode switch is in the left position to allow mo-
mentary simultaneous independant normal speed boom
hoist and telescope functions.

NOTE: When Two Mode switch is in the right position this

button is nonfunctional.

37. MAIN WINCH LEVER - Push to lower load. Pull to

raise load.

2-7 Issued:Sept. 96
 TABLE OF CONTENTS

CONTROLS & INSTRUMENTS

mine the cause of the malfunction.

ACCESORIES
The amber FLAME SW indicator light must light within 60
44. WIPER seconds after ignition. When it does, release the START-
RUN-OFF switch to the RUN position. If the light goes off,
45. DEFROSTER (OPTIONAL) again move the switch to START and repeat the procedure
until the light stays on. Adjust the HI-LO control to the de-
Not Shown Tachometer (optional) sired temperature. Both indicator lights will remain on until
the burner cycles off under control of the HI-LO control and
46. HEATER CONTROLS (OPTIONAL) - Turn the HI-LO the microswitch.
control to HI, and hold START-RUN-OFF switch in
START POSITION. The green HEATING indicator To shut off the heater, move the START-RUN- OFF switch
light must light immediately. If it does not, refer to Sec- to the OFF position. The green HEATING indicator light
tion 5, “Troubleshooting”. should go out immediately. The heater may not shut off im-
mediately because it incorporates purge cycle circuits. The
35. WINDOW WASHER SWITCH blower will continue to run until all the fuel in the burner is
consumed and the heat exchanger cools sufficiently to open
46A. HEATER CONTROLS FOR DIESEL FUELED the flame switch. When this oc- curs, the blower motor will
HEATER - Use the preheat/choke switch to preheat the car- stop and the amber FLAME SW indicator will go out.
buretor and burner head (refer to the Mfgs. Manual for the
complete procedure) 47. CIRCUIT BREAKERS

48. FIRE EXTINGUISHER

If the heater fails to produce heat within 30 seconds, turn off

power immediately to prevent build-up of propane in the
burner head. Refer to Section 6, “Troubleshooting”, to deter-

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 TABLE OF CONTENTS

CONTROLS & INSTRUMENTS

50

51

49

ANTI-TWO BLOCK SYSTEM

It is recommended that the system override key be used with
49.TWO BLOCK WARNING LIGHT - This machine is discretion. Unwarranted use of it to override the shut-off
equipped with a two block warning system designed to system can result in harm to the crane and danger to property
alert the operator of impending two block conditions i.e., and personnel. Whereas, the key can be used to override the
a condition where the hook or hook block may be drawn system in a case of extreme emergency, the operator using
into the boom point sheaves). the key in an emergency must exercise sound judgment.

Note: If the crane is equipped with an Rated Load Indicator The crane is equipped with anAnti-Two Block disconnect
the Anti-Two Block System is incorperated in the Rated Load system on the control linkage, it is activated when the hook
Indicator System. block contacts the anti-two block counterweight. This sys-
tem will prevent the hook block from contacting the boom
A visual warning light indicates this condition and appropri- head, which can cause the hoist rope to fail. When the sys-
ate counteraction should be taken to prevent two-blocking. tem is activated as described above, winch hoisting will
cease, the boom cannot be extended or lowered, however
50.TWO BLOCK AUDIBLE WARNING SWITCH - A boom hoist, boom retract, and winch down functions will
switch has been provided to activate an audible warning still be operational. This allows the operator to use the ap-
system (in addition to the one for visual warning), to propriate function to lower the hook block away from the
warn of possible approaching two-block conditions. boom head.

51.ANTI-TWO BLOCK BYPASS KEY SWITCH - A key

switch has been provided so that, under certain circum-
stances, an operator may override the anti-two block sys-
tem; thereby allow

ing the hook or block to be drawn closer to, or in contact

with, the boom point.

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 TABLE OF CONTENTS

OPERATING PROCEDURES

INDEX

SUBJECT PAGE

PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1

STARTING THE ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

OPERATING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

COLD WEATHER STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3

JUMP STARTING AN ENGINE WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . 3 - 3

VEHICULAR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4

MAKING A TYPICAL LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6

CRANE HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10

“ON TIRES” LIFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11

HOIST LINE REEVING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12

HOIST LINE REEVING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

WIRE ROPE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

AUXILIARY WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13

SIDE STOW OFFSET JIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14

UNUSUAL OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18

LOAD RATING CHART INTERPRETATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21

Issued: Sept 96
 TABLE OF CONTENTS
OPERATING PROCEDURES

PRE-START INSPECTION

The following items should be checked each day been started and the transmission warmed to
before start-up and the start of operations. Also 180-200 deg. F allow the engine to idle and en-
see Section 4, “Daily Check.” sure that the fluid level is between the “full” and
“add” marks.
ENGINE OIL The level should be at the full mark. FUEL FILTER Water should be drained from the
water separator on a Daily Basis. Both the water
COOLANT The level should be near the top of the separator and fuel filters have drain cocks locat-
radiator tank. ed at the bottom of each. Separator and filters are
located in the engine compartment on the right
LEAKAGE Make a ground check below the ma- side of the machine. For further information, See
chine for signs of leaks. Section 4, “Engine Maintenance Checks”.

FUEL Engine fuel and propane/diesel for the up- ANTI-TWO BLOCK SYSTEM Inspect all anti-two
per unit heater should be adequate for sustained block switches found on boom, jib and auxiliary
operations. sheave heads for damage. Check the freedom of
counterweight attached to these switches; and al-
LUBRICATION Perform the daily lubrication as so, that counterweight is attached around correct
required in the Lubrication Recommendations. line of hoisting cable in the proper manner. In-
spect all electrical connections and wires as well
HYDRAULIC SYSTEM Check hoses, tubes, com- as the entire length of cable attached to the cable
ponents, reservoir sight gauge, valves, pumps, reel and it’s connections for evidence of excessive
motors, connections, reservoir oil temperature, wear, damage or improper installation. Check
cylinder mounting bushings and pins. spring loaded cable reel for proper tension and to
insure that reel is free to rotate. Verify visual and
LINES AND BLOCKS Inspect the hoist lines, audible warning devices by lifting each of the
hoist block, hook latch, and ball hook, as well as counter- weights.
the crane attachment in general for readiness.
NOTE: A warning light will appear on the dash
SAFETY EQUIPMENT Check the safety equip- mounted panel and an audible signal will be
ment, including all lights, brakes and hazard war heard thorn switch is in ON position.
ing devices.
The crane is equipped with a shut-off or discon-
TIRES The tires should be checked for proper nect system on the control linkage, a check of
pressure before traveling the machine. The tires this system should be made prior to lifting. Hoist
should only be checked when cold. Refer to the the hook block to the boom point so that actual
Tire Pressure Chart on the Load Rating Chart. contact between block and anti-two block coun-
terweight is made. If all functions are operating
WHEEL NUTS Torque wheel nuts to 400-500 Ft. properly, winch hoist will cease and boom cannot
Lbs. Tighten daily during the first 50 miles of ser- be extended or lowered. Should any of these
vice on new units and any time the wheels have functions continue, disconnect system is func-
been removed. Tighten nuts alternately around tioning improperly and a complete system check
the wheel. must be made. Boom retract, boom raise and
winch down functions remain active and will be
GENERAL CONDITION Inspect the machine in unaffected by the two block system.
general for wear, leakage and damage.

AIR TANKS Open the air tank drain cocks to

blow out moisture and sediment.
When performing disconnect test, care should be
TRANSMISSION OIL Check the transmission oil taken as damage may result if system malfunc-
level. If oil is 2-3 inches above the full mark there tions and the hook is drawn into the boom point.
is enough to start the engine. After the engine has

3-1
RT400 Series Issued: Sept 96
 TABLE OF CONTENTS
OPERATING PROCEDURES

STARTING THE ENGINE

Once the pre-start inspection has been complet- up procedure, allow the engine to stop revolving
ed, the engine may be started. At ambient tem- before re-engaging the starter.
peratures over 32 deg. F. on Cummins Engines,
follow the starting procedure below: Do not engage the starter motor for more than 30
seconds at a time. Should the engine fail to start
1. Open the governor to the idle position. within 30 seconds, allow the starter motor to cool
for 2 minutes before attempting to start the en-
2. Move the transmission shift lever to the neu- gine again.
tral position.
Once the engine is started, check the gauges for
3. Put the parking brake switch in the “ON” posi- proper readings. If the gauges do not register nor-
tion. mal readings, stop the engine and determine the
cause. Avoid full Throttle operation when the en-
4. Turn the ignition switch to the “ON” position. gine is cold. Always allow the engine to reach nor-
mal operating temperature before commencing
5. Turn the ignition switch to the “START” posi- operations.
tion to start the engine.
NOTE: On machines equipped with a turbo-
Release the ignition switch key as soon as the en- charged engine, the oil pressure gauge MUST reg-
gine starts. If the engine stalls during the start- ister 10 psi (60 kpa) at idle speed to ensure full
lubrication of turbo-charger.

OPERATING THE ENGINE

If the engine oil pressure gauge does not register Throttle down to half speed or slower with no load
normal operating pressure within 30 seconds of for at least 5 minutes before stopping. This gives
starting, shut down the engine, determine the the engine a chance to cool off gradually before it
cause and effect repairs before re-starting the en- is stopped.
gine.
NOTE: This cool down period is extremely critical
When the engine reaches operating temperature, on machines equipped with turbocharged engines
operations may begin. While the engine is run- due to the excessive build up of heat during nor-
ning, check the gauges at frequent intervals and mal load operations.
be alert for any abnormal engine sounds or faulty
engine performance. Consult the engine manufacturer’s manual for
further operating instructions.
NOTE: Most alternators have a speed which must
be exceeded to turn them on. It is recommended
that the engine be speeded up to at least 2/3
speed after start-up and before any extended peri-
ods of low rpm operation to maintain battery
charge.

When idling for extended periods, maintain an

idle speed sufficient to prevent the battery from
being discharged. Keeping the battery in a fully
charged state is important both for starting the
engine and for powering the emergency steering
pump.

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RT400 Series Issued: Sept 96
 TABLE OF CONTENTS
OPERATING PROCEDURES

6. Restart engine. Be alert for signs of pump cav-

COLD WEATHER STARTING itation as described in (3) above. Increase en-
gine speed GRADUALLY, allowing sufficient
At ambient temperatures below 32 deg. F. on all time to warm the system before commencing
Cummins Engines, the “Quick-Start” device operation.
should be used before engaging the starter. Push
the “Quick-Start” button for three seconds, re- JUMP STARTING AN ENGINE WITH
lease it and engage the starter. BOOSTER CABLES

Position the vehicle with the booster battery adja-

cent to the vehicle with the discharged battery so
that booster cables can be connected easily to the
batteries in both vehicles. Make certain vehicles
The handling and storage of “Quick-Start” should do not touch each other.
strictly conform to manufacturer’s recommenda-
tions. 1. On both vehicles turn off all electrical loads.
Set the parking brake. Place transmission in
At very low temperatures, when the engine is dif- “PARK”.
ficult to start and operator experience so indi-
cates, follow the starting procedure outlined be- 2. Determine whether the discharge battery has
low: the negative (-) or positive (+) terminal con-
nected to ground. The ground lead is connect-
1. Disengage the pumps. ed to the engine block, frame, or some other
good metallic ground. The battery terminal
2. Start the engine as described above, using the connected to the starter relay is the one which
“Quick-Start” device. ALLOW THE ENGINE TO is not grounded.
WARM UP. This is recommended so that opti-
mum engine power is obtained at low speed for 3. Be sure that the vent caps are tight and level
the protection of the hydraulic system. on both batteries. Place a damp cloth over the
vent caps of each battery making certain it is
clear of fan blades, belts and other moving
parts.

3. BE ALERT FOR SIGNS OF CAVITATION. The The following steps must be performed in se-
hydraulic oil provides lubrication for the quence.
pumps. When to heavy or stiff, it will not flow
fast enough to meet pump demand and a vac- 4. On a negative grounded system, connect both
uum or “cavitation” will be created. A “scream- ends of one cable to positive (+) terminals of
ing” noise indicates inadequate pump each battery.
lubrication, and, if allowed to continue for
more than a short period, will result in serious 5. Connect one end of the other cable to negative
damage to the pumps. (-) terminal of the booster battery.

If cavitation noise is noticed, the hydraulic oil 6. Connect other end of cable, away from bat-
must be warmed by use of a reservoir immersion tery, to engine block, frame or some other good
heater. When the reservoir is warm to the touch, metallic ground, except carburetor or tubing
the starting procedure may be continued. Refer on vehicle with discharged battery.
to the lubrication chart for the recommended oil
viscosity for the winter season. 7. Make certain that all cables are clear of fan
blades, belts and other moving parts of both
4. Stop engine. engines and be sure everyone is standing
away from vehicles. Then start the engine with
5. Re-engage pumps. the booster battery. Wait a few minutes, then
at tempt to start the engine of the vehicle with
the discharged battery.

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RT400 Series Issued: Sept 96
 TABLE OF CONTENTS
OPERATING PROCEDURES

when traveling, or to secure it to the bumper

8. After starting, allow the engine to return to idle ring, will result in excessive swinging of the
speed and remove the cable connection at the en- hook block and possible damage to crane.
gine block or good metallic ground. Then remove
the other end of the same cable from the booster
battery.

Continuing to pull the block up after contact has

been made may result in damage to the boom
WARNING - BATTERIES PRODUCE EXPLOSIVE head, sheaves and anti-two block switch.
GASES. These instructions are designed to mini-
mize the explosion hazard. Keep sparks, flames, 3. Check hydraulic outrigger beam retaining
cigarettes, etc. away from batteries at all times - pins.
protect eyes at all times - do not lean over batter-
ies during this operation. 4. Disconnect the main pump if the crane is to be
driven more than approximately 2 miles.
Both batteries should be of the same voltage.
5. Shift into high range (two wheel drive).
5. Connect one end of the other cable to negative
Both batteries should be of the same voltage. 6. Check the tires for proper inflation pressure as
indicated on the “Crane Load Chart”.

VEHICULAR OPERATION 7. Check that the rear wheels are centered and
switch to 2-wheel steer.
The Rough Terrain Crane is capable of both off
road and limited on-road travel. The kind of trav- 8. Adjust the seat and mirrors for clear vision to
el undertaken will determine how the carrier is the rear.
operated.
9. Check that the transmission oil pressure is
Before moving the Before moving the crane, ei- within the normal operating range of 240 to
ther around the work site or between sites, care- 260 psi. Low pressure may indicate a worn
fully consider the terrain type, road conditions charge pump, clogged filter, or low oil level.
and any hazards likely to be encountered en-
route. Think the move through in advance and
carry it out safely.

PRE-MOVE CHECK LIST Before moving the

crane to and from job sites, make sure the follow- Never move the carrier if the transmission oil
ing safety check have been made: pressure is below 200 psi. Low pressure will
cause transmission slippage and consequent
NOTE: When properly adjusted the parking premature failure of the clutch packs.
brake will hold this machine on a 30%
grade, if the tires have adequate traction. MOVING THE CRANE TO A JOB SITE The pro-
It is recommended that when parked on a cedure for moving a crane is as follows:
grade that the wheels be chocked.
1. Start the engine, following the procedure given
1. Lock the upperstructure swing brake. Engage in the topic “Starting the Engine”.
the swing lock.
2. Allow air pressure build-up.
2. Secure hook block to the bumper loop. If this
is impractical, pull the two block system coun- 3. Apply the swing brake.
terweight up to within approximately 1” of the
load sheaves, or until block lightly contacts 4. Aplly the swing lock.
boom head. On machines equipped with con-
trol system disconnects, use override switch. 5. Apply the Service Brake.
Failure to pull the hook block up to the head

3-4
RT400 Series Issued: Sept 96
 TABLE OF CONTENTS
OPERATING PROCEDURES

6. Release the Parking Brake. at excessive speeds will overspeed the drive train
components with possible resultant damage to
7. Select the desired transmission range. the drive shafts.

Good judgment in the selection of gear range and Do not travel for extended periods at wide open
route of travel is essential when operating off the throttle.
road.
Four wheel drive engagement is accomplished by
Though designed primarily for use in off-road a solenoid shifted coupling in the transmissions.
conditions, there may be instances when high- In the ranges F1 thru F3 and R2 and R3.
way travel is necessary. In such instances, the
crane is subject to the same regulations which
govern the operation of other heavy equipment on
public roads. Adequate lighting, flares, flags and
safety equipment should be on the cranes at all Observe the restrictions given in the following
times. chart during on-the-road operation. Maximum
permissible running intervals are given in terms
of miles and hours of travel time. Stop the crane
when either limit has been reached (whichever
comes first) and allow the crane to cool for the pe-
When operating on hard surfaces, use high range riod indicated.
F4 thru F6 two-wheel drive only.Failure to do so
may result in severe drive line “wind-up” and
component failure.

The operator may start from rest in either forward

or reverse in F4 or F2.

In addition to conditions of terrain, gear selection

while traveling is also determined by transmis- 6. Stop the engine.
sion temperature. Normal operating temperature
is 160 to 200 deg. F. If the transmission temper- Before stopping the engine, put the transmission
ature rises above 250 deg. F. (121.1 deg. C.) while in neutral, and reduce the engine speed.
traveling, the crane must be stopped and allowed
to cool. Shift to neutral and run the engine at Always idle the engine for at least 5 minutes be-
1000-1200 rpm. The temperature should drop fore stopping it. This gives the engine a chance to
rapidly to the engine coolant temperature. If the cool down and prevents overheating which can be
temperature does not drop, trouble is indicated, caused by localized hot spots in the engine. The
and should be determined before moving again. idle speed must be high enough to charge the
Overheating generally occurs due to working in battery but not higher than half speed. This cool
too high a gear ratio. DO NOT SHUT OFF THE down period is extremely critical on machines
ENGINE WHEN THE TRANSMISSION IS OVER- equipped with a turbo-charged engine.
HEATING.
After several minutes at idle, the engine may be
shut off by pushing the engine stop button. Turn
the ignition switch to the OFF position after the
engine has stopped.
NEVER SHIFT BETWEEN FORWARD AND
REVERSE WHILE THE CRANE IS IN MOTION. VEHICLE TOWING If the vehicle is to be towed, it
wil be necessary to run the engine at idle speed to
Full power shifts under load may be made with- lubricate the transmission clutches. If the engine
out endangering the transmission or drive com- cannot be run, towing must be limited to 3 mph
ponents. However, downshifts should not be and and one mile (max. total). If exceeded drive
made when the vehicle speed exceeds the maxi- lines must be disconnected, tow at 20 mph max.
mum speed of the next lower range. Downshifting

RT400 Series 3-5 Issued: Sept 96

 TABLE OF CONTENTS
OPERATING PROCEDURES

TRAVELING AROUND THE JOB SITE

- Do not travel with boom above horizontal

unless the surface is firm, level and free of
bumps and potholes.

- Watch for overhead obstructions such as

When traveling around a job site, it is very trees, power lines, or bridges.
important that the crane operator is very
aware of what is happening with the crane - If the terrain is rough or uneven it may be
as well as with other vehicles and person- necessary to travel at a reduced speed to
nel on the job site. The crane operator prevent instability or damage to the crane.
should observe the following rules as well
as good common sense while moving a - Operating on steep grades requires caution
crane around a job site. because the oil in the engine or transmis-
sion will move to one side of the engine or
NOTE: See the “ON TIRES LIFTS” instructions transmission. As a result, the engine or
found later in this section for instructions transmission may not be fully lubricated
on moving the crane with a load. which could damage the engine or transmis-
sion.
- Carry the boom over the front only.
- The operator must be very careful on steep
- Lock the swing brake and swing lock. side slopes to avoid tipping the crane.

- Secure the hook block or ball to the bumper NOTE: This machine can travel on 15° side slopes
loop or raise the hook block or ball close to which have a firm level prepared surface.
the boom head sheaves before moving. Due to variations in surface, tire pressure,
bumps, potholes, etc., we recommend
- Make sure all outriggers are completely that travel on side slopes be limited to 5°
retracted before moving the crane. and that the boom be horizontal or below.

RT400 Series 3 - 5a Issued: Sept 96

 TABLE OF CONTENTS
OPERATING PROCEDURES

MAKING A TYPICAL LIFT

LIFT PROCEDURE In making lifts, the operator The outrigger beams MUST BE FULLY EX-
must successfully coordinate several crane func- TENDED, and the crane leveled prior to extend-
tions. These include the boom raise/lower, boom ing the boom or lifting loads. To achieve this con-
extend/retract, load hoist/lower and swing func- dition, the vertical jack cylinders should be
tions. Although experienced operators tend to op- extended only enough to lift the wheels off the
erate two or more of these functions simultan- ground.
eously, the lift procedure can be broken down
into the following sequence of operations.

OUTRIGGERS Set the outriggers as follows

FULL extension of the vertical jack cylinders
before initiating any lifting operations:
should be avoided if not necessary to level crane
1. Remove the outrigger beam retaining pins. and raise wheels clear of ground because oil ex-
pansion under extreme heat conditions can
2. To set the four(4) outriggers evenly, operate cause cylinder seal failure. Check to ensure that
switches to raise crane to a level position. all beams are fully extended, swinging the upper
When level, retract jacks (together) at one end if necessary to visually check that each beam
of crane an inch or so, and then extend them reaches full extension. Level the crane using the
again (together) until crane is level. Then re- bubble indicator to determine when a level condi-
peat this process for the opposite end of crane. tion is achieved. While operating the crane, fre-
quently check and level the outriggers between
This equalizes pressure in all four jacks. The
lifts.
controls for the out and down outriggers are
mounted on the dash. The extend/retract
master switch must be actuated before the ap-
propriate function switches can be actuated to
operate the outriggers. The operator must exercise sound judgment in
positioning the outriggers. The outriggers should
not be set near holes, on rocky ground or on ex-
tremely soft ground. Setting the outriggers in
such locations may result in the crane tipping,
causing personal injury or property damage.
Where a firms footing or level ground is not oth-
This is a safety feature to prevent accidental ac- erwise available, it should be provided by sub-
tuation of the outriggers while the crane is in mo- stantial timbers, solid blocking, or other
tion because the STEERING IS NON- structural members sufficient to distribute the
FUNCTIONAL WHILE THE OUTRIGGERS ARE load so as not to exceed the safe bearing capacity
BEING OPERATED. of the underlying material, and to enable leveling
of the crane.

Proper positioning of the outriggers is critically

important to both the safety and effectiveness of
craning operations.

Before making any crane lift, make sure the hook

is properly engaged with the slings, or lifting de-
vice employed to make the lift. Be certain the
hook latch is not supporting any of the load. Re-
fer to the warning tag on the hook block.

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RT400 Series Revised: October 2001
 TABLE OF CONTENTS
OPERATING PROCEDURES

winch drum, which could cause breakage of the

winch rope, or of unseating the rope wedge in the
winch drum, which could result in the uncon-
trolled fall of the hook block and load.

4. Raise the boom to the required angle, consult-

ing the boom angle indicator which indicates
boom angle relative to upperstructure.

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
3. Use the load rating chart attached to the crane back. To LOWER the boom, slowly depress the
to interpret the conditions and limitations that RIGHT boom control pedal or push the lever for-
exist when making a lift with the crane. The ward. Improved control is obtained by operating
determining factors are lifted load, radius, the engine at low speed while “metering” the con-
boom angle, working position, hoist line reev- trols. Always operate and release the controls
ing, tire pressure, travel data, and use of a jib. slowly to minimize dynamic effects of the load.
During a lift where precise control of the load is
The examples given in this section pages 3-21 required, do not attempt to use more than one
thru 3-29 are given for your interpretation of the function at a time.
terminology used on the chart. CAUTION: The
load rating chart values used in the examples
may not be the same as those on your load rating
chart. Use the numbers from the chart attached
to your crane whenever making lift calculation

Always consider possible obstructions when

varying boom height or length; not only those to
the front of the cab at the time of the adjustment,
but those which may be encountered during
swings.
Always consider, anticipate, and/or determine by
trial the maximum amount of wire rope which Think the swing through, considering all obsta-
will be payed off the winch drum to perform each cles, before making the swing.
different craning application of this crane. Be
sure to provide for no less than two full wraps of
wire rope remaining on the winch drum as spec-
ified in all applicable crane operating safety stan-
dards.

The increased possibility for inadequate wraps Never hold the controls in an “activated” position
remaining on the winch drum occurs when oper- once the hoist/lower cylinder or extend/retract
ating with a higher number of parts of line than cylinders have reached the limits of their travel.
are required for the load being lifted, particularly This can cause overheating of the hydraulic oil if
at longer boom lengths and high boom angles. it is run over relief for prolonged periods.
Sufficient wire rope is initially provided to allow
the hook block to reach ground level when reeved 5. Swing the boom over the load.
for the required parts of line indicated on the ca-
pacity chart for all given loads. Reeving with more Upperstructure swing is controlled by the swing
parts of line than required may result in all of the lever. To swing the upperstructure to the RIGHT,
wire rope being payed off the winch drum. PUSH the lever forward. To swing LEFT, PULL the
lever backwards. Swing speed increases as the le-
The intent of this caution is to prevent any pos- ver is moved further forward or back. Swing
sibility of either reverse winding of the rope on the speed also varies with the engine speed.

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OPERATING PROCEDURES

Before attempting to swing the upperstructure,

make sure the swing brake is not set and the
swing lock is not engaged. Be certain that no ob-
structions will block the swing.
While extending the boom, be sure to pay out suf-
When ready, try for a smooth, controlled, safe ficient hoist rope to prevent the hook block from
swing. The swing should be SLOW. Start the being drawn up to the boom peak. The force of
swing SLOWLY and allow the load to build up the extend cylinders can easily break the hoist
only enough momentum to carry it through to the line, dropping the hook block and load which
point where it is to be lowered. may result in personal injury or property dam-
age.
Begin slowing the swing in advance of the point
where the load is to be lowered. Slow the swing Be sure full powered sections are extended equal-
GRADUALLY, so that it appears to “coast” to a ly before lifting load. If sections are out of phase
stop over the desired spot. by more than one of the triangular decals, then
the sections must be resynchronized by either
GRADUALLY slow the swing by use of the swing fully extending or fully retracting the boom.
lever. First, move the lever to the neutral position
and then VERY SLOWLY into the opposite swing The boom extend function on this crane has two
direction position as required to slow the swing. positions and two speeds. When the lever is all
Apply the swing brake, with the foot pedal, when the way forward, the regenerative mode provides
the swing is stopped or when emergency situa- increased speed. With the lever approximately
tions dictate that the swing be terminated one half of the way forward, increased “PUSH” is
abruptly. available at reduced speed.

If properly executed, the load will hang motion- 7. Lower the hook block to the load and fasten the
less when the swing is terminated. If the load is hook.
oscillating, the swing was made too rapidly and/
or stopped too abruptly. Make certain the hook is properly engaged with
the slings, or lifting device employed to make the
lift. Be certain the hook latch is not supporting
any of the load. Refer to warning tag on hook
block.

Stopping the swing too abruptly will cause the Hoisting or lowering of the load with the winch is
load to oscillate and impose side loads on the controlled by the winch lever. LOWER the load by
boom. Because side loading can damage boom, pushing the lever FORWARD and RAISE the load
ALWAYS START AND STOP SWINGS GRADUAL- by pulling the lever BACK. Improved control is
LY. obtained by operating the engine at low speed
while “metering” the control. Always actuate and
release this lever slowly to minimize dynamic eff-
ects of the load and to prevent “birds-nesting” of
the cable on the winch drum.
Never pull sideways with a crane boom. Crane
booms are not designed for excessive side pull To shift the winch into the high-speed mode the
and may collapse if subjected to excessive side winch lever is moved through the normal “low
loading. speed” position and then further, shifting a sec-
ond valve spool. When slowing the winch, reverse
6. Extend the boom to the desired length. Do not the above procedure to bring the load to a gradual
extend the boom further than necessary to stop. When the winch is operated in this mode,
per- form the lift. available line pull is reduced to approximately
one- half of the normal value. NOTE: Two speed
EXTEND the boom by pushing the extend-retract winch will operate in low speed mode ONLY if op-
lever FORWARD and RETRACT it by pulling the erating telescope, auxiliary winch or a clam bucket
lever BACK. simultaneously with the winch functions.

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OPERATING PROCEDURES

8. Lift the load to the desired height. For safety, When operating a hydraulic crane, the operator
lift the load no higher than necessary. should realize that hydraulic and structural com-
petence, NOT TIPPING LOAD, is often the deter-
The crane is equipped with a two block system, in minant of lifting capacity.
the event that the hook or block is raised beyond
a safe position, a warning light appears on the Therefore, THE OPERATOR MUST BE GUIDED
dash and, if horn switch is activated, an audible SOLELY BY THE APPROPRIATE MANUFACTUR-
warning will sound. Some cranes may be ER’S LOAD RATING CHART OR BY THE LOAD
equipped with control disconnects which will pre- RATING PLATE MOUNTED ON THE CRANE
vent the winch from raising the load and the when considering load weight. The manufactur-
boom from extending or lowering. To continue er’s rated loads must never be exceeded.
crane operation, retract or raise the boom and/or
lower the hook. Cranes which are factory equipped with auxiliary
winches may require additional counteweight if
If the operator wishes to raise the hook block be- the auxiliary winch is removed. Refer to the ca-
yond the point at which the two block is activat- pacity chart (load rating plate) for the required
ed, he may override the system by using the key counterweight total.
switch (shown in control and instrument sections).

When lowering light loads, be sure to maintain

Continuing to pull the block up after contact has sufficient cable tension to prevent the cable from
been made with the boom head may result in becoming loose on the cable drum. Loose cable
damage to boom head and sheaves or the cable can slip and then bind suddenly, causing “jerky”
may be broken causing the load to drop. lowering and shock loading of the boom. Loose
wraps may form loops which can be overlain
9. Swing and spot the load over the location when the cable is wound onto the winch drum.
where it is to be deposited. These conditions can result in personal injury or
property damage.

10. Lower the load and unfasten the hook.

When spotting the load it may be necessary to al-

ter the boom length or boom angle. In making
these adjustments, the operator must guard
against exceeding the rated load as determined
by the load rating charts.

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OPERATING PROCEDURES

CRANE HAND SIGNALS

HOIST. With forearn vertical fore LOWER. With arm extended USE MAIN HOIST. Tap fist on USE WHIPLINE. (Auxiliary RAISE BOOM. Arm extended,
finger pointing up, move hand in downward forefinger pointing head; then use regual signals. Hoist) Tap elbow with one hand, fingers closed, thumb pointing
small horizontal .circle. down, move hand in small circle. then use regular signals. upward.

MOVE SLOWLY. Use one hand to RAISE THE BOOM AN LOWER LOWER THE BOOM AND RAISE,
give any motion signal and place THE LOAD. With arm extended, THE LOAD With arm extended,
LOWER BOOM. Arm extended other hand motionless in front of thumb pointing up, flex fingers in thumb pointing dowm, flex fingers SWING. Arm extended, point with
fingers closed, thumb pointing hand gving the motion signal. (Hoist and out as load movement is in and out as long as load finger in direction of swing of boom.
downward. slowly shown as example.) desired. movement is desired.

TRAVEL. Arm extended forward, TRAVEL.( Both Tracks.) Use both

STOP. Arm extended, palm EMERGENCY STOP. Both arms hand open and slightly raised, fists in front of body, making a
down , move arm back and forth extended, plams down, move arms make pushiing motion in direction DOG EVERYTHING. Clasp circular motion about each other,
horizontally. back and forth horizontally. of travel. hands in front of body. indicating direction of travel, forward
or backward. (for land cranes only.)

TRAVEL. (One Track) Lock the

track on one side indicated by EXTEND BOOM. (Telescoping
raised fist. Travel opposite track in EXTEND BOOM. (Telescoping RETRACT BOOM. Telescoping RETRACT BOOM. (Telescoping
Booms.) Both fists in front of Boom.) One Hand Signal. One Boom.) One Hand Signal. One fist in
direction indicated by circular Booms.) Both fists in front of body fist in front of chest with thumb
motion of other fist, rotated in with thumbs pointing outward. body with thumbs pointing front of chest, thumb pointing outward
toward each other. tapping chest. and heel of fist tapping chest.
front of body. (land cranes only.)

KNOW THE CRANE SIGNALS! Poor communica-

tion between the operator and personnel directing
lifts can result in property damage or personal in-
jury.

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OPERATING PROCEDURES

“ON TIRES” LIFTS

Listed below are special precautions for “On

Tires” lifts.

All crane load ratings are based on nonuse of the

travel function while handling loads. However,
cranes may be utilized for pick and carry opera- Insufficient tire pressure reduces the “ON TIRES”
tions. Traveling with suspended loads involves so capacity. Attempts to pick rated capacity without
many variables such as ground conditions, boom properly inflated tires may cause crane to tip
length, momentum in starting and stopping, etc., and/or result in damage to tires and rims.
that it is impossible to devise a single standard
rating procedure with any assurance of safety.
For such operations the user must evaluate pre-
vailing conditions and determine safe practices,
exercising precautions, such as the following:
The axle lockout system should be bled and filled
1.The boom shall be carried straight over the whenever oil seepage, dirt or oil is detected at the
front of the crane. breather plug or on the rod.

2. Travel speed reduced to suit conditions. Air in the axle lockout system decreases stability.
Bleed and fill the system IMMEDIATELY when-
3. Maintain specified tire pressures. ever this condition occurs.

4. Avoid sudden starts and stops.

5.Provide tag or restraint lines to snub swinging

of the load.
Excessive high hydraulic oil temperatures cause
6. Keep the load as close to ground as possible. rapid deterioration of rubber components (hose,
0-rings, etc.). A hydraulic oil cooler is required if
7. Set the swing brake and swing lock. high cyclic operations (clam, concrete bucket,
unloading) are performed. If hydraulic reservoir
8. Travel must be on a smooth level surface that temperature reaches 200 deg. F, reduce the duty
is capable of supporting the weight of the load- cycle. Stop operations as required to prevent fur-
ed crane. The travel surface must also be free ther increase in the hydraulic oil temperature.
of holes or debris that can cause crane insta-
bility.

These precautions are necessary to prevent a

“pendulum” effect of a swinging load. The results
of this happening can cause a machine tip over.

Any variation from the above conditions will re-

quire the operator to consider the prevailing con-
ditions and reduce the lift capacities accordingly.

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OPERATING PROCEDURES

HOIST LINE REEVING

AUXILIARY WINCH SEE PAGES 3-13 AND 4-33

FOR CABLE AND SOCKET
MAIN WINCH SPECIFICATIONS

DEAD END FOR

EVEN PARTS
OF LINE

DEAD END FOR

5 SHEAVE ODD PARTS
OF LINE

WINCH
DEAD 4 SHEAVE
END

PARTS LINE BOOM HEAD HOOK BLOCK

1 2 D

2 3D 3

CABLE SOCKET 3 23 3D

4 14D 14

NOTE: 5 234 24D

SHEAVES IN BOOM HEAD AND HOOK
BLOCK ARE NUMBERD FROM LEFT 6 234D 234
TO RIGHT AS VIEWED FROM THE OP-
7 1234 234D
ERATOR’S STATION. “D” INDICATES
PINNED END OF ROPE. 8 1234D 1234

9 12345 1234D

10 12345D 12345

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OPERATING PROCEDURES

HOIST LINE REEVING WIRE ROPE SPECIFICATIONS

MAIN WINCH
When reeving the crane in preparation for any
job, it should be kept in mind that hoisting and STD.-5/8” dia. 6X19 OR 6X37 CLASS
lowering speeds decrease as the number of parts
IWRC REG. LAY WIRE ROPE
of line increases. For the most efficient use of the
MINIMUM BREAKING STRENGTH-17.9 TONS
crane, it is therefore desirable to use the mini-
mum required number of parts for lifting the load
OPT.- 5/8” ROTATION RESISTANT
as determined by referring to the load rating
COMPACTED STRAND 18X19 OR 19X19
chart.
MINIMUM BREAKING STRENGTH 22.7 TONS
This crane incorporates a “Quick Reeving” boom
head and block which do not require removal of
AUXILIARY WINCH
the wedge and socket from the rope in order to
change the reeving. Removal of two pins in the
boom head and three in the hook block will allow
STD.-1/2” 6X19 OR 6X37 CLASS
the wedge and socket to pass through.
IWRC REG. LAY WIRE ROPE
MINIMUM BREAKING STRENGTH 13.3 TONS

OPT.-9/16” ROTATION RESISTANT

COMPACTED STRAND 18X19 OR 19X19
MINIMUM BREAKING STRENGTH 18.5 TONS
Never use less than the number of parts called for
by the load rating chart.

If it is not practical to alter the reeving during the

course of the work, the required number of rope
parts must be determined on the basis of the
heaviest load to be lifted during operations.
UNDER NO CONDITIONS CAN ANY OTHER SIZE,
TYPE, OR LENGTH OF WIRE ROPE BE USED ON
When the required number of rope parts has THIS EQUIPMENT SINCE IT CONSTITUTES A
been determined, reeve the rope as shown on SAFTY HAZARD
page 3-14. attach a wedge type rope socket to the
wire rope dead end and secure it to either the
boom peak or hook block as required. Dead end
the rope on the hook block for an odd number of
line parts, and on the boom peak for an even TRANSPORTING THE CRANE
number of parts.

As shipped from the factory, the crane has suffi-

cient wire rope provided to allow the hook to each
ground level with any boom length and elevation
when reeved with minimum parts of line required
for the load being lifted. Refer to the Crane Ca- The boom extend sections should be restrained to
pacity Chart for parts of line required. prevent gradual rollout when transporting the
crane on a semi-trailer. The hydraulic system will
not hold the sections against the hard breaking
jolts while the crane is being transported.

Restrain the boom by snugging the hook block

against the boom head, or secure the boom head
back to the base section of the boom with chains
or cable. An extended(ing) boom can cause sub-
stantial damage.

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OPERATING PROCEDURES

4. Boom down slowly and the jib will swing

SIDE STOW OFFSET JIB around close to engagement with the ears on
the L.H. side. Manually push jib into engage-
ERECTING JIB ment with the L.H. ears.
1. The upper machine should be positioned over
the rear with the outriggers set and the boom 5. Pin jib to the boom and secure with hair pin
in a horizontal position. Retract the boom cotters.
completely until the mounting holes on the
boom head and the holes in the jib align on the 6. In this erected position the jib can be reeved
R.H. side of the boom. with hoist cable and the offset attitude may
also be set to a 15° or 30° degree position.
2. Pin the jib to the boom and secure with the
hair pin cotters JIB STOWAGE
. 1. Before stowing the jib if it has been offset it
must be returned to a straight attitude and
the hoist cable removed. Position the boom
over the rear with the outriggers set. Boom
down so that the attachment pins on the L.H.
side can easily be removed.

2. Extend boom approximately 2 feet and unpin

the L.H. side. Manually swing the jib to a po-
sition of about 30° degrees to the right to dis-
JIB PINS engage the attaching ears on the left side.

3. Slowly boom up to horizontal and the jib will

swing around to 90° degrees. When it reaches
this point slowly boom up to finish swinging it
into the side of the boom. If booming up high
enough to completely swing the jib in is not
possible attach a tether rope to the jib tip and
pull the rope through the ring on the ramp
and pull it in and tie it off.
3. Disengage the spring pin from the front cap-
turing spear. Extend the boom enough to dis-
engage both the front and rear spears. The jib
will begin to swing out to an approximate 45°
degree angle.

RING

SPRING PIN

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OPERATING PROCEDURES

4. With the cam roller aligned on the ramp retract 5. Secure the front spear with the spring pin lo-
the boom back until the capture spears en- cation. Remove the remaining mounting pins
gage and seat. on the R.H. side of the boom head.

SPRING
PIN
CAM ROLLER
RAMP

6. Jib is stowed.

JIB ERECTION JIB EXTENSION

The jib will be in the Straight no offset attitude If extending the jib stinger remove the extension
when it is erected. To use the jib, reeve a single retaining pin (6). Change the two block plug to
part of hoist rope (1) over the mast sheave (2) the appropriate receptacle. Pull out the exten-
and over the jib tip sheave (3). Use the quick sion manually until the outer retaining holes
reeving pins (4) so that the rope socket end can line up. Lower the boom down below horizontal
be left on the end of the rope while reeving. to aid in extension. Reinstall retaining pin and
cotter pin. To retract extension, remove the re-
taining pin. Pull against the jib head slowly with
the socket attached to the hoist rope. Replace re-
taining pin and cotter.

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OPERATING PROCEDURES

JIB OFFSET pin (5). With the pin removed pay out hoist cable
To change to either a 15° or 30° offset the exten- to lower the jib. At the same time raise the boom
sion stinger must be in the retracted position. Re- so that the adjustable links will slide down an-
lieve the weight of the jib from pin (5). Do this by dalign with the 15° or 30° pin location.Reinstall
dead ending the rope end with socket attached to pin (5) in the desired location. Remove the ten-
the dead end bracket. Put a slight hoisting pres- sion from the rope and detach it from the dead-
sure on the rope to support the jib while removing end. If extending the jib leave attached until
extension is complete.

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OPERATING PROCEDURES

EXTENDING THE STINGER IN THE OFFSET

POSITION
If extending the stinger remove pin (6) and pay
out rope allowing the stinger to slide out. It may
be necessary to extend the boom and lower the jib
tip to the ground. Then if necessary continue to
retract and lower the boom simultaneously to When extending the stinger and rope do not allow
lower the pin position near enough to the ground any slack rope on the winch drum or to loop off
to pin the stinger in the extended position. Whe- of the sheave. It will whip when the stinger slides
nin the desired offset position relieve tension on out.
the rope enough to remove the socket from the
deadend. NOTE: The jib will have to be returned to the
straight position and the stinger retracted before
it can be restored on the side of the boom for
transportation purposes.

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OPERATING PROCEDURES

UNUSUAL OPERATING CONDITIONS

Special problems in maintenance and operation repair any cooling system component found to be
are caused by unusual conditions such as ex- defective.
tremes in heat, cold and humidity, high altitude,
salt water, and dusty or sandy work sites. When 2. Condensation in the fuel tank contaminates
operating under such conditions, special precau- the fuel supply with water, which can freeze in
tions must be taken to prevent damage, minimize the fuel lines and block the fuel flow to the en-
wear, and avoid component deterioration. gine. To minimize this possibility, keep the
tank as full as is practical during cold weather.
EXTREME COLD In periods of extreme cold, the This may entail refilling the tank more fre-
problems of freeze damage, adequate lubrication quently than usual, but the inconvenience is
and battery failure may become particularly trou- small compared to clearing a blocked fuel line.
blesome. With the onset of very cold weather, it is
advisable to “winterize” the crane by servicing the If water should be noticed in the fuel supply,
cooling system and switching to the lubricants drain the tank and refill it with uncontaminated
recommended for cold weather usage. Follow the fuel.
recommendations in this manual when the crane
must be operated in very cold conditions. 3. Lubricate the crane with the lubricants recom-
mended for cold weather operation on the Lu-
1. To prevent freeze damage to the cooling system brication Chart. If necessary, change the en-
and cracking of the engine block or head, gine oil and other lubricants in order to con-
drain and flush the cooling system. Clean the form to the recommendations.
radiator exterior, making certain the air pas-
sages through the core and the cooling fins are 4. The battery is more likely to sustain freeze
free of foreign matter. damage if not kept fully charged because its
electrolyte will freeze at a higher temperature
Refill the cooling system, adding an anti-freeze than that in a fully charged battery. Be certain
solution recommended by the engine manufac- the battery is charging when the engine is run-
turer in an amount and strength appropriate to ning and use an external charger to restore
the anticipated temperatures. A corrosion inhibi- full charge when the crane is not being operat-
tor is recommended. ed.

The battery can discharge if snow or ice short cir-

cuits the terminals. Keep the battery posts and
cable connectors clean and dry. Remove any cor-
rosion with a solution of soda and water.

Never use a chromate base corrosion inhibitor During extremely cold weather, it is advisable to
when the coolant contains ethylene glycol. Use remove and store the battery in a heated area
only non-chromate base inhibitors. Chromate when the crane is to remain idle overnight or for
base inhibitors reacting with ethylene glycol can any extended period.
produce chromium hydroxide, commonly known
as “green slime”. This substance reduces the heat AIR BRAKES At least once a day, drain the water
transfer rate and can cause serious engine over- accumulation from the air tanks, and check the
heating. alcohol evaporator fluid level. Fill with methyl al-
cohol only.
Inspect the thermostat, clamps, radiator hoses
and radiator core for proper condition. Replace or

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OPERATING PROCEDURES

5. Special attention must be given to the hydrau- eratures. Refer to the Lubrication Chart and
lic oil during very cold weather. lubricate the crane using the lubricants rec-
ommended for the expected temperatures.

Crankcase oil is particularly important because

it helps dissipate heat. Check the oil level fre-
quently and add oil as necessary to maintain re-
quired level. Too little oil will hinder heat dissipa-
NEVER ENGAGE THE HYDRAULIC PUMP AND tion.
ACTUATE THE HYDRUALIC SYSTEM BEFORE
THE HYDRAULIC OIL IS WARM. Cold, sluggish 2. To ensure proper coolant circulation, drain
oil can cause pump cavitation. If the crane is not and flush the cooling system, clean any for-
equipped with a reservoir immersion heater and eign matter from the radiator cooling fins and
running the oil over relief will not warm it suffi- through core air passages, replace defective
ciently to prevent pump cavitation with the en- hoses, tighten hose clamps, tension the water
gine running very slowly, cease attempts to pump drive belt properly, eliminate any leaks
engage the pump until an external heat source detected and fill the system with a 50% solu-
can be obtained. tion of ethylene glycol. A corrosion inhibitor is
recommended.
Once the reservoir is warm to the touch, actuate
the hydraulic system by engaging the hydraulic Engine overheating due to loss of coolant will
pump. Continue warming the oil and slowly cycle most often be corrected by SLOWLY adding cool-
all crane functions, actuating all cylinders in ant while the engine is running at FAST IDLE.
turn, swinging the upper and operating the Should this fail to correct the problem, drain and
winches in both directions. flush the system and refill with fresh coolant
(50% solution of ethylene glycol) and a corrosion
The hydraulic oil may be run over relief to aid in inhibitor.
the warm-up process. To do this, actuate a func-
tion, allow the cylinders involved to reach the lim-
its of their travel and hold the control in the en-
gaged position for a few seconds.

When running hydraulic oil over relief to warm it,

be sure to restrict the flow to as slow a speed as Allow the engine to cool before draining and
possible by moderating pressure on the controls flushing the cooling system.
being engaged and running the engine at low
speed. Water containing more than small concentra-
tions of salt or minerals should not be used in the
6. At the end of the work period, or whenever the cooling system. Salt facilitates corrosion and
crane is to be left idle for extended periods, minerals deposited on the coolant passage walls.
prevent it from being frozen to the ground by Both processes inhibit proper cooling.
parking it on a wood, concrete, asphalt or mat
surface. 3. Air circulation around the engine and battery
must not be restricted. Keep air intake and ex-
EXTREME HEAT Like extreme cold, requires haust openings clear of leaves, paper or other
that precautions be taken with respect to the foreign matter which may restrict air flow.
cooling system, the battery and lubrication. Pro-
tect the crane by performing the following recom- 4. Keep the engine clean of dirt, grease and other
mended procedures: substances which inhibit heat dissipation.

1. High temperatures necessitate the use of lubri- 5. Use sound judgment in operating the engine.
cants which are both more viscous and which Avoid the two extremes of racing and lugging.
resist deterioration at higher operating temp-

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OPERATING PROCEDURES

Advance the throttle only enough to handle the cation and service should be adjusted according-
load, yet be certain that the engine speed is high ly.
enough to maintain adequate fan speed for cool-
ing. HIGH HUMIDITY OR SALTWATER In some loca-
tions, such as coastal areas, the crane may be ex-
Run the engine only when engaged in work oper- posed to the deteriorating effects of salt,
tions or when traveling the crane. Avoid pro- moisture, or both. To protect exposed metallic
longed periods at idle and shut the engine down surfaces, wiring, hoist rope, paint and other
if operations are interrupted. items, keep them dry and well lubricated where
salt or high humidity are encountered. Follow the
SANDY OR DUSTY WORK SITES The presence recommendations below when operating in these
of large amounts of sand or dust at the work site conditions:
can contribute to accelerated component wear.
Either substance will act as an abrasive when de- 1. Make frequent inspections for rust and corro-
posited on moving parts of the crane. The prob- sion and remove them as soon as they are de-
lem is combated by more frequent lubrication tected. Dry and paint exposed surfaces after
and by the servicing of breathers and filters at rust and corrosion have been removed.
shorter intervals. Follow the recommendations
below when operating in sand or dust on a regu- 2. Where paint may not be applied, such as on
lar basis. polished or machined surfaces, coat the area
with grease or lubricant to repel water.
1. Keep sand and dust out of the hydraulic sys-
tem by keeping the reservoir filler cap tight 3. Keep bearings and their surrounding surfaces
and servicing the hydraulic system filters fre- well lubricated to prevent the entry of water.
quently.
4. Hoist rope must be kept well lubricated to pre-
2. The fuel system should be kept free of sand vent moisture and salt from penetrating the
and dust by keeping the tank filler cap tight cable strands.
and servicing the fuel filters frequently.
HIGH ALTITUDES Variations in altitude alter the
3. The engine breathers and air cleaner should fuel-air mixture burned in the engine and affect
also be serviced frequently to prevent sand the engine’s performance. At high altitudes, at-
and dust from entering the engine. The engine mospheric pressures are lower and less oxygen is
oil and oil filter should be changed at shorter available for combustion of the fuel. Above
than normal intervals to ensure a clean oil 10,000’ the engine fuel injectors may have to be
supply to the engine’s moving parts. changed to ensure proper performance. Consult
engine manufacturer should this problem arise.
4. When lubricating the crane, thoroughly clean
each grease fitting before attaching the grease Keeping the air cleaner clean and free of obstruc-
gun. Pump generous amounts of grease into tions will help alleviate high altitude problems.
all lubrication points, using the fresh grease to
pump out the old. At high altitudes, closely monitor the engine tem-
perature for overheating.
5. Adequate ground bearing support must be
provided for the outrigger floats when operat-
ing in sand. Be alert for signs of carrier move-
ment during operations.

The increased frequency of lubrication and ser-

vice discussed above should be determined by
observations made at the work site. Inspection
will determine how long it takes for lubricants,
breathers and filters to accumulate unacceptable
amounts of sand or dust. The frequency of lubri-

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OPERATING PROCEDURES

of the crane is always the end opposite the en-

LOAD RATING CHART INTERPRETATION gine.

In the following pages are examples of a load “Front” when the crane is on outriggers is the
chart, these example charts may differ from the area inside the are bounded by lines from the
chart supplied with your crane. Always use the centerline of rotation through the front outrigger
load rating chart supplied with the crane to inter- vertical jack cylinders.
pret the conditions and limitations that exist
when making a lift with the crane. The determin- “St. over Front” when operating on tires means
ing factors are lifted load, radius, boom angle, the boom and load must be positioned straight to
working position, hoist line reeving, tire pressure, the front of crane and not swung to right or left.
travel data, use of a jib, and any other special
conditions that exist, such as wind velocity, soil 360° means the load can be swung to any posi-
conditions, etc. tion around the crane.

DEFINITIONS OF LOAD CHART TERMS

Deducts:
Lifted Load: The “on outriggers” rated capacities are for lifting
The lifted load is the total weight of all the items over the main boom point. Jibs, if so equipped,
suspended on the wire rope. are in the stowed position. Any specialty items at-
tached to the boom head should be removed. In
Example certain instances, it is advantageous, from a job
set-up point of view, to lift over the boom point
Hook block 750 lbs. with the jib erected. In these instances, it is nec-
Slings 215 lbs. essary to make deductions from the rated loads
Object Lifted 19,000 lbs. shown in the load rating chart to determine the
Lifted Load 19,965 lbs. correct rated load. Hook blocks or any specialty
items should be removed from the jib point when
Radius: lifting over the main boom point.
The radius is the horizontal distance from the
center of the swing bearing to the center of the
lifted load.

Deflection of the crane boom will tend to increase

the radius as the load is lifted. To minimize this,
use the combinations of boom angle and length
shown in the load rating chart. Do not allow the
radius to exceed that given for the rated load.

Boom Angle :
The boom angle is the angle of the boom mea-
sured from horizontal. Use the angles shown to
approximate the loaded radius, but do not rely
solely on a boom angle indicator to determine ra-
dius. Always measure the actual radius when de-
termining main boom capacities. Also, there are deductions for jib operation due to
hook blocks hanging on the main boom point. In
Front and 360°: this circumstance, reduce the jib capacity by the
The “crane working position” diagram is a view weight of the hook block and/or other specialty
looking straight down on the crane with the up- items hanging from the main boom point.
perstructure and the boom removed. The “front”

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OPERATING PROCEDURES

Cut-Offs:
Rated chart values of less than 1,000 lbs. for on
outriggers, side-stow and stow-away jibs are not
shown. On rubber values less than 600 lbs. are
not shown. This is done because the effects of
wind, pendulum action, jerking, etc., can cause a
tip over. Therefore:

Extending the boom or boom and jib combina-

tion into unrated areas of the chart can
cause tip over. See Note 19 on Load Chart.

LOAD CHART NOTE

19. CRANE LOAD RATINGS WITH AN ASTERICK (*) BESIDE
THEM ARE BASED ON THE CRANE’S STUCTURAL
STRENGTH. ALL OTHER RATINGS ARE BASED ON STABIL-
ITY AND DO NOT EXCEED THE SPEWCIFIED PERCENTAGE
OF TIPPING LOAD AS DETERMINED BY SAE CRANE STA-
BILITY TEST CODE J-765A.

Note on the accompanying examples that a sig-

nificant portion of the range of the machine is un-
rated. The side stow jib at 30° offset, with full
boom is longer than 123 ft. but is cutoff at 123 ft.
radius. The “On Tire” chart shows the crane can-
not be operated beyond a 60 ft. radius on tires.

Do not operate at a longer radius than those

listed on the applicable load rating charts as
tipping can occur without a load on the hook.

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OPERATING PROCEDURES

On Outriggers Load Ratings: 6. Determine load radius, boom angle, and boom
To determine the boom extension capacities with length.
the crane on outriggers, use the following proce-
dure: 7. Compare load weight with chart rated capacity
for the boom length, radius, and boom angle.
1. Determine weight of load to be lifted.
8. The lifted load must not exceed the chart rated
2. Determine weight of slings and rigging hard- capacity for the boom length and radius.
ware.
In this example, the lifted load of 25,300 lbs. is
3. Determine weight of hook block. less than the rated load of 27,800 lbs. and can be
handled as long as the machine is on outriggers
4. Determine other capacity deductions. per Notes 6 & 7, the load stays at 30 feet of radius
or less, the conditions of Note 18 are met and the
5. Calculate weight of lifted load. machine is equipped per Lift Chart specifications.

LOAD CHART NOTES

6. CRANE LOAD RATINGS ARE BASED ON THE CRANE BEING LEV-
ELED AND STANDING ON FIRM, UNIFORM SUPPORTING SUR-
FACE.
7. CRANE LOAD RATINGS ON OUTRIGGERS ARE BASED ON ALL OUT-
RIGGER BEAMS FULLY EXTENDED AND THE TIRES RAISED FREE
OF THE SUPPORTING SURFACE.
18.PRACTICAL WORKING LOADS DEPEND ON THE SUPPORTING
SURFACE, WIND VELOCITY, PENDULUM ACTION, JERKING OR
SUDDEN STOPPING OF LOADS, HAZARDOUS SURROUNDINGS,
EXPERIENCE OF PERSONNEL AND PROPER OPERATION, TIRE IN-
FLATION, TIRE CONDITION, TRAVELING WITH LOADS, MULTIPLE
CRANE LIFTS, PROXIMITY OF ELECTRICAL WIRES, ETC. APPRO-
PRIATE REDUCTION OF LOAD RATINGS MUST BE MADE FOR
THESE AND ANY OTHER CONDITIONS WHICH MAY AFFECT PRAC-
TICAL WORKING LOADS.

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OPERATING PROCEDURES

JIBS SIDE-STOW JIB

To determine the jib capacities of the crane with
all boom lengths, use the following procedure:

1. Determine weight of load to be lifted.

2. Determine weight of slings and rigging hard- Jibs are rated by boom angle #? only and not by
ware. radius. This means that as long as the boom is at
61° boom angle and the jib at 30° offset, before
3. Determine weight of hook block. loading, no matter if the boom is fully extended or
retracted, it can only lift a maximum of 3,300 lbs.
4. Determine capacity deductions. on a 33 foot side-stow jib. The radius shown in
the jib chart is the expected radius with a fully
5. Calculate weight of lifted load. extended boom and jib after loading and deflec-
tion.
6. Determine jib type and length, jib offset, main
boom angle.

7. Select correct jib load chart (stowaway or side-

stow).
Never use a jib for clamshell or magnet operation.
8. Compare load weight with chart rated capacity The heavy side load due to swinging and bounc-
for the jib length, boom angle, and jib offset (if ing that can occur could damage jib or boom
applicable). point. This is also true of pick and carry opera-
tions.

Example

Hook & Ball 239 lbs.

Slings 300 lbs.
Object Lifted 2,500 lbs

Load Lifted = 3,039 lbs.

In this example the total load

lifted is 3,039 lbs. The boom
angle is 61°, the jib is at the 30°
offset and the machine is on
outriggers. In this case the load
can be safly lifted.

= 61°

3,039
POUNDS

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OPERATING PROCEDURES

JIBS In the following example the crane is set up as fol-

To determine the jib capacities of the crane with lows:
all boom lengths, use the following procedure: 1. On outriggers.
2. Side stow jib erected at 30° offset.
1. Determine weight of load to be lifted. 3. Auxiliary boom head sheave erected but not
used.
2. Determine weight of slings and rigging hard- 4. Hook block off the main head but not used.
ware. 5. Boom angle of 61°.

3. Determine weight of hook block. At first glance it appears that the 2,350 lb. object
to be lifted is well within the capacity of the jib
4. Determine capacity deductions. however after making the deductions for the
erected and unused equipment and figuring the
5. Calculate weight of lifted load. additional weight for slings and the hook & ball
this lift CANNOT be made.
6. Determine jib type and length, jib offset, main
boom angle. Note: Deductions for erected but unused equip-
ment can either be deducted from the capacity OR
7. Select correct jib load chart (stowaway or side- added to the weight to be lifted. In this case we
stow). will add the weight to the load.

8. Compare load weight with chart rated capacity

for the jib length, boom angle, and jib offset (if
applicable).

This lift cannot be made.

EXAMPLE

Hook & Ball 239 lbs.

Slings 300 lbs.
Auxiliary Head 110 lbs.
Hook Block 750 lbs.
Object 2,350 lbs.

Actual Load = 3,749 lbs.

= 61°

3,749
POUNDS

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OPERATING PROCEDURES

ON TIRES

On tires operation, particularly pick and carry, Ensure that the tires are inflated as shown in the
must be done in a slow, smooth manner over level recommended tire pressure chart. Refer to pro-
terrain that will support the crane, with the loads cedure for tire inflation in Section 4, Page 4-12.
close to the ground and the boom as low as pos-
sible to avoid the load swinging unintentionally,
causing injury or tip over. Do not pick and carry
with the jib since the load is further extended
from the machine and the jib can be easily dam-
aged.

“Creep” means the crane can be moved at a max-

imum speed of one (1) MPH for a distance of 200
feet and then a 30 minute waiting period is nec-
essary to cool the tires. Overheating will greatly
reduce the life of the tires.

The maximum boom length shown on the On Tire

chart is the maximum boom length that can be
used at the radius shown. This is done to limit
the boom height when working on tires. Do not
exceed the maximum boom length for the given Never move the crane carrying a load with the
radius. boom in any position except straight over the
. front.

2.5 MPH means the crane can be driven at this

speed, or slower, with the tires at the proper infla-
tion pressure with the boom straight over the
front.

“Stationary” means that the crane cannot be

moved when loaded to the levels shown in the on
tire load chart.

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OPERATING PROCEDURES

STABILITY/ STRUCTURAL STRENGTH

.
Crane load ratings with an asterisk (*) beside
them are based on the machine’s structural
strength. All other ratings are based on stability.
Therefore, when lifting in an area where the rated
load is governed by strength, an overload can
produce an abrupt failure. This may be in the Therefore: CAUTION - Do not attempt to tip the ma-
boom, outrigger beam, or elsewhere. For exam- chine to determine allowable load.
ple, this is particularly true when the operator
does not know the weight of the lifted load or fails MAXIMUM PERMISSIBLE HOIST LINE LOAD
to account for the forces necessary to unstick a By lifting with the boom or telescope cylinders,
load from the mud or the extra ice, snow, mud, the crane can easily exceed the rated capacity of
etc. on the load. the wire rope and even the breaking strength of
the wire rope. It is mandatory that wire rope uti-
In the stability zone, some operators foolishly at- lized on the crane have adequate breaking
tempt to determine if the crane can lift the load strength as rated by the rope manufacturer, be in
by allowing the crane to tip. This can result in a good condition, and proper number of parts of
tip over, particularly if the boom point moves out line be used. See Page 4-32 for maintenance and
to a greater radius than the load centerline, inspection and consult PCSA Std. No.4 and ANSI
which it tends to do due to boom deflection and Standard B30.5 and the wire rope users manual.
machine tipping. In this condition, when the load
comes free of the ground, it swings out rapidly,
endangering workmen and can pull the crane
into a tip over condition. Also, if the load is heavy
enough and will not move and the boom point
moves out far enough, the rating can change
back to structural with the associated abrupt
failure discussed above

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 TABLE OF CONTENTS

MAINTENANCE CHECKS

INDEX

SUBJECT PAGE

MACHINE MAINTENANCE CHECK LIST 4-2

ENGINE MAINTENANCE 4-6

ENGINE RADIATOR MAINTENANCE 4-7

TRANSMISSION MAINTENANCE 4-8

TRANSMISSION 4-10

AXLE MAINTENANCE 4-11

TIRES 4-12

AIR SYSTEM MAINTENANCE 4-14

BRAKE SYSTEM 4-15

TURNTABLE & SWING PINION 4-17

SWING REDUCER 4-18

HYDRAULIC SYSTEM MAINTENANCE 4-19

HYDRAULIC OIL REQUIREMENTS 4-21

CABLE LUBRICATION METHODS 4-26

ELECTRICAL SYSTEM BATTERY CHECK 4-27

ELECTRICAL SYSTEM COLLECTOR RING 4-29

CABLE REEVING 4-31

SPOOLING WIRE ROPE ON DRUMS 4-31

WIRE ROPE & REEVING 4-32

WIRE ROPE SPECIFICATIONS 4-32

CRANE BOOM 4-35

Issued: Sept 96
 TABLE OF CONTENTS

MAINTENANCE CHECKS

4-0
Issued: Sept 96
 TABLE OF CONTENTS

MAINTENANCE CHECKS

INTRODUCTION or while operating the crane.

A regular program of periodic preventive maintenence is es- Visual Inspection - Check complete machine for any unusu-
sential to prolong crane operating life, maximize efficient al condition.
service and minimize downtime. This section details a series
of checks and procedures which are to be performed at daily, Check for any leaks or damage to the hydraulic system.
weekly, monthly and semi-annual intervals. These intervals
are stated both in terms of calendar periods and hours of op- Check in the engine compartment:
eration. * Belts for tension and wear
* Coolant level
The checks prescribed for longer intervals include all the * Oil level
checks required for the shorter intervals. Thus, the weekly * Transmission oil level
check includes all items in the daily check, the monthly * Air cleaner sight gauge
check includes weekly and daily checks, and so on through * Air intake
the semi-annual check, which includes the quarterly, month- * Muffler and exhaust
ly, weekly and daily checks.
Check battery box - For battery condition
A convenient check chart provides a means of recording
preventive maintenance performed and serves as a tool de- Crane boom - Check for:
tecting problem areas and reanalyzing maintenance require- * Hook block for wear or damage
ments. The items in each check interval on the check chart * Two block system for proper function
are grouped under their respective headings and covered in * Cable and cable spooling on winch
detail over the course of Section 6. * Cylinder pin connections for wear

This maintenance schedule is a guide which ensures that ba- Check tires, axles, and drive lines, for wear or damage.
sic preventive maintenance requirements will be met under
average operating conditions. Conditions which impose Check in the cab for:
greater wear, loads or strain on the crane may dictate re- * Instruments functioning properly
duced check intervals. Before altering the maintenance * Control operation
schedule, reevaluate crane operation and review the crane * Glass for good visibility
maintenance records. Consider all factors involved and de- * Safety equipment is ready for use
velop a revised schedule adequate to meet routine mainte- * All lights work properly
nance requirements. * Cleanliness - Free from mud and debris.

As a part of each periodic check, refer to the engine manu-

facturer’s manual for engine maintenance requirements.
When servicing the engine, the engine manufacturer’s rec-
ommendations take precedence over those in this manual,
should any discrepancy be noted.

OPERATOR OBSERVATION

As the operator, it is your responsibility to observe and re-

port any unusual sounds, odors, or other signs of abnormal
performance that could indicate trouble ahead. On a routine
basis the following items should be checked before starting

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Issued: Sept 96
 TABLE OF CONTENTS

MAINTENANCE CHECKS

MACHINE MAINTENANCE
CHECK LIST

DAILY CHECK (8 HOURS)

Drain Air Tanks
Perform Daily Lubrication
Check Wire Rope And Related Components
Check Hydraulic Reservoir Fluid Level
Check Air Cleaner
Fill Fuel Tank
Check Controls
Check Engine Oil Level
Check Instruments, Gauges, & Safety Equipment
Check Coolant Level
Make Overall Visual Inspection
Check Hydraulic Cylinder Mounting Bush- ings And
Pins Torque Swing Bearing Bolts *

Check Hydraulic Components Torque Wheel Nuts First 50 Miles*

Check Transmission Oil Level Check Anti-Two Block System

Check Axle Lockout System Check Engine Manufacturer’s Manual For Additional
Maintenance Requirements
Drain Fuel Filters or Water Separator

WEEKLY CHECK (40 HOURS) Check Hydraulic Cylinders And Rods

Perform The Daily Check Make Thorough Inspection Of Wire Rope

Perform Weekly Lubrication Make Initial Replacement Of Hydraulic Return Line

Filter*
Check Swing Reducer Oil Level
Check Alcohol Evaporator Fluid Level
Perform Initial Axle Oil Change*
Visuaily Inspect All Structural Members And
Check Axle Oil Level (after initial change) Welds For Cracks, Alignment and Wear

Check Battery Condition Check Boom For Wear Cracked Welds, Alignment
And Missing Or Illegible Decals
Check Tire Pressure And Condition
Check Engine Manufacturer’s Manual For Additional
Check Air System Safety Valve Maintenance Requirements

* Interval given applies only to initial period of use (break-in).

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MAINTENANCE CHECKS

MONTHLY CHECK (160 HOURS)

Perform Daily And Weekly Checks Obtain Hydraulic Oil Sample for Analysis as
Required in Section 9.
Perform Monthly Lubrication
Clean Radiator Exterior
Check Engine Belts
Check Engine Manufacturer’s Manual For
Drain Hydraulic Reservoir Of Moisture Additional Maintenance Requirements

QUARTERLY CHECK (500 HOURS)

Perform Daily, Weekly And Monthly Checks Replenish Cooling System Corrosion Inhibi-
tor
Perform Quarterly Lubrication
Check Engine Manufacturer’s Manual For
Drain Fuel Tank Of Water And Sediment Additional Maintenance Requirements

Change Transmission Oil And Filter Lubricate Valve Disconnects

Change Hydraulic Return Line Filters

SEMI. ANNUAL CHECK (1000 HOURS)

Perform Daily, Weekly, Monthly And Quar- Change Axle Oil

terly Checks
Check Brake Shoes for Wear Condition
Clean Crankcase Breather
Check Relief Valve Pressure Settings
Clean Cooling System
Torque Swing Bearing Bolts
Check Reservoir Relief Valve
Check Engine Manufacturer’s Manual For
Clean Reservoir Intake Suction Filter Additional Maintenance Requirements

4-3

RT400 Revised: January 2003

 TABLE OF CONTENTS

MAINTENANCE CHECKS

OTHER INTERVALS

200 HOURS: Change Transmission Oil Filter

250 HOURS - CUMMINS ENGINE:

Change Engine Oil and Filter All handles, steps, walkways and platforms must be kept
Check Engine Air Intake free of grease, oils, fuel, mud snow and ice.
Change Engine Air Cleaner Element
Check Engine Drive Belt Tension

600 HOURS: Change Transmission Oil

1500 HOURS: Drain And Clean Hydraulic Reservoir;

Change Hydraulic Fluid
Sand-painted or other grit type anti-slip surfaces must be re-
4000 HOURS/2 YEARS: Disassemble And Inspect newed when ever the surface begins to appear worn.
Winch Components

SPECIAL BREAK IN REQUIREMENTS FOR

NEWCRANES

8 HOURS - During the first 50 miles of service and any

time the wheels have been removed, retorque the
wheel nuts to 400-500ft. lbs.

40 HOURS - After forty hours of travel, drain and refill

the transmission with new fluid.

40 HOURS - Retorque the swing bearing bolts to a

torque of 600 ft. lbs. Recheck every 40 hours until all
bolt are found properly torqued. Thereafter checks
should be performed quarterly.

100 HOURS - After one hundred hours drain and

change the winch lubricant.

100 HOURS - Retighten winch base mounting cap-

screws to 225 ft. lbs. of torque after one hundred hours
of operation.

100 HOURS - Retighten counterweight capscrews to

845 ft. lbs.

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 TABLE OF CONTENTS
WIRE ROPE INSPECTION RECORD
(Refer to Wire Rope Users Manual For Criteria

PLACE OF INSPECTION DATE

DESCRIPTION OF CRANE

Make Model Serial No.

Type and Arrangement of Attachments

DATE OF LAST ROPE INSPECTION

HOURS AND TIME OF SERVICE SINCE LAST INSPECTION

RESULTS OF INSPECTION

Rope Inspected Type and Size Conditions Noted Recommendations

INSPECTOR:

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 TABLE OF CONTENTS

MAINTENANCE AND LUBRICATION

ENGINE MAINTENANCE

For Cummins engine maintenance refer to Cummins Operation and Maintenance Manual for “B” Series engines.

Engine productivity, longevity, and low-cost performance

depend on a regular program of periodic maintenance. The
materials presented here are listed in accordance with the
MAINTENANCE CHECK LIST in Section 4. Consider-
ation may dictate a revision in scheduling for the periodic
Never operate the machine when the oil is above the full
checks.
mark or below the low mark.
As a part of each periodic check, refer to the engine manu-
WATER SEPARATOR
facturer’s manual for engine maintenance requirements.
A water separator is used to remove water contamination
When servicing the engine, the engine manufacturer’s rec-
from the fuel before it enters the engine. Water contamina-
ommendations take precedence over those in this manual,
tion should be drained daily or before it becomes 1/2 full.
should any discrepancy be noted.

AIR CLEANER Inspect the air cleaner and it’s connections

DAILY: for leaks, dents and damage.
FUEL LEVEL The fuel tank is located on the left side of
the machine. Keep the tank as full as possible to minimize
A vacuum actuated indicator mounted on the air cleaner as-
condensation in cold weather. sembly indicates conditions of restricted flow through the
air cleaner. With the engine running at maximum governed
rpm, observe the yellow band on the indicator piston. If the
yellow band reaches the red band on the plastic cylinder, ser-
FILLER PIPE vice is necessary. At this time, change the air cleaner filter
element and clean the intake screen

When using a degreasing agent to clean the engine, be sure

to cover the vacuum actuated indicator (filter minder) with a
protective material. Engine degreasing solvents have a poly-
carbonate base and can damage or destroy the indicator.

Use a good grade of No. 2 diesel fuel. The tank capacity is

50 gallons.

ENGINE OIL LEVEL The engine oil level is checked with

the dipstick located on the left side of the engine (right side
of machine). DO not check the oil level while the engine is
running nor immediately after stopping the engine. For an
accurate reading, allow 15 minutes for the oil to drain into
the sump before checking. Keep the oil level as close to the
full mark as possible. DO NOT OVERFILL

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 TABLE OF CONTENTS

MAINTENANCE AND LUBRICATION

Reset the filter indicator each time the hood is opened as it If a large amount of sediment has accumulated, drain the tank
provides a built-in check to assure proper functioning. If it completely and flush liberally with kerosene until all sedi-
does not reset then the orifice is plugged and must be ment has been removed. Allow the tank to drain completely
cleaned. before refilling with fuel.

A clogged filter restricts engine power output. SEMI ANNUALLY:

CRANKCASE BREATHER Service the crankcase breather
ENGINE BELTS Check all engine belts for condition and following the procedures given in the manufacturer’s manual.
proper adjustment. Consult the engine manufacturer’s man-
ual for the recommended belt tension and tensioning meth- FUEL FILTER ELEMENTS On all machines with Cat en-
ods. gines, remove the fuel filter casings and replace the fuel filter
elements every six months (1000 hours) or when there is ev-
QUARTERLY: Drain accumulated water and sediment idence of plugging.
from the fuel tank by removing the drain plug and allowing
the tank to drain until all water is removed and the fuel flow-
ing from the tank is free of sediment.

ENGINE RADIATOR
MAINTENANCE

DAILY/8 HOURS: MONTHLY/160 HOURS:

COOLANT LEVEL Check the engine radiator coolant RADIATOR EXTERIOR Clean any foreign matter from
level and add coolant if necessary. A solution of 50% eth- the radiator cooling fins and through-core cooling passages
ylene glycol by volume is the recommended year-round by directing compressed air and flushing water over the entire
coolant. Replenish the corrosion inhibitor if necessary. Re- area of the core in the reverse direction of normal air flow.
fer to the “Operation Guide” supplied with the engine, or
the nearest Engine manufacturer’s service center for guid- QUARTERLY:
ance in selecting the proper conditioner for the cooling sys- CORROSION INHIBITOR Replenish the cooling system
tem. corrosion inhibitor every 500 hours of operation.,

Never use a chromate based inhibitor corrosion inhibitor

when the cooling system contains ethylene glycol. Use only
non-chromate based inhibitors. Chromate base inhibitors re-
acting with ethylene glycol can produce hydroxide, common-
ly known as “green slime”. This substance reduces the heat
transfer rate and can cause serious engine overheating.
FILLER
CAP
SEMI ANNUALLY:
COOLING SYSTEM Clean the cooling system 1,000 hours
or annually whichever comes first. Use a radiator cleaning
compound, following the instructions on the container. Flush
the system with fresh water and refill with an ethylene glycol
solution of 50% by volume.
In climates where freezing does not occur, use a solution of
clean water with a corrosion inhibitor for optimum cooling.

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Issued: Sept 96
 TABLE OF CONTENTS

MAINTENANCE AND LUBRICATION

TRANSMISSION MAINTENANCE

DAILY MAINTENANCE CHECK On a daily basis, check If this happens, check the converter out oil temperature. If
the TRANSMISSION OIL LEVEL. the temprature is in the normal working range, the filter
should be changed. If the converter out oil temperature is be-
Start the engine and run it at 1000 to 1500 rpm until the low the normal working range, stop the machine and warm
transmission reaches a normal operating temperature of the oil up to the normal working range by stalling the con-
(160° to 200°F.). Then idle the engine and shift through all verter, and observing the bypass indicator to be deactivated
range positions slowly. This will ensure that all parts of the as the oil warms up. If this disarms the system, work the
system are filled with oil. Shift to neutral and set the engine transmission in a higher gear to keep the converter out oil
speed at idle rpm. Remove the dipstick located under the ac- temperature in the normal working range. If this does not
cess door on the rear deck. .fhe oil should be at the “full” lev- disarm the system, change the filter.
el. Add or drain oil to bring it to this level.

SERVICING MACHINE AFTER

TRANSMISSION OVERHAUL
When servicing the unit for the first time after vehicle instal-
lation and/or after repair, the unit is filled as follows:
WHEN STALLING THE CONVERTER MAKE SURE
A. Fill the unit with 4 gallons (15.1 liters) of the recom- THE TRANSMISSION IS IN HIGH GEAR, THE VEHI-
mended lubricant. CLE BRAKES SET, AND THE IMMEDIATE AREA IS
B. Start the engine and run at idle speed to let the converter CLEAR OF PERSONNEL AND OBSTRUCTIONS. DO
and oil lines fill. NOT EXCEED 30 SECONDS OR 250°F CONVERTER
C. With the engine at idle speed, finish filling the unit to the OUT OIL TEMPRATURE, WHICHEVER COMES FIRST,
full level. The amount needed will vary with each appli- AT FULL GOVERNED ENGINE RPM STALL SPEED.
cation.

Note : The oil level is always checked with the engine run- Note: The preceeding lubricant change recommendations
ning at idle speed, the transmission in neutral, and the oil can be neglected if a lubricant analysis indicates that the fol-
temperature at 160-200° F. (71.93.5° C). lowing limits are not exceeded:

DO NOT OVERFILL THE TRANSMISSION.

Recommended lubricant and Filter Change Intervals

Refer to page 4-10 for lubricant recommendtions.

Recommendations utilizing the Funk Filter with the bypass

indicator inoperative or not connected:

The lubricant and filter should be changed after the first 20

hours of transmission operation. After the initial lubricant
and filter change, it is recommended that the filter be
changed every 250 hours of operation and the lubricant be
changed quarterly or after 500 hours of operation
Note: In cold weather operation and/or initial start up
(when the transmission oil is cold) the oil will have a higher
viscosity which may allow the filter to bypass intermittently.
When this happens, the filter bypass indicator will be acti-
vated.

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TRANSMISSION

Lubrication Recommendations, Series Shift-0-Matic Transmission

Recommended Oils: Commercial Powershift Transmissions

Prevailing Ambient Temperature Oil Recommendation

Above -23° C (-10° F) Hydraulic Transmission Fluid

Type C-3 (Except Grade 30)

Below -23° C (-10° F) Hydraulic Transmission Fluid

Type C-3 (Except Grade 30)
Auxiliary preheat required to
raise temperature in the sump
to above -23° C (-10° F)

Above 0° C (32° F) Hydraulic Transmission Fluid

Type C-3 or C-3 Grade 30

Funk Manufacturing does not recommend the use of any hydraulic transmission fluid that uses an “EP” (Extreme Pressure) ad-
ditive.

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MAINTENANCE AND LUBRICATION

AXLE MAINTENANCE

MAINTENANCE CHECK As a part of the WEEKLY

MAINTENANCE CHECK, inspect the axle and differential
levels. When checking the AXLE OIL LEVEL, rotate each
wheel until the planet cover is positioned as shown in the il-
lustration below. the arrow on the planet cover points hori-
zontal when the cover is properly positioned for checking
the oil.

On a SEMI-ANNUAL basis, drain the oil from the differen-

tial by removing the drain plug at the bottom of the differen-
tial housing. Replace the plug and refill the differential with
the lubricant specified on the lubrication chart. To the level
Remove the oil level plug in the planet cover and add oil as specified above.
necessary to bring the oil level to the bottom of the fill and
check hole See the lubrication chart. Drain the oil from hubs removing the fill and check plug by
rotating the hub until the hole is at the extreme low position.
Check the DIFFERENTIAL OIL LEVEL by removing the After draining, rotate the hub until the hole is at the check po-
fill and check plug indicated in the illustration . Add oil as sition. Refill the hub with the lubricant specified on the lubri-
necessary to bring the oil level to the bottom of the hole. See cation chart. Refill to the level of the bottom of the check
lubrication chart. plug.

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MAINTENANCE AND LUBRICATION

TIRES

MAINTENANCE CHECK As a part of the WEEKLY

MAINTENANCE checks, inspect the tires and rims for
damage. Cuts and bruises, snags, punctures, and abrasions
should be repaired before they can cause tire failure. Bent,
cracked or loose rims should be repaired or replaced.
The explosive stored in a tire and rim assembly under pres-
Check tire valve condition and make sure each valve has a sure makes changing truck and off-road tires hazardous.
cap. Death or personal injury can occur while handling or main-
taining these tires. Special procedures must be followed and
Check the wheel retaining nuts for proper tightness. Wheel special tools must be used if tires are to be changed safely.
retaining nuts should be torqued to 400-500 ft.lbs. Whenever possible, let your service company handle this job.
If you must change a tire, follow the step by step instructions
TIRE PRESSURES Always maintain the recommended detailed in a tire repair manual. Should low pressures make it
tire inflation pressures in all tires. Refer to page 3-6 of the necessary to add air, never stand beside the tire tread. Instead
“Operating Procedures” section for complete tire in inflation use a extension hose long enough to permit you to stand be-
data. hind the tire tread. Always use a tire cage or equivalent pro-
tection when adding air.
When driving, some increase in tire pressures can be expect-
ed due to heat generated by friction. Overspeeds may also
produce increased tire pressures. In such circumstances,
NEVER BLEEED THE TIRES. Instead slow down or stop RIGHT WAY
until the tires cool.

Inflation pressure should be checked when tires are cool, us-

ing an accurate tire pressure gauge. Check pressures at reg-
ular intervals.

Bleeding the air from hot tires is dangerous and should not
be attempted. While the pressure will be reduced, an in-
crease in temperature of the tire will take place as soon as
driving is resumed and tire failure will result.

UNDERINFLATION Too little air pressure increases de-

flection, causes the tread to wipe and scuff over the road, re-
sults in extra strain on the tire, and increases the chances for
bruising.

PROPER INFLATION Maintaining the proper air pres- WRONG WAY

sure provides maximum road contact and results in in-
creased tire life.

OVERINFLATION Overinflation reduces tire deflection

and tire contact area, causing the tire to ride on the crown,
and results in rapid wear in the center of the tread.

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SAFETY PRECAUTIONS
FOR MOUNTING OR DEMOUNTING
RIMS AND WHEELS

DO’S AND DON’TS

DO DON’T

1. Follow mounting and demounting procedures outlined 1. Don’t use mis-matched parts. Mis-matched parts are
in the manufacturer’s instruction manual or other recog- dangerous. Make sure side ring and lock ring designa-
nized industry instruction manual. tions match those of the base.

2. Deflate tires completely prior to demounting by remov- 2. Do not use loads or inflation pressures exceeding the
ing the valve core. manufacturer’s recommendations.

3. Replace bent, cracked,worn, corroded, or damaged 3. Don’t re-inflate a tire that has been run flat or seriously
parts. underinflated without first demounting and inspecting
the tire and rim assembly.
4. Double check to see that removable rings are seated
properly before inflating. 4. Never use tire and rim combinations that are not ap-
proved by the Tire & Rim Association.
5. Check for excessive side ring play and ring butting. Ei-
ther one of these conditions is an indication of mis-
matched parts.

6. Inflate tires in a safety cage.

7. After inflating the tire, be sure that between a 1/16” min-

imum and a 1/4” maximum remains in a split ring or
lock ring.

8. Inspect wheel nuts and rim clamps periodically for ex-

cessive wear, corrosion, proper centering and nut
torque.

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MAINTENANCE AND LUBRICATION

AIR SYSTEM MAINTENANCE

Inadequate delivery pressure or defective components oper-

ations can generally be traced to leakage, blocked lines, or
the buildup of moisture and sediment in the system. A regu-
lar program of preventive maintenance is an essential part of
air system operation. The materials presented here are listed
in accordance with the MAINTENACE CHECK LIST in
this section. Consideration of severe working conditions
may dictate a revision in schedule periodic checks.

DAILY:

AIR TANKS Open the air tank drain cocks at least once dai-
ly to blow out moisture and accumulated sediment. The
drain cocks are located on the frame rail by the battery box.

WEEKLY:

AIR SYSTEM SAFTY VALVE Manually actuate the air

system safety relief valve bypushing inon the stem. This will
ensure that the valve is not sticking. If the valve cannot be
actuated in this manner, it should be repaired or replaced

SAFETY VALVE

RIGHT SIDE
AIR TANK

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MAINTENANCE AND LUBRICATION

BRAKE SYSTEM

BRAKE PEDAL:
All rubber components in the treadle valve should be re-
placed yearly.

IMPORTANT!
An increase in stopping distance or a low pressure warning
light indicated a malfunction in the brake system, and al-
though the vehicle brake system may continue to function,
the vehicle should not be operated until the necessary repairs
have been made and both braking circuits are operating nor-
mally.

LEAKAGE CHECK

1. Make and hold full brake application.

2. Coat the exhaust port and body of the brake valve with
soap solution.

3. Leakage is not to exceed a 1” bubble in 3 seconds in both

MAINTENANCE Every 3 months or quarterly: the applied and released position.

1. Lubricate fulcrum and roller pin with oil. If the brake does not function as described above or leakage
is excessive, it is recommended that it be replaced with a
2. Free pedal travel should be checked as follows: new or remanufactured unit, or repaired with genuine Ben-
Check to be certain plunger is in contact with spring seat. dix parts available at Bendix outlets.
The stop button should be adjusted so that the roller and
plunger just contact.

3. Apply oil or light grease between plunger and valve body.

Do not overoil.

4. Clean exhaust check depending on type of service.

Every 12 months or annually:

1. Disassemble, clean parts with mineral spirits. Replace all

rubber parts or any part worn or damaged. Check for
proper operation before placing vehicle in service.
NOTE:

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MAINTENANCE AND LUBRICATION

DISC PARKING BRAKE

ROUTINE MAINTENANCE The routine maintenance 5. Check that 0.0l0” to 0.020” clearance exists between pad
presented below is suggested to keep the brake system in and the disc. Remove cotter pin and adjust castle nut to
good working order. achieve these dimensions.

1. Check that floating parts move freely and all other parts 6. Check to see if friction pads are worn to less than 1 /32 ‘,
are mounted securely. Tighten hardware as required. thick. Replace if they are. In normal service, pads will
need replacing only after prolonged use. Always replace
2. Clean and lubricate cam and push pins with molybdenum both pads at the same time.
disulfide or graphite-based dry lubricant.
Generally, if the disc is still running true within 0.010” and
3. Check actuator linkage and see that there is adequate free- the pad clearance is still adjustable, no other maintenance is
dom of movement for positive brake operation. required.

4. Check disc surface condition. Replace if it is badly

warped or pitted.

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MAINTENANCE AND LUBRICATION

TURNTABLE & SWING PINION

Under extremely dirty or dusty conditions, sufficient grease

Lubricate every 100 operating hours as follows: should be added to flush out contaminated grease. Under
less severe conditions, add grease until it appears at the bot-
Inject grease as recommended below through one fitting lo- tom seal.
cated beneath an access panel in the operator’s cab just be-
hind the shift lever, as the machine is rotated at least two While swinging the machine, apply gear grease to the exter-
complete revolutions. When complete rotation is impracti- nal ring gear with sufficient frequency to insure that the
cal, inject grease through each fitting and rotate machine teeth remain coated.
back and forth as far as possible as each fitting is greased.
Some lubricants recommended by the manufacturer are:

MOBIL TEXACO SUNOCO AMOCO EXON

RACE Mobilux Mutifak Prestige Amolith Beacon

EP1 EP1 742EP EP1 EP1

GEAR Mobiltac Crater 407 Amovis Surett

375NC 2X Compound B 8-X Fluid 4k

NOTE: Other manufacturers’ lubricants of the same quality are suitable.

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MAINTENANCE AND LUBRICATION

SWING REDUCER

MAINTENANCE CHECK On a WEEKLY basis, check

the swing reducer oil level and add oil as needed to maintain
the level at the “FULL” mark on the dipstick. Recommend-
ed lubricant is Sunep # 1060 or equivalent.

DIPSTICK

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MAINTENANCE AND LUBRICATION

HYDRAULIC SYSTEM MAINTENANCE

MAINTENANCE CHECKS A regular program of period-

ic maintenance is an essential part of con- tinued hydraulic The hydraulic reservoir is sealed and has a 14 psi relief
system operation. Allowing ac- cumulations of moisture and valve. Exercise extreme care when removing the filter cap.
sediment to build-up in the system will damage hydraulic The pressure is relieved by turning the reservoir cap coun-
valves, pumps and motors. The presence of leaking connec- terclockwise to the first stop. DO NOT turn the cap beyond
tions or damaged components effect the efficiency of oper- the first stop until all pressure has been released. This will
ation and are dangerous. The materials presented here are cause the cap to be blown off the reservoir with sufficient
listed in accordance with the MAINTENANCE CHECK force to cause personal injury. DO NOT place any portion of
LIST. Consideration of severe working conditions may dic- your body above the reservoir cap while relieving the pres-
tate a revision in scheduling periodic checks. sure or removing the cap.

DAILY: HYDRAULIC COMPONENTS Check the hydraulic

HYDRAULIC FLUID LEVEL The hydraulic reservoir, valves, motors, pumps, hoses, tubes and connections for ex-
fluid level indicators, and filler cap are on the right side of cess dirt, oil and grease. Clean these items if necessary and
the machine. check for leaks and damage. Tighten leaky connections and
repair any damaged components.

WEEKLY:
RETURN LINE FILTER Change the hydraulic reservoir
return line filters after the first 40 hours of the break-in peri-
od; thereafter follow the quarterly check recommendation.

RESERVOIR
FLUID LEVEL MONTHLY:
INDICATORS HYDRAULIC RESERVOIR Drain any accumu- lated
moisture from the hydraulic reservoir by parking the ma-
chine on a slight incline and loosen the pipe plug in the bot-
tom of the reservoir.

HYDRAULIC OIL Visually check the condition of the hy-

draulic oil once each month. Thickening of the oil or a
change in its appearance, such as darkening, may serve as a
Retract all cylinders to return the maximum amount of oil to rough indicator of when an oil change is needed. Periodic
the reservoir and note the oil level indicators. The fluid level testing of the oil is the safest, most accurate method of de-
should be between the indicators. The top mark indicates termining the condition of the oil. An oil supplier can be
system capacity with all cylinders retracted. Reservoir ca- consulted for assistance in testing the oil.
pacity is 81 gallons and system capacity varies with equip-
ment up to a maximum of approximately 130 gallons. Change the oil whenever testing and/or inspection reveals
the oil to be unsuitable for safe and efficient operation.
Do not overfill.

Refer to Section 4, page 23 for hydraulic oils meeting the

manufacturer’s specifications. Do not use oils which have
detergent additives.

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QUARTERLY: RESERVOIR RELIEF VALVE Check the hydraulic res-

HYDRAULIC FILTER Remove and replace the hydraulic ervoir relief valve for proper function- ing. The valve is lo-
reservoir return line filters. Access is gained by removing cated in the filler cap and is checked by extending all the
the cover plate on the reservoir. boom cylinders and then retracting them to slightly pressur-
ize the reservoir. When the cap is turned to the first notch, air
When replacing the filters, clean the spring and bypass should be heard escaping if the system is holding pressure.
valves. Inspect the gasket for damage and replace if neces- The system is sealed and has a relief valve pressure setting
sary. of 14 psi.

1500 HOURS:
HYDRAULIC RESERVOIR Drain and clean the hydrau-
lic reservoir. Change the hydraulic oil.

A change interval cannot be established which would apply

to all oils and all operating conditions of temperature and
cleanliness. However, a reputable brand of turbine grade oil
can be ex- pected to deliver 1500 hours of service under av-
erage operating conditions. Although conditions may neces-
sitate shorter change intervals, do not use hydraulic oil for
more than 1500 hours.

Whenever a visual inspection, chemical test or light test in-

dicates that an oil change is necessary, proceed as follows:

1. Warm the oil prior to draining but avoid drain- ing imme-
diately after prolonged continuous use to reduce the danger
of being burned by hot oil.

2. Retract all cylinders to return the maximum amount of oil

Before discarding the old filter element, examine the type of to the reservoir. Loosen the top covers and remove the drain
material trapped in it. This may indicate which, if any, hy- plug(s) at the bot- tom of the reservoir. Allow sufficient time
draulic system components are deteriorating. for the reservoir to drain thoroughly.

SEMI ANNUALLY: 3. Remove the return filters, clean springs, bypass valves
SUCTION FILTER Remove and clean the hydraulic reser- and inspect cover gasket for damage and deterioration. Re-
voir intake suction filter. This per- manent screen type filter place gasket if necessary.
is located inside the reservoir on the intake to the pump
manif old. Access to the filter is accomplished by removing
the cover with filler neck and filter holding device from the
top of the reservoir. Move the lever towards the front of the
machine and lift out the filter.

Remove the “O” ring from the adapter and check it for dam-
age or deterioration. If the ring is at all damaged, replace it.

Clean the filter by immersing it in a non-caustic cleaning

solvent. Rub the screen surface with a soft brush to dislodge
accumulated foreign matter. Reinstall filter, filter hold-down
device and cover.

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MAINTENANCE AND LUBRICATION

A good lubrication program requires that all nor- mal wear

points be lubricated according to a set schedule with specific
types of lubricants. Refer to the lubrication chart and the
special items covered in this section for the recommended
lubricants, time intervals and lubrication procedures. 3. Check the oil viscosity versus the recommened
Where components such as the engine, transmis- sion and Ambient Temperature may require an oil
axles are not manufactured by this com- pany, the original change.
manufacturer’s recommenda-
4. Check the hydraulic system efficiency a pump may be
failing or a relief valve set low.
HYDRAULIC OIL REQUIREMENTS
5. Reduce the duty cycle of the machine.
The hydraulic system is filled with KOEHRING SPEC 805
hydraulic oil to give the unit the highest performance as a 6. Consult an authorized DISTRlBUTOR.
hvdraulic machine and to provide proper lubrication for the
hydraulic components. To ensure the longest life for this ENGINE OILS: Engine oils that meet Mil Spec 2104 and
piece of equipment, particular attention must be paid to have the anti-wear additive zinc DO dithiophosphate can be
maintain oil at the proper level with an approved hydraulic used as hydraulic oils. NOT USE C.D. rated engine oil,
oil and to keep the circuit system clean. some of which will not protect against wear in hydraulic
pumps and motors.
The oil for the hydraulic system performs the dual function
of lubrication and transmission of power. Oil must, there-
fore, be selected with care and with the assistance of a repu-
table supplier. To guide in the selection of this oil, the
general requirements are specified below. Good oils are eco-
nomical in the long run. Check with the oil manufacturer pri- Not all motor oils have zinc dithiophosphate. Those that do
or to the use of his product. not have this heavy duty additive can cause immediate fail-
ure of pumps.
Oils which conform to Koehring Specification 805 are rec-
ommended for most conditions. Under certain climate and Engine oils tend to form sludge in the presence of water.
operating conditions, it may be advisable to use a fluid of This sludge can plug the filters so they will require frequent
heavier or lighter viscosity in order to maintain a viscosity changing. This is not detrimental to the machine unless the
less than 7500 SSU at start-up and more than 50 SSU during filters are allowed to plug so badly that they by-pass oil.
operation. These machines should not be operated with hy-
draulic reservoir temperatures in excess of 200°F (87°C) Never use multi-viscosity grades of engine oil because of
due to possible excessive damage to the hydraulic oil and the shear and thin out characteristics of this type of oil.
rubber components (hoses, seals, shaft seals, motor seals
etc.). If over-heating occurs, discontinue operation and: TRANSMISSION FLUIDS: DO NOT use transmission
fluids. These fluids have been design- ed to work in auto-
1. Check the hydraulic fluid level. matic transmissions and they will not necessarily work in
hydraulic systems.
2. Check the oil cooler for cleanliness.

tions take precedence should any discrepancy occur. If there

is any doubt about the proper lubricants, intervals or lubrica-
tion procedures, refer to the original manufacturer’s manual.
The lubrication intervals recommended in this section as-
sume normal operating conditions. Where dust, dirt, high
humidity or extreme heat
are encountered, lubrication intervals should be shortened
accordingly.

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MIXING: Mixing different brands of oil is not recommend- Particle Contamination - Excess contamination in a hydrau-
ed. Various companies use different additive packages, lic system will greatly shorten the life of pumps and motors.
which when mixed together, may cause problems in a hy- Your oil sample analysis will show the number of particles
draulic system. This type of problem is rare but can cause per milliliter greater than a given micron size. The number
sludge which can plug the filters or acid which will etch the of particles in your sample should be less than the following:
pump plates.
Particle Size No. of Particles/Milliliter
PRE-FILTER: Oil should be filtered through a 10 micron
nominal filter before it enters the hydraulic system. New hy- 10 micron or larger 3,000
draulic fluid as received by the user is generally NOT in a
satisfactory cleanliness condition for long component life. 20 micron or larger 300

OIL MAINTENANCE: Optimum life from hydraulic 30 micron or larger 100

equipment can only be obtained with proper hydraulic oil
maintenance. This includes checking the oil every three to 40 micron or larger 30
six months. An oil should be checked for viscosity, oxida-
tion, water content, contamination and copper particles. A 50 micron or larger 10
record should be kept of each check to detect signs of pro-
gressive deterioration. Oil samples should be taken with the 100 micron or larger 1
system running at normal operating temperature. It is impor-
tant to use good technique in obtaining an oil sample. The If your oil sample shows numbers greater than in the chart,
exact same procedure should be followed each time an oil your hydraulic system is contaminated. The system should
sample is taken. Most fluid suppliers will provide assistance be checked for broken or torn filters, plugged filters, stuck
in analyzing your oil sample. The following are some guide- filter bypass valves and so forth. Continued operation with
lines to use in this analysis. particle counts greater than those shown in the chart will re-
sult in short pump and motor life.
Viscosity - Many hydraulic fluids will shear or thin out with
use. The viscosity at each check should be compared to the Copper Particle Counts - The oil sample analysis should in-
viscosity when new. At no time should the viscosity be less clude a copper particle count in parts/million. This number
than 45 SSU at 210°F. If viscosity is less than 45 SSU at should normally be less than 100. A high copper particle
2I0°F, the oil must be replaced immediately. count indicates that a gear pump or motor is rapidly deterio-
rating. A count of 200 or more would be cause for concern.
Oxidation - Oil oxidation will occur with age and use and is The most important thing to look for is a sudden increase in
evidenced by a change in color and/or odor, increased acid- the copper particle count. This indicates that a gear pump or
ity, and possible formation of sludge, gum or varnish in the motor has suddenly begun deteriorating and a catastrophic
system. The rate of oxidation increases significantly with failure can be expected shortly.
operations at temperatures over 140°F (60°C). The oil
should be checked more often if operation is at high temper-
ature. The oxidation process increases the acidity of the fluid
and is measured by a neutralization number. The oxidation
process is typically slow at first and then increases sharply
in the final stages of complete oxidation. A sharp increase
(by factor of 2-3) in a neutralization number is a good indi-
cation that the fluid is reaching the limit of its oxidation life
and should be replaced.

Water Contamination - All hydraulic oils in the following

charts will readily separate water which will settle to the bot-
tom of the reservoir. This water should be drained off. The
water that is measured in the oil sample will be dissolved
water. This should be less than .05%. If it is greater than
.05%, the oil in the system should be drained and replaced.

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MAINTENANCE AND LUBRICATION

VISCOSITY: Oils are available in various grades (viscosi-

ties). The ISO (International Organization for Standardiza-
tion) viscosity classification system is currently being
adopted. The ISO grade applies strictly to viscosity and does This machine is factory filled with Koehring spec 805
NOT imply type of oil. (engine, anti-wear, hydraulic, hydraulic fluid that is acceptable for start-up at ambi-
gear.etc.). A viscosity grade should be selected that will ent temperatures of 20°F and should not be operated
meet the minimum start up temperature requirement and the above a hydraulic reservoir temperature of 200°F. If
maximum operating hydraulic oil temperature. these limits are exceeded damage can result. For oper-
ation outside these ranges, select the proper hydraulic
fluid from the charts on this and the following pages or
from a reputable supplier.
HYDRAULIC OIL (Initial Fill)
KOEHRING SPEC 805 DATA

PHYSICAL
PROPERTIES TEST METHOD REQUIRMENT

A. A.P.I. Gravity ASTM D287 28 Min.

B. FLash Point ASTM D92 380° F Min.

C. Viscosity Index 100°F ASTM D445 200-220 SSU

210°F ASTM D445 46 SSU MIn.

D. Viscosity Index ASTM D2270 95 Min.

E. Pour Point ASTM D97 -25° F Max.

F. Oxidation Test ASTM D943 2500 Hours Min.

to 2.0 Neut. No. ASTM D943 2500 Hours Min.

G. Rust Test ASTM D665 Procedure A Pass

H. Foam Test ASTM D892 Foam Tendency Foam Stability

Sequence l 25 ml Max. Nil
Sequence 11 50 ml Max. 10 ml Max.
Sequence lll 25 ml Max. Nil

I. Demulsibility ASTM D1401to 40-37-3 point 30 Min. Max.

J. Aniline Point ASTM D611 200-230° F

K. Pump Wear Dennison HFO Satisfactory

or Vickers M2905 (100 Hrs.@150°
F)

L. % Zn ASTM D1549 .07 Min.

M. Filterability Fluid shall show no additive loss when

filtered through 5.0 micron filter.

N. Cleanliness Fluid shall appear bright and clear

and shall be free of visible contami-
nates or sludge.

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MAINTENANCE AND LUBRICATION

GRADE SELECTION CHART

Maximum life of pumps, motors, hoses, and seals will be obtained by selecting an oil as far down the chart as possible.

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. Temp.
(New) (Old)
* Extreme cold start can be
-30°F 160°F 195°F
used year round in most ma-
Synthetic (-8°C) (71°C) (91°C)
chines in temperature cli-
mates

Cold Climate Year Round.

Multi. Must Be Changed More
Viscosity 0°F 130°F 190°F Frequently Than Straight
(-17.8°C) (54°C) (88°C) Grades

Winter Oil For

Ambient Temperatures
22 0° F 105°F 160°F Up TO 60°F
(-17.8°C) (41°C) (71°C) (16°C)

150 5°F 120°F 180°F For Ambient

(-15°C) (49°C) (82°C) Temperatures Up To 80°F
(27°C)

32 10°F 120°F 180°F

(-12.2°C) (49°C) (82°C)
Can Be Used Year
Round In Most Machines In
215 15°F 140°F 200°F Temperate
(-9.4°C) (60°C) (93°C) Climates

46 20°F 145°F 200°F

(-6.7°C) (63°C) (93°C) Well Suited For Most Ma-
chines In Southern U.S. And
315 25°F 155°F 200°F As Summer Oil For Heavily
(-3.9°C) (68°C) (93°C) Loaded Machines In Central
And Northern U.S.

68 30°F 160°F 200°F Especially Suited For Re-

(-1.1°C) (71°C) (93°C) gions With Ambient Temp.
Range From 100°F To 120°F

100 35°F 175°F 200°F

(-1.1°C) (80°C) (93°C)

Minimum temperature for starting without extended warmup. For lower temperatures, follow warm up procedure in the
* operators manual.

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 TABLE OF CONTENTS

MAINTENANCE AND LUBRICATION

PREMIUM GRADE ANTI-WEAR

HYDRAULIC OILS

OIL COMPANY ISO BRAND NAME OIL COMPANY ISO BRAND NAME

32 Ama-Oil R&O 100 AW 32 Kenoil R&O AW 32

Amalie Refining Co. 46 Ama-Oil R&O 200 AW Kendll Refining Co. 46 Kenoil R&O AW 46
(USA) 68 Ama-Oil R&O 300 AW (USA) 68 Kenoil R&O AW 68
100 Ama-Oil R&O 500 AW 100 Kenoil R&O AW 100

32 Amoco AW 32 32 DTE 24/DTE-13M

Amoco Oil Co. 46 Amoco AW 46 Mobil Oil Corp. 46 DTE 25/DTE-15M
(USA) 68 Amoco AW 68 68 DTE 26/DTE-16M

32 Duro AW 32 Northland 32 Talamar 150

Arco 46
68
Duro AW 46
Duro AW 68
Products
(USA)
46
68
Talamar 215
Talamar 315 *
100 Duro AW 100 100 Talamar 465

Conoco DN 600 (Artic) AWX Multi-Viscosity

Conoco Super Hyd. 5W-20 Pennzoil Products Co. 32 AW 32 Hyd. Fluids
Conoco (Multi Vicosity) (USA) 46 AW 46 Hyd. Fluids
32 Conoco Super Hyd. 32 68 AW 68 Hyd. Fluids
46 Conoco Super Hyd. 46 100 AW 100 Hyd. Fluids
68 Conoco Super Hyd. 68 Shell Co. (Canada)
100 Conoco Super Hyd. 100 37 Tellus T37 (Multigrade)

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 filled with Northland Talamar 215 or equivalent.
Imperial Oil Limited 32 Nuto H 32
(Canada) 46 Nuto H 46
68 Nuto H 68
80 Nuto H 80
100 Nuto H 100

KOEHRING SPEC 805 IS EQUIVALENT TO HYDRAULIC OILS SHOWN ABOVE

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CABLE LUBRICATION METHODS

Hot Application
GENERAL We are covering the more commonly used
methods of lubricating cable (wire rope). For special cable
lubrication problems consult the cable manufacturer.

HOT APPLICATION A heated bath is placed in the path

of the wire rope, and the rope is passed through the hot lu-
brication over sheaves and a center guide wheel. Hot oils or
greases have excellent penetrating qualities and upon cool-
ing have high adhesive and film strength around each wire.

Continuous Bath
CONTINUOUS BATH Run an operating rope through a
specially constructed casing that has been packed with
swabbing and loaded with lubricant. This affords continuous
lubrication.

DRIPPING A container can be placed above the sheave, so

that the rope can be lubricated by opening a spigot. Sheaves
are the best location for lubricating operating wire ropes, be-
cause the wires and strands open somewhat as they bend
Dripping
along the groove.

POURING Lubricant can be poured on. The rope should be

lightly loaded and run slowly while being lubricated.

SWABBING AND PAINTING Lubricant can be swabbed

on with rags, or painted on with a brush. Both are quick
methods which can be made part of the operating routine.

Pouring
SPRAYING A light lubricant containing solvents can be
applied to a wire rope by a properly directed spray nozzle.

AEROSOL SPRAYING Installations requiring only small

amounts of lubricants, or only occasional applications, may
find the new aerosol cans of lubricant useful. They are avail-
able from several lubricant manufacturers.

Swabbing
And Painting

Aerosol Spraying

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ELECTRICAL SYSTEM
BATTERY CHECK

MAINTENANCE CHECK Observe all instruments and Step 2 -Electrolyte Levels And State OF Charge- Check
gauges while operating machine and carrying out your DAI- the electrolyte level in the cells if possible. The level can be
LY MAINTENANCE checks. Replace or repair any mal- seen through translucent plastic cases. It can also be checked
functioning instruments or gauges. in batteries which are not sealed. If the electrolyte level is
below the tops of the plates in any cell, add water if the vents
BATTERY The maintenance free battery is located under are removable. If the battery is sealed, and water cannot be
the battery cover on the left hand side of machine. Use main- added to it, replace the battery and check the charging sys-
tenance free battery charging information. tem for a malfunction such as a high voltage regulator set-
ting. Follow instructions of manufacturer if the battery has a
A maintenance-free battery does not require the addition of special indicating device.
water during its life in normal service. This is due to the fact
that maintenance-free bat- teries produce little gas at normal If the level is O.K., unknown or water can be add- ed to the
charging voltages. battery, and the stabilized open circuit voltage is below 12.4
volts, charge the battery as described under “Charging”. The
TESTING MAINTENANCE-FREE BATTERIES voltage is stabilized if the battery has stood overnight with-
out being charged or discharged. 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
stabilization is to turn on the headlamps for 15 seconds.
Read the voltage at least three minutes after the discharge
Whenever the battery is placed on charge. Wear safety glass- load is removed. When a hydrometer reading can be taken,
es. Do not break “live” circuits at the battery terminals. a value of 1.225 @ 80°F (26.7°C) can be used instead of the
Maintenance-free batteries of the latest design incorporate 12.4 voltage reading. If the battery has a test indicator follow
flame arrester vents to reduce the possibility of explosions the instructions of the manufacturer. After the battery is re-
caused by external sparks. Therefore, during charging, the charged, stabilize the voltage as described above, then pro-
vents, if removable, should remain in place. A wet cloth ceed to Step 3.
should be placed over the vent openings as an additional pre-
caution. If the stabilized voltage of the battery was above 12.4 volts
when it was first examined, or the test indicator indicated the
Step 1 -Visual Inspection- Visually inspect the outside of battery is charged, proceed to Step 3 without charging the
the battery for obvious damage such as a cracked or broken battery.
case or cover which would allow electrolyte loss. Check for
terminal damage. If obvious physical damage is found, re- Step 3 -Load Test Procedure- The load test procedure is
place the battery. If possible, determine the cause of damage conducted to determine if the battery requires recharging or
and correct. replacement.

Check the condition and size of the cables. Are the cable
clamps tight? Check for corrosion on the terminal or clamps.
Clean corroded parts and/or tighten clamps if necessary. Re-
place badly corroded cables or cables with defective termi-
nals. Make certain the negative cable is making a good
connection where it is grounded to the engine and the posi-
tive cable to. the starter relay. If the “Visual Inspection” is
satisfactory, proceed to Step 2.

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A. Disconnect the battery cables (ground connection first)

and connect the voltmeter and load test leads to the bat-
tery terminals, making sure the load switch on the tester
is in the “OFF” position.
B. Apply a test load equal to 1 /2 the Cold Cranking Am-
peres @ 0°F (-l8°C) Rating of the battery, for 15 sec-
onds. (Example: a battery has a Cold Cranking Rating
@ 0°F (- 18°C) of 350 amperes. Use a test load of 175
amperes.)
C. Read the voltage at 15 seconds and remove the load. If Place a wet cloth over the vent opening or open- ings. If,
the voltage is less than the minimum specified in the when charging the battery, violent gassing or spewing of
“Voltage Chart” (see “Maintenance-Free Battery Test- electrolyte occurs, or the battery case feels hot (125°F,
ing Chart”, in Troubleshooting section) replace the bat- 52°C), reduce or temporarily halt charging to avoid damag-
tery. If the voltage meets or exceeds the specified ing the battery.
minimum, clean and return battery to service.
If the state of charge of a battery cannot be deter- mined and Follow the manufacturer’s instructions on the charger. If
the battery fails the load test, it must be recharged and retest- they can no longer be read and a copy of them is not avail-
ed. If it meets the specified voltage on the second test return able, write to the manufacturer for a copy and paste it on the
it to service. If it does not meet the specified voltage on the charger. Never use a charger without these instructions.
second test, replace the battery.
Always turn the charger to the “OFF” position before con-
The above is a standard test procedure to deter- mine the necting the leads to the battery. If you have any doubts that
ability of a battery to function properly. If a commercially the charger is actually “OFF”, disconnect it from the power
available tester is being used to analyze the battery, follow source.
the instructions of the equipment manufacturer.
The state-of-charge of maintenance-free batteries can be de-
CHARGING MAINTENANCE-FREE BATTERIES termined with an accurate voltmeter. A voltmeter should not
be used unless it can be checked frequently against one of
Maintenance-free batteries contain sulfuric acid and gener- known accuracy. If the stabilized voltage of a battery at
ate explosive hydrogen and oxygen gases the same as all room temperature is 12.2 volts, is should be charged for one-
lead acid batteries. No one should charge a battery unless half the time shown in the “Slow Charge” column of the
they have been thoroughly instructed concerning the step by Charging Guide, at the applicable rate in amperes. If the
step procedures to use and the safety precautions to take. voltage is 12.4 volts, it should be charged for one-fourth the
time shown in the “Slow Charge” column, at the applicable
It must be realized that maintenance-free batteries cannot be charging rate. Follow the manufacturers instructions on bat-
charged at ampere rates or periods of time greater than spec- teries equipped with state-of-charge
ified in the “12-Volt Maintenance-Free Battery Charging indicators.
Guide”. If the battery is charged more than specified, it loses
water which cannot be replaced in some constructions so the
life of the battery is shortened. Battery chargers for mainte-
nance-free batteries should include a charge duration control
of some sort. The simplest control is a timer which the oper-
ator sets. Voltage controls can limit the charge more consis-
tently and accurately. Such controls also may have a safety
feature that prevents sparks and reverse charging when the
clamps are connected in reverse, by mistake.

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Any battery which is known to be discharged or has a stabi- BOOST CHARGE If a battery requires a boost charge, it
lized voltage below 12.2 volts should be charged as shown should be charged at 45 amperes for 20 minutes. This cannot
below. be used for a new battery being prepared for installation.

12-VOLT MAINTENANCE-FREE BATTERY CHARG- MODIFIED CONSTANT POTENTIAL TAPER

ING GUIDE CHARGING It is recommended that maintenance-free bat-
Battery Capacity teries be recharged on a modified constant potential taper
(Reserve Minutes) Slow Charge chargers. The total charge must not exceed the ampere-hour
equivalent of the values shown in the “Charging Guide”. It
Above 125 to 170 20 Hours @ 5 Amps is recommended that the initial charging rate not exceed 30
Minutes 10 Hours @ 10 Amps amperes.

NOTE: If a battery is to be charged overnight, (16 hours) a

timer or voltage controlled charger is recommended. If the
charger does not have such controls, a 3 ampere rate should
be used for batteries of 80 minutes or less capacity and 5 am-
peres for above 80 to 125 minutes reserve capacity batteries.
Batteries over 125 minutes should be charged at the specified
SLow Charge rate.

ELECTRICAL SYSTEM COLLECTOR RING

ELECTRICAL COLLECTOR RING When troubleshoot- COLLECTOR RING MAINTENANCE If not revolved
ing the electrical system, always check the collector ring first for some time, under some conditions, the ring will have a
to see that the spring-loaded brushes are centered in the tendency to collect fine silt, or salt atmosphere will cause cor-
bands. Keep free of any foreign material. rosion. If this happens, the crane should be rotated through
several revolutions if possible. The cleaning action of the
Keep the set screws on the collector ring tight. Otherwise the brushes should clean the ring surfaces. If it does not, or it is
wire harness may wrap up as the machine is swung. not practical to revolve the machine, it may be necessary to
use a standard non-residue solvent to clean the ring. Then
The cover should allow for free operation of the collector ring lightly sand the brushes and rings with a fine grade of sand-
and the brake. If linkages bind, erratic operation may result. paper and dust off with compressed air.
Check for unrestricted operation.

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MAINTENANCE AND LUBRICATION

MAINTENANCE CHECKS On a daily basis, inspect the These include the gearing, bearings, and brake friction discs.
cylinder mounting brackets, bushings, and pins for wear, Refer to the Service Manual for disassembly procedures.
tightness and damage. If misalignment or excessive play or
wear are detected, replace the defective pin or bushing. LUBRICATION Lubrication for the winch is provided by
Check the rod eye welds for cracks and breaks. weepage flow from the drive motor. Oil enters the final drive
end through the drive shaft tube in the drum. A drain line on
Inspect the hydraulic cylinder rods for nicks, dents, and the main drive end cover returns excess oil to the reservoir.
scoring as part of your WEEKLY MAINTENANCE check.
Also check the cylinders for leaks at the wiper seals. Repair
or replace any damaged components.
MAINTENANCE CHECK Every TWO YEARS OR 4000
HOURS disassemble and inspect the winch components.

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CABLE REEVING

CABLE REEVING When reeving the machine for any job, This machine incorporates a “Quick Reeving” boom head
remember that hoisting and lowering speeds decrease as the and block which do not require removal of the wedge and
number of parts of line in- creases. For the most efficient use socket from the rope in order to change the reeving. Re-
of the machine, it is desirable to use the minimum number moval of two pins in the boom head and three in the hook
of required parts for lifting the anticipated loads. block will allow the wedge and socket to pass through.

Never use less than the number of parts called for by the NOTE: If a socket is changed or replaced, or if you are
load rating chart. The minimum required - number of parts changing hook block weights, it is IMPORTANT to use the
is determined by referring to the load rating chart. correct socket.

SPOOLING WIRE ROPE ON DRUMS

Care must be exercised when installing wire rope on the

winch drum. Improper spooling can. result in rope damage
through crushing, kinking, dog- legs, abrasion and cutting.
Poorly installed wire rope will also adversely affect the op-
erating characteristics of the machine by causing uneven ap-
plication of force and motion. This, in turn, can cause
premature fatiguing and failure of the rope.

Thoroughly inspect and clean the winch before proceeding

with the installation. Check the lagging and drum flanges for
cracks, breaks and excessive wear. Deformed or outsized
drum and excessive undercutting at the base of the flange
also indicate that repair or replacement of the drum is neces-
sary.

Check the bearings for excessive wear and play.

After correcting any defects revealed by the inspection and
determining that the winch is in good operating condition, Apply braking force to the reel flange in order to prevent
spool the wire rope as follows: overrun as the rope is being drawn off. Loops formed by
overrun can cause kinks and doglegs in the rope, resulting in
Mount the cable shipping reel vertically on jacks or a suit- damage and premature rope failure. A timber or block
able supporting structure, with a pipe or bar through the reel forced against the shipping reel flange can be used to pro-
center. The cable should be drawn from the top of the reel, vide the required braking force.
as shown, in order to avoid reverse bending as it is spooled
onto the
If cable is wound from the storage reel onto the drum, the
reel should be rotated in the same direction as the hoist.

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WIRE ROPE AND REEVING

MAINTENANCE All wire ropes in active service should Replace or repair any items found to be in unsatisfactory con-
be inspected DAILY along with spooling, sheaves, wedge dition.
sockets, and any otherwire rope fittings for damage. Once
WEEKLY a through wire rope inspection should be made by
a competent inspector. A record should be kept of the in- In addition to damage such as kinking, crushing and broken
spections on 4-5. wires, factors such as corrosion, abrasion, pitting, peening
and scrubing of the outside wires, redution of rope diameter,
Refer to Wire Rope Users Manual, section 9 and ANSI Stan- the condition of other components and proper lubrication are
dard B30.5 for guidlines covering the inspection, mainte- considered. Refer to page 4-26 for wire rope lubricating pro-
nance, repair, and replacement of wire rope. Worn, kinked,
cedures.
birdcaged, fatigued or otherwise damaged wire rope must be
removed immediately. Wire rope when properly installed,
lubricated and employed, will give many hours of satisfac- Before installing a new or replacement rope, make certain the
tory use. Whereas, a new piece of wire rope can be immedi- rope to be used is the proper type and size. The wrong rope
ately ruined if misused. will not fuction properly and may even be dangerous.

WIRE ROPE SPECIFICATIONS

MAIN WINCH

STD.-5/8” dia. 6X19 OR 6X37 CLASS

IWRC REG. LAY WIRE ROPE
MINIMUM BREAKING STRENGTH-17.9 TONS

OPT.- 5/8” ROTATION RESISTANT

COMPACTED STRAND 18X19 OR 19X19
MINIMUM BREAKING STRENGTH 22.7 TONS

AUXILIARY WINCH

STD.-1/2” 6X19 OR 6X37 CLASS

IWRC REG. LAY WIRE ROPE
MINIMUM BREAKING STRENGTH 13.3 TONS

OPT.-9/16” ROTATION RESISTANT

COMPACTED STRAND 18X19 OR 19X19
MINIMUM BREAKING STRENGTH 18.5 TONS

Koehring permits the use of rotation resistant wire rope, other

types are not approved. When this rope is used the working
load shall not exceed 1/5th (20%) of the rated breaking
strenght. The retirement criteria shall be as follows: two bro-
ken wires in six rope diameters or four broken wires in thirty
rope diameters.

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MAINTENANCE AND LUBRICATION

Install cable on the winch drum in accordance with the fol- NOTE: If the wedge does not seat properly in the slot, care-
lowing procedure. fully tap the top of the wedge with a mallet.

1.Position the cable over the boom tip sheave and route back
to the winch drum.

2.Position the winch drum with the cable anchor slot on top.
WEDGE
3.Insert cable through slot and position around the cable
wedge.

4.Position the anchor wedge in the drum slot; pull firmly on

the free end of the cable to secure the wedge.

5.Slowly rotate the drum, ensuring the first layer of cable is

evenly wound on the drum.

6.Install the remainder of the cable, as applicable.

The end of the cable should be even with the bottom of the
anchor wedge.

WINCH DRUM WEDGES

WHERE USED PART NUMBER

MAIN WINCH B49411

AUXILIARY WINCH B52661

CABLE SOCKETS AND WEDGES

WHERE USED PART NUMBER

5/8” CABLE SOCKET 1234-18

5/8” SOCKET WEDGE 1234-19

9/16” CABLE SOCKET B4070

9/16’ SOCKET WEDGE 707 6999

1/2” CABLE SOCKET B4070

1/2” SOCKET WEDGE B17006

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MAINTENANCE AND LUBRICATION

The wrong cable wedge could permit the wire rope to work
lose and detach itself from the drum; possibly causing prop-
erty damage or personal injury. 2. Insert the wedge and allow the rope strands to adjust
around it.
Tension the wire rope by braking the shipping reel and slow-
ly operate the winch in the raise mode to wind the cable onto
the winch drum. As the spooling proceeds, make sure the ad-
jacent turns are tight against one another. A lead or brass
hammer may be used to tap the rope over against preceding
turns. Tight winding on the drum is absolutely essential.

3. Seat the wedge and loop just tightly enough to allow han-
dling by attaching the socket to a strong support and en-
Never use a steel hammer or pry bar to move the rope over gaging the winch to take a strain on the rope.
on the drum. These tools can easily damage the rope.
4. Final seating of the wedge is accomplished by making lifts
After the rope is wound onto the winch drum, reeve the ca- of gradually increasing loads. avoid imposing shock loads
ble as desired. on the rope until the wedge is firmly in place.

Use only factory supplied sockets, wedges and pins of the

proper size; make no substitutions.

Follow the procedure below when installing wedge type

sockets on wire rope. Be certain the correct socket and 5. After the wedge has been firmly seated, a short length (6
wedge are used. inches) of the cable should be secured to the free end of the
wire rope to act as a stop as shown. DO NOT clamp the
1. Lead the rope through the socket, form a large loop and free end to the load supporting end as this will weaken the
draw the rope end back through the socket. A length of rope.
rope equal to at least one rope lay should be drawn back
through.

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MAINTENANCE AND LUBRICATION

CRANE BOOM

WEEKLY: If any cracks in either fillet welds or plates are noted, the
STRUCTURAL MEMBERS AND WELDS Visually in- particular component must be replaced before any further
spect all structural members and welds including (but not crane operations are performed. This is necessary to main-
limited to) the extended boom for straightness, roller (or tain the structural strength of the boom and prevent possible
pad) adjustment, and cracks. Pay special attention to the lon- catastrophic failure resulting in injury or property damage.
gitudinal welds joining the top, side and bottom plates.
Check the welds attaching the jib ears to the boom head and Field repair of boom sections is NOT recommended because
the welds attaching the boom head to the tip section. Inspect distortion may be introduced and original structural strength
the cylinder attaching supports and the boom pivot area. not restored.

On the superstructure, inspect the superstructure as well as Boom extension indicator decals are extremely important
the welds on the hoist cylinder supports and the welds be- and must be maintained in place at all times. Boom section
tween the bottom mounting plate and the vertical plates. failures can occur due to overstressing within rated capaci-
This is especially important if the machine is being used ex- ties if the sections are not equally extended within one indi-
tensively in clamshell, pile driving, concrete pouring, head- cator mark difference between the telescoping sections.
ache ball, or other high duty cycle applications.
NOTE: Sections are equalized byfully extending or fully re-
On the carrier, inspect the swing bearing weld band and sup- tracting the boom. When the boom reaches either full exten-
porting header welds. Check the outrigger attaching welds, sion or retraction continuing to hold the telescope lever in
outrigger box ends at the collar, jack cylinder mounting the extended or retracted position will allow the boom sec-
tube, and the beam welds. tions to be proportioned equally.

If any indicator decals are missing or illegible (either trian-

BOOM Visually inspect all boom sections a minimum of gle markers or boom length numbers), order the applicable
weekly or every fifty (50) hours, whichever occurs first. Pre- items through your distributor and apply them using the di-
paratory to making the inspection, set the outriggers and ro- mensions given on the following page.
tate the upper to an area where the boom can be fully
lowered and extended.

With the boom fully lowered and extended, visually inspect

the sides, top and bottom of each section for any unusual de-
formation, scrubbing, wear, or cracking in either the plates
or welds, particularly the fillet welds along the bottom edge
of the side plates of the telescoping sections. In addition,
note any missing or illegible indicator mark decals on the
telescoping sections.

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MAINTENANCE AND LUBRICATION

Markers and numbers are located on the left hand side of the
boom sections. Apply them with the boom fully extended.
Start at the rear of each section and apply the first marker, or
appropriate number, at the first over-lap point. Measure for-
ward for each subsequent location.

BASE
2nd SECTION
SECTION

2nd
3rd SECTION
SECTION

4th 3rd
SECTION SECTION

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 TABLE OF CONTENTS

SERVICE AND ADJUSTMENTS

INDEX

SECTION 5

SUBJECT PAGE

VALVE ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

BOOM MAIN RELIEF VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2

MID-INLET MAIN RELIEF VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

MAIN WINCH RELIEF VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4

AUXILIARY WINCH RELIEF VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

STEERING/OUTRIGGER RELIEF VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . 5 - 6

STEERING PRIORITY VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

SWING RELIEF VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8

BOOM ALIGNMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9

BOOM CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 11

AXLE LOCKOUT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13

SWING BRAKE CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14

RING GEAR BOLTING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 16

TORQUE WRENCH EXTENSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17

WELDING RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18

WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20

RT400 Series Revised: June 1999

 TABLE OF CONTENTS

SERVICE AND ADJUSTMENTS

As the operator, it is your responsibility to detect any un- If you can’t 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,
mance that could indicate trouble ahead. testing equipment and service knowledge to pin-point
the problem in minutes instead of the hours consumed
By detecting any problems in their early stages, you can in hit-or-miss methods. TIME IS MONEY! He will
save yourself unnecessary downtime and your employer save it for you.
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
repairing them. If you don’t, one failure can lead to an- a logical TROUBLE SHOOTING PROCEDURE.
other. Don’t simply replace parts until the trouble is found.

Before attempting to make an adjustment yourself, ask

yourself if you have the RIGHT TOOLS, IF you have the
PROPER TEST EQUIPMENT and IF you can accurate-
ly DIAGNOSE the cause of the problem.

VALVE ADJUSTMENTS

Setting hydraulic pressure is an complex operation and MAINTENANCE CHECKS All the relief valve
should be performed only after satisfying the following maintenance checks are conducted an a SEMI-ANNU-
conditions. AL BASIS. Check the relief valves and make the nec-
essary adjustments by the following procedures.
1. Warm the hydraulic oil to 130° F in normal conditions.
NOTE: If the normal hydraulic operating temperature The relief valves used on this hydraulic crane have a
is substantially above or below 130° F use that value in- screw type adjustment. If it is determined that the
stead. valve is out of adjustment, follow this general adjust-
ment procedure.
2. Be sure the correct engine speed is used as the relief
valve setting will vary with the flow rate. NOTE: Some machines are equipped with auxiliary
winch plumbing even though an auxiliary winch is not
3. Be certain to calibrate the pressure gauge used. Gauge installed. on these machines you must follow the pro-
calibration can be lost if the gauge is subjected to pul- cedure for setting the auxiliary winch relief valve.
sating pressure for a few seconds. The gauge must have
a proper snubber to read center of pump pressure ripple
or erroneous readings will result.

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SERVICE AND ADJUSTMENTS

RELIEF VALVE ADJUSTMENTS

BOOM MAIN RELIEF Check this relief setting as fol- 4. Lower the boom completely and continue to boom down
lows: with the engine running at full governed RPM. The relief
setting should be 3500 PSI ± 50 PSI. If necessary, adjust the
1. Operate the boom over relief to warm the oil if necessary. relief valve.

2. Switch the Two Mode Switch Located on the dash panel

to the split flow mode. (switch depressed to the right) see
illustration below and also refer to page 2 - 7 in the oper- BOOM MAIN RELIEF VALVE ADJUSTMENT Ad-
ation manual. just the relief using the following procedure:

Loosen the jam nut on the relief valve. Adjust the relief
with the adjusting screw while booming down over relief at
full engine RPM. Screw in the adjustment to increase the
pressure setting and out to decrease it. When the pressure is
at 3500 PSI ± 50 PSI tighten the jam nut.

NOTE: The Two Mode Switch located on the dash must be

depressed to the right as described earlier.

Recheck the pressure setting after tightening the jam nut as

the pressure may change due to tightening the jam nut.

DEPRESS SWITCH
TO THE RIGHT
3. Attach a calibrated pressure(Split
gaugeFlow)
in test port “A” see il-
lustration below. This test port is located on the inlet
pressure port on the right side of the control valve.

TEST PORT
“A”

BOOM MAIN
RELIEF VALVE

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MID INLET MAIN RELIEF Check this relief setting as

follows: 4. Retract the boom completely and continue to retract with
the engine running at full governed RPM. The relief set-
NOTE: Prior to checking the mid inlet main relief valve set- ting should be 3500 PSI ±50 PSI. If necessary, adjust the
ting the boom main relief MUST be set to the proper pres- relief valve.
sure.

1. Operate the boom over relief to warm the oil if necessary. MID INLET MAIN RELIEF VALVE ADJUSTMENT
Adjust the relief using the following procedure:
2. Switch the Two Mode Switch located on the dash panel to
the combined flow mode. (switch depressed to the left) Loosen the jam nut on the relief valve. Adjust the relief with
see illustration below and also refer to page 2 - 7 in the the adjusting screw while retracting the boom over relief at
operation manual. full engine RPM. First lower the pressure setting below
3500 PSI by turning the adjusting screw out, then slowly
raise the pressure setting to 3500 PSI ± 50 PSI and tighten
the jam nut.

NOTE: The Two Mode Switch located on the dash must be

depressed to the left as described earlier.

Recheck the pressure setting after tightening the jam nut as

the pressure may change due to tightening the jam nut.

DEPRESS SWITCH
TO THE LEFT
(Combined
3. Attach a calibrated Flow)
pressure gauge in test port “A” see il-
lustration below. This test port is located on the inlet
pressure port on the right side of the control valve.

MID INLET
MAIN RELIEF

TEST PORT
“A”

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MAIN WINCH RELIEF Check this relief setting as fol- the one way sprag clutch in the winch will allow the winch
lows: to raise.

1. Operate the boom over relief to warm the oil if necessary. 4. Actuate the winch down function in low speed with the
engine running at full governed RPM. The relief setting
2. Attach a calibrated pressure gauge in test port “B” see il- should be 3500 PSI ± 50 PSI. If necessary, adjust the re-
lustration below. lief valve.

3. Disconnect the winch brake release line located on the left

side of the winch. This is a small hydraulic hose running MAIN WINCH RELIEF VALVE ADJUSTMENT
from the winch hold valve to the brake section of the Adjust the relief using the following procedure:
winch. Cap and plug this line. This will deactivate the
brake release feature and allow the winch to stall to be NOTE: The winch brake release line must be disconnected,
able to read the winch pressure. plugged, and capped as described earlier.

Loosen the jam nut on the relief valve. Adjust the relief with
the adjusting screw while running the winch down function
(In low speed) over relief at full engine RPM. Screw in the
adjustment to increase the pressure and out to decrease it.
When the pressure is at 3500 PSI ± 50 PSI tighten the jam
DISCONNECT, PLUG, nut.
AND CAP THIS LINE
Recheck the pressure setting after tightening the jam nut as
the pressure may change due to tightening the jam nut.

NOTE: This will only stop the winch from turning in the low-
ering position. If the winch is activated in the raise position

MAIN WINCH
RELIEF

TEST PORT
“B”

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AUXILARY WINCH RELIEF (IF EQUIPPED) NOTE: This will only stop the winch from turning in the
Check the auxiliary winch relief setting as follows: lowering position. If the winch is activated in the raise po-
sition the one way sprag clutch in the winch will allow the
NOTE: Prior to checking the Auxiliary winch relief valve winch to raise.
setting the Main winch relief MUST be set to the proper
pressure. 4. Activate the winch down function with the engine run-
ning at full governed RPM. The relief setting should be
1. Operate the boom over relief to warm the oil if necessary. 3500 PSI ± 50 PSI. If necessary adjust the relief valve.

2. Attach a calibrated pressure gauge in test port “B” see il- AUXILARY WINCH RELIEF VALVE ADJUST-
lustration below. MENT Adjust the relief using the following procedure:

NOTE: The winch brake release line must be disconnected,

plugged, and capped as described earlier.
TEST PORT
“B”
The auxiliary winch relief valve is located in the auxiliary
winch valve bank towards the rear of the machine inside
the superstructure just ahead of the counter weight.

Loosen the jam nut on the relief valve. Adjust the relief
with the adjusting screw while running the winch down
function over relief at full engine RPM. Screw in the ad-
justment to increase the pressure and out to decrease it. Set
the pressure at 3500 PSI ± 50 PSI then screw in the adjust-
ment an additional 1/2 turn.

3. Disconnect the winch brake release line located on the left

side of the winch. This is a small hydraulic hose running
from the winch hold valve to the brake section of the
winch. Cap and plug this line. This will deactivate the
brake release feature and allow the winch to stall to be FRONT OF MACHINE
able to read the winch pressure.

AUXILARY WINCH
RELIEF VALVE

DISCONNECT, PLUG,
AND CAP THIS LINE

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STEERING/OUTRIGGER RELIEF Check third relief

using the following procedure: NOTE: There are two relief valves shown in the illustration
below. The relief valve in the lower valve section is not used
1. Operate the boom over relief to warm the oil if necessary. and should be deactivated by turning it in until it bottoms
out. This should be checked prior to setting the outrigger re-
2. Attach a calibrated pressure gauge in test port “C” see il- lief valve.
lustration below.
Loosen the jam nut on the relief valve. Adjust the relief with
NOTE: Test port “C” is located on the outrigger deverter the adjusting screw while fully retracting and continuing to
valve which is mounted on the inside of the left frame rail hold an outrigger jack or beam with the engine at full RPM.
just ahead of the swing bearing. Screw in the adjustment to increase the pressure and out to
decrease it. Set the pressure at 2500 PSI ± 50 PSI.
3. Stall an outtrigger function over relief by retracting either
a beam or jack and continuing to hold the function at full Recheck the pressure setting after tightening the jam nut as
engine RPM. The relief setting should be 2500 PSI ± 50 the pressure may change due to tighten the nut.
PSI. If necessary adjust the relief valve.
STEERING/OUTRIGGER RELIEF VALVE ADJUST-
MENT Adjust this relief using the following procedure:

OUTRIGGER
RELIEF VALVE

TEST PORT
“C”

BOTTOM THIS
RELIEF VALVE

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STEERING PRIORITY VALVE

1. Remove the hydraulic hose connected to fitting “A”.
The steering priority valve is preset at the factory and will
normally not require any additional adjustment. In the event 2. Remove fitting “A”.
that a new valve is installed or steering performance is poor
and all other components and adjustments have been verified, 3. Turn adjustment “B” clockwise until it bottoms out.
adjustment of the valve may be required.
4. Turn adjustment “B” counterclockwise 2 full turns.
The steering priority valve is located inside the super struc-
ture just to the right of the rotary manifold. 5. Reinstall Fitting “A” and the hydraulic hose.

STEERING PRIORITY VALVE ADJUSTMENT

Adjust this valve using the following procedure:

FITTING “A”

STEERING PRIORITY VALVE

ADJUSTMENT “B”
TURN IN UNTILL BOTTOMED
OUT THEN OUT 2 FULL TURNS

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SWING RELIEF Check the swing relief using the follow- speed slowly. The swing pressure should be 2000 PSI ±
ing procedure: 50 PSI. If necessary adjust the relief.

NOTE: Prior to checking the swing relief valve pressure set- NOTE: If the swing pressure is low be certain to use cation
ting the outrigger relief MUST be set to the proper pressure. when adjusting, if the swing brake is not in proper working
order the increase in pressure may allow the machine to
1. Operate the boom over relief to warm the oil if necessary. swing through the brake.

2. Attach a calibrated pressure gauge in test port “D” see il- SWING RELIEF VALVE ADJUSTMENT Adjust this re-
lustration below. lief using the following procedure:

NOTE: Test port “D” is located on the swing valve which is Remove the acorn nut and loosen the jam nut on the relief
mounted inside the super structure just to the left of the valve. Adjust the relief valve with the adjusting screw while
swing reduction unit. attempting to swing against the swing brake at full engine
RPM. Screw in the adjustment to increase the pressure and
out to decrease it. When the pressure is at 2000 PSI ± 50 PSI
tighten the jam nut.

Recheck the pressure after tightening the jam nut as the pres-
sure may change due to tightening the jam nut.

3. Set the swing brake and begin to attempt to swing the ma-
chine against the swing brake. You should exercise cau-
tion in doing this until you know that the swing brake is
in good working order and will hold against the swing
pressure.
Once you have verified that the swing brake is holding
the engine RPM should be brought up to full governed

FRONT OF MACHINE

TEST PORT
“D”

SWING RELIEF
VALVE

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A E
C G I
K

BASE SECTION #2 #3 #4

L
H J
B D F

BOOM ADJUSTMENT

The 105 foot boom installed on this machine must be kept in clearance on each side between the roller and the boom
proper alignment and adjusted as required. Boom lubrica- section.
tion intervals should also be used to inspect boom align-
ment. Should adjustment be necessary use the following 3. Lubricate pads “A”, “C”, “E”, “G”, “I”, and “K” and ex-
procedure: tend the boom.

1. With the boom retracted and level, remove the three top 4. Visually align #2 boom section with base section by shim-
covers on the base section. If pad “C” is installed remove ming pad “B” on either side to bring the #2 section into
the shims. If pads “B”, “F”, “G”, “J”, and “K” are in- alignment. Check the alignment of the #2 section by run-
stalled, loosen the capscrews . The retaining bolts and ec- ning a string along the top of the base and #2 section as
centrics at pads “A”, “E”, and “I” are to be backed off to shown below. Shim and install the other pad “B” to a 1/
enable aligning the boom sections later. 32 inch clearance between the pad surface and the #2
2. With the boom still retracted adjust eccentrics on lower boom section.
front rollers “D”, “H”, and “L” to center the boom sec-
tions at the front and allow approximately 1/16 inch

CHECKING FOR PROPER ALIGNMENT

TOP BOOM PLATE

STRING

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5. Align the #3 boom section with the #2 boom section in the

same manner as step 4 by shimming and installing pads
“F”.
PAD ADJUSTMENT

6. Align #4 (tip) boom section with the #3 boom section in BASE

the same manner as step 4 by shimming and installing

pads “J”.

7. Shim and tighten pads “C”, “G”, and “K” to 1/32 inch
clearance between the pad surface and the boom section
on each side.‘
1/32 inch
8. Grease the boom ahead of wear pads.

9. Retract the boom, checking that no excessive binding oc-

curs.

10. Adjust the brackets on pads “A”, “E”, and “I” so the pads
contact the base boom section. Then “back off” until BOOM TOP PLATE
there is 1/32 inch clearance between the pad adjustment
base and the pad. This must be done for the left and
right pad for each section. This will maintain a total
clearance of 1/16 inch. Tighten the lock bolts. 11. A final check of boom alignment should be made by
“stringing” as described earlier and also by a visual in-
spection with the boom fully extended and at maximum
angle.

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BOOM CHAIN ADJUSTMENT

For proper operation and boom life the extend and retract 5. If the gap is more than .75” loosen adjustment B and
chains must be adjusted properly. To adjust these chains use tighten adjustment A, until the gap is within specifica-
the following procedure: tions.

Second Section Extend and Retract Chains: 6. Fully retract the boom and recheck the gap. Repeat steps
3 through 5 if necessary.
1. Fully retract the boom.
7. Fully extend the boom horizontal.
2. Measure the gap between the front of the base section
and the back of the second section. This gap should be 8. Measure the sag of the retract chain. This measurement
.50” +.25” - 0.0”. Refer to figure 5-1. must be taken from the bottom of the second section to
the top of the chain, in the middle of the second section.
3. If adjustment is required extend the boom approximate- The sag should be 8.5” +.50” - 0.0”. Refer to figure 5-2.
ly 1/2 way.
9. If the sag is greater than 9.0” tighten adjustments A & B
NOTE: Before attempting to turn one of the adjusting nuts ex- equal amounts until the sag is within specifications.
tend or retract the boom slightly to relieve the tension on that
nut. After extending the boom Adjustment B will be under ten- 10. If the sag is less than 8.5” loosen adjustments A & B
sion and A will be free. After retracting the boom adjustment equal amounts until chain sag is within specifications.
A will be under tension and B will be free.

4. If the gap is less than .50” loosen adjustment A and

tighten adjustment B, until the gap is within specifica-
tions.

GAP
B A

Figure 5-1

SAG

Figure 5-2
B A
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Tip Section Extend and Retract Chains. 5. Fully extend the boom in the horizontal position.

1. Fully retract the boom. 6. Refer to figure 5-3. Measure the sag of the two retract
chains. Do this by measuring from the bottom of the
2. Measure the gap between the front of the third section chains to the bottom plate of the second section at the
and the back of the tip section. This gap should be .50” ends of the chains (E). Then measure the gap (F) be-
+ .25” - 0.0”. Refer to figure 5-3. tween the bottom of the chains and the bottom plate of
the second section at the last access hole in the side of
3. If the gap is less than .50” loosen adjustment C and tight- the boom. Subtract measurement F from measurement E
en adjustment D, until the gap is within specifications. to obtain the chain sag. Chain sag must be 1.00” + .25”
- 0.0”.
NOTE 1 : Before attempting to turn one of the adjusting nuts
extend or retract the boom slightly to relieve the tension on 7. If the sag is less than 1.00” loosen adjustments C and D
that nut. After extending the boom Adjustment D will be under equally until the sag is within specifications.
tension and C will be free. After retracting the boom adjust-
ment C will be under tension and D will be free. 8. If the sag is greater than 1.25” tighten adjustments C and
D equally until the sag is within specifications.
NOTE 2 : There are two retract chains for the Tip Section. Ad-
justment C must be done in two places equally, one on the left
side of the boom and one on the right. To be sure that they are
equal, measure the threads protruding from each nut. These
two measurements should be equal.
4. If the gap is more than .75” loosen adjustment D and
tighten adjustment C, until the gap is within specifica-
tions.

Measure
Two
Places

D
F E

Chain
Sag GAP

Measure Pro-
truding
Threads
C (Both Sides)
Two Places

Figure 5-3

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AXLE LOCKOUT SYSTEM

BLEED
SCREWS

AXLE LOCKOUT
LOW POINT ON
VALVE
MANIFOLD

.005 / .010

AXLE LOCKOUT SYSTEM axle lockout valve should be checked daily as follows:

1. Place boom in travel position.

2. Drive one tire of the rear (oscillating) axle up on an eight

Air in the axle lock circuit decreases sta- inch block.
bility. Bleed the system immediately
whenever this occurs. 3. Swing the retracted unloaded boom approximately 20
degrees from the center position.
If the axle does not hold in the blocked position or oscillates
when the upper structure is swung 20 degrees from the travel 4. Drive the crane off the block. If the tire remains in the
position, bleed the system. up position proceed with step (5). If the tire does not re-
main in the up position readjust or replace lockout valve.
Swing the retracted unloaded boom into the travel position so
that the lock valve will open. With the engine running at an 5. Allow crane to set for three to five minutes.
idle, loosen the bleeder screw. When a steady flow of oil is
running from the bleed screw, retighten the bleeder screw. 6. Observe the tire, it should remain in the up position.

ADJUSTMENT 7. Swing the crane back to the center position, the tire
should return to its original position. If not readjust or
With the cam plunger fully retracted, adjust valve position for replace the lockout valve and repeat this procedure.
.005-.010 inches gap between the cam roller and the cam trav-
el area on the manifold. Do not measure at the low point on
the manifold.

Tighten and secure with nuts, washers, and capscrews.

OPERATION CHECK

For safe operation of the crane when operating on rubber, the

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SERVICE & ADJUSTMENTS

CONTROL LINKAGE ADJUSTMENTS

FIGURE 1

Console Frame

Bumper

Adjust this
end of the
Swing Brake Pedal In The cable first.
First Click Position

Swing Brake Pedal In The

Seventh Click Position

Adjust this end of the

cable if necessary.

Swing Brake Cable

Swing Speed Reducer

Swing Brake Control Adjustment:

(a) During normal operation, the swing brake pedal should

be operating in the 4 to 5 click range if the swing brake
pedal is properly adjusted. If the swing brake pedal is The cables used on this machine are
operating in the 6 or 7 click range during normal opera- sealed. Never adjust a cable to the point
tion, the swing brake cable will need to be adjusted. that the threads on the rod end are
pulled into the seal.
CLICK DESCRIPTION
1 Bumper should rest against the pedal.
2 Brake disks should begin to engage. Note: If the machine is not equipped with a swing brake
3 pedal bumper on the console frame, skip step “b”.
4 Brake discs should be fully engaged
(b) Refer to figure 1. Release the swing brake and move the
5 and should hold at full engine RPM.
swing brake pedal to the first click position. Adjust the
6 Swing brake cable should be adjusted bumper to rest against the swing brake pedal.
7 and/or brake pads may need replacing.

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SERVICE & ADJUSTMENTS

CONTROL LINKAGE ADJUSTMENTS

Anchor

Cable Shaft
Yoke

Swing speed reducer

FIGURE 2

the 6 or 7 click range, the swing brake cable and/or the

(c) Adjust the pedal end of the swing brake cable by brake discs may need to be replaced.
increasing the thread length as indicated in Figure 1
until the swing brake pedal is operating in the 4 to 5
click range. After the adjustments are made, sufficient
thread must remain so that all the threads of the jam nuts
are engaged.

Note: Any adjustment required on the swing speed

reducer end of the swing brake cable will require
that the swing brake cable is disconnected from the
swing brake pedal.

(d) Set the swing brake and begin to attempt to swing the
machine against the swing brake. You should exercise
caution in doing this until you know that the swing
brake is in good working order and will hold against the
swing pressure. Once you have verified that the swing
brake is holding, the engine RPM should be brought up
to full governed speed slowly.

(e) If the swing brake fails to prevent the boom from rotat-
ing or if the swing brake pedal continues to operate in

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SERVICE AND ADJUSTMENTS

TORQUE WRENCH EXTENSIONS

FRONT

MAINTENANCE CHECK A number of causes can reduce tension in the bolts when
torquing and after use. These include rust on the threads,
It is very important to perform periodic ring gear bolt damaged or rough threads on bolts and nuts, shanks of blots
checks. The bolts MUST BE KEPT TORQUE TIGHTENED which hang up on holes, etc. All of these causes have a ten-
to a rating of 600 Ft. Lbs. (813 NM). After the initial 40 dency to absorb the torque when bolts are being tightened.
hours of machine operation, check and tighten the bolts. If
additional torque is required after the first 40 hours, then It is important to make periodic checks of the ring rear bolts.
recheck each 40 hours until all bolts are found properly The bolts Must be kept torque tightened.
torqued. Thereafter, checks should be performed QUAR-
TERLY. Torque the inner race first, then the outer race as shown in
the bolting sequence. Torque the 7/8 inch, Grade 8, bolts to
RING GEAR TORQUING 600 Ft. Lbs. (813 NM)

The gear and bearing assembly consists of an inner race and

ring gear, an outer race, bearing rollers, spacer and a seal
ring. The inner race is bolted to the carrier; the outer race to
the turntable.

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SERVICE AND ADJUSTMENTS

TORQUE WRENCH EXTENSIONS

A B

In some applications, a standard torque wrench and socket

cannot be fitted to the bolt (s) to be tightened because of Torque wrench (600 ft. lb.) times (“B”)
=
restricted access. In other instances, the torque value speci- setting (TWS) (“B”) plus (“A”)
fied cannot be obtained because sufficient force cannot be
applied to the standard length wrench. Both of these prob- = lpq -Plw
lems may be solved by the use of appropriate torque wrench
extensions - either commercially made or fabricated by the
user.
EXAMPLE
When using an extension, it must be remembered that the
wrench torque (the actual torque reading or setting of the A = 10.25”
wrench) and the wrench force (the force applied to the B = 43”
wrench) must be adjusted to compensate for the added length
and produce the desired bolt torque. TWS = (600 FT.LB.) X 43
42 + 10.25
Refer to the illustration and formula below when calculating
the proper adjusted values for wrench torque, wrench force = 2580
and bolt torque. 53.25

NOTE: Torque wrench setting at length “B” would be 600 ft. = 485 FT. LB.
lb. (813 NM) for capscrews not requiring us of
adapter.

FORMULA

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SERVICE AND ADJUSTMENTS

WELDING INSTRUCTIONS

Before welding on the unit, contact the factory service de-

! partment for approval.

When doing repair welding on your unit take precaution Always have a fire extinguisher on hand in case of fire. Ade-
attaching your ground to the component being repaired. This quate ventilation and dry area are necessary. Protective cloth-
will reduce the chance of arcing through a bearing, cylinder, ing should be used and all persons in the welding area should
etc., damging the component. Paint should be removed from have protection for their eyes. Follow instructions for weld-
the surface to be used as the “ground” (earth). ing and cutting on paint.

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 intershield welds.

Use necessary precaution when welding around fuel tanks, AWS CLASS E11018G Low hydrogen rod for repair on
oil reservoir, batteries, tubing and pressure systems. high strength alloy steel such as T-1, 80,000 to 100,000
yield. All position welding, good penetration, and high ten-
sile stength up to 110,000.

When welding close to glass, cylinder rods, or any polished Note: Low hydrogen rod E7018 must be used within four
surface, provide adequate protection from splatter. (4) hours upon removal from a freshly opened con-
tainer or from a storage oven.

Low hydrogen rod E11018G must be used within 1/2

hour upon removal from its container or from a
storage oven.

Never weld when the engine is running. Always disconnect

the battery cables and apllicable grounds before welding.

All welding procedures and welding operator qualifications

shall be in accordance with ANSI/AWS D14.3 when welding
Do not weld on wet surfaces since this will cause hydrogen on load sustaining members (ANSI/ASME B30.5)
embrittlement of the weld.

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SERVICE AND ADJUSTMENTS

WELDING & CUTTING

ON PAINTED SURFACES

When welding or cutting steel coated with a certain paint systems,

the worker is exposed to decomposition products (metal fumes, gases
or vapors, particulate) which vary depending on the type of process
being used to weld or cut, the nature of the base metal, and the type
of coating system. The following control procedures should be uti-
lized when one is welding or cutting coated steel:

• Use a power brush or grinding wheel to strip the coating from the
steel in the vicinity where the cut or weld is to be made. Remove
the paint far enough from the weld to prevent any remaining paint
from becoming heated and bubbling. If this happens, continue to
brush or grind the paint away.

• A toxic dust respirator and eye protection should be used while

stripping the paint.

• Welder should be outfitted with a fresh air supplied respirator and

other personal protective equipment required for welding.

• Other employees should be removed from the area or told to stand

back a minimum of 10 feet from the welder. Do not be in direct
line with the weld fumes.

• Use a local exhaust hood to remove fumes during the welding or

cutting operation if one is available.

RT400 Series 5 - 19 May 1998

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WINCH

MAINTENANCE CHECK winch. When disassembly is necessary, all items such as “O”
Rings, back-up rings, and seals should be replaced even
Every TWO YEARS OR 4000 HOURS, disassemble and though inspection shows them to be serviceable. Their cost
inspect the winch components. These include the gearing, is negligible compared to labor or down-time caused by the
bearings, and brake friction discs. Refer to the following failure of such items. A seal kit should be on hand before
pages for disassembly procedures. disassembly is started. Inspect all new parts before installa-
tion on reassembly. Cleanliness is of prime importance when
In the event that the winch does not function correctly, DO servicing this winch. The work area and the winch itself
NOT disassemble the winch until all other possible causes should be cleaned and the motor ports, drain, and brake ports
have been examined such as pumps, relief valves, line con- plugged to prevent contamination.
nections, and the hydraulic system in general. Refer to the
hydraulic system “Trouble Shooting” pages located else-
where in the maintenance section of the Operator’s Manual.

The following service procedure is arranged to provide the

best method of assembly and disassembly of the hydraulic

RT400 Series 5 - 20 May 1998

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SERVICE AND ADJUSTMENTS

WINCH

DISASSEMBLY OF THE MAIN DRIVE END PISTON HOUSING

(1) Remove the hose from the motor valve at the

piston housing and cap all fittings.

MOTOR VALVE
Figure 1

(2) Remove the four capscrews which secure the

motor. See Figure 1.
CAPSCREWS

Figure 2

(3) With a rubber mallet, tap the motor to break

the seal and work the motor out of the pilot in
the winch end cover. See figure 2. Save the
motor shim for use in reassembly. See Figure
3.
MOTOR SHAFT
Note:The motor shaft is free to move and will
allow the timing mechanism to drop out of
engagement in the motor. Remove and
install the motor horizontally and DO NOT
allow the shaft to move out of the motor.

Figure 3

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SERVICE AND ADJUSTMENTS

WINCH

DISASSEMBLY OF THE MAIN DRIVE END

CAPSCREWS
(4) Remove the end cover by removing six of
the twelve capscrews as shown in Figure 4.
The belleville spring is compressed against
the cover. Remove the remaining six bolts,
loosening each bolt equally until the cover is
free. This will prevent binding and protect
the bearing.

Figure 4

(5) Remove the belleville spring. See Figure 5.

BELLEVILLE SPRING

Figure 5

(6) Remove the piston housing and piston using

four 3/8 UNC capscrews as shown. See Figure
6.

3/8 UNC CAPSCREWS

Figure 6

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SERVICE AND ADJUSTMENTS

WINCH

DISASSEMBLY OF THE MAIN DRIVE END

CAPSCREWS
(4) Remove the end cover by removing six of
the twelve capscrews as shown in Figure 4.
The belleville spring is compressed against
the cover. Remove the remaining six bolts,
loosening each bolt equally until the cover is
free. This will prevent binding and protect
the bearing.

Figure 4

(5) Remove the belleville spring. See Figure 5.

BELLEVILLE SPRING

Figure 5

(6) Remove the piston housing and piston using

four 3/8 UNC capscrews as shown. See Figure
6.

3/8 UNC CAPSCREWS

Figure 6

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WINCH

DISASSEMBLY OF THE MAIN DRIVE END

SEPARATOR DISK
(7) Remove the clutch and separator disc. A tool
as shown below will facilitate removal. See
Figure 7 and 8.

Figure 7

DISC,SEPARATOR

DISC,CLUTCH

Figure 8

(8) Remove the outer race and hub with bear-

ings. See Figure 9

HUB

Figure 9

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WINCH

(9) Remove the Spirolox Retaining ring as

shown in Figure 10.

SPIROLOX

Figure 10

(10) Block the drum so that the main drive mount

can be removed. Install the tube spacer and
necessary shims over the shaft behind the
puller bar. Using two capscrews as shown in PULLER BAR
Figure 11, remove the main drive mount by
turning the capscrews equally into the tapped
holes.

Figure 11

(11) Inspect the seal, bearing, retaining ring

groove on the drum hub. If bearing replace- DRUM HUB
ment is necessary, remove the seal and
spirolox retaining ring. See figure 12 and 13.

Figure 12

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WINCH

FINAL DRIVE MOUNT

SPIROLOX

LIP SEAL

RACE SEAL

Figure 13

DISASSEMBLY OF THE FINAL DRIVE END

CAPSCREWS

(13) Remove the twelve capscrews and lift off

cover. See Figure 14.

END COVER

Figure 14

(14) Inspect the seal, bearing, retaining ring

groove on the drum hub. If bearing replace-
ment is necessary, remove the seal and
spirolox retaining ring. See figure 12 and 13.
BRONZE PLUG

RETAINING BOSS

SPIROLOX

Figure 15

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WINCH

(15) With a punch and hammer, tap the shaft out

from the main drive end. See Figure 16. MAIN DRIVE END FINAL DRIVE END

DRIVE SHAFT
PUNCH THROUGH HOLE
Figure 16

(16) Remove the thrust washer and the spirolox

retaining ring. See Figure 17.

THRUST WASHER

Figure 17

(17) Lift out the planetary case assembly. See

Figure 18.

PLANETARY CASE

Figure 18

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WINCH

(18) With a prybar, remove the ring gear as

shown in Figure 19.

RING GEAR

Figure 19

(19) Install a tube spacer against the drum hub

and, using shims as necessary, install the
puller bar as shown in Figure 20. Block
against the drum and tighten the capscrews
in the outer holes of the puller bar equally to
remove the planetary drive mount.

SHIMS

PULLER BAR

Figure 20

(20) Inspect the seal and bearing in the assembled

condition. See figure 21.

SEAL AND BEARING

Figure 21

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WINCH

PISTON DISASSEMBLY & REASSEMBLY

PISTON HOUSING
1. Tap the piston out of the outer piston housing. See Figure
22.

2. Inspect the piston and housing for any scored or nicked PISTON
surfaces which might allow leakage.

3. Install new “O” rings and back-up rings.

O-RINGS

Figure 22

Place the back-up rings to the outside so that the pres-

sure pushes the “O” ring against the back-up assembly as
shown in Figure 23. BACK-UP
RINGS
4. Coat the working surfaces with lubricant and insert the
piston into the housing carefully. As the piston is edged O-RINGS
past the “O” Ring in the housing, use a dull thin tool to
seat the “O” Ring into the housing, being very careful
not to shear the “O” Ring or back-up ring. Gently tap the
piston into place. See Figure 22.

Figure 23

REASSEMBLY OF THE FINAL DRIVE END

1. Clean the bearing and oil seal with a suitable solvent and
dry with compressed air. Do not spin the bearing. Lubri-
cate the oil seal with a light coating of grease. Inspect the
seal race on the drum hub for scoring or roughness.
Smooth the race with fine emery cloth. Replacement is
possible if necessary. Install the bearing retaining ring,
and oil seal into the final drive mount. See Figure 24.

2. Install the final drive mount into the drum hub. The bear-
ing should fit snugly.
SEAL AND BEARING

Figure 24

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WINCH

3. Coat the mating surfaces of the final drive mount and

ring gear with liquid gasket. Install the planetary case
assembly. See Figure 25.

PLANETARY CASE

Figure 25

4. Install the retaining ring and then the thrust washer. See
Figure 26.

THRUST WASHER

Figure 26

5. Install the drive shaft. See Figure 27.

MAIN DRIVE END FINAL DRIVE END

DRIVE SHAFT

Figure 27

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WINCH

6. Install retaining boss, bronze plug, and the spirolox teta-

ining ring. See figure 28.

BRONZE PLUG
RETAINING BOSS

SPIROLOX

Figure 28

7. Coat the mating surfaces of the ring gear and cover with
liquid gasket. Install the cover and twelve capscrews. See
Figure 29.
CAPSCREWS

END COVER

Figure 29

REASSEMBLY OF THE MAIN DRIVE END

8. Repeat Step 1 for main drive mount. See Figure 30.

SEAL AND BEARING

Figure 30

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WINCH

9. Install the main drive mount onto the drum hub. Install
the spirolox retaining ring. See Figure 31.
MAIN DRIVE MOUNT

SPIROLOX

10. Remove the inner bearing from the hub assembly with
a wheel puller that will not push against the outer race. Figure 31
Loading against the outer race can damage the sprag
clutch. Remove the spacer and slide the outer race
from the hub. Inspect the sprag clutch for flat surfaces.
See Figure 32.

11. Clean the two hub bearings with solvent and dry with
compressed air. See Figure 32.

12. Inspect the hub clutch surface for wear.

13. Reassemble the hub and outer race and install over the
drive shaft and into the drive mount. See Figure 32.

Figure 32

If the sprag clutch is not installed correctly,

the winch will not function. Install the sprag
clutch cages toward the inside of the winch
when assembled. The hub must rotate in the
direction as shown with respect to the outer
race. See Figure 32.

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WINCH

14. Coat the mating surfaces of the main drive mount and
the piston assembly with liquid gasket. Place the plastic
shims on both mating surfaces of the piston housing. MATING SURFACE
Install the piston assembly. See figure 33 and 34.

15. Inspect the clutch and separator disc for wear or dam-
aged teeth. The original total thickness of the clutch disc
is 0.156/0.150”. If wear is more than 0.020” per disc,
replace the clutch and separator disc. See Figure 23 and
33.

CLUTCH AND SEPARATOR DISCS

Figure 33

16 Install the belleville spring. See Figure 34.

PLASTIC SHIMS

BELLEVILLE SPRING

Figure 34

17 Coat the mating surfaces of the piston assembly and the

end cover with liquid gasket. Install the end cover.
Tighten opposite capscrews evenly, around the cover to
PISTON HOUSING
prevent binding while compressing the belleville spring.
See Figure 35. Inspect the outboard bearing of the hub
to insure a clearance of .005” between it and the shoul-
der in the end cover. If a preload occurs, the bearings
will fail prematurely. Adjust the shims between the end
cover and the piston housing to prevent this situation.

END COVER

Figure 35

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WINCH

18 Clean the mating surfaces of the motor and end cover

and coat with liquid gasket. Install the motor using the MOTOR
existing shim.

The motor shaft is free to move and will allow

the timing mechanism to drop out of engage-
ment in the motor. Install the motor horizon-
tally and DO NOT allow the shaft to move out
of the motor.

Figure 36

19 Align the winch upon installation as follows: With

feeler gauges, measure distances A and B approxi-
mately 180° apart on the drum at locations C and D. See
Figure 37. Distance A should be the same with .020” at
locations C and D. Likewise for distance B. Place shims
under the mounting feet until these distances A and B
do not have to be equal.

Figure 37

LUBRICATION
Lubrication for the winch is provided by seepage
flow from the drive motor. Oil enters the final
drive end through the drive shaft tube in the drum.
A drain line on the main drive end cover returns
excess oil to the reservoir.

Following reassembly of the winch, fill the winch

to the level of the drain line port with the hydraulic
fluid specified in Section 9.

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WINCH MOTOR

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WINCH MOTOR

REASSEMBLY & TIMING

OF THE WINCH MOTOR

1. Place mounting plate on table as shown. Install the four

STUDS
studs into plate. (The long threads go into the plate).
Lubricate the “O” Ring and install into plate. See Figure
38 & 39. 7 17/32”

Before reassembling the motor, clean all parts and dry with
compressed air.

MOUNTING PLATE
Figure 38

Do not allow the rollers to fall out of the geroler assem-

bly.

The rollers are individually honed and must remain in their

original position. Hold the geroler with your hand to prevent
their falling out. Do not use shop cloths as lint deposits may
cause malfunction. Inspect all parts for wear and replace as
necessary. Replace all “O” Rings and seals. “O” RING

Figure 39

2. Install the wear plate over the studs. The smaller bore
goes up. See Figure 40.

WEAR PLATE

Figure 40

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SERVICE AND ADJUSTMENTS

WINCH MOTOR

3. Place the mounting plate assembly on a spacer as shown

in Figure 41. Install the output shaft or “large dog bone”
with the short spline up. Place shims under the shaft so
that it extends approximately 1 3/8” above the wear
plate.
1 3/8”

SPACER OUTPUT SHAFT

Figure 41

4. Place “O” Rings into each side of the geroler. See Fig-
ure 42.
TOP BOTTOM

“O” RING

CHAMFERED

Figure 42

5. Install the geroler assembly as shown in Figure 43.

Note: The chamfered side as indicated in Figure 42 (top)

goes up. The small drain port in the wear plate,
GEROLER
geroler, and timing valve plate are not functional but
should be lined up during assembly.

VALVE PLATE

Figure 43

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WINCH MOTOR

3. Place the mounting plate assembly on a spacer as shown

in Figure 41. Install the output shaft or “large dog bone”
with the short spline up. Place shims under the shaft so
that it extends approximately 1 3/8” above the wear
plate.
1 3/8”

SPACER OUTPUT SHAFT

Figure 41

4. Place “O” Rings into each side of the geroler. See Fig-
ure 42.
TOP BOTTOM

“O” RING

CHAMFERED

Figure 42

5. Install the geroler assembly as shown in Figure 43.

Note: The chamfered side as indicated in Figure 42 (top)

goes up. The small drain port in the wear plate,
GEROLER
geroler, and timing valve plate are not functional but
should be lined up during assembly.

VALVE PLATE

Figure 43

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WINCH MOTOR

6. Determine the center axis of the geroler assembly by

STRAIGHT EDGE
jointing the “high” and “low” positions of the center star
rotor. See figure 44 & 45.
POINT “B”

POINT “A”

Figure 44

The straight edge represents this axis. Looking down on the

geroler, you will note that going clockwise from Point A, the
TOP VIEW
volume between the star and the rollers gets larger. Make
note of the location of Point A on your motor. See Figure 45.

Figure 45

7. Position the valve plate over the studs so that the small
ports are up.

VALVE PLATE
VALVE DRIVE GEAR

If this plate is installed upside down, the winch will raise up GEROLER
not lower. Place the valve drive gear or “small dog bone”
through the valve plate either end up. As the valve plate is
lowered into place, locate the drive gear into the geroler
assembly. See Figure 46.

Figure 46

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WINCH MOTOR

8. Upon inspection of the valve plate, you will see the cir-
TIMING VALVE
cular path that the valve runs in. The valve must be kept
in this path while performing the following steps.

Note: Disregard the studs when timing the valve. The

geroler in your motor may be in a different location
relative to the studs than shown in the photos.

Examine the timing valve. The bottom is shown in Figure

47. Note the gear teeth that synchronize the timing valve to
the geroler. The relationship between the valve and geroler is
the key to proper operation.

Figure 47

Look at the slots in the valve plate and find the first two
“open” ports clockwise form Point A. See Figures 46 & 48.

Place the valve in its path on the valve plate and inspect the
ports going clockwise form Point A. They should become
increasingly open from Point A to Point B. If not, lift the
valve off the drive gear and turn one tooth at a time until
going clockwise form Point A, the slots get more open from “OPEN” PORTS
Point A to point B and more closed from Point B to Point A.

Figure 48

Pour oil through the top of the timing valve for initial lubri-
cation. TOP OF TIMING VALVE

Figure 49

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WINCH MOTOR

9. Install the four springs into the end housing. Grease the
spring holes to hold the springs in place. Install the “O” END HOUSING
Ring seal. See Figure 51.
SPRINGS

“O” RING SEAL

Figure 51

10. Install the inner and outer face seals into the balancing
plate.
BALANCE PLATE OUTER FACE SEAL
Note: The bevel of both seals goes down. See Figure 52.

11. Align the dowel pins of the balance plate with the holes
in the end housing and install the balance plate into
cover. Hold with fingers, through the drain ports, and
install the cover over the studs. See Figure 53. Position
the housing so that the drain ports are aligned.
INNER FACE SEAL
Note: The balancing plate assembly provides the seal
between the pressure and return ports and also END HOUSING
loads

Figure 52

END HOUSING

12. When the end housing is in place, it should be sus-

pended as shown in Figure 53. If the housing cannot be SPRING GAP
compressed by hand, a spring has fallen out of place.
Make this check before installing the nuts.

Figure 53

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WINCH MOTOR

13. Hold the end housing firmly in place and install the four CAP NUTS
nuts. Torque to 70 to 75 ft. lbs. See Figure 54.

14. Tip the motor to a horizontal position being very careful

not to let the shaft slip out of the motor. If the shaft slips
out of the motor, the motor may have to be re-timed.

Figure 54

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TROUBLESHOOTING

INDEX

SECTION 6
SUBJECT PAGE

GENERAL PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

HYDRAULICS - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

OPERATOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

SWING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

BOOM HOIST CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

BOOM TELESCOPE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

WINCH CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

OUTRIGGER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

STEERING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13

PUMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

FLUID MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22

ROTARY FLOW DIVIDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

EXCESSIVE HEATING OF OIL IN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29

RELIEF VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30

AIR SYSTEM - COMPRESSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

TRANSMISSION TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

PROPANE HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36

DIESEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-40

MAINTENANCE-FREE BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-45

TWO BLOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-46

TWO-BLOCK SYSTEM WITH FUNCTION DISCONNECTS . . . . . . . . . . . . . . . . . .6-48

Issued: Sept 96
 TABLE OF CONTENTS

TROUBLESHOOTING

in order of obviousness, until the source of the failure is

INTRODUCTION found. The machine can then be repaired at minimal cost and
downtime. Make the repair. Recheck to ensure that nothing
As the operator, it is your responsibility to detect any unusu- has been overlooked, functionally test the repaired part in
al sounds, odors or other signs of abnormal performance that the system.
could indicate trouble ahead.
7 - REVIEW MAINTENANCE PROCEDURES Prevent
By detecting any failures in their early stages, you can save recurrences of all premature failures by regularly checking
yourself unnecessary downtime and your employer a lot of the filters, temperature, adjust- ments and lubrication. Make
money! Therefore, it is also your responsibility to use good daily inspections.
judgment in detecting failures in the bud and repairing them
quickly. If you don’t, one failure may lead to another. NOTE: Your safety and that of others is always the number
one consideration when working around cranes. Safety is a
Before attempting to repair a failure yourself, ask yourself matter of thoroughly understanding the job to be done and
IF you have the RIGHT TOOLS, IF you have the PROPER the application of good common sense. It is not just a matter
TEST EQUIPMENT and IF you can accurately DIAG- of “do’s” and “don’ts”. Stay clear of all moving parts.
NOSE the cause of the failure.

If you can’t answer YES to all three questions, rely on your

Distributor Serviceman. He has the tools, testing equipment HYDRAULICS - GENERAL
and service knowledge to pin-point the problem in minutes
instead of the hours consumed in hit-or-miss methods. Before any troubleshooting is attempted, become fully ac-
TIME IS MONEY! He will save it for you. quainted with the following two (2) basic fundamental facts
of a hydraulic system:
If you decide to attempt a repair yourself, follow a logical
TROUBLE-SHOOTING PROCEDURE. Don’t simply re- 1 - SPEED The speed of a hydraulic function is directly re-
place parts until the trouble is found. lated to the system flow. A reduction in speed of a cylinder
or motor is caused by an insufficient quantity of oil being de-
GENERAL PROCEDURE livered to the component.

I - KNOW THE SYSTEM Study this manual and learn 2 - POWER The power or force of a hydraulic function is
what makes the machine “tick”, how it should behave, related to pressure.
sound and smell.
If an understanding of the differences between speed and
2 - OPERATE THE MACHINE Test operate all machine power of a hydraulic system is under- stood correctly, then
functions. Note all abnormal sounds, odors and movements. accurate troubleshooting can be accomplished in a mini-
Always proceed in the most logical order to determine the mum amount of time.
cause.

3 - INSPECT THE MACHINE Look for leaks, listen for

the source of abnormal sounds, detect the origin of unusual
odors. Check the condition of the oil and filters.

4 - LIST THE POSSIBLE CAUSES Use your best judg-

ment in listing all possible causes of the failure.

5 - REACH A CONCLUSION Review your list of possi-

ble causes and decide which are the most likely to cause the
failure. Consider the most obvious first.

6 - TEST YOUR CONCLUSION Test your conclusions,

6-1

Issued: Sept 96
 TABLE OF CONTENTS

TROUBLESHOOTING

CONTROL LEVER STICKS OR BINDS

Disconnect linkage at valve and again check for binding.

If binding is still present, check linkage. Starting from the

valve end, disconnect the components one at a time until the
NEVER resort to increasing the valve relief pressure in an malfunction is located, and then repair or replace that com-
attempt to cure the ills of the system. Fully diagnose the ponent. Note: Binding push-pull cables may simply have too
problem. tight a bend at some point in their length.

Hydraulic components are precision units and their contin- If the linkage is free, see the section on trouble- shooting of
ued smooth operation depends on proper care. Therefore, do the particular circuit involved.
not neglect hydraulic systems. Keep them clean and change
the oil and oil filter at established intervals. NO MOVEMENT OF THE FUNCTION

If, in spite of these precautions, improper opera- tion does Check to see that valve spool actuates when control is oper-
occur, the cause can generally be traced to one of the follow- ated.
ing:
WITH CABLE CONTROLLED VALVES, visually check
1. Use of the wrong viscosity or type of oil. spool for full travel when control is fully shifted.

2. Insufficient fluid in the system. If spool does not shift, check linkage and repair or replace
faulty component.
3. Presence of air in the system.
If spool shifts, refer to sections on 1) Relief Valve Trouble-
4. Mechanical damage or structural failure. shooting; 2) Motor, Cylinder or Winch Troubleshooting ac-
cording to circuit being checked; 3) Pump Troubleshooting;
5. Internal or external leakage. 4) Control Valve Troubleshooting.

6. Dirt, decomposed packing, water, sludge, rust, etc., in the WITH THE ELECTRICALLY CONTROLLED VALVES
system. on the outriggers, three (3) spools must be checked.

7. Improper adjustments. The diverter valve should be checked by using a test gauge
on the test port and activating the outrigger controls. If pres-
8. Oil cooler plugged, dirty or leaking. sure (2500 psi) is indicated, the spool is shifting.

Whenever hydraulic, fuel, lubricating oil lines, or air lines Check the outrigger extend-retract and function valves by
are disconnected, clean the adjacent area as well as the point pushing the. pins in prior to activating the functions. Check
of disconnect. As soon as the disconnection is made, cap, to see if the appropriate pin has been pushed back out as the
plug or tape each line or opening to prevent the entry of for- functions are activated. If they have, the spools are shifting.
eign material. The same recommendations for cleaning and
covering apply when access covers or inspection plates are
removed.

Clean and inspect all parts. Be sure all passages and holes
are open. Cover all parts to keep them clean. Be sure parts
are clean when they are installed. Leave new parts in their
containers until ready for assembly.

Clean the rust preventive compound from all machined sur-

faces of new parts before installing them.

OPERATOR CONTROLS

6-2

Issued: Sept 96
 TABLE OF CONTENTS

TROUBLESHOOTING

If the spools do not all shift, check the electrical connec-

tions.

If no electrical power is present at the valve, check the elec-

trical wiring and correct the fault.

If power is present, repair or replace the solenoid or valve

section which is not shifting.

If the spools shift, see page 6-11, “Outrigger Cir- cuit”.

6-3

Issued: Sept 96
 TABLE OF CONTENTS

TROUBLESHOOTING

NOTES

6-4 Issued: Sept 96

 TABLE OF CONTENTS
TROUBLE SHOOTING

SWING CIRCUIT

SWING COMPLETELY INOPERATIVE.

CAUSE REMEDY

Mechanical swing lock applied .............................................................................. Disengage the swing lock.

Swing brake applied............................................................................................... Disengage the swing brake.

Swing brake stuck in applied position.................................................................... Disassemble swing brake and free-
................................................................................................................................ up unit

Swing valve main relief valve stuck in open position............................................ See page 6-30, “Relief Valves”.

Steering/swing flow divider in upperstructure malfunctioning.............................. See page 6-13, “Steering Circuit.”

Swing motor leaks excessively internally .............................................................. See page 6-22, “Fluid Motor”.

Mechanical fault in swing reducer gear box or swing bearing .............................. Repair swing reducer or replace
................................................................................................................................ swing bearing

Hose plugged or liner collapsed............................................................................. Replace hose.

Low oil level........................................................................................................... Add oil as required.

Rotary manifold leaking internally ........................................................................ Reseal rotary manifold.

Swing/steer pump faulty. ........................................................................................ See page 6-18, “Pumps”.

SWING MOTION SLUGGISH

CAUSE REMEDY

Faulty swing pump ................................................................................................. Repair or replace swing pump.

Swing motor leaks excessively, internally ............................................................. Replace or reseal motor.

Main relief valve stuck in open position... ............................................................. Replace.

Excessive leakage around swing control ............................................................... Reseal or replace control valve.

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SWING MOTION ERRATIC

CAUSE REMEDY

Low hydraulic oil level.... ....................................................................................... Add oil as required.

Brake not releasing completely ............................................................................... Check operation of swing brake and/or and/
or swing lock.

Swing bearing not lubricated properly ....................................................................Lubricate swing bearing.

Main relief malfunctioning...................................................................................... See page 6-30, “Relief Valves”.

BOOM HOIST CIRCUIT

BOOM HOIST ONLY INOPERATIVE OR ERRATIC

CAUSE REMEDY

Boom hoist hold valve malfunctioning................................................................... Replace hold valve.

Boom hoist cylinder binding................................................................................... Repair or replace.

Load is too great...................................................................................................... Consult capacity chart.

Piston packings damaged. ....................................................................................... Replace packings.

Low oil level............................................................................................................ Add oil as required.

Hose plugged or liner collapsed. .............................................................................Replace hose.

BOOM DROPS SLIGHTLY AS RAISE CONTROL IS RELEASED

CAUSE REMEDY

Boom hoist hold valve free flow check not seating properly...........Replace hold valve

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BOOM HOIST AND TELESCOPE INOPERATIVE OR ERRATIC

CAUSE REMEDY

Pump disconnect not engaged. ................................................................................Engage pump disconnect.

Main relief valve malfunctioning. ........................................................................... See page 6-30, “Relief Valves”.

Low oil level............................................................................................................Add oil as required.

Rotary manifold leaking internally.......................................................................... Reseal rotary manifold.

Tandem pump faulty................................................................................................ See page 6-18, “Pumps”.

BOOM DRIFTS DOWN

CAUSE REMEDY

Hold valve not seating properly. .............................................................................Replace hold valve.

Hoist cylinder by-passing........................................................................................ See page 6-26, “Cylinder Leakage”.

BOOM TELESCOPE CURCUIT

TELESCOPE FUNCTION ONLY WILL NOT OPERATE

CAUSE REMEDY

Load too great.......................................................................................................... Move lever to first position, not “high-

speed”. Reduce load or set boom
length before lifting load.

Boom telescoping proportionator malfunctioning .................................................. See page 6-24, “Rotary Flow Divider”.

Both port relief valves sticking ............................................................................... See page 6-30, “Relief Valves”.

Hose plugged or liner collapsed.............................................................................. Replace hose.

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TELESCOPE CYLINDER EXTENDS BUT WILL NOT RETRACT

CAUSE REMEDY

Port relief valve sticking .........................................................................................See page 6-30, “Relief Valves”.

Needle valve on bottom of cylinder rod eye unit

turned all the way in. ...............................................................................................Back out 1/4 to 1/2 turn.

Hold valve malfunctioning. ..................................................................................... Repair or replace.

Internal leakage in cylinder ..................................................................................... See page 6-26, “Cylinder Leakage”.

Extend valve malfunctioning .................................................................................. Repair or replace.

BOOM SECTIONS RETRACT UNDER LOAD

CAUSE REMEDY

‘”O” ring around hold valve damaged ....................................................................Replace “O” rings.

Hold valve not seating properly .............................................................................. Repair or replace.

Telescope cylinder by-passing................................................................................. See page 6-26, “Cylinder Leakage”.

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WINCH CIRCUIT

WINCH WILL NOT DEVELOP MAXIMUM LINE PULL

Main relief valve is set too low ............................................................................... Readjust the main relief.

Main relief valve is sticking.................................................................................... See page 6-30, “Relief Valves”.

Winch motor worn excessively or damaged ........................................................... See page 6-22, “Fluid Motor”.

Tandem pump worn excessively or damaged.......................................................... See page 6-18 “Pumps”.

Rotary manifold leaking internally ......................................................................... Reseal rotary manifold.

Low oil level............................................................................................................ Add oil as required.

WINCH WILL LOWER BUT WILL NOT RAISE

The sprag clutch is assembled backwards............................................................... Be certain that the rounded edges of
.................................................................................................................................the sprag clutch cages are toward
.................................................................................................................................the inside of the winch when assem-
.................................................................................................................................bling.

Insufficient parts of line for the load being lifted.................................................... See the reeving diagram on the
.................................................................................................................................capacity chart.

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WINCH WILL RAISE BUT NOT LOWER

CAUSE REMEDY

The winch hold valve is mounted on the

winch motor incorrectly .......................................................................................... Be certain that the adjusting nut
.................................................................................................................................points toward the center of winch.

The winch is not releasing....................................................................................... Be certain that the brake release line
.................................................................................................................................is open. If necessary, disassemble
.................................................................................................................................and inspect the brake components.

Winch brake piston “O” ring damaged ................................................................... Replace “O” ring.

WINCH WILL NOT HOLD LOAD (LOAD DRIFTS DOWN)

CAUSE REMEDY

System back pressure too high ................................................................................Warm oil; check for restriction in down down
stream flow.

The belleville spring in the brake is installed backwards or

damage. ................................................................................................................... Be certain that the concave side is
.................................................................................................................................installed away from the center of the winch.
Replace if damaged.

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.

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WINCH CHATTERS WHEN LOWERING

REMEDY
CAUSE

The winch hold valve is set wrong or is

malfunctioning ........................................................................................................To set the holding valve, insert a
gauge in the pressure port on the
outside end of the hold valve and
lower very slowly (with no hook
load). With the adjusting screw and
lock nut, set the gauge pressure to
375 ± 10 psi on main and auxiliary
winches. If the winch continues to
chatter, the holding valve is sticking.
Inspect it for worn or damaged seals
or contamination

WINCH IS ROUGH (NOISY) WHEN RUNNING AT HIGH SPEED

CAUSE REMEDY

The winch mount is not level .................................................................................. Shim winch mount to level it. Be
certain that the winch alignment, as
spelled out under Winch Reassem-
bly is maintained.

Air in hydraulic system ........................................................................................... Bleed system

OUTRIGGER CIRCUIT

CAUSE REMEDY

Electrical malfunction ............................................................................................. See page 6 - 3.

Outrigger relief valve malfunctioning ..................................................................... See page 6 - 30, “Relief Valves”.

Outrigger diverter valve malfunctioning.................................................................See page 6 - 3. Repair or Replace.

Line to or from steer pump plugged or

liner collapsed ......................................................................................................... Clear blockage or replace hose.

Low oil level............................................................................................................ Add oil as required.

Steer pump worn or damaged.................................................................................. Page 6 - 18, “Pumps”.

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INDIVIDUAL OUTRIGGER INOPERATIVE

CAUSE REMEDY

Electrical Malfunction ............................................................................................. See Page 6-3.

Cylinder leaking internally......................................................................................See pages 6-25 and 6-27, “Cylin-

ders”.

Hold valve on jack cylinder not operating ..............................................................Repair or replace.

Line plugged or collapsed between outrigger

valve and cylinder ................................................................................................... Replace hose.

Beam wedged in extended position ......................................................................... Extend jack far enough to pick up
end of beam and retract. Adjust
slider pad discs on top of outrigger
box to pick up end of beams.

OUTRIGGERS WILL NOT LIFT MACHINE

-CAUSE- -REMEDY-

Outrigger relief valve malfunctioning ..................................................................... See page 6-30, “Relief Valves”.

Outrigger diverter valve malfunctioning. ................................................................ Repair or replace.

Steering pump worn or damaged ............................................................................ See page 6-18 “Pumps”.

Cylinders by-passing ...............................................................................................See pages 6-25 and 6-27, “Cylin-

ders”.

JACK CYLINDER DRIFTS DOWN

-CAUSE- -REMEDY-

Hold valve on top of cylinder malfunctioning. ....................................................... Replace cartridge.

Thermal relief cartridge (two male hex heads)

mounted in wrong end.............................................................................................Cartridge with double male hex caps
should be installed above external
port tube.

Cylinder by-passing................................................................................................. See page 6-27, “Cylinders”.

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OUTRIGGERS WORK ONLY AT HIGHER ENGINE RPM

-CAUSE- -REMEDY-

Outrigger relief valve malfunctioning ..................................................................... See page 6-30, “Relief Valves”.

Outrigger diverter valve malfunctioning.................................................................Repair or replace.

Steering pump worn or damaged ............................................................................ See page 6-18, “Pumps”.

STEERING CIRCUIT

Most steering problems can be corrected if the problem is properly defined. The entire steering system should be evaluated be-
fore removing any components. The steering control unit is generally not the cause of most steering problems. The following
is a list of steering problems along with possible causes and suggested corrections.

SLOW STEERING, HARD STEERING, OR LOSS OF POWER ASSIST

- -CAUSE- -REMEDY-

Worn or malfunctioning pump ................................................................................Replace pump.

Stuck flow divider piston ........................................................................................ Replace flow divider.

Malfunctioning relief valve allowing the system

pressure to be less than specified ............................................................................ Replace the relief valve.

Overloaded steer axle .............................................................................................. Reduce load.

Leaking or kinked load sensing signal line ............................................................. Correct.

Malfunctioning priority valve.............. ................................................................... Check spring and sticking piston.

Check damping orifices in both ends
of main bore.
Check adjustment See page 5-7.
Check system pressure at SCU inlet
for proper system pressure. If not
correct replace priority valve relief
cartridge.

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WANDER
VEHICLE WILL NOT STAY IN A STRAIGHT LINE

-CAUSE- -REMEDY-

Air in the system due to low level of oil,

cavitating pump, leaky fitting, pinched hose, etc. ................................................... Correct.

Worn mechanical linkage ........................................................................................ Repair or replace.

Bending of linkage or cylinder rod ......................................................................... Repair or replace.

Loose cylinder piston .............................................................................................. Repair or replace.

Severe wear in steering control unit........................................................................ Replace the steering control unit.

DRIFT
VEHICLE VEERS SLOWLY IN ONE DIRECTION

-CAUSE- -REMEDY-

Leaking cylinder seals ............................................................................................. Reseal cylinders.

Worn or damaged steering linkage ..........................................................................Replace linkage and align front end.

SLIP
A SLOW MOVEMENT OF STEERING WHEEL FAILS TO
CAUSE ANY MOVEMENT OF STEERED WHEELS

-CAUSE- -CAUSE-

Leakage of cylinder piston seals or accessory

valve between cylinder lines or ports ...................................................................... Replace seals or accessory valve.

Worn steering control unit meter.............................................................................Replace steering control unit.

TEMPORARY HARD STEERING OR HANG-UP

-CAUSE- -REMEDY-

Thermal Shock* ...................................................................................................... Check unit for proper operation and

cause of thermal shock.

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ERRATIC STEERING

-CAUSE- -REMEDY-

Air in system due to low level of oil,

cavitating pump, leaky fitting, pinched hose, etc. ................................................... Correct condition and add fluid.

Loose cylinder piston .............................................................................................. Replace cylinder.

Thermal shock damage*.......................................................................................... Replace steering control unit.

Sticking flow control spool ..................................................................................... Replace flow control valve.

“SPONGY” OR SOFT STEERING

-CAUSE- -REMEDY-

Air in hydraulic system. Most likely air

trapped in cylinders or lines .................................................................................... Bleed air out of system.

Low fluid level ........................................................................................................Add fluid and check for leaks.

FREE WHEELING
STEERING WHEEL TURNS FREELY WITH NO FEELING OF
PRESSURE AND NO ACTION ON STEERED WHEELS

-CAUSE- -REMEDY-

Steering column upper shaft is loose or damaged................................................... Tighten steering wheel nut.

Lower splines of column may be disengaged

or broken .................................................................................................................Repair or replace column.

Steering control unit meter has a lack of oil.

This can happen on start-up, after repair, or
long periods of non use ........................................................................................... Usually starting engine will cure
problem. If not, stop engine, discon-
nect steer pump outlet hose and
pour in hydraulic oil to prime pump.

No flow to steering unit can be caused by:

1. Low fluid level ................................................................................................... Add fluid and check for leaks.
2. Ruptured hose.....................................................................................................Replace hose.
3. Internal steering control unit damage
due to thermal shock* ............................................................................................Replace the unit.

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FREE WHEELING STEERING

WHEEL TURNS WITH SLIGHT RESISTANCE BUT
RESULTS IN LITTLE OR NO STEERED WHEEL ACTION

-CAUSE- -REMEDY-

Piston seal blown out ...............................................................................................Determine cause. Correct and

replace seal.

EXCESSIVE FREE PLAY AT STEERING WHEEL

-CAUSE- -REMEDY-

Loose steering wheel nut. Steering column

shaft worn or damaged. There should be very little
free play in the unit itself.........................................................................................Repair or replace steering wheel con-
nection or column.

EXCESSIVE FREE PLAY AT STEERED WHEELS

-CAUSE- REMEDY-

Broken or worn linkage between cylinder and

steered wheels ......................................................................................................... Check for loose fitting bearings and
anchor points in steering linkage
between cylinder and steered wheels.

Leaky cylinder seals ................................................................................................ Replace cylinder seals.

BINDING OR POOR CENTERING OF STEERING WHEEL

-CAUSE- -REMEDY-

Binding or misalignment in steering column

or splined input connection .................................................................................... Align column pilot and spline to
steering control unit.

High back pressure in tank line can cause

slow return to center. Should not exceed 300 psi.................................................... Check circuit return line for block-
age.

Large particles can cause binding between

the spool and sleeve................................................................................................ Clean unit and filter oil. If another
component has failed, generating
contaminants, flush system while
bypassing steering control unit.

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STEERING UNIT LOCKS UP

-CAUSE- -REMEDY-

Large particles in meter section............................................................................... Clean the unit.

Insufficient hydraulic power (units over 15 in3) ..................................................... Check hydraulic power supply.

Severe wear and/or broken pin................................................................................Replace the unit.

Thermal shock* ....................................................................................................... Replace the unit.

STEERING WHEEL OSCILLATES OR TURNS BY ITSELF

-CAUSE- -REMEDY-

Parts assembled wrong. Steering unit improperly timed......................................... Correct timing.

Lines connected to wrong ports .............................................................................. Reconnect lines correctly.

Leaking seal in rotary manifold .............................................................................. Reseal.

STEERED WHEELS TURN IN WRONG DIRECTION

WHEN OPERATOR ACTIVATES STEERING WHEEL

-CAUSE- -REMEDY-

Lines connected to wrong cylinder ports ................................................................ Reconnect lines correctly.

3-way steering valve malfunctioning ...................................................................... See “Operator Controls”.

Cab facing toward rear reverses response ............................................................... Be alert when operating with cab
over rear.

STEERING WHEEL KICKS AT START OF STEERING

-CAUSE- -REMEDY-

No inlet check valve on steering control unit .......................................................... Install a check valve.

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INSTABILITY
LOAD SENSING SYSTEMS
HOSES JUMP

-CAUSE- -REMEDY-

Air in lines............................................................................................................... Check pump inlet. Bleed sensing

lines.

Harmonic system .....................................................................................................Add hose or an accumulator.

Relief setting ...........................................................................................................Pump relief should be 100 psi below

priority relief.

Priority valve ...........................................................................................................Bleed by holding against stop for 30

seconds on models w/built in relief
only.
Decrease damping orifice by adding
small wire.
Increase spring rate (this will raise
the standby pressure).

*Thermal shock-A condition caused when the hydraulic system is operated for sometime without turn- ing the steering wheel
so that fluid in the reservoir and system is hot and the steering control unit is relatively cool (more than50 deg. F temperature
differential). When the steering wheel is turned quickly, the result is temporary seizure and possible damage to internal parts of
the steering control unit. The temporary seizure may be followed by total free wheeling.

PUMPS

FAILURE OF PUMP TO DELIVER FLUID

-CAUSE- -REMEDY-

Pump disconnect not engaged................................................................................. Engage pump disconnect.

Low fluid level in reservoir..................................................................................... Add fluid.

Air leak in suction line, preventing priming

or causing noise and irregular action of
control circuit .......................................................................................................... Repair leaks.

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Oil viscosity too heavy to pick up prime.................................................................Use lighter viscosity oil. Follow
recommendation.

Broken pump shaft or parts broken inside

pump ........................................................................................................................ Replace parts.

Dirt in pump ............................................................................................................ Dismantle and clean.

NO PRESSURE IN SYSTEM

-CAUSE- -REMEDY-

Pump disconnect not engaged................................................................................. Engage pump disconnect.

Pump not delivering oil for any of the

reasons listed previously .........................................................................................Follow remedies given previously.

Relief valve not functioning due to:

Valve setting not high enough ................................................................................. Increase pressure setting of valves.

Valve leaking ...........................................................................................................Check seat for score mark & re-seat.

Spring in relief valve broken ...................................................................................Replace spring and readjust valve.

Internal leakage in control valves or

cylinders .................................................................................................................. To determine location, progressively
block off various parts of circuit.
When trouble is located, repair.

Cold fluid.................................................................................................................Warm up system. Operate only at

recommended operating temperature
range. (See Operation section)

Fluid viscosity wrong .............................................................................................. See Section 4. Use only those

lubricants listed.

Air leak or restriction at inlet line ........................................................................... Repair or clean.

Internal parts of pump are worn excessively........................................................... Replace pump.

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PUMP MAKING NOISE

-CAUSE- -REMEDY-

Partially clogged intake line, intake filter

or restricted intake pipe ........................................................................................... Clean out intake filter screen or
eliminate restriction. Be sure suction
line is completely open.

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.

Air bubbles in oil.....................................................................................................Use hydraulic oil containing a foam

depressant.

Reservoir air vent plugged ......................................................................................Air must be allowed to breathe in the

reservoir. Clean or replace breather.

Pump running too fast Check recommended maximum

speeds for engine.

Too high oil viscosity .............................................................................................. Use lower viscosity oil.

Rag, paper, etc., pulled into suction line or pump ................................................... Remove.

Worn or broken parts ............................................................................................... Replace.

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EXTERNAL OIL LEAKAGE AROUND PUMP

-CAUSE- -REMEDY-

Shaft seal worn causing oil to leak into

gear drive housing ................................................................................................... Replace.

Loose fitting on pump intake or discharge ..............................................................Keep all joints tight.

Damaged “0” ring seals between pump sections .................................................... Replace.

Damaged “0” rings at split flange fittings ............................................................... Replace.

EXCESSIVE WEAR

-CAUSE- -REMEDY-

Abrasive matter in the hydraulic oil being

circulated through the pump.................................................................................... Clean suction filter and replace re-
turn filter. Change oil.

Viscosity of oil too low at working conditions ....................................................... Check oil recommendation.

Sustained high pressure above maximum pump rating ........................................... Check relief valve maximum setting.

Air recirculation causing chatter in system ............................................................. Check for air being drawn into
system. Use hydraulic oil with a
foam depressant.

BREAKAGE OF PARTS INSIDE

PUMP HOUSING

-CAUSE- -REMEDY-

Excessive pressure above maximum pump rating ................................................. Check relief valve maximum 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.

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FLUID MOTOR

MOTOR WILL NOT TURN

-CAUSE- -REMEDY-

No oil.......................................................................................................................Fill reservoir to proper oil level.

Pump broken ...........................................................................................................Replace pump.

Relief valve stuck open or set too low ....................................................................Clean and free relief valve spool and
adjust to proper setting.

Work load jammed, stuck or too heavy................................................................... Remove obstruction from work load.

Large contaminating foreign bodies in fluid........................................................... Flush hydraulic system completely.

Use new oil and install good filtration
system.

SLOW OPERATION

-CAUSE- -REMEDY-

Wrong oil viscosity ................................................................................................. Use proper viscosity oil.

Worn pump ..............................................................................................................Repair or replace pump.

Extremely high fluid temperatures

causing pump and motor to slip
(temperature increases as pump and motor wear) ................................................... Add heat exchangers.

Relief setting too low .............................................................................................. Set relief valve for proper psi.

MOTOR TURNS IN WRONG DIRECTION

-CAUSE- -REMEDY-

Hose connections wrong .........................................................................................Reverse connections.

Wrong timing .......................................................................................................... Re-time motor.

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ERRATIC MOTOR OPERATION

-CAUSE- -REMEDY-

Relief valve pressure set too low .............................................................................Adjust relief valve setting.

Low oil level in reservoir permitting air

to enter system......................................................................................................... Fill reservoir to proper level.

Air being “sucked in” on inlet side of pump ............................................................Tighten fitting(s) on pump inlet side.

LEAK AT SHAFT

-CAUSE- -REMEDY-

Worn or cut shaft seal............................................................................................. Replace shaft seal.

LEAK BETWEEN HOUSING AND WEAR PLATE

OR BETWEEN
WEAR PLATE AND GEROLER ASSEMBLY

-CAUSE- -REMEDY-

Motor housing bolts loose ....................................................................................... Clean mating surfaces and tighten
nuts to appropriate value.

Pinched “O” ring seal.............................................................................................. Replace.

LEAK AT OIL PORTS

-CAUSE- -REMEDY-

Poor fittings............................................................................................................. Replace fittings carefully.

Damaged threads..........................................................................Replace housing.

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ROTARY FLOW DIVIDER

NO OIL BEING DELIVERED

-CAUSE- -REMEDY-

No oil being supplied to flow divider...................................................................... Check components that route the oil
to the flow divider:
1. Oil level in reservoir
2. Pump operation
3. Rotary manifold
4. Any valves in supply lines
5. Relief valve
6. Pumps not engaged.

Large contaminating foreign body in fluid..............................................................Flush hydraulic system completely.

Use new oil and change filters.

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CYLINDERS

CYLINDER STICKING OR BINDING

-CAUSE- -REMEDY-

Dirt or contamination .............................................................................................. Check oil condition. Check filters,

Clean or replace filter elements.
Change oil if condition requires it.

Air leaks .................................................................................................................. Check for air being drawn into sys-
tem.

Worn parts ............................................................................................................... Repair or replace. (Excessive wear

may be due to oil contamination)

Loose parts ..............................................................................................................Tighten cylinder rod eyes if

loose. Check cylinder heads and
tighten, if loose.

Misalignment...........................................................................................................Check mounting pins and bushings.

Tighten rod eyes.

ERRATIC ACTION OF CYLINDERS

-CAUSE- -REMEDY-

Main relief pressure too low or valve sticking ........................................................ See page 6-30, “Relief Valves”.

Air in system:

Oil level too low...................................................................................................... Add or change.

Air leak ....................................................................................................................Locate and correct

Foaming in reservoir ...............................................................................................Use hydraulic oil containing a foam

depressant.

Internal leakage ....................................................................................................... See page 6-26, “Cylinder Leakage”.

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TROUBLESHOOTING

cates a defective rod weldment or seals on the port tube in

the rod.
CYLINDER LEAKAGE
WHEN REASSEMBLING THE CYLINDER, care should be
taken to keep the piston rod assembly parallel in all planes
TELESCOPE CYLINDER with the cylinder barrel as the piston enters and is pushed
down the barrel prior to gland engagement. Adjust the nee-
If excessive leak-down is encountered, check items in the dle screw to I/8 to 1/4 turn open. Install needle valve seal
following sequence: washer, back-up washer with chamfer toward seal, and lock-
nut.
1. With boom off side and horizontal, extend the boom ap-
proximately 6 ft. per section, mark the side of the 3rd tele- NOTE: An external leak from telescope cylinder or hydrau-
scoping section at the end of the 2nd section. lic lines within the boom assembly does not cause leak-
down without also having one or more of the above condi-
2. With the hydraulic oil at 160° F, elevate the boom to max- tions present.
imum angle and suspend a load on the hook. (7 tons on a 2-
part line would approximate manufacturer’s inspection pro- BOOM LIFT CYLINDER
cedures).
The suggested procedure for identifying the specific cause
3. With engine shut off, hold or tie the telescope function le- of leak-down should be performed in the following se-
ver in the full “extend” position for approximately 15 min- quence:
utes.
ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE, not
4. Return the telescope lever to neutral, start engine, ground completely extended, with a boom length sufficient to winch
the load, and return the boom to horizontal. remark the 3rd up a convenient pay load approximately one (1) foot from
boom section as in (1). Extend boom and measure the dis- ground level. Shut off engine and remove pressure from the
tance between marks to determine leakdown of the cylinder. hy- draulic reservoir by loosening the filler cap.

The manufacturer’s allowable drift specification for produc- DISCONNECT THE EXTEND HOSE AND THE SMALL
tion machines is as follows: PILOT LINE HOSE at the holding valve ports and cap the
pilot line hose end.
With 14,300 lb. hook load, 2 part hoist line, boom extended
about 6 ft. per section at maximum boom angle, and 160 de- IF HYDRAULIC OIL CONTINUES TO RUN after the initial
gree F. hydraulic oil temperature, the leakdown of the cylin- draining from either port of the hold valve as the hoist cyl-
der (sections 2 & 3) is not to exceed 3/4 inch in a 15 minute inder continues to leak down, the cause is within the hold
period. valve.

IDENTIFY A DEFECTIVE HOLD VALVE in the cylinder by IF CYLINDER LEAK-DOWN OCCURS with no oil leak
replacement with a new cartridge. Before installing the car- from the hold valve ports, the cause is within the cylinder.
tridge, visually inspect the external “0” rings and back-up
washers. Retest per the procedure above to determine if hold NOTE: There is no allowable leakage rate given for the
was defective. boom hoist cylinder.

IF THE HOLD VALVE IS NOT FOUND DEFECTIVE, the

cylinder must be removed from the boom assembly for re-
packing and checking. Prior to reassembly of the cylinder,
conduct an air test on the piston rod by blocking the retract
ports on the rod near the piston end. Slip a plastic bag over
piston end of rod and retain and seal with a rubber band. Re-
move the locknut, seal washer, and chamfered washer from
the needle valve at the trunnion end of the piston rod and
firmly seat the needle valve by bottoming. Apply and hold a
slight amount of air pressure at the retract port of the rod.
(Port stamped with “R”.) Expansion of the plastic bag indi-

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REINSTALL HYDRAULIC RESERVOIR FILLER CAP.

DO NOT START THE ENGINE UNTIL THE HOSES HAVE

BEEN RECONNECTED. The control valve spool is open-
center to reservoir in the neutral position and return line oil
would be pumped out.

OUTRIGGER JACK CYLINDER

The suggested procedure for identifying the specific cause

of leak-down is similar to the boom lift cylinder procedure:

SET THE OUTRIGGERS.

ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE, not

completely extended, with a boom length sufficient to winch
up a convenient payload approximately one (1) foot from
ground level. Shut off engine and remove pressure from the
hydraulic reservoir by loosening the filler cap.

DISCONNECT THE EXTEND HOSE FROM THE HOLD

VALVE. This is a hose farthest away from the port tube and
should have an “E” stamped next to it.

IF HYDRAULIC OIL CONTINUES TO RUN after the initial

draining from either port of the hold valve as the cylinder
continues to leak-down, the cause is within the hold valve.

IF CYLINDER LEAK-DOWN OCCURS with no oil leak

from the hold valve port, the cause is within the cylinder.

RE-INSTALL HYDRAULIC RESERVOIR FILLER CAP.

DO NOT START THE ENGINE UNTIL THE HOSES HAVE

BEEN RECONNECTED. The control valve spool is open-
center to reservoir in the neutral position and return line oil
would be pumped out.

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EXCESSIVE HEATING OF OIL IN SYSTEM

HEATING CAUSED BY POWER UNIT

(RESERVOIR, PUMP, RELIEF VALVE AND COOLERS)

-CAUSE- -REMEDY-
Relief valve set at a higher or lower pressure
than specified. Excess oil dissipated through
increased slippage in various parts, or through relief valve.................................... Reset relief valve to recommended
pressure.

Internal oil leakage due to wear .............................................................................. Repair or replace pump.

Viscosity of oil too high or too low......................................................................... Follow recommendations for correct
viscosity grade to be used.

Pump assembled after overhaul may be

assembled too tightly. This reduces clearances
and increases rubbing friction ................................................................................. Follow instructions when re-assem-
bling.

Leaking relief valves ...............................................................................................Repair.

Improper functioning of oil cooler or

coolant is cut off ...................................................................................................... Inspect cooler and see that it is work-
ing properly.

Improper machine operation ...................................................................................Return control to neutral when

stalled, cylinder at end of stroke, etc.

High duty cycle ....................................................................................................... Install oil cooler. Consult service rep-
resentative.

HEATING BECAUSE OF CONDITIONS IN SYSTEM

-CAUSE- -REMEDY-

Restricted lines ........................................................................................................If lines are crimped, replace; if par-

tially plugged for any reason, remove
obstruction.

Internal leaks ...........................................................................................................Locate leaks and correct.

Low oil level............................................................................................................ Check oil level and fill if necessary.

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CONTROL VALVES

STICKING PLUNGERS

-CAUSE- -REMEDY-

Excessively high oil temperature ............................................................................ Eliminate restriction in pipe lines

and filtering system.

Dirt in oil .................................................................................................................Change oil. Clean system.

Fittings too tight ...................................................................................................... Check torque.

Valve warped from mounting.................................................................................. Loosen valve and check.

Excessively high pressure in valve..........................................................................Check with gauge on inlet and cylin-

der lines.

Linkage binding....................................................................................................... Free up linkage.

Plunger damaged .....................................................................................................Replace valve.

Return spring damaged ............................................................................................Replace faulty parts.

Spring or detent cap binding ...................................................................................Loosen cap, re-center and re-tighten.

Valve not at thermal equilibrium.............................................................................Let system warm up.

LEAKING SEALS

-CAUSE- -REMEDY-

Paint on or under seal .............................................................................................. Remove and clean.

Excessive back pressure .......................................................................................... Open or enlarge line to reservoir.

Dirt under seal ......................................................................................................... Remove and clean.

Scored plunger......................................................................................................... Replace valve.

Loose seal plates...................................................................................................... Clean and tighten.

Cut or scored seal .................................................................................................... Replace faulty parts.

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UNABLE TO MOVE PLUNGER IN OR OUT

-CAUSE- -REMEDY-

Dirt in valve ............................................................................................................. Clean and flush out.

Plunger cap full of oil.............................................................................................. Replace seals.

Bind in linkage ........................................................................................................Free up linkage.

RELIEF VALVES

CAN’T GET PRESSURE

-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-

Pilot poppet seat damaged. Poppet seat damaged................................................... Replace damaged parts. Clean dirt
and remove surface marks for free
(May not be applicable to all valves) movement.

PRESSURE SETTING NOT CORRECT

-CAUSE- -REMEDY-

Wear due to dirt. Lock nut and adjustment screw loose.......................................... See Section 5.

LEAK

-CAUSE- - REMEDY-

Damaged seats, worn “O” rings, parts

sticking due to dirt ................................................................................................... Replace worn or damaged parts.
Inspect for free movement of compo-
nents. Check seats for
scratches, nicks or other marks.

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AIR SYSTEM-COMPRESSOR

PRESSURE BUILDS TOO HIGH

-CAUSE- -REMEDY-

Gauge inaccurate .....................................................................................................Recalibrate or replace gauge.

Governor doesn’t pressurize unloader..................................................................... Repair or replace governor.

Governor reservoir unloader line plugged ..............................................................Replace line.

Unloader/plungers sticking/worn ............................................................................ Lubricate, install umloader kit, head

kit, or replace head.

WILL NOT PUMP AIR

-CAUSE- -REMEDY-

Gauge failed ............................................................................................................ Replace gauge.

Compressor drive belts slipping or broken ............................................................. Adjust tension or replace.

Compressor inlet valves/plungers stuck.................................................................. Install unloader kit, head kit, or

replace head.

PRESSURE BUILD-UP SLOW

-CAUSE- -REMEDY-

Air leakage in system .............................................................................................. Locate and correct.

Gauge malfunction ..................................................................................................Recalibrate or replace.

Compress or drive belts slipping .............................................................................Adjust tension or replace.

Restriction in intake system .................................................................................... Remove restriction or replace line.

Restriction in discharge line .................................................................................... Remove restriction or replace line.

Unloader malfunctioning .........................................................................................Lubricate or install kit.

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EXCESSIVE OIL ACCUMULATION IN RESERVOIR

(COMPRESSOR PUMPING EXCESSIVE OIL)

-CAUSE- -REMEDY-

Oil return hose restricted, kinked, or looped........................................................... Remove restriction or replace hose.

Gasket sealant obstructing oil return line ................................................................ Remove sealant from line.

Compressor intake vacuum too high .......................................................................Replace air filter element.

Excessive engine crankcase pressure ...................................................................... Correct engine ventilation.

Compressor ring wear ............................................................................................. Replace compressor unit.

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TRANSMISSION TROUBLE SHOOTING GUIDE

PROBLEM POSSIBLE CAUSE REMEDY

1. Erratic oil A. Low oil level A. Add oil to proper level

pressure
*B. Pump gasket not B. Replace gasket
sealing
*C. “O” ring on sump C. Replace “O” ring
tube not sealing
*D. Oil passage cover D. Replace seal, apply sealant per
plate leaking in instructions in assembly manual.
front cover
E. Foreign object in E. Remove object and check for
suction port other contamination.

*Some indications of a suction leak are:

1. Erratic oil pressure (rapid fluctuation of gauges)

2. Pump and filter hoses jumping
3. Excessive air entrainment in the transmission oil
4. A long prime time (time elapsed from engine start to an indication of pump pressure)

*Note: To determine if a suction leak exists, fill the transmission completely full of transmission fluid. Then start the engine to
see if there is an indication of erratic oil pressure. If none, a suction leak probably exists.

DO NOT NEGLECT TO DRAIN THE TRANSMISSION BACK TO THE CORRECT LEVEL AFTER THE TEST. FAILURE
TO DO SO WILL RESULT IN POOR PERFORMANCE AND OVER HEATING.

2. Excessive oil A. Excessive amount of A. Install correct amount of

pressure regulator valve shims shims
B. Sticking main reg- B. Check main regulator
ulator valve for contamination and clean orifice
C. Faulty spring C. Change spring

3. Low oil pressure A. Sticking main A. Clean main regulator

in all gears regulator valve valve
B. Oil pressure set B. Add shims (5 maximum)
too low
C. “O” ring on charge C. Replace “O” ring
pump mount defective
D. Charge pump defective D. Replace pump
E. Internal Disconnect E. Replace seal and install
seal damaged or in- correctly
stalled incorrectly

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PROBLEM POSSIBLE CAUSE REMEDY

4. Low pressure A. Contaminated solenoid A. Disassemble and clean
in one gear valve spool entire control valve.
but all right Replace filter and
in other gears transmission fluid.
B. Broken wire to one B. Repair wire (see sole-
solenoid, or dirty noid chart for elect-
connection rical valves and locations.)
C. Broken seal ring on C. Replace seal ring
input end of clutch
assembly
D. Outer or inner piston D. Replace seals seal leaking

IF A SOLENOID IS REMOVED FROM THE VALVE IT HAS TO BE

REINSTALLED IN THE SAME LOCATION.

Note: To determine the defective clutch is simply a matter of elimination. For example, if the gear selected uses solenoids 6 and
3, and low pressure is indicated, select another clutch that uses one of those solenoids. If pressure is good, then the solenoid or
clutch not selected is the one that is bad. To confirm that this is the faulty circuit, select another clutch that uses this solenoid,
to assure that the discrepancy is actually in this solenoid or clutch.

EXAMPLE: CLUTCH SELECTED INDICATION

Uses solenoids 6&3 Low Pressure Solenoid or clutch 6 or 3 is defective. Uses so-
lenoids 5&3 Pressure O.K. Solenoid or clutch 6 is defective
Uses solenoids 6&2 Low Pressure Confirms solenoid or clutch 6 is de-
fective

5. Vehicle will A. Voltage to wrong A. Check wiring and

not move but solenoids on connectors
all pressures control valve -
are normal. see schematic
B. No voltage to all B. Check wiring,
solenoids controller and connectors
C. Voltage to all C. Check wiring and
solenoids controller
D. Solenoid valve D. Inspect, clean and
spool stuck replace if necessary. Replace oil & fil-
ter.

6. Low or no A. Converter bypass A. Replace converter

converter valve defective bypass valve
pressure B. Converter hub seal B. Replace seal ring
ring not sealing
. C. Converter bypass C. Install plug (see
valve pipe plug assembly manual)

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PROBLEM POSSIBLE CAUSE REMEDY

7. Filter or filter oil A. Hose bends too A. Reroute hoses

lines blow out sharp
B. Defective hose B. Replace hose
C. Main regulator C. Clean valve and
valve stuck change filter & oil.

8. Clutch selected A. Contaminated sole- A. Clean valve and re-

pressure does noid valve spool place oil & filter
not return to B. Accumulator spring B. Replace spring
normal too strong
C. Primary pump defec- C. Replace primary pump
tive
D. Excessive internal D. Inspect seal ring,
leakage to clutch piston seals, and all
sealing surfaces (See assembly manu-
al}

9. Excessive noise A. Charge pump defective A. Replace pump

B. Excessive backlash B. Replace bearings and
in gear train inspect for defective gears
C. Auxiliary driven C. Remove pump and check
pump bad for noise.

10. Blows oil out A. Transmission over A. Establish proper oil

of breather or filled with oil level (check front seal
dipstick tube on auxiliary driven hydraulic pump if
in- stalled}
B. Converter seal ring B. Remove transmission and
broken install new seal ring
on converter hub

11. Transmission A. Converter stalling A. Shift to lower gear

overheating B. Oil level too high B. Establish proper oil level (check
front seal on auxiliary driven hydrau-
lic pump, if installed)
C. Engine overheating C. Check engine coolant
D. Water lines defec- D. Replace lines
tive on heat exch.
E. Heat exchanger dirty E. Clean heat exchanger
F. Clutch slipping F. Check clutch pressure

12. Transmission A. Converter sprag A. Disassemble converter

pressure checks clutch damaged and inspect (see assem-
okay, but has or installed wrong bly manual for correct
no power and installation.}
possibly over- B. Converter relief B. Replace relief valve
heating valve broken

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PROBLEM POSSIBLE CAUSE REMEDY

13. Oil leaking A. Converter front A. Replace seal

from engine cover seal leaking
flywheel and/or B. Converter hub seal B. Replace seal
weep hole in or “o” ring damaged
transmission C. Bearing retainer C. Replace gasket
bell housing plate gasket leaking
D. Converter not pro- D. Check engine flywheel
perly positioned offset dimensions and
within bell housing, converter pilot bush-
causing converter ing length against
and seal to leak vehicle manufacture standards.

INTERNAL DISCONNECT MODELS ONLY

14. 4 Wheel drive A. Solenoid stuck open. A. Repair or replace

will not engage Voltage applied all solenoid. Check wiring
the time diagram and connectors.
B. Damaged or missing B. Replace or install spring.
spring.
C. Bleed port blocked C. Check for proper instal-
lation of gasket and solenoid cap
or contamination.

15. 4 wheel drive A. No power to solenoid, A. Check for electric

will not disengage. solenoid inoperative power to solenoid -
check wiring and connectors-
replace solenoid
B. Check valve installed B. Install check valve
backwards properly
C. Piston seal damaged C. Replace seal or install
or installed backwards properly.

PROPANE HEATER

HEATER FAILS TO START

(MOTOR DOES NOT RUN)

-CAUSE- -REMEDY-

Fuse defective or burnt out......................................................................................Check fuse replace if necessary.

Electrical connection(s) defective ........................................................................... Check all electrical connections,

including ground repair any defects.

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).

Motor Defective ...................................................................................................... Check motor. Replace if necessary.

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MOTOR RUNS, BUT NO COMBUSTION

-CAUSE- - REMEDY-

Fuel supply blocked ................................................................................................ Check fuel supply by loosening the

fitting on the outside of the heater
and checking for propane 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 be-
come contaminated when a liquid
take-off bottle is used instead of the
required vapor take-off bottle. If the
fuel system is contaminated, the
lines and solenoid must be cleaned
with a degreasing solvent.

Temperature control &/or microswitch

defective or out of adjustment................................................................................. Check temperature control switch
and microswitch for adjustment.
Adjust, repair or replace as neces-
sary. See Section 6, “Repairs And Ad-
justments”.

Ignition pack defective or inoperative ..................................................................... Check for spark by holding an insu-
lated-handle screwdriver with the
shaft grounded and the tip approxi-
mately 1/8” away from the high ten-
ion lug of the ignition coil. There
should be a continuous strong
spark. If no spark is produced, check
that there is voltage applied to the ig-
nition pack. If input voltage is
present and no spark or a weak
spark is produced, replace or repair
the ignition pack.

Tilt switch defective, improperly

mounted or not getting power ................................................................................. Check tilt switch. The switch must
be secure in its bracket and be in the
vertical position with the electrical
leads pointing down. Check leads on
both sides of switch for power. Re-
place if defective.

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MOTOR RUNS, BUT NO COMBUSTION (cont.)

-CAUSE- - REMEDY-

Igniter defective or inoperative ............................................................................... Check the igniter. To check, shut off
the fuel at the 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 produced,
the igniter may be dirty or defective.
Before removing the igniter from
burner head, check inside the burn-
er 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 -10 F., propane may not pro-
duce enough pressure to pass
through the regulator.

HEATER REMAINS ON BURNER CYCLE

AFTER HEAT DEMANDS ARE MET

-CAUSE - - REMEDY-

Temperature control &/or microswitch

defective or out of adjustment................................................................................. Check temperature control switch
and microswitch for adjustment. Ad-
just, repair or replace as necessary.
See Section 6, “Repairs And Adjust-
ments”.

Bi-metal blade broken or linkage out of adjustment............................................... Check bi-metal blade and linkage
and adjust, repair or replace as nec-
essary.

Dirt on fuel solenoid valve lip ................................................................................. Clean solenoid valve lip.

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EXCESSIVE POPPING OR BACKFIRING

-CAUSE- -REMEDY-

Ignition pack defective or inoperative ..................................................................... Check for spark by holding an insu-
lated-handle screwdriver with the
shaft grounded and the tip approxi-
mately 1/8” away from the high ten-
sion lug of the ignition coil. There
should be a continuous strong
spark. If no spark is produced, check
that there is voltage applied to the ig-
nition pack. If input voltage is
present and no spark or a weak
spark is produced, replace or repair
the ignition pack.

Full voltage not available at heater ......................................................................... Using voltmeter, check to be sure full
voltage is available for heater opera-
tion, 11 VDC minimum with heater
turned on. Trace system to find fault.

Solenoid defective ................................................................................................... Check solenoid. When the START-

-RUN-OFF switch is in the START
position, the solenoid should prod-
duce an audible click and remain
open until heater cycles off.

In extremely cold weather, the regulator

may become frosted. As it thaws and freezes,
the heater will burn intermittently........................................................................... No action recommended.

Clogged or restricted exhaust.................................................................................. Check exhaust for blockage or re-

strictions. Clean and clear as neces-
sary.

EXCESSIVE SMOKING AT EXHAUST PORT

AND BUILDUP OF CARBON IN HEAT EXCHANGER

- CAUSE - -REMEDY-

Air inlet tube blocked.............................................................................................. Check for plugged or blocked air in-
let tube and clear if necessary.

Low voltage............................................................................................................. Check for low voltage, at least 11

VDC.

Defective pressure regulator.................................................................................... Check for defective pressure regula-

tor There should be 11 inches water
pressure in the propane supply line
at the connector.

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DIESEL HEATER

HEATER FAILS TO START

(MOTOR DOES NOT RUN)

- CAUSE - - REMEDY -

Fuse defective or burnt out......................................................................................Check fuse; replace if necessary.

Electrical connection(s) defective ........................................................................... Check all electrical connections, in-

cluding ground; repair any defects.

Full voltage not available at heater ......................................................................... Check for power at the heater; at
least llVDC is required. Trace system
to find any fault(s).

Motor defective ....................................................................................................... Check motor. Replace if necessary.

HEATER FAILS TO START

(MOTOR RUNS)

- CAUSE - - REMEDY -

Full voltage not available at heater ......................................................................... Excessive voltage drop during pre-
heat. (Use of PREHEAT/CHOKE
switch draws 18 amps at 12 volts
and START switch adds 8 amps.) If
wire size is too small or ground con-
nection poor, low voltage at heater
may result.

Burner floods when starting .................................................................................... Too much fuel during starting. Do
not operate PREHEAT/CHOKE and
START switches simultaneously for
long periods of time, or burner may
he flooded.

Incorrect starting procedure .................................................................................... Refer to page 2-8 for correct starting
procedure.

If the high tension lead is discon-

nected from the igniter for any rea
son, DO NOT energize the unit with
out first providing a discharge gap of
1/8 inch or less from the high ten-
sion lead to the grounded igniter.

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With a larger gap, electrical potential
can cause an insulation breakdown
in the ignition pack or in the high
tension lead. The same also applies
if the high tension lead is attached
to the igniter with the igniter rem-
moved from the unit. Provide a gap of
1/8 inch or less here also.

Use insulated tools and take care to

prevent contact with the high ten-
sion lead. High voltage is present
which could cause injury.

Ignition pack defective or inoperative ..................................................................... Check for spark hy holding an insu-
lated-handle screwdriver with the
shaft grounded and the tip approxi-
mately 1/8 inch away from the high
tension lug of the ignition pack.
There should be a continuous strong
spark. If no spark is produced, check
that there is voltage applied to the ig-
nition power supply. If input voltage
is present and no spark or a weak
spark is produced, replace the igni-
tion pack.

Ignition defective or inoperative .............................................................................Check the igniter. To check, remove

and examine. The electrode should
be centered, and not clogged or
shorted with carbon. Visually check
operation with the igniter removed
from burner head, but connected to
the high tension lead with body
grounded. Shut off fuel and ground
igniter on heater case to cheek for
spark. Replace if defective.
Fuel supply not suitable for ambient temperature or
insufficient for starting ............................................................................................Check for adequate fuel supply and
correct grade of fuel.

MOTOR RUNS, BUT NO COMBUSTION

- CAUSE - - REMEDY -

Fuel supply blocked ................................................................................................ Check for fuel at the float bowl. Re-
move the pipe plug at the side of the
float bowl and gently depress the
float. If fuel is present, it will show on
the object used to depress the float
and buoyancy can be felt.

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Temperature control or microswitch
defective or out of adjustment................................................................................. Check HI-LOW control and micro-
switch adjustment. Refer to section
5. Adjust, repair or replace.

Ignition pack defective or inoperative ..................................................................... Check for spark by holding an insu-
lated-handle screwdriver with the
shaft grounded and the tip approxi-
mately 1/8 inch sway from the high
tension lug of the ignition pack.
There should be a continuous strong
spark. If no spark is produced, check
that there is voltage applied to the ig-
nition power supply. If input voltage
is present and no spark or a weak
spark is produced, replace the igni-
tion pack.

Igniter defective or inoperative ............................................................................... Check the igniter. To check, remove

and examine. The electrode should
be centered, and not clogged or
shorted with carbon. Visually check
operation with the igniter removed
from burner head, but connected to
the high tension lead with body
grounded. Shut off fuel and ground
igniter on heater case to check for
spark. Replace if defective.
Tilt switch defective, improperly mounted or
not getting power.................................................................................................... Check tilt switch. The switch must
be secure in its bracket and be in the
vertical position with the electrical
leads pointing down. Check leads on
both sides of switch for power. Re
place if defective.

Insufficient fuel flow ...............................................................................................Check float level, fuel pressure, and

carburetor fuel needle setting. Ex-
cessive fuel flow will cause rapid
buildup of carbon in the heat ex-
changer. Correct fuel feed is 6-1/2 cc
per minute (4-1/2 minutes per
ounce).

Inadequate ventilation ............................................................................................. Check for restricted circulating air

flow which could cause overheating.

Fuel heater or glow plug circuits defective ............................................................. Check fuel heater and glow plug cir-
cuits with PREHEAT/CHOKE switch
energized. If there is power but no
heat from these parts, replace the
faulty component. If there is no pow-
er to the fuel heater during preheat-
ing, check all connections, wires,
and the switch.

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INADEQUATE HEAT OUTPUT

- CAUSE - - REMEDY -

Full voltage not available at heater ......................................................................... Check for low voltage. Heater must
have 11 volts minimum so that mo-
tor turns fast enough to ensure ade-
quate combustion air flow

Insufficient fuel flow ...............................................................................................Check float level, fuel pressure, and

carburetor fuel needle setting. Ex-
cessive fuel flow will cause rapid
buildup of carbon in the heat ex-
changer. Correct fuel feed is 6-1/2 cc
per minute (4-1/2 minutes per
ounce).

Temperature control or microswitch out of adjustment .......................................... Check HI-LOW control and micros-
witch adjustment. Refer to Section 5.

FAN WILL NOT OPERATE AT HIGH SPEED

DURING BURNING CYCLE

- CAUSE - - REMEDY -

Electrical connection(s) defective ........................................................................... 1. Check relay. Replace if defective.

2. Check motor and connections.
With the power on, touch orange mo-
tor lead to red motor lead; speed
must increase. Replace motor if de-
fective.
3. Check electrical connections.

Temperature control or microswitch defective

or out of adjustment................................................................................................. Check temperature control switch
and microswitch for adjustment. Ad-
just, repair or replace as necessary.
Refer to Section 5.

HEATER REMAINS ON BURNER CYCLE

AFTER HEAT DEMANDS ARE MET

- CAUSE - - REMEDY -

Temperature control &/or microswitch

defective or out of adjustment................................................................................. Check temperature control switch
and micro- switch for adjustment.
Adjust, repair or replace as neces-
sary. See Section 5.

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Bi-metal blade broken or linkage out of adjustment............................................... Check bi-metal blade and linkage
and adjust, repair or replace as nec-
essary.

Dirt on fuel solenoid valve lip ................................................................................. Clean solenoid valve lip.

EXCESSIVE SMOKE IN EXHAUST

- CAUSE - - REMEDY -

Low voltage............................................................................................................. Check for low voltage. Heater re-

quires 11 volts minimum so that mo-
tor turns fast enough to en- sure ad-
equate air flow. Combustion air pres-
sure should be at least 3-1/2-4 inch-
es of water.

Excessive fuel flow ................................................................................................. Fuel needle open too far. Adjust fuel
needle as described in Section 6.

Clogged or restricted exhaust.................................................................................. Check for mechanical binding in

combustion air blower.

Ignition pack defective or inoperative ..................................................................... Check for spark by holding an insu-
lated-handle screwdriver with the
shaft grounded and the tip approxi-
mately 1/8 inch away from the high
tension lug of the ignition pack.
There should be a continuous strong
spark. If no spark is produced, check
that there is voltage applied to the ig-
nition power supply. If input voltage
is present and no spark or a weak
spark is produced, replace the igni-
tion pack.

Igniter defective or inoperative ............................................................................... Check igniter. To check, remove and

examine. Electrode should be cen-
tered, and not clogged or shorted
with carbon. Visually check opera-
tion with igniter removed from burn
er head, hut connected to high ten-
sion lead with body grounded. Shut
off fuel and ground igniter on heater
case to check for spark. Replace if
defective.

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 TABLE OF CONTENTS
TROUBLE SHOOTING

MAINTENANCE FREE BATTERY TESTING

VISUAL INSPECTION

- CAUSE - - REMEDY -

Visible damage, terminal leakage, etc. ....................................................................Cannot he used. Replace.

ELECTROLYTE LEVELS & STATE OF CHARGE

-CAUSE- - REMEDY-

Level at top of plates. Water cannot be added......................................................... Replace.

Indicator indicates low level ...................................................................................Replace.

Level OK, unknown or water can be added.

Stabilized voltage below 12.4 volts.*...................................................................... Charge, then turn on high-beam
head lamps for 15 amp load for 15
seconds).

Indicator indicates low charge................................................................................. Charge, then turn on high-beam

head lamps for 15 amp load for 15
seconds).

Stabilized voltage above 12.4 volts* or

indicator indicates charged ......................................................................................Perform load test.

LOAD TEST

- CAUSE - - REMEDY -

Perform load test using the following procedure:

1. Connect voltmeter and ampere load equal to 1 /2
cold cranking amperes @ 0 deg. F (- 18 deg. C) rating of
battery for 15 seconds.
2. Observe voltage at 15 seconds with load on.
3. Refer to voltage chart. .........................................................................................If the voltage remains below the volt-
age chart levels, replace battery. If
the voltage is equal to or above chart
values, return to service.

6 - 45

Issued: Sept 96
 TABLE OF CONTENTS
TROUBLE SHOOTING

VOLTAGE CHART
ESTIMATED ELECTROLYTE
MINIMUM REQUIRED VOLTAGE UNDER 15 SEC. LOAD
TEMPERATURE

70 deg F (21 deg C) & ABOVE 9.6

60 deg F (16 deg C) 9.5
50 deg F (10 deg C) 9.4
40 deg F (4 deg C) 9.3
30 deg F (- 1 deg C) 9.1
20 deg F (- 7 deg C) 8.9
10 deg F (-12 deg C) 8.7
0 deg F (- 18 deg C) 8.5

*IF WATER CAN BE ADDED TO BATTERY A HYDROMETER READING OF 1.225 @ 80 deg. F (27 deg.
C) CAN BE USED INSTEAD OF THE 12.4 VOLTAGE READING.

TWO BLOCK SYSTEM

PANEL LIGHT & HORN WILL NOT COME ON WITH BOOM SWITCH WEIGHT LIFTED
(IF EQUIPPED WITH DISCONNECTS CONTROLS WILL NOT ENGAGE)

- CAUSE - - REMEDY -

Burned out fuse ....................................................................................................... Check and replace fuse (8 amp only).

Broken wire ............................................................................................................. Check voltage in control panel be-

tween terminals #0 and #37. If 0
volts, check between ignition post of
ignition switch and ground. If 12
volts available, wire to control panel
is bad. Correct.

HORN WORKS BUT NO LIGHT WITH SWITCH WEIGHT LIFTED

(AND IF EQUIPPED W/DISCONNECTS CONTROLS WILL ENGAGE)

-CAUSE- - REMEDY -

Light bulb burned out .............................................................................................. Replace bulb.

6 - 46

Issued: Sept 96
 TABLE OF CONTENTS
TROUBLE SHOOTING

LIGHT AND HORN ARE ON WITH HOOK BLOCK NOT CONTACTING SWITCH WEIGHT
(IF EQUIPPED WITH DISCONNECTS CONTROLS WILL NOT ENGAGE)

- CAUSE - - REMEDY -

Jumper wire or jib/rooster sheave not

plugged in boom head ............................................................................................. Plug in.

Boom head weight wire rope broken or hung up .................................................... Check that weight is attached to wire
and hanging freely. If rope is caught
up on something; correct.

Jib or Auxiliary boom head switch plugged

in, but no weight ...................................................................................................... Attach weight.

Broken electrical cable or bad connection ..............................................................Check all cable for visible damage,
then remove wire from terminals #3
and #G 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
#G check the relay in the panel.

Defective two block switch ..................................................................................... Check for correct mechanical opera-
tion. If ok remove cover and wires
from terminals #1 and #. With arm
pulled down there should be a clos-
ed 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 #G (ground). If
voltage is 0 check for voltage be-
tween pin #7a and ground. If 12 volts
replace relay. (With no electrical
power to the relay, pins #30 and #7a
should show continuity. With 12
volts to either #5 or #G and the other
grounded, there should be continu-
ity between pins #7 and #30.)

6 - 47

Issued: Sept 96
 TABLE OF CONTENTS
TROUBLE SHOOTING

TWO BLOCK SYSTEM

FOR CRANES EQUIPPED WITH FUNCTION DISCONNECTS

LIGHT AND HORN ARE ON BUT CONTROLS WILL NOT DISENCAGE

- CAUSE - - REMEDY -

Defective function disconnect................................................................................. Check voltage across disconnect ter-

minals. If 12 volts check override key
switch in control panel. If 0 volts re
pair or replace disconnect. (Check
other disconnects for condition.) To
operate the crane the solenoid must
have 12 volts supplied to one side
and have a good ground on the other
side. Under this condition the dis-
connect should act as a solid link.
With the 12 volts removed the dis-
connect should allow free motion of
the control lever in one direction
and operate the valve spool in the
other direction.

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 con-
trol panel.

NO LIGHT AND HORN BUT CONTROL WILL NOT ENGAGE

- CAUSE - - REMEDY -

Broken wire or bad connection ............................................................................... Check voltage across disconnect ter-
minals. If 0 volts, check voltage
across terminals in the control pan
el. If 12 volts, replace wire. If 12 volts
across disconnect, then disconnect
is defective.

Defective function disconnect................................................................................. Check solenoid for function. Apply

ing 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,

6 - 48

Issued: Sept 96
 MACHINE STORAGE TABLE OF CONTENTS

INDEX

SECTION 7

SUBJECT PAGE

SHORT TERM STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1

LONG TERM STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1

ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1

RESTORING ENGINE TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4

TRANSMISSION STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4

RESTORING TRANSMISSION TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5

RESTORATION TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5

CHROME CYLINDER ROD STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6

Revised: May 2002

 TABLE OF CONTENTS
MACHINE STORAGE

Machines being placed in storage must be adequately pro- 4. Clean and tape the battery cables after removing and stor-
tected from deterioration during the period of idleness. This ing the battery.
will ensure that they can be restored to active service with a
minimum effort. 5. Coat the external ring gear of the swing bearing with oper
gear lubricant.
Before removing this hydraulic crane from service for ex-
tended periods, it should be prepared for storage as pre- 6. Fill the hydraulic reservoir to the top AFTER THE MA-
scribed in the following paragraphs. In general, three (3) CHINE IS PARKED IN ITS STORAGE SPOT.
major components must undergo preparation. These are the
Machine Proper, the Engine and the Transmission. The spe- 7. Coat wire rope with lubricant.
cific procedure to be followed depends upon the expected
period of storage. 8. Coat exposed cylinder rods with grease.

The ENGINE should be prepared as prescribed on page 7-

2, the topic “Engine Storage”.
SHORT TERM STORAGE - 30 DAYS OR LESS
Short term storage requires minimal preparation. The TRANSMISSION should be prepared as prescribed
on page 7-4, the topic “Transmission Storage.”
The MACHINE should be thoroughly cleaned, lubricated
in accordance with Section 4, and painted surfaces re-
touched where the paint has deteriorated. exposed portions
of all hydraulic cylinders should be coated with multipur- ENGINE STORAGE
pose grease. Coat unpainted metal surfaces with multipur-
pose grease after removing any rust accumulations.

The ENGINE should be prepared as prescribed on page 7- PREPARING ENGINE FOR STORAGE - When an
2, the topic “Engine Storage”. engine is to be stored or removed from operation for a period
of time, special precautions should be taken to protect the in-
The TRANSMISSION should be prepared as prescribed on terior and exterior of the engine, transmission, and other
page 7-4, the topic “Transmission Storage”. parts from rust accumulation and corrosion. The parts re-
quiring
attention and the recommended preparations are given be-
low.
LONG TERM STORAGE - 30 DAYS OR MORE
It will be necessary to remove all rust or corrosion complete-
Long term storage requires greater preparation than short ly from any exposed part before applying a rust preventive
term storage and must be undertaked with greater care. compound. Therefore, it is recommended that the engine be
processed for storage as soon as possible after removal from
The MACHINE should be prepared as follows: operation.

1. Perform the short term machine storage preparation, mak-

ing certain that All points with grease fittings are liberally
lubricated.

2. Drain and refill the swing reducer, winch(es), axle differ-

entials, planetary hubs and the hydraulic reservoir. Refer to
page 4-19 when servicing the reservoir.

3. Distribute the new hydraulic fluid to all parts of the sys-

tem by operating all function.

7-1 Revised: November 2000

 TABLE OF CONTENTS
MACHINE STORAGE

The engine should be stored in a building which is dry and 1. Drain and thoroughly flush the cooling systemwith clean,
can be heated during the winter months. Moisture absorbing soft water
chemicals are available commercially for use when exces-
sive dampness prevails in the storage area. 2. Refill the cooling system with clean, soft water.

3. Add a rust inhibitor to the cooling system (re

TEMPORARY STORAGE (30 DAYS OR LESS) fer to page 4-7, “Corrsion Inhibitor).
To protect an engine for a temporary period of time proceed
as follows: 4. Remove, check and reconditon the injectors, if necessary,
to make sure they will be readyt to operate when the engine
1. Drain the engine crankcase. is restored to service.

2. Fill the crankcase to the proper level with the recom- 5. Reinstall the injectors in the engine, time them, and adjust
mended viscosity and grade of oil. the valve clearance.

3. Fill the fuel tank with the recommended grade of fuel oil. 6. Circulate the coolant through the entire system by oper-
Operate the engine for two minutes at 1200 rpm and no load. ating the engine until normal operating temperature is
reached (160°F. to 185°F).
NOTE: Do not drain the fuel system or the crankcase after
this run. 7. Stop the engine.

4. Check the air cleaner and service it, if necessary as out- 8. Remove the drain plug and completely drain the engine
lined under Air System. crankcase. Reinstall and tighten the drain plug. Install new
lubricating oil filter elements and gaskets.
5. If freezing weather is expected furing the storage period,
add a high boiling point type antifreeze solution in accor- 9. Fill the crankcase to the proper level with a 30-weight
dance with the manufacturer’s recommendations. Drain the preservative lubricating oil MIL-L-21260, Grade 2 (P10), or
raw water system and leave the drain cocks open. equivalent.

6. Clean the entire exterior of the engine (except the electri- 10. Drain the engine fuel tank.
cal system) with fuel oil and dry it with air.
11. Refill the fuel tank with enough rust preventive fuel oil
7. Seal all of the engine openings. The material used for this such as Americal Oil Diesel Run-In Fuel (LH 4089), Mobil
purpose must be waterproof, vaporproof and possess suffi- 4Y17, or equivalent, to enable the engine to operate 10 min-
cient physical stength to resist puncture and damage fro m utes.
the expansion
of entrapped air. 12. Drain the fuel filter and strainer. Remove the retaining
bolts, shells and elements. Discard the used elements and
An engine prepared in this manner can be returned to service gaskets. Wash the shells in clean fuel oil and insert new el-
in a short time by removing the seals at the engine openings, ements. Fill the cavity between the element and shell about
checking the engine coolant, fuel oil, lubricating oil, trans- two-thirds full of the same rust preventive compound as
mission, and priming the raw water pump, if used. used in the fuel tank and reinstall the shell.

EXTENDED STORAGE (30 DAYS OR MORE)

When An Engine Is To Be Removed From Operation For An
Extended Period Of Time,prepare It as follows:

7-2 Revised: November 2000

 TABLE OF CONTENTS
MACHINE STORAGE

13. Operate the engine for 5 minutes to circulate the rust pre- 20. Remove and clean the battery and battery cables with a
ventive throughout the engine. baking soda solution and rinse them with fresh water. Store
the battery in a cool (never below 32°F.) dry place. Keep the
14. Refer to page 4-6 and service the air cleaner. battery fully charged .

15. With an all-purpose grease such as Shell Alvania No. 2, 21. Insert heavy paper strips between the pulleys and belts to
or equivalent, lubricate the clutch throwout bearing, clutch prevent sticking.
pilot bearing, drive shaft main bearing, clutch release shaft,
and the outboard bearings (if so equipped). 22. Seal all of the openings in the engine, including the ex-
haust outlet, with moisture resistant tape. Use cardboard,
16. Remove the inspection hole cover on the clutch housing plywood or metal covers where practical.
and lubricate the clutch release lever and link pins with a
hand oiler. Avoid getting oil on the clutch facing. 23. Clean and dry the exterior painted surfaces of
the engine. Spray the surfaces with a suitable liquid automo-
17. Apply a non-friction rust preventive compound, to all bile body wax, a synthetic resin varnish or a rust preventive
exposed parts. If it is convenient, apply the rust preventive compound.
compound to the engine flywheel. If not, disengage the
clutch mechanism to prevent the clutch disc from sticking to 24. Cover the engine with a good weather-resistant tarpaulin
the flywheel. or other cover if it must be stored outdoors. A clear plastic
cover is recommended for indoor storage.

The stored engine should be inspected periodically. If there

are any indications of rust or corrosion, corrective steps
Do not apply oil, grease or any wax base compound to the must be taken to prevent damage to the engine parts. Per-
flywheel. The cast iron will absorb these substances which form a complete inspection at the end of one year and apply
can “sweat” out during operation and cause the clutch to additional treatment as required.
slip.

18. Drain the engine cooling system (tag cap).

19. The oil may be drained from the engine crankcase if so

desired. If the oil is drained, reinstall and tighten the drain
plug (tag cap).

7-3 Revised: November 2000

 TABLE OF CONTENTS
MACHINE STORAGE

14. After all of the preparations have been completed, start

RESTORING ENGINE TO SERVICE the engine. The small amount of rust preventive compound
which remains in the fuel system will cause a smoky exhaust
for a few minutes.
1. Remove the valve rocker cover(s) and pour at least one-
half gallon of oil, of the same grade as used in the crankcase, NOTE: Before subjecting the engine to a load or high speed,
over the rocker arms and push rods. it is advisable to check the engine tune-up.

2. Reinstall the valve rocker cover(s).

TRANSMISSION STORAGE
3. Remove the covers and tape from all of the openings of
the engine, fuel tank, and electrical equipment. Do not over-
look the exhaust outlet.
PRESERVATIVE SELECTION When transmissions are
4. Wash the exterior of the engine with fuel oil to remove to be stored or remain inactive for extended periods of time,
the rust preventive. specific preservative methods are recommended to prevent
rust and corrosion damage. The length of storage will usu-
5. Remove the rust preventive from the flywheel. ally determine the preservative method to be used. Various
methods are described below.
6. Remove the paper strips from between the pulleys and the
belts.
STORAGE NEW UNITS
7. Check the crankcase oil level. Fill the crankcase to the New units contain preservative oil when shipped for Funk
proper level with the heavy-duty lubricating oil recommend- and can be safely stored for 6 weeks without further treat-
ed under Lubricating Oil Specifications. ment. Refer to the Funk Transmission manual for additional
information.
8. Fill the fuel tank with the fuel specified under Diesel Fuel
Oil Specifications.
STORAGE, 30 DAYS TO 1 YEAR - WITHOUT OIL
9. Close all of the drain cocks and fill the engine cooling
system with clean soft water and a rust inhibitor. If the en- 1. Drain Oil.
gine is to be exposed to freezing temperatures, add a high
boiling point type antifreeze solution to the cooling system 2. Seal all openings and breathers, except oil drain hole,
(the antifreeze contains a rust inhibitor). with moisture-proof cover or tape.

10 Install and connect the battery. 3. Coat all exposed, unpainted surfaces with Nox Rust X-
110.
11. Service the air cleaner as outlined under Air System.

12. Prepare the generator for starting.

13. Remove the inspection hole cover and inspect the clutch
release lever and link pins and the bearing ends of the clutch
reliease shaft. Apply engine oil sparingly, if necessary to
these areas.

7-4 Revised: November 2000

 TABLE OF CONTENTS
MACHINE STORAGE

4. Atomize or spray 4 ounces of Nox Rust VCI No. 10 oil,

or equivalent, into the transmission through the oil drain
hole. Install the drain plug. Refer to page 7-4, “Restoring Engine to Service”, and page
7-5 and 7-6, “Restoring Transmission to Service”, for the
5. If additional storage time is required, (3) and (4) above procedures required to restore these components to service.
should be repeated at yearly intervals.
Remove the MACHINE from storage via the following pro-
cedure:
*Nox Rust is a preservative additive manufactured by
the Daubert Chemical Company, Chicage, Illinois. Mo- 1. Remove preservative lubricants from all surfaces.
torstor is covered by US Military Specifications MIL-L-
46002 (ORD) and MIL-1-23310 (WEP). 2. Check all fluid levels, adding or draining as required.

3. Lubricate the machine according to Section 9, making

RESTORING TRANSMISSION TO SERVICE certain that all points with grease fittings are lubricated.

4. Make a thorough visual inspection of the entire machine,

1. If Nox Rust, or equivalent, was used in preparing the placing special emphasis on the condition of all hydraulic
transmission for storage, use the following procedures to re- hoses.
store the unit to service.

2. Remove the tape from openings and breather.

3. Wash off all the external grease with solvent.

4. Add hydraulic transmission fluid, type C3 to proper level.

NOTE: It is not necessary to drain C3 oil and Nox Rust mix-

ture from the transmission.

5. If Nox Rust or equivalent, was not used in preparing the

transmission for storage, use the following procedures to re-
store the unit to service.

6. Remove the tape from openings and breathers.

7. Wash off all the external grease with solvent.

8. Drain oil.

9. Install a new oil filter element(s).

10. Refill transmission with hydraulic transmission fluid,

type C3 to proper level.

RESTORATION TO SERVICE

7-5 Revised: November 2000

 MACHINE STORAGE TABLE OF CONTENTS

CHROME CYLINDER ROD STORAGE 4. Inspect the cylinder rod surfaces and reapply
at three to six month intervals.

5. If the equipment is to be moved and then

Hard chrome plating is primarily applied to steel stored again for an extended period of time
cylinder rods for its wear resistant properties, al- or if the cylinder is cycled, steps 1 thru 4
though it does provide considerable corrosion re- should be repeated for all cylinder rods that
sistance as well. Once the chrome-plated rod is were exposed.
assembled into a cylinder and put into service,
the hydraulic fluid on the surface of the rod pro-
vides all the corrosion resistance required for the *Ferro-Kote 5856-BF is a product of Quaker
rod during its life cycle. As a cylinder cycles, hy- Chemical Company, Conshohocken, PA
draulic fluid is driven into any surface cracks 19428
that exist in the chrome plate. When these
cracks are filled with hydraulic fluid, moisture or For the protection of Older Equipment that is to
corrosive fluids can not penetrate the cracks. be stored, the procedure outlined above can be
However, some machining and cleaning opera- used, but greater attention to cleaning the ex-
tions can negatively impact the future corrosion posed portions of each cylinder rod is required.
resistance of chrome-plated shafting. For exam- Solvent applied with plastic or copper wool can
ple, additives such as chlorine, sulfur, and sodi- be used, but abrasives such as sandpaper
um found in Extreme Pressure (EP) coolants and should never be used to clean the exposed sur-
some washing solutions are known rust acceler- faces of the cylinder rod. If surface damage to
ates and can strip chrome plating from the base the chrome plate is discovered, the frequency of
metal. Cleaning processes, such as phosphate corrosion barrier applications should be in-
washing are also known to be detrimental to the creased.
corrosion resistance of hard chrome plated
shafting. Note: Caution must be used when cleaning
equipment in service with high pressure
If the rod is not periodically cycled and is subject washes. Soaps or chemicals containing
to a corrosive environment, moisture and oxygen chlorines or other corrosive elements
can work its way down through the chrome layer should be avoided. Cylinders should be
and begin to corrode the base metal. Brand new cleaned in a retracted position as not to
equipment may be stored outside for a consider- expose rods to the chemicals. Cylinders
able period of time at the equipment dealership should be cycled immediately following
before it is sold. During these times, a protective the wash. If rods are to be stored in the
barrier must be applied to the exposed cylinder extended position, refer to steps 1-4
rod. This protective barrier will preserve the in- above.
tegrity of the chrome plating by preventing the
elements of corrosion from getting to the metal
substrate.

Cylinders should be stored in the retracted posi-

tion, if at all possible. The steps outline below
cover the procedures to be followed for protect-
ing New Equipment from corrosion if it must be
stored in the extended position:

1. Position the equipment as it will be stored

and identify all the exposed portions of the
chrome plated cylinder rods.

2. Clean any dirt and dust from the exposed

portions of the cylinder rods using a dry
cloth or a cloth which has been dampened
with an appropriate solvent. Do not use
caustics or acids.

3. Apply a thin coating of “Ferro-Kote 5856-BF”

to the exposed surfaces of the chrome plated
cylinder rods. The ferro-Cote may be
thinned using a 40% Kerosene or no. 1 fuel
oil mixture.

7-6 Issued: May 2002

 TABLE OF CONTENTS

GENERAL INFORMATION

INDEX

SECTION 8

SUBJECT PAGE

CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1

AVERAGE WEIGHT OF MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3

SUGGESTED TORQUE RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4

ROUGH TERRAIN CRANE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6

MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 7

MACHINE CYCLE TIMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10

Issued: December 1999

 TABLE OF CONTENTS
GENERAL INFORMATION

CONVERSION TABLES

DECIMAL AND METRIC EQUIVALENTS OF FRACTIONS OF AN INCH

Fractions Decimals Milli Fractions Decimals Milli

of an inch of an inch meters of an inch of an inch meters

1/64 .0156 0.397 33/64 .5156 13.097

1/32 .0313 0.794 17/32 .5313 13.494
3/64 .0469 1.191 35/64 .5469 13.891
1/16 .0625 1.588 9/16 .5625 14.287
5/64 .0781 1.985 37/64 .5781 14.684
3/32 .0938 2.381 19/32 .5938 15.081
7/64 .1094 2.778 39/64 .6094 15.478
1/8 .1250 3.175 5/8 .6250 15.875
9/64 .0406 3.572 41/64 .6406 16.272
5/32 .1563 3.969 21/32 .6563 16.688
11/64 .1719 4.366 43/64 .6719 17.085
3/16 .1875 4.762 11/16 .6875 17.462
13/64 .2031 5.159 45/64 .7031 17.859
7/32 .2188 5.556 23/32 .7188 18.256
15/64 .2344 5.953 47/64 .7344 18.653
1/4 .2500 6.350 3/4 .7500 19.050
17/64 .2656 6.747 49/64 .7656 19.447
9/32 .2813 7.144 25/32 .7813 19.843
19/64 .2969 7.541 51/64 .7969 20.240
5/16 .3135 7.937 13/16 .8125 20.637
21/64 .3281 8.334 53/64 .8281 21.034
11/32 .3438 8.731 27/32 .8438 21/430
23/64 .3594 9.128 55/64 .8594 21/827
3/8 .3750 9.525 7/8 .8750 22.224
25/64 .3906 9.922 57/64 .8906 22.621
13/32 .4063 10.319 29/32 .9063 23.018
27/64 .4219 10.716 59/64 .9219 23.415
7/16 .4375 11.12 15/16 .9375 23.812
29/64 .4531 11.509 61/64 .9531 24.209
15/32 .4688 11.906 31/32 .9688 24.606
31/64 .4844 12.303 63/64 .9844 25.003
1/2 .5000 12.700 1 1.0000 25.400

8-1 Issued: December 1999

 TABLE OF CONTENTS
GENERAL INFORMATION

LIQUID WEIGHTS AND MEASURES METRIC EQUIVALENTS

LIQUID MEASURE LIQUID MEASURE

4 gills equals 1 pint 1 litre equals .0353 cu. ft.
2 pints “ 1 quart 1 litre “ .2642 gallon
4 quarts “ 1 gallon 1 litre “ 61.023 cu. in.
7.48 gallons “ 1 cu. ft. 1 litre “ 2.202 lbs. of
240 gallons of “ 1 Ton water(62°F.)
water 1 cu. foot “ 28.32 litres
340 gallons of “ 1 Ton 1 gallon “ 3.785 litres
gasoline 1 cu. inch “ .0164 litre

MEASURES OF WEIGHTS MEASURE OF WEIGHTS

16 ounces equals 1 pound 1 gram equals .0353 ounce
2000 pounds “ 1 short ton 1 kilogram “ 2.205 lbs.
2240 pounds “ 1 long ton 1 ounce “ 28.35 grams
100 cu. feet " 1 register ton 1 pound “ .454 kilogram
40 cu. feet “ 1 U.S. shipping 1 ton “ .907 metric ton
ton

CIRCULAR MEASURE ELECTRICAL UNITS

60 seconds equals 1 minute 1 kilowatt equals 1.34 H.P.

60 minutes “ 1 degree 1 horsepower “ 746 watts
90 degrees “ 1 quadrant
360 degrees “ circumference

SURVEYOR’S MEASURE

7.92 inches equals 1 link

100 links “ 66 feet
or 4 rods
or 1 chain
80 chains “ 1 mile

8-2 Issued: December 1999

 TABLE OF CONTENTS
GENERAL INFORMATION

AVERAGE WEIGHT OF MATERIALS

Lb. per Cu. Ft.

METALS, ALLOYS, ORES EARTH

Aluminum, Cast-Hammered 165 Clay, Dry 63

Brass, Cast-Rolled 534 Clay, Damp, Plastic 110
Bronze 509 Clay & Gravel, Dry 100
Copper, Cast-Rolled 556 Earth, Dry Loose 76
Gold, Cast-Hammered 1205- Earth, Dry Packed 95
Iron, Gray-Cast 442 Earth, Moist Loose 78
Iron Slag 172 Earth, Moist Packed 96
Lead 710 Earth, Mud Flowing 108
Manganese 475 Earth, Mud Packed 115
Mercury 847 Riprap, Limestone, Sandstone,
Nickel 537 Shale 80-105
Steel 481-489 Sand, Gravel, Dry Loose 90-105
Tin, Cast-Hammered 459 Sand, Gravel, Dry Packed 100-120
Tin, Cast-Hammered 459 Sand, Gravel, Wet 126
Tungsten 1200
Zinc, Cast-Rolled 440
EXCAVATIONS IN WATER

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, Snadstone, 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 Issued: December 1999

 TABLE OF CONTENTS
GENERAL INFORMATION

TORQUE RATINGS

ES - 100.0
TORQUE RATINGS
FOR
DRY - UNCOATED FASTENERS

TORQUE VALUES TO BE WITHIN ± 5%

ALL FIGURES IN FOOT POUND

THIS TABLE DOES NOT APPLY TO HY-

DRAULIC CONNECTIONS. WHEN
TORQUING HYDRAULIC CONNECTIONS
REFER TO ES-100.1

NOM. DIA. IN. GRADE 2 GRADE 5 GRADE 8

1/4 6 -*4 8 12 BOLT HEAD MARKING

5/16 12 - * 7 20 25
3/8 20 - * 12 30 45
7/16 35 - * 20 50 75
1/2 50 - * 30 80 110
9/16 75 - * 45 115 160
GRADE 2
5/8 100 - * 60 160 225
3/4 180 - * 110 280 400
7/8 175 450 640
1 265 680 970
GRADE 5
1-1/8 375 840 1,380
1-1/4 530 1,200 1,930
1-3/8 700 1,570 2,540
1-1/2 930 2,080 3,380
1-3/4 1,460 2,090 5,300 GRADE 8

2 2,200 3,200 7,990

2-1/4 3,200 5,350 11,690
2-1/2 4,400 7,300 15,990
The above information was compiled for U.N.C. Threaded Fasteners.

NOTE: * = Torque Values For Bolts And Screws Longer Than 6”

Fasteners as supplied by the vendor are considered not

lubricated.

8-4 Issued: December 1999

 TABLE OF CONTENTS
GENERAL INFORMATION

TORQUE RATINGS

ES - 100.1
TORQUE RATINGS
FOR
LUBRICATED OR PLATED FASTENERS

TORQUE VALUES TO BE WITHIN ± 5%

ALL FIGURES IN FOOT POUND

REFER TO THIS TABLE WHEN TORQU-

ING HYDRAULIC CONNECTIONS (Piping
& Cylinders).

NOM. DIA. IN. GRADE 2 GRADE 5 GRADE 8

1/4 5 -*3 7 10 BOLT HEAD MARKING

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.

NOTE: If threads are not lubricated prior to assembly or are not

plated use Torque Spec. ES-100.0

* = Torque Values for Bolts and Screws longer than 6”

Fasteners as supplied by the vendor are considered not

lubricated.
8-5 Issued: December 1999
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8-6 Issued: December 1999

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8-7 Issued: December 1999

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8-8 Issued: December 1999

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8-9 Issued: December 1999

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GENERAL INFORMATION

All cycle times should be taken at full engine RPM with the
hydraulic oil temperature at 120° F.

Cycle times are for full cylinder stroke. Boom is to be fully

retracted for boom up and down cycle times. Boom is to be at
60° boom angle for extend and retract cycle times.

FUNTION DESCRIPTION CYCLE TIMES (SECONDS) *

BOOM UP 35 ± 5

BOOM DOWN 40 ± 5

BOOM EXTEND 50 ± 10

BOOM RETRACT 50 *

SWING 34 ± 5

OUTRIGGER BEAM EXTEND OR RETRACT 5±2

OUTRIGGER JACK EXTEND OR RETRACT 8±2

* TELESCOPE CYCLE TIMES WILL VARY CONSIDERABLY DUE TO OIL VISCOSITY, BOOM SLIDER PAD
ADJUSTMENT AND GREASING.

8 - 10 Issued: December 1999

 TABLE OF CONTENTS
WIRE ROPE USER’S MANUAL

INDEX

SECTION 9

SUBJECT PAGE

WIRE ROPE USER’S MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

May 1998
 TABLE OF CONTENTS

WIRE ROPE
USERS MANUAL

COMMITTEE OF WIRE ROPE PRODUCERS

American Iron and Steel Institute
(Edited version by Terex Cranes)
 TABLE OF CONTENTS

This publication is a joint effort of the

COMMITTE OF WIRE ROPE PRODUCERS/
American Iron and Steel institute
and the
WIRE ROPE TECHNICAL BOARD

The Wire Rope Technical Board (WRTB) is an association of engineers representing

companies that account for more than 90 percent of wire rope produced in the United
States; it has the following objectives:
• To promote development of engineering and scientific knowledge relating to
wire rope;
• To assist in establishing technological standards for military, governmental and
industrial use;
• To promote development, acceptance and implementation of safety standards;
• To help extend the uses of wire rope by disseminating technical and engineering
information to equipment manufacturers; and
• To conduct and/or underwrite research for the benefit of both industry and user.

Data, specifications, architectural/engineering information and drawings presented in

this publication have been delineated in accordance with recognized professional prin-
ciple and practices, and are for general information only. Suggested procedures and
products should not, therefore, be used without first securing competent advice with
respect to their suitability for any given application.

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.

COMMITTEE OF WIRE ROPE PRODUCERS

American Iron and Steel Institute
1000 16th Street, N.W.
Washington, D.C. 20036

Copyright © 1979 by American Iron and Steel Institute

All rights reserved
Printed in the U.S.A.

Permission to reproduce or quote any portion of this book as editorial

reference is herby granted. When making such reproductions or quota-
tions, the courtesy of crediting this publication and American Iron and
Steel Institute will be appreciated.

2
 TABLE OF CONTENTS

CONTENTS

1. INTRODUCTION / 5
2. BASIC COMPONENTS / 7
3. WIRE ROPE INDENTIFICATION AND CONSTRUCTION / 9
4. HANDLING WIRE ROPE / 17

Wire Rope Installation / 18

Unreeling & Uncoiling / 19
Seizing Wire Rope / 22
Cutting Wire Rope / 24
End Attachments / 25
Efficiency of End Attachments / 27
Socketing / 28
Wire Rope Clips / 28
How to Apply Clips 28, 29, 31
Wedge Sockets / 33, 33R
Drums-Grooved / 34
Drums-Plain (Smooth) / 35R

5. OPERATION AND MAINTENANCE OF WIRE ROPE / 37

Breaking in a New Wire Rope / 45
Wire Rope and Operations Inspection / 45

3
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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
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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:

600 ft 3/4” 6x25 FW Left lang lay

Improved plow IWRC

(Rope described above would be made PREFORMED.)

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Table 1 WIRE ROPE CLASSIFICATIONS

Based on the Nominal Number of Wires in Each Strand

Classification Description

6x7 Containing 6 strands that are made up of 3 through 14 wires,

of which no more than 9 are outside wires.

6x19 Containing 6 strands that are made up of 15 through 26

wires, of which no more than 12 are outside wires.

6x37 Containing 6 strands that are made up of 27 through 49

wires, of which no more than 18 are outside wires.

6x61 Containing 6 strands that are made up of 50 through 74

wires, of which no more than 24 are outside wires.

6x127 Containing 6 strands that are made up of 75 through 109

wires, of which no more than 36 are outside wires.

8x19 Containing 8 strands that are made up of 15 through 26

wires, of which no more than 12 are outside wires.

19x7 Containing 19 strands, each strand is made up of 7 wires.

and It is manufactured by covering an inner rope of 7x7 left
18x7 lang lay construction with 12 strands in right regular lay.
(The rotation-resistant property that characterizes this
highly specialized construction is a result of the counter
torques developed by the two layers.) When the steel wire
core strand is replaces by a fiber core, the description
becomes 18x7.

When a center wire is replaces by a strand, it is considered as a single wire,

and the rope classification remains unchanged.
There are, of course, many other types of wire rope, but they are useful only
in a limited number of applications and, as such, are sold as specialties. Usually
designated according to their actual construction, some of these special construc-
tions are listed in Table 2 and show in Figure 8.

13
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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*
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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 dam-
aged 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 cor-
rect this condition, the kinks must be cut out, and the shortened pieces use for some other
purpose.
 TABLE OF CONTENTS

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.
 TABLE OF CONTENTS

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.
 TABLE OF CONTENTS

SEIZING WIRE ROPE

While there are numerous ways to cut wire rope, in every case, certain precau-
tions 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
normally sufficient. But for those that are not preformed, a minimum of two seiz-
ings 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 OF CONTENTS

TABLE 4 SEIZING
Suggested Diameters and Lengths

23
 TABLE OF CONTENTS

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 OF CONTENTS
 TABLE OF CONTENTS

TABLE 5 TERMINAL EFFIECIENCIES (APPROXIMATE)

Efficiencies are based on nominal strengths
 TABLE OF CONTENTS

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.

WIRE ROPE CLIPS

Wire rope clips are widely used for attaching wire rope to haulages, mine cars,
hoist, and for joining two ropes.
Clips are available in two basic designs: the U-bolt and fist grip (Fig. 23).
The efficiency of both types is the same.
When using U-bolt clips, extreme care must be exercised to make certain that
they are attached correctly, i.e., the U-bolt must be applied so the “U” section is in
contact with the dead end of the rope (Fig. 24). Also, the tightening and retight-
ening of the nuts must be accomplished as required.

HOW TO APPLY CLIPS

U-BOLT CLIPS (Table 6, page 30)
Recommended Method of Applying U-Bolt Clips to Get Maximum
Holding Power of the Clip
1) Turn back the specified amount of rope from the thimble. Apply the first clip
one base width from the dead end of the wire rope (U-bolt over dead end-live
end rest in clip saddle). Tighten nuts evenly to recommended torque.
2) Apply the next clip as near the loop as possible. Turn on nuts firm but do not
tighten.
3) Space additional clips is required equally between the first two. Turn on nuts-
take up rope slack-tighten all nuts evenly on all clips to recommended torque.

28
 TABLE OF CONTENTS

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

IMPORTANT: Failure to make a termination in accordance with aforemen-

tioned instructions, or failure to periodically check and retighten to the recom-
mended torque, will cause a reduction in efficiency rating.

29
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 TABLE OF CONTENTS

FIST GRIP CLIPS (Table 7, on the following page)

RECOMMENDED METHOD OF APPLYING FIST GRIP CLIPS

1) Turn back the specified amount of rope from the thimble. Apply the first clip
one base width from the dead end of the wire rope. Tighten nuts evenly to rec-
ommended torque.
2) Apply the next clip as near the loop as possible. Turn on nuts firmly but do not
tighten.
3) Space additional clips if required equally between the first two. Turn on nuts-
take up rope slack-tighten all nuts evenly on all clips to recommended torque.
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 used 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, fibre core or IWRC, IPS or EIPS. If Seale con-
struction or similarly 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, 8x 19
class, fibre core, IPS, sizes 11/2 inch and smaller; and right regular lay wire rope,
18 x 7 class, fibre core, IPS or EIPS, sizes 1 1/2 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 proportionately. AVORED BASED ON USE
OF FIST GRIP CLIPS ON NEW WIRE ROPE.

IMPORTANT: Failure to make a termination in accordance with aforemen-

tioned instructions, or failure to periodically check and retighten to the recom-
mended torque, will cause a reduction in efficiency rating.

31
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32
 TABLE OF CONTENTS

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.
 TABLE OF CONTENTS

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
 TABLE OF CONTENTS

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.

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 TABLE OF CONTENTS

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.
 TABLE OF CONTENTS

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.

BREAKING IN A NEW WIRE ROPE

A new wire rope requires carefully installation and close adherence to following
all the appropriate procedures previously noted. After the rope has been installed
and the ends secured in the correct manner, the mechanism should be started care-
fully and then permitted to run through a cycle of operation at a very slow speed.
During this trial operation, a very close watch should be kept on all working
parts-sheaves, drums, rollers-to make certain that the rope runs freely, and with-
out any possible obstructions as it makes its way through the system. If no prob-
lems appear in running the rope, the next step should include several run-throughs
of the normal operational cycle under light load and at reduced speed. This pro-
cedure allows the component parts of the new rope to make a gradual adjustment
to the actual operating conditions.

WIRE ROPE AND OPERATIONS INSPECTION

To assume a high level of safety while keeping the annual cost of wire rope at a
reasonably low level, it is essential to maintain a well-planned program of peri-
odic inspection. Frequently, there are statutory and/or regulatory agencies whose
requirements must be adhered to, but whether or not these exist in a given locale,
the wire rope user can be guided by the suggested procedures that follow.
Abrasion, bending and crushing represent the ABC’s of wire rope abuse, and
it is the primary goal of good inspection practice to discover such conditions early
enough so that corrections can be made or ropes replaced safely and with mini-
mum effort. When any degradation indicates a loss of original rope strength, a
decision must made quickly as to allowing the rope to remain in service. But such
a decision can only be made by an experienced inspector. And his determination
will be based on:
1) Details of the equipment’s operation: Will the rope break?
2) Frequency of inspection: Will it be safe until the next scheduled inspection?
3) Maintenance history: How rapid is the degradation?
4) Consequences of failure: Will it present hazards to humans?
5) Historical records of similar equipment
To make certain that sufficient information is obtained, following are guide-
lines that should be adhered to:

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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.

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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.

WIRE ROPE INSPECTION

The following is fairly comprehensive listing of critical inspection factors. It is
not, however, presented as a substitute for an experienced inspector. It is rather a
user’s guide to the accepted standards by which ropes must be judged.
1) Abrasion
Rope abrades when it moves through an abrading medium or over drums and
sheaves. Most standards require that rope is to be removed if the outer wire
wear exceeds 1/3 of the original outer wire diameter. This is not easy to deter-
mine and discovery relies upon the experience gained by the inspector in mea-
suring wire diameters of discarded ropes.

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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
rope’s 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.

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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 rope’s diameter at the time of inspection.
Currently this practice has undergone significant modification.
Previously, a decrease in the rope’s diameter was compared with pub-
lished standards of minimum diameters. The amount of change in diameter is,
of course, useful in assessing a rope’s 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 reduc-
tion 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

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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 rope’s 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 rope’s 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.

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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.
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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.

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TABLE 14 DIAGNOSTIC GUIDE TO COMMON WIRE ROPE ABUSES

Abuse Symptoms Possible Causes

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.

Abrasion Reduced cross-section is broken off A long term condition normal

plug Fatigue square thereby producing a chisel shape. to the operating process.

Abrasion Reduced cross-section is necked down A long term condition normal

plus Tension as in a cup and cone configuration. Tensile to the operating process.
break produces a chisel shape.

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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.

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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 rope’s 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.

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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).
 TABLE OF CONTENTS

TEREX
CRANES

MINIMUM
SAFETY REQUIREMENTS
FOR
WORK PLATFORMS USED
ON TEREX LIFT CRANES

WORK PLATFORM SUSPENDED ON A LOAD LINE PAGE ii

WORK PLATFORM RIGIDLY MOUNTED ON THE BOOM PAGE vi

12261-80
 TABLE OF CONTENTS

MINIMUM SAFETY REQUIREMENTS and with automatic braking which is applied when the applicable
FOR WORK PLATFORMS SUSPENDED ON control is in neutral;
LOAD LINE OF A TEREX LIFT CRANE
(2)A control or device which will deactivate any “free fall” load line
Scope function during the hoisting of personnel;

When it is determined that use of a work platform suspended from the (3)An operable anti-two block warning device which automatically
load line of a lift crane manufactured by Terex Cranes (hereinafter deactivates the control function bringing about the two-blocking
“Terex”) creates the least hazard to personnel and is the only practical condition;
means of accomplishing a task, the following procedures and minimum
requirements shall apply: (4)Crane controls which return to neutral when released (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
1. The requirements and procedures set forth herein are applicable to hy- maximum boom angle “kickout”, and an audio/visual alarm;
draulic lift cranes, with or without a telescopic boom, and mechanical/
friction operated lattice boom lift cranes manufactured by Terex. (6)Appropriate load charts for the lift crane;

2. Hydraulic lift cranes shall comply with PCSA Std. No. 2 and No. 4, (7) A winch drum rotation indicator.
and ANSI B30.5-1983 and mechanical/friction operated lattice boom
lift cranes shall comply with PCSA Std. No. 1 and No. 4, and ANSI 4. Such cranes shall not be equipped with a “free fall” (live boom)
B30.5-1983, as applicable. boom hoist.

3. The lift cranes referred to in A.1 shall include the following equipment Work Platform Minimum Requirements
and/or controls when used to suspend work platforms from the load
line. Work platform manufacturers shall comply with the following mini-
mum requirements. Users of work platforms shall ensure that the fol-
a)Hydraulic Lift Cranes lowing minimum requirements have been met before personnel are
hoisted.
(1)A boom and load line with power lowering and raising and with
automatic braking which is applied when the applicable control is 1.Work platforms suspended from the load line of a lift crane shall com-
in neutral; ply with all applicable governmental and/or industry standards relat-
ing to design and manufacture including, but not limited to, ANSI
(2)A control or device which will deactivate any “free fall” load line A92.2-1979. Design considerations shall include,but not be limited
function during the hoisting of personnel; to:

(3)Crane controls which return to neutral when released (unless a a) the material and design safety factors;
second operator is in the cab at all times);
b) construction, including fasteners and welding;
(4)An operable anti-two block warning device which automatically
deactivates the control function bringing about the two-blocking c) flooring;
condition;
d) hand rails;
(5)A boom angle indicator having high and low set points and hav-
ing an audio/visual alarm; e) toe boards;

(6)Appropriate load charts for the lift crane; f) safety lanyard attachment;

(7)A boom extension indicator (when crane is equipped with a tele- g) gates;
scopic boom);
h) hoisting and tag line attachments; and
(8) A winch drum rotation indicator.
i) load limit, occupant limit, and work platform weight instructions,
b)Mechanical/Friction Operated Lattice Boom Lift Cranes labels and warnings.

(1)A boom and load line with power lowering and raising 2.The specifications for the work platform shall be in writing and shall
describe the platform weight, load and occupancy limit, platform
inspection and maintenance

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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 manufacturer’s 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 User’s 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
 TABLE OF CONTENTS

3. Operation and Safety telephone communication with the machine operator and signal
person at all times. In the event of failure of the communication
a)Mobile lift cranes shall be erected to obtain maximum machine sta- system, personnel will immediately be returned to ground level us-
bility and must be level and on firm ground. Rubber tired lift cranes ing hand signals until the communications system is operational.
shall have outriggers fully extended and the tires clear of the ground
before beginning any operation utilizing a work platform suspended l) If other cranes or equipment may interfere with the lifting of per-
from the load line. No operations utilizing a work platform shall be sonnel, signals or other means of communication between all crane
conducted while any rubber tired lift crane is “on rubber”. or equipment operators shall be maintained to avoid interference by
other operations.
b)The operator’s experience and physical condition shall meet all ap-
plicable industry standards and/or governmental regulations. m)No lifts shall be made on another of the crane’s load lines while per-
sonnel are suspended in a work platform.
c)The operator shall not leave the operator’s station when the work
platform is occupied. He shall remain at his work station with the n) After position ing of the work platform, all brakes and locks in the
engine running and the master clutch engaged whenever the work lift crane shall be set before personnel perform any work.
platform is occupied.
o) Work platforms shall not be used in winds in excess of 10 m.p.h.,
d)Unauthorized personnel shall not be in the operator’s cab, on the lift electrical storms, snow, ice, sleet, or other adverse weather condi-
crane, or near the lift crane while a work platform is suspended from tions which could affect the safety of personnel.
the load line.
p) Movement of the work platform with personnel shall be done in a
e)Any operation in which the work platform is to be suspended from slow, controlled, cautious manner with no sudden movements of the
the load line shall be carefully planned by the operator, signal per- crane or work platform.
son, supervisory personnel, and personnel to be lifted prior to com-
mencement of such operation. q) At no time shall personnel stand on or work from the top rail, mid-
rail, or toe board of the work platform.
f) The operator shall make no sudden movements of the crane or the
work platform while suspended from the load line and shall engage r) Personnel shall keep all parts of the body, tools, and equipment in-
in no reckless operation or horseplay at any time. side the work platform during raising, lowering, and positioning.

g)A distance no less than twice the minimum distance to power lines s) If not resting on the ground, the work platform shall be secured to
as specified in OSHA 29CFR, Part 1910 shall be maintained when the structure by rope or other means before personnel enter or leave.
a work platform is attached to the load line of a Terex lift crane.
Further, work on any energized power line or any other energized t) When working from a work platform, belting off or otherwise at-
device used for electric power generation or transmission is prohib- taching a work platform to an adjacent pole, structure, or other
ited. equipment shall not be permitted, except as specified in subsection
“s” above.
h)The combined weight of the work platform plus any attachment de-
vice, personnel, tools and other equipment shall not exceed 50% of u) Employees on the work platform shall wear safety belts with lan-
the lifting capacity specified by the applicable lift crane load chart. yards attached, preferably above the hook or shackle.

i) A work platform stabilizing tag line shall be attached when practical v) When welding is done by an employee on the platform, the elec-
to a work platform corner and controlled so as to prevent rotation of trode holders shall be protected from contact with metal compo-
the work platform and to minimize any swaying motion of the work nents of the platform. If electrically connected electrode holders
platform. contact work platform, work platform could be dropped due to
burning/melting of wire ropes suspending the work platform.
j) When lifting personnel in a work platform, no more than one crane
funtion shall be utilized at any time. The lift crane shall not be trav- w)Work platform lifts shall be a single crane operation. A work plat-
elled while the work platform is occupied. form shall not be lifted using two cranes.

k)Personnel in the work platform shall have radio or x) Before positioning or repositioning the work platform, the lift crane
operator shall locate soa s toavoid all obstructions and high voltage
conductors in the area.

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 TABLE OF CONTENTS

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.

z)No external load shall be lifted by attaching to the load platform.

NOTE:
The criteria and procedures set forth herein are minimum require-
ments only to be used in the absence of any more stringent applica-
ble standard and/or regulation. Applicable government and/or
industry standards (e.g., federal or state OSHA, MESA, Industrial
OSHA, etc.) must be reviewed and adhered to in conjunction with
the contents hereof.

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 TABLE OF CONTENTS

MINIMUM SAFETY REQUIREMENTS b) construction, including fasteners and welding;

FOR WORK PLATFORMS RIGIDLY MOUNTED ON THE
BOOM OF TEREX HYDRAULIC LIFT CRANE c) flooring;

Scope d) hand rails;

When it is determined that use of a work platform rigidly mounted on e) toe boards;
the boom of a hydraulic lift crane manufactured by Terex Cranes (here-
inafter “Terex”) creates the least hazard to personnel and is the only f) safety lanyard attachment;
practical means of accomplishing a task, the following procedures and
minimum requirements shall apply: g) gates;

Terex Hydraulic Lift Cranes and Their Equipment h) a means of adjusting and locking the work platform level; and

1. The requirements and procedures set forth herein are applicable to all i) load limit, occupant limit, and work platform weight instructions,
Terex hydraulic lift cranes with or without a telescopic boom. labels and warnings.

2. Hydraulic lift cranes shall comply with PCSA Std. No. 2 and No. 4 as 2.The specifications for the work platform shall be in writing and shall
applicable, and ANSI B30.5-1983. describe the platform weight, load and occupancy limit, platform
inspection and maintenance procedures; procedures for attachment
3. Such hydraulic lift cranes shall include the following equipment and/ of the platform to the boom, and any appropriate precautionary infor-
or controls when used with rigidly mounted work platforms on the mation applicable to the platform itself, and shall be permanetly
boom. placed in the lift crane and in or on the work platform.

(a)A boom with power lowering and raising and with automatic 3)Such cranes shall not be equipped with a “free fall” (live boom) boom
braking which is applied when the applicable control is in neutral; hoist.

(b)Crane controls which return to neutral when released (unless a Inspection and Rigging, Testing and Operation
second operator is in the cab at all times);
The inspection, operation and safety requirements of PCSA Standard
(c)A boom angle indicator having high and low set points and hav- No. 2 and No. 4, as applicable, and ANSI B30.5-1983 for lift cranes
ing an audio/visual alarm; shall be complied with at all times. Applicable governmental requla-
tions shall also be adhered to. In addition, the following limitations and
(d)Appropriate load charts for the lift crane; minimum requirements shall apply:

(e)A boom extension indicator (when crane is equipped with a tele- 1. Inspection and Rigging
scopic boom); and
a) The lift crane and work platform shall be inspected immediately pri-
(f) A means to rigidly attach the basket to the boom tip which is sup- or to commencement of operation. Inspection shall include, but not
plied by or approved by Terex; be limited to, brakes, boom and other mechanical and rigging
equipment vital to the safety of the operation.
Work Platform Minimum Requirements
b) The inspection shall be performed at least once daily when the ma-
Work platform manufacturers shall comply with the following mini- chine is being used in work platform service or each time the ma-
mum requirements. Users of work platforms shall ensure that the fol- chine is converted from material handling to personnel operation.
lowing minimum requirements have been met before personnel are In the event the operator is replaced, a new inspection is required.
hoisted.
c) Any structural or functional defect which adversely affects the safe
1.Work platforms rigidly mounted on the boom of a Terex hydraulic lift operation of the lift crane shall be corrected before any operation
crane shall comply with all applicable governmental and/or industry utilizing a work platform begins or continues.
standards relating to design and manufacture including, but not lim-
ited to, ANSI A92.2-1979. Design considerations shall include,but d) No work platform shall be mounted to the jib of any hydraulic lift
not be limited to: cranes.

a) the material and design safety factors;

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 TABLE OF CONTENTS

2. Crane Test Procedures mounted on the boom of a hydraulic lift crane shall be carefully
planned by the operator, signal person, supervisory personnel, and
The test procedures listed below shall be conducted at the following personnel to be lifted prior to commencement of such operation.
intervals:
f) The operator shall make no sudden movements of the lift crane or
(1) daily, the work platform and shall engage in no reckless operation or
horseplay at any time.
(2) when an operator is replaced, and
g) A distance no less than twice the minimum distance to power lines
(3) when, in the judgement of responsible jobsite managemant, as specified in OSHA 29CFR, Part 1910 shall be maintained when
there has been a significant change in the conditions of the per- a work platform is mounted on the boom of a Terex lift crane. Fur-
sonnel lifting operation. ther, work on any energized power line or any other energized de-
vice used for electric power generation or transmission is
No personnel shall ride the work platform during any of the tests recom- prohibited.
mended in this Standard.
h) The combined weight of the work platform plus any attachment de-
a)The work platform shall be loaded with ballast at two times the in- vice, personnel, tools and other equipment shall not exceed 50% of
tended load. the lifting capacity specified by the applicable lift crane load chart.

b)The boom shall be raised to test the set point limits of the boom an- i) When lifting personnel in a work platform, no more than one crane
gle indicator and the audio/visual warning alarms. funtion shall be utilized at any time. The lift crane shall not be trav-
elled while the work platform is occupied.
c)This test load shall be raised and lowered between boom angle set
points at maximum controlled hoist speed. The acceleration must j) Personnel in the work platform shall have radio or telephone
be smooth and controlled. The specific operation to be undertaken communication with the machine operator and signal person at all
shall then be simulated in its entirety. The work platform shall then times. In the event of failure of the communication system, person-
be inspected for any evident sign of damage or defect. nel will immediately be returned to ground level using hand signals
until the communications system is operational.
d)The operator shall have demonstrated his ability to operate the lift
crane prior to hoisting personnel in a work platform mounted on the k) If other cranes or equipment may interfere with the lifting of per-
boom. sonnel, signals or other means of communication between all crane
or equipment operators shall be maintained to avoid interference by
3. Operation and Safety other operations.

a)Mobile hydraulic lift cranes shall be expected to obtain maximum l) A hydraulic lift crane on which a work platform is mounted shall
machine stability and must be on firm ground with the outriggers not be used for any other function or operation during lifting of per-
fully extended and the tires clear of the ground before beginning sonnel.
any operation utilizing a work platform. No operations utilizing a
work platform shall be conducted while any rubber tired lift crane m)After positioning of the work platform, all brakes and locks in the
is “on rubber”. lift crane shall be set before personnel perform any work.

b)The operator’s experience and physical condition shall meet all ap- n) Work platforms shall not be used in winds in excess of 10 m.p.h.,
plicable industry standards and/or governmental regulations. electrical storms, snow, ice, sleet, or other adverse weather condi-
tions which could affect the safety of personnel.
c)The operator shall not leave the operator’s station when the work
platform is occupied. He shall remain at his work station with the o) Movement of the work platform with personnel shall be done in a
engine running and the master clutch engaged whenever the work slow, controlled, cautious manner with no sudden movements of the
platform is occupied. crane or work platform.

d)Unauthorized personnel shall not be in the operator’s cab, on the lift p) At no time shall personnel stand on or work from the top rail, mid-
crane, or near the lift crane while a work platform is mounted on the rail, or toe board of the work platform.
boom.

e)Any operation in which the work platform is to be

vii
 TABLE OF CONTENTS

q)Personnel shall keep all parts of the body, tools, and equipment in-
side the work platform during raising, lowering, and positioning.

r) If not resting on the ground, the work platform shall be secured to

the structure by rope or other means before personnel enter or leave.

s) When working from a work platform, belting off or otherwise at-

taching a work platform to an adjacent pole, structure, or other
equipment shall not be permitted, except as specified in subsection
“r” above.

t) Employees on the work platform shall wear safety belts with lan-
yards attached, preferably above the hook or shackle.

u)When welding is done by an employee on the platform, the elec-

trode holders shall be protected from contact with metal compo-
nents of the platform. If electrically connected electrode holders
contact work platform, work platform could be dropped due to
burning/melting of wire ropes suspending the work platform.

v)Before positioning or repositioning the work platform, the lift crane

operator shall locate soa s toavoid all obstructions and high voltage
conductors in the area.

w)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.

x)No external load shall be lifted by attaching to the load platform.

NOTE:
The criteria and procedures set forth herein are minimum require-
ments only to be used in the absence of any more stringent applica-
ble standard and/or regulation. Applicable government and/or
industry standards (e.g., federal or state OSHA, MESA, Industrial
OSHA, etc.) must be reviewed and adhered to in conjunction with
the contents hereof.

viii
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems

M I CROGUARD ®
TEREX RCI 510
TELESCOPIC BOOM CRANES

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

OPER A TOR'S MANUAL

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 1
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems

TABLE OF CO N TENTS
Introduction

Outline of Operation ............................................................................................................ 4

What Does It Tell You?

The Pictograph ................................................................................................................... 5

Information Screen ............................................................................................................. 6

Parts-of-Line Indicator ......................................................................................................... 6

Operator Alarms Indicator ................................................................................................... 6

Pre-Alarm Indicator............................................................................................................. 6

Overload Indicator .............................................................................................................. 6

Anti Two-Block Indicator...................................................................................................... 6

Bar Graph for Percentage of Rated Load.............................................................................. 7

Actual Load ........................................................................................................................ 7

Rated Capacity................................................................................................................... 7

Radius, Length, Angle ......................................................................................................... 7

What Must You Tell It?

Parts-of-Line....................................................................................................................... 8

Point of Lift ......................................................................................................................... 8

Auxiliary Head On or Off ..................................................................................................... 8

Stowed and/or Erected Attachments .................................................................................... 8

Manual Section or Boom Mode ............................................................................................ 8

Jib Stowed on Boom ........................................................................................................... 8

Winch ................................................................................................................................ 8

Counterweight .................................................................................................................... 8

Tires .................................................................................................................................. 8

Outriggers .......................................................................................................................... 8

Power Up Self-Test ....................................................................................................................... 9

Start-Up Screen .......................................................................................................................... 10

Brightness and Contrast Controls.............................................................................................. 11

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 2
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems
Outriggers ........................................................................................................................ 13

Tires/Rigging Travel Mode................................................................................................. 14

Stowed Jibs ...................................................................................................................... 15

Erected Jibs ..................................................................................................................... 16

Auxiliary Head .................................................................................................................. 17

Choosing the Winch.......................................................................................................... 18

Choosing the Point of Lift .................................................................................................. 19

Setting the Parts-of-Line.................................................................................................... 20

Notes ............................................................................................................................... 21

Cancel Alarm

Push Button to Cancel Audible Alarm ................................................................................. 22

Reset Function Kick-Out ................................................................................................... 23

Operator Settable Alarms

Accessing the Operator Alarms ......................................................................................... 24

Setting Minimum and/or Maximum Boom Angle.................................................................. 25

Setting Maximum Length, Maximum Height ........................................................................ 26

Accessing Swing and Work Area Alarms ............................................................................ 27

Swing Alarms ................................................................................................................... 28

Setting the Left and Right Swing Alarms............................................................................. 29

Work Area Selection Mode............................................................................................30-31

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 3
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems
OUTLINE OF O PERATION
SYSTEM COMPONENTS EXTENSION SENSOR
• ®
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 PRESSURE TRANSDUCERS

• 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 ANTI TWO BLOCK (A2B)
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.
FUNCTION KICK-OUT
DISPLAY
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
OPERATOR SETTABLE ALARMS
• 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 AREA ALARM
the system. When set, this alarm permits the operator to define
BOOM ANGLE SENSOR the operating zone by only two set points. The use
Boom angle is measured by means of a high- of this method of setting results in a greatly enhanced
accuracy potentiometer/pendulum assembly that is working area, and also clearly defines the
damped to prevent overswing. It provides a voltage operating zone.
proportional to boom angle. The boom angle sensor is
mounted inside the cable extension reel assembly.

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 4
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems

THE PICTOGRAPH

MANUAL SECTION
/ BOOM MODE STOWED JIB WINCH

JIBS

COUNTERWEIGHT
AUX HEAD

POINT OF LIFT TIRES

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, LED’s 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 5
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems

WHAT DOES IT TELL YOU?

4 5 6

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

2 3
1

1. The INFORMATION SCREEN contains 5. The OVERLOAD INDICATOR (RED)

details of the currently selected illuminates at a preset value of 100% of
configuration. Rated Capacity and provides a visual
indication of Maximum Allowed Load.
2. PARTS-OF-LINE displays the parts of line
currently selected. 6. The ANTI TWO-BLOCK lamp illuminates
when the A2B limit switch detects approach
3. The OPERATOR ALARM lamp illuminates
to a Two-Block condition.
when operator alarms have been set.

4. The PRE-ALARM (AMBER) indicator

illuminates at a preset value of 90% of
Rated Capacity and provides a visual
indication of approach to overload.

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 6
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems

WHAT DOES IT TELL YOU?

7 9 11 12

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360 o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
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.

10. The RADIUS display shows radius of the

load. Radius is the horizontal distance from
the centerline of rotation to the centerline of
the lifting point.

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 7
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems

WHAT MUST YOU TELL IT?

13 15 16 17 18 19

MAX
23,500 44.8
20
6 62.7

i2,300 26.4
21
ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

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 8
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems

POWER UP SELF - TEST

MAX 888;800 I88.8

I8 I88.8

888;800 I88.8

TEREX CD 225 SET

SYSTEM SELF TEST IN PROGRESS

TEST CHART 12262-1205/20W

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 9
 TABLE OF CONTENTS

GREER COMPANY
Crane Systems
START UP SCREEN

MAX
--- - -- -

- -- -

--- - -- -

READ/UNDERSTAND THE FOLLOWING... SET

CIMA MANUAL,ASME/ANSI B30.5

OSHA REGS AND OPERATORS MANUAL
TEST
PRESS TO CONTINUE>

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.

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BRIGHTNESS AND CONTRAST CO N TROLS

MAX
23,500 44.8

6 62.7

i2,300 26.4

LED BRIGHTNESS UP CONTRAST UP SET

TEST
LED BRIGHTNESS DOWN CONTRAST DOWN

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 LED’s 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.

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Crane Systems
SYSTEM SETUP

MAX
23,500 44.8
20
6 62.7

i2,300 26.4

SET

9,700lb Counterweight
TEST 12,000lb Counterweight

1
COUNTERWEIGHT
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
Ø 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
Ø 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. Ø 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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GREER COMPANY
Crane Systems
SYSTEM SETUP

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

1 22
OUTRIGGERS

• 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
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GREER COMPANY
Crane Systems
SYSTEM SETUP

MAX
23,500 44.8

6 62.7

i2,300 26.4

SET
TIRES, 2.5MPH, FRONT RIGGING/TRAVEL

TEST STATIONARY

1 21
TIRES/RIGGING TRAVEL
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 Ø 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
Ø 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
Ø 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).

DO NOT PERFORM CRANE LIFTING OPERATIONS WHILE

WARNING
! THE RIGGING/TRAVEL MODE IS SELECTED.

ALL CRANE CONTROLS REMAIN ACTIVE WHILE THE

RIGGING/TRAVEL MODE IS SELECTED.

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SYSTEM SETUP

18

MAX
23,500 44.8

6 62.7

i2,300 26.4

SET

NO STOWED JIB

TEST 60' TELEJIB STOWED

1
STOWED JIBS

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
Ø 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.
Ø 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
Ø 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
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SYSTEM SETUP

16

MAX
23,500 44.8

6 62.7

i2,300 26.4

SET

38' JIB@2degs 38' JIB@17degs

TEST 38' JIB@30degs MORE >

1
ERECTED JIBS
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 Ø 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
Ø 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. Ø If only a single option is available, it
• Start the choice by pressing the erected jib will automatically be selected.
push button (item 16).

• The available erected jib options will be

displayed in the information screen (item 1).

GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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GREER COMPANY
Crane Systems
SYSTEM SETUP

15

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

1
AUXILIARY HEAD

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
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SYSTEM SETUP

19

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

1
CHOOSING THE WINCH

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).

GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
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GREER COMPANY
Crane Systems
SYSTEM SETUP

14

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

1
CHOOSING THE POINT OF LIFT
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 Ø 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).
Ø 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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SYSTEM SETUP

13

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

S E T T I N G T H E P A R T S - OF - L I N E

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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Crane Systems

SYSTEM SETUP

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

NOTES

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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CANCEL AUDIBLE ALARM

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360o SET

ERECTED 60' TELEJIB 17 o AUXHD ON
PICK FROM MAIN BOOM FRONT WINCH
TEST

23
PUSH BUTTON T O CANCEL AUDIBLE ALARM
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:
Overload The CANCEL ALARM push button is also used
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

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CANCEL AUDIBLE ALARM CONTINUED

MAX
23,500 44.8

6 62.7

i2,300 26.4

ORs Full 9.7Klb Ctwt 360 o SET

ERECTED 60' TELEJIB 17 o AUXHD ON

PICK FROM MAIN BOOM FRONT WINCH
TEST

23

RESET FUNCTION KICK-OUT

When the crane is to be rigged, it is often

necessary to put the boom in a position that
WARNING
could cause function kick-out. Using the bypass
is necessary in this situation.
!
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.

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OPERATOR SETTABLE ALARMS

MAX 23,500 44.8

6 62.7

i2,300 26.4

MIN ANGLE OFF MAX ANGLE OFF SET

TEST MAX LENGTH OFF MAX HEIGHT OFF

28 29 24
25 27
ACCESSING THE OPERATOR ALARMS

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 Tip Height (item 27) maximum boom length and maximum tip height.

Return to the main screen by pressing the

operator alarm push button (item 24) two
times.

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OPERATOR SETTABLE ALARMS CONTINUED

MAX
23,500 44.8

6 62.7

i2,300 26.4

MIN ANGLE 32.0 MAX ANGLE 67.0 SET

TEST MAX LENGTH OFF MAX HEIGHT OFF

28 29 24
SETTING MINIMUM BOOM AN
ANGLE ALARM SETTING MAXIMUM BOOM ANGLE ALARM

• 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.

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OPERATOR SETTABLE ALARMS CONTINUED

MAX
23,500 44.8

6 62.7

i2,300 26.4

MIN ANGLE OFF MAX ANGLE OFF SET

TEST MAX LENGTH 58.0 MAX HEIGHT 78.0

24
25 27
S E T T ING MAXIMUM BOOM LENGTH
LENGTH ALARM SETTING MAXIMUM TIP HEIGHT ALARM
• 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.

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OPERATOR SETTABLE ALARMS CONTINUED

MAX 23,500 44.8

6 62.7

i2,300 26.4

LEFT SWING OFF RIGHT SWING OFF SET

TEST LEFT POINT OFF RIGHT POINT OFF

29
28 24
25 27

ACCESSING SWING AND

WORK AREA ALARMS 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.

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OPERATOR SETTABLE ALARMS CONTINUED

SWING ALARMS
These alarms, when set, permit the operator to define a Working Arc and an Exclusion Zone by two set
points. The following diagram illustrates the Working Arc and Exclusion Zone.

WORKING ARC AND EXCLUSION ZONE

Right Swing

A left swing alarm is activated when

WORKING ARC
swinging to the left.
Left Swing
A right swing alarm is activated when
swinging to the right
EXCLUSION ZONE
In this example, the working arc is the
smaller piece of the pie.

WORKING ARC AND EXCLUSION ZONE

A left swing alarm is activated when
Left Swing
swinging to the left.
EXCLUSION ZONE

A right swing alarm is activated when

Right Swing swinging to the right

In this example, the working arc is the larger

WORKING ARC
piece of the pie.

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.

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OPER ATOR SETTABLE ALARMS CONTINUED

MAX
23,500 44.8

6 62.7

i2,300 26.4

LEFT SWING 325 0 RIGHT SWING 35 0 SET

TEST LEFT POINT OFF RIGHT POINT OFF

1 24
28 29

SETTING LEFT SWING ALARM SETTING RIGHT SWING ALARM

• 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.

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OPERATO R SETTABLE ALARMS CONTINUED
WORK AREA SELECTION MODE
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.

Operator Area Alarm and Operating Zones

Operating Zone Operating Zone

Set Point 2

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
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GREER COMPANY
Crane Systems
OPERATOR SETTABLE ALARMS CONTINUED

MAX
23,500 44.8

6 62.7

i2,300 26.4

LEFT SWING OFF RIGHT SWING OFF SET

TEST LEFT POINT SET RIGHT POINT SET

25 1 27 24

WORK AREA SELECTION MODE

• 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
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
31 of 31
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GREER COMPANY
Crane Systems
GLOSSARY OF TERMS

ACTUAL LOAD The load suspended below the lifting point.

ALARM A signal that warns or alerts, such as a flashing light or loud noise.

ANGLE SENSOR A device that measures the inclination of a boom.

ANTI TWO-BLOCK A device that, when activated, prevents movement that causes two-
blocking.

AUDIBLE ALARM A signal that alerts by means of noise.

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)

BARGRAPH A pictorial device used to illustrate quantitative relationships.

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 HOIST A device for controlling the boom angle.

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.

CAPACITY CHART A table showing the rating of a crane.

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.

COMMISSIONING Preparing to be put into service.

CONFIGURATION An arrangement of the lifting elements of a crane.

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
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GREER COMPANY
Crane Systems
COUNTERWEIGHT A weight used to supplement the weight of the crane to provide
(CTWT) stability for lifting.

CURSOR A pointer on a display that indicates the position where data is to be

entered.

DEDUCT A reduction in rated capacity for an unused stowed or erected

attachment.

DIRECTION The direction of rotation of the superstructure.

DUTY A working configuration on a crane usually contained in a single column of a

capacity chart.

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.

HORIZONTAL Parallel to the horizon.

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).

JIB Something attached such as a lattice fly or jib on a crane boom.

MANUAL SECTION The tip section of the main boom that can be telescoped independently of
the other sections.

MICROPROCESSOR A computer processor contained on an integrated chip.

MOMENT The product of force and distance to a particular axis or point.

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
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
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GREER COMPANY
Crane Systems
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.

PICTOGRAPH A pictorial representation of the crane.

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.

PRESSURE Hydraulic pressure in the boom hoist cylinder

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.

RATING A factor determined by legislation that limits the proportion of the

capability of the cranes that may be utilized in a lifting operation.
Usually expressed as a percentage of strength or stability.

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.

SENSOR A device that responds to physical stimulus and transmits a resulting

impulse.

SHEAVE A grooved wheel or pulley.

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
TEREX RCI 510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
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GREER COMPANY
Crane Systems
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
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Greer Company

MICROGUARD
TEREX RCI 500
TELESCOPIC BOOM CRANES

OPERATOR'S MANUAL

TEREX CRANES FULL OUTRIGGERS

SWING 360 o

AUX HEAD FITTED

ERECTED
33' TELEJIB, 30 o
REAR WINCH
LIFTING FROM
MAIN BOOM

MAX

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL: (714) 259-9702 FAX: (714) 259-
7626
1 of 1 PN W450200 REV A
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OPERATORS MANUAL

TABLE OF CONTENTS
TEREX RCI 500 TELESCOPIC BOOM CRANES

PAGE
Introduction Outline of operation 3

What Does It Tell You ?

Overload, Pre-alarm Indicators 4
Parts of line Indicator 4
Anti two-block Warning 4
Information Screen 4
Length, Radius, Angle Displays 5
Load Displays, Rated and Actual 5
Percentage of Rated Load Bargraph 5
What Must You Tell It ?
Counterweight 6
Outriggers or Tires 6
Stowed and/or Erected Attachments 6
Manual Boom or Boom Mode 6
Auxiliary Head 6
Point of Lift 6
Winch in Use 6
Parts of Line 6
System Set Up
Information Screen 7
Counterweight 8
Outriggers 9
Tires/Rigging Travel Mode 10
Stowed Attachments 11
Erected Attachments 12
Auxiliary Head 13
Choosing the Lifting Point 14
Winch in Use 14
Setting the Parts of Line 14
Cancel Audible Alarm 15
Reset Function Kick-Out 16
Contrast Adjustment (Information Screen) 16
Operator Settable Alarms
Accessing the Alarms 17
Minimum and/or Maximum Boom Angle 18
Maximum Length, Maximum Height 19
Swing Alarms
Access to Swing Alarms 20
Setting Swing Alarms 21
Area Alarms 22

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL: (714) 259-9702 FAX: (714) 259-
7626

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OUTLINE OF OPERATION

SYSTEM COMPONENTS EXTENSION SENSOR

• MicroGuard Display Unit The extension of the boom is measured by means of
• MicroGuard Computer Unit a potentiometer actuated by a recoil drum. The recoil
• Pressure Transducers drum is attached to the boom head by a cable that
• Reeling drum, with length and angle sensors also carries the A2B signal back through the reeling
• Anti 2-Block switches drum to the computer.
• Cables
• Installation/Operator Manuals PRESSURE TRANSDUCERS
The system is intended to aid the crane operator by The pressure in the boom hoist cylinder is meas-
continuously monitoring the load and warning of an ured by two pressure transducers. The resultant
approach to an overload or two-block condition. Total Moment signal is processed to provide a con-
Crane functions are monitored by means of high tinuous display of the load suspended below the
accuracy sensors. The system continuously com- boom head.
pares the load suspended below the boom head
with the crane capacity chart stored in the computer ANTI TWO BLOCK (A2B)
memory. At approach to overload, the system warns The approach of the hook block or overhaul ball to
by means of audible and visual alarms. The system the boom head is monitored by a switch. The switch
can be configured to cause function kick-out by is held in the closed position until the hook block or
sending a signal to function disconnect solenoids. overhaul ball raises a weight that is axially mounted
around the hoist rope. When the weight is raised it
DISPLAY
causes the magnet to move away from the reed relay
The display contains eight liquid crystal displays which opens the switch. The resultant signal is sent
(LCD) each with characters approximately 8.0 mm to the computer and the A2B alarm operates.
high and viewable over a wide angle. The displays
are backlit and are readable in all lighting conditions. FUNCTION KICK-OUT
The operator is provided with a continuous display Electrically operated hydraulic solenoids are used to
of: cut off the flow of oil to hydraulic functions when an
• Rated Load overload or an A2B condition occurs.
• Actual Load
OPERATOR SETTABLE ALARMS
• Bar graph showing Percentage of Rated Load
These alarms, when properly set by the operator
• Radius of the Load
define the operating range. This is achieved by
• Boom Angle means of minimum and maximum angle, maximum
• Main Boom Length height and/or maximum length or radius alarms.
• Working Area These alarms can be programmed for each job site
and allow the operator to work in a defined area.
• Crane Configuration
On screen messages provide the operator with vi s- AREA ALARM
ual warnings of conditions that occur during opera-
This alarm, when set, permits the operator to define
tion of the system.
the operating zone by only two set points. The use of
this method of setting results in a greatly enhanced
BOOM ANGLE SENSOR
working area, and also clearly defines the operating
Boom angle is measured by means of a high zone.
accuracy potentiometer/pendulum assembly that is
damped to prevent over swing.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL: (714) 259-9702 FAX: (714) 259-
7626

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OPERATORS MANUAL

1 2 3 4 5

TEREX CRANES FULL OUTRIGGERS

SWING 360 o

AUX HEAD FITTED

ERECTED
33' TELEJIB, 30 o
REAR WINCH
LIFTING FROM
MAIN BOOM

MAX

WHAT DOES IT TELL YOU ?

1. The OVERLOAD INDICATOR (RED) 3. PARTS OF LINE displays the parts of line
illuminates at a pre-set value of 100% of currently selected.
Maximum Rated Capacity and provides a
4. The ANTI TWO-BLOCK lamp will illuminate
visual indication of Maximum Allowed Load.
when the contacts on the A2B limit switch
2. The PRE-ALARM (AMBER) indicator open, indicating an approach to a two-block
illuminates at a pre-set value of 90% of condition.
Maximum Rated Capacity and provides a vi s-
5. The INFORMATION SCREEN contains
ual indication of an approach to an overload.
details of the currently selected configuration
and is used to input additional information
about crane set up.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL: (714) 259-9702 FAX: (714) 259-
7626

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OPERATORS MANUAL

TEREX CRANES FULL OUTRIGGERS

SWING 360 o

AUX HEAD FITTED

ERECTED
33' TELEJIB, 30 o
REAR WINCH
LIFTING FROM
MAIN BOOM

MAX

11 10 9 8 7 6

WHAT DOES IT TELL YOU ?

6. The LENGTH display shows the length of the 9. ACTUAL LOAD display shows total load
Main Boom from the boom foot pin to the suspended below the boom or jib head.
sheave pin of the head machinery.
10. MAXIMUM RATED CAPACITY shows the
7. The RADIUS display gives an indication of RATED CAPACITY of the machine in the cur-
the radius of the load which is the horizontal rent configuration.
distance from the center line of rotation to the
11. The BARGRAPH gives a quick indication of
center line of the hook.
the lifted load as a PERCENTAGE OF
8. The ANGLE display gives an indication of the RATED LOAD.
angle, in degrees, of the main boom relative
to horizontal.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL: (714) 259-9702 FAX: (714) 259-
7626

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17 16 15 21

TEREX CRANES FULL OUTRIGGERS

SWING 360 o

AUX HEAD FITTED

ERECTED
33' TELEJIB, 30 o
REAR WINCH
LIFTING FROM
MAIN BOOM

19

MAX

12

20 18 14 13

WHAT MUST YOU TELL IT ?

17. Are any attachments such as FLYS or JIBS

12. Which COUNTERWEIGHT is fitted
erected?
(if applicable).
18. What is the POINT OF LIFT (e.g. main
13. Whether you are on OUTRIGGERS fully ex-
boom, auxiliary head or jib)?
tended, partly extended, retracted or on
TIRES. 19. Which WINCH will the pick be made with?
14. Which JIBS are stowed on the boom. 20. The number of PARTS OF LINE.
Use these push buttons to input additional in-
15. Is the MANUAL SECTION extended,
formation during set up.
(if applicable)?
16. Is the AUXILIARY HEAD fitted?

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7626

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OPERATORS MANUAL

SYSTEM SET UP

21 5

TEREX CRANES
Set Operator Alarms

Set Jib Selection

Set Swing Alarms

Return To Main Screen

MAX

USING THE INFORMATION SCREEN (item 5).

• The information screen (item 5) is used in • Press any push-button on the left edge of the
conjunction with other push-buttons to set up screen to access the information screen.
the system.
• The options are:
• There are 4 push-buttons (item 21) on the left
“Set Operator Alarms”
edge of the information screen which are
“Set Jib Selection”
used to access the screen and to make
“Set Swing Alarm”
selections.
“Return to Main Screen”

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL: (714) 259-9702 FAX: (714) 259-7626

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OPERATORS MANUAL

SYSTEM SET UP
21

TEREX CRANES
NO COUNTERWEIGHT

3,000# C'TW'T

6,000# C'TW'T 5

12,000# C'TW'T

MAX
13

COUNTERWEIGHT
• Pressing the push-button (item 21) which is
• On machines which have counterweight
pointing to the appropriate counterweight will
options the operator must tell the
select that counterweight option.
MicroGuard system which counterweight is
currently fitted. • The information screen will then revert to the
normal working display, the selected
• Start the choice by pressing the counter-
counterweight will be displayed in the working
weight push-button (item 13). The light in
display and the counterweight push-button
the center of the counterweight push-button
will stop flashing and revert to a
will start to flash indicating that a selection is
continuous red light.
available.
• If the counterweight push-button is pressed
• The selections for the machine will appear in
on a machine which does not have a
the window of the Information Screen
counterweight option the message “no coun-
(item 5).
terweight options” will appear in the
information display. The light in the
counterweight push-button will not illuminate.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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OPERATORS MANUAL

SYSTEM SET UP
5

TEREX CRANES FULL OUTRIGGERS

SWING 360 o

AUX HEAD FITTED

ERECTED
33' TELEJIB, 30 o
REAR WINCH
LIFTING FROM
MAIN BOOM

MAX

13
OUTRIGGERS

• On machines that have multiple outrigger se- • The information screen (item 5) will
lections, e.g. full outriggers, intermediate out- indicate full outriggers, half outriggers or
riggers or retracted outriggers the operator retracted outriggers dependent upon the se-
must select the outrigger push-button choice lection.
which corresponds to the current outrigger
• The light in the center of the outrigger push-
position.
button selected will be illuminated.
• Press the outrigger push-button (item 13)
which corresponds to the outrigger position.

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OPERATORS MANUAL

SYSTEM SET UP
21 5

TEREX CRANES
STATIONARY, 360 o

CREEP

2.5 MPH

RIGGING/TRAVEL

MAX

13

TIRES/RIGGING TRAVEL

• On machines that have more than one tire • Pressing the push-button (item 21) which is
selection, e.g. stationary, pick and carry etc., pointing to the appropriate tire option will se-
the operator must select the tire lect that operating mode.
configuration that corresponds to the current
• The information screen will revert to the nor-
tire chart.
mal working display, the selected tire
• Start the choice by pressing the tire push- operating mode will be displayed in the work-
button (item 13). The light in the center of the ing display, the tire push-button will stop
tire push-button will start to flash flashing and revert to a continuous red light.
indicating that a selection is available.
• RIGGING/TRAVEL MODE is selected when
• The selections for the machine, e.g. station- the machine is in the rigging process or, in
ary, pick and carry etc., will appear in the the case of a Rough Terrain machine, is to
window of the information screen (item 5). travel between jobs.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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OPERATORS MANUAL

SYSTEM SET UP
14 21 5

TEREX CRANES
No Fly Selection

33' Offset Jib

33'-58' Tele Jib

MAX

STOWED ATTACHMENTS
and the stowed selection push-button (item
• The attachments available on your machine
14) will flash until the selection is made.
are selectable via the “INFORMATION
• Press the push-button (item 21) which points
to the fly/jib currently installed on your crane.
• To select the current jib press any one of the
The selected attachment will automatically be
information screen push-buttons (item 21)
stowed and the flashing red light in the
• The menu for the information screen will be “stowed push-button” (item 14) will become
displayed. continuous indicating a stowed attachment.
• Press the button (item 21) which points to • If there is no fly/jib, or if the fly/jib is to be
“Set Jib Selection” removed from the machine, press “No Jib Se-
lection”. The flashing red light in the stowed
• The available options will appear in the
push-button (item 14) will go out
window of the Information Screen (item 5),
indicating that there is no stowed
attachment.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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OPERATORS MANUAL

SYSTEM SET UP

17 21 5

TEREX CRANES
No Jib Selection

33' Offset Jib

33'-58' Tele Jib

MAX

ERECTED ATTACHMENTS

• To erect any attachment it must first have • If there is a choice of offsets or lengths for
been selected and stowed as detailed on the any given attachment then the light in the se-
previous page. lected push-button will flash indicating that
the choice must be made in the
• To erect a stowed attachment, press the ap-
INFORMATION SCREEN (item 5)
propriate push-button from fly/jib group (item
17). • The choice of offset or length will appear in
the INFORMATION SCREEN (item 5).
• The attachment will be selected and the
light in the chosen push-button will become il- • Press the push-button (item 21) which points
luminated. to the fly/jib to be chosen The flashing red
light in the erected push-button (item 17) will
• The red light in the “stowed push-button” will
become continuous indicating that there is a
be automatically extinguished.
selected offset attachment.
• The INFORMATION SCREEN (item 5) will
indicate which erected attachment
has been chosen.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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OPERATORS MANUAL

SYSTEM SET UP
16 5

TEREX CRANES FULL OUTRIGGERS

SWING 360 o

AUX HEAD FITTED

ERECTED
33' TELEJIB, 30 o
REAR WINCH
LIFTING FROM
MAIN BOOM

MAX

AUXILIARY HEAD
• On machines fitted with an auxiliary head, red light in the Aux. Head push-button will not
this must be included in the machine set-up. be illuminated.
FOR MACHINES WHERE THE AUXILIARY
• To set-up the machine with an auxiliary head,
HEAD WAS NOT PART OF ORIGINAL
press the auxiliary head push-button, (item
EQUIPMENT AND IS NOW TO BE FITTED
16).
• If the machine was not equipped for auxiliary
• The message AUX HEAD FITTED will
head when it was originally calibrated then
appear in the window of the INFORMATION
the message “No Aux. Head Options” will ap-
SCREEN (item 5) and the red light in the
pear in the window of the Information Screen
Aux. Head push-button will be illuminated.
and the red light in the Aux. Head push-
• If the machine is not equipped for auxiliary button will not be illuminated.
head then the message “No Aux. Head
• Contact the Terex factory for details of the
Options” will appear in the window
start-up adjustments that must be made
of the Information Screen and the
before fitting and using an auxiliary head.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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OPERATORS MANUAL

SYSTEM SET UP
5

TEREX CRANES FULL OUTRIGGERS

SWING 360 o

AUX HEAD FITTED

ERECTED
33' TELEJIB, 30 o
REAR WINCH
LIFTING FROM
MAIN BOOM

MAX

19

20 18

After configuration has been set, CHOOSING THE LIFTING POINT

operation of the system depends upon only
Choose the lifting point from the main boom, aux-
three settings:
iliary head, or fly/jib by pressing the
appropriate push buttons (item 18).
LIFTING POINT TO BE USED
CHOOSING THE WINCH

WINCH IN USE Choose the winch that you will be using by press-
ing the appropriate winch push-button
(item 19).
PARTS OF LINE RIGGED
SETTING THE PARTS OF LINE
Set the parts-of-line that you will be using by
pressing the parts-of-line push-button (item 20)
until the correct number appears in the screen.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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 TABLE OF CONTENTS
TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL

SYSTEM SET UP
5

TEREX CRANES
FULL OUTRIGGERS
SWING 360 o

AUX HEAD FITTED

ERECTED
33' TELEJIB, 30 o
REAR WINCH
LIFTING FROM
MAIN BOOM

MAX

22 23

CANCEL ALARM PUSH BUTTON

The Cancel Alarm push-button (item 22) is then recurs, the new alarm condition will
used to silence the audible alarm. Pressing cause the audible alarm to sound again.
this button once will cancel an audible alarm
The CANCEL ALARM push-button is also
which has occurred as a result of either an;
used to reset the function kick-out relay when
Overload it is necessary to by-pass the function dis-
A2B Alarm connects.
Operator Settable Alarm Examples of when it may be necessary to
The audible alarm remains canceled until the override a function disconnect condition:
condition that caused the alarm has been • If the boom hoist cylinder is fully
removed. For example, if the audible alarm extended, the pressure in it will rise.
sounded because of an overload condition it This will be seen by the system as an
will remain canceled until the overload condi- overload and will not allow the operator to
tion has been removed. If another alarm con- boom down. Using the by-pass is neces-
dition that normally causes an alarm to sary in this situation to move away from
sound, such as A2B, occurs while the audi- the fully extended position.
ble alarm is canceled or if the
previous condition (overload) is removed and

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714)
259-7626

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 TABLE OF CONTENTS
TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL

SYSTEM SET UP
5

TEREX CRANES
FULL OUTRIGGERS
SWING 360 o

AUX HEAD FITTED

ERECTED
33' TELEJIB, 30 o
REAR WINCH
LIFTING FROM
MAIN BOOM

MAX

22 23

CANCEL ALARM (continued)

• When the machine is to be rigged, it is often WHEN THE FUNCTION DISCONNECT RELAY IS
necessary to put the boom in a position RESET BY MEANS OF THE CANCEL ALARM
which will cause function disconnect. Using PUSH-BUTTON, YOU ARE NO LONGER
the by-pass is necessary in this situation. PROTECTED AGAINST THE CONDITION THAT
CAUSED THE FUNCTION KICK-OUT.
RESET FUNCTION KICK-OUT
CONTRAST CONTROL
The relay is re-set by pressing and holding the
CANCEL ALARM push-button for approximately 5 Pressing the Contrast Control push button (item
seconds until a second beep is heard. When the 23) can increase the contrast in the Information
condition which caused the alarm is no longer Screen (item 5). Successive pressing of the con-
present the function disconnect relay will reset to trast control push-button will cause the contrast
the normal condition. Should a different alarm of the Information Screen to increase in fixed
condition occur while the relay is steps until reaching maximum. When the maxi-
over-ridden the new alarm condition will cause the mum contrast is reached further pressing of the
controls to disconnect again. push-button will cause the contrast to go to its
lowest level. Continuing to press the push-button
can continue the cycle.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714)
259-7626

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 TABLE OF CONTENTS
TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL

OPERATOR SETTABLE ALARMS

ACCESSING THE OPERATOR ALARMS

FULL OUTRIGGERS
SWING 360 o

AUX HEAD FITTED

Access to the Operator Alarms from the main
working screen is obtained by pressing any one ERECTED
33' TELEJIB, 30 o
of the push buttons to the left of the 3”x3”
REAR WINCH
INFORMATION SCREEN (item 5). LIFTING FROM
MAIN BOOM

The Information Screen will show the available Set Operator Alarms
choices. Press the push-button pointing to
“Set Operator Alarms” to access the Operator Set Jib Selection
Alarms. If no choice is made, the system will
return to the main screen after 30 seconds or you Set Swing Alarms
can return to the main screen by pressing the
push-button (21).
Return to main screen

There are four alarms available:

MIN ANGLE OFF
Minimum Boom Angle
Maximum Boom Angle
MAX ANGLE OFF
Maximum Boom Length
Maximum Tip Height
MAX LENGTH OFF
To exit from the alarm screen, press the
Contrast push-button or wait for the 30-second MAX HEIGHT OFF
time-out. Exit

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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 TABLE OF CONTENTS
TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL

OPERATOR SETTABLE ALARMS

SETTING MINIMUM BOOM ANGLE ALARM

• Move the boom to the desired minimum

angle, in this example 30 degrees. MIN ANGLE 30 SET

• Access the operator alarm screen. MAX ANGLE OFF

• Press the push-button pointing to MAX LENGTH OFF
minimum angle.

• The display will read MAX HEIGHT OFF

MIN ANGLE 30 SET Exit

The red warning light will now flash and the audi-
ble alarm will sound whenever the boom angle is
below 30 degrees.

Pressing the MIN ANGLE push-button again will

cancel the alarm and the display will read MIN
ANGLE OFF.

SETTING MAXIMUM BOOM ANGLE ALARM

• Move the boom to the desired maximum an-

gle, in this example 65 degrees. MIN ANGLE OFF

• Access the operator alarm screen. MAX ANGLE 65 SET

• Press the push-button pointing to maximum MAX LENGTH OFF

angle.
MAX HEIGHT OFF
• The display will read:
MAX ANGLE 65 SET.
Exit

The red warning light will now flash and the audi-
ble alarm will now sound whenever the boom an-
gle is above 65 degrees.

Pressing the MAX ANGLE push-button again will

cancel the alarm and the display will read MAX
ANGLE OFF.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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 TABLE OF CONTENTS
TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL

OPERATOR SETTABLE ALARMS

SETTING MAXIMUM BOOM LENGTH ALARM

• Extend the boom to the desired maximum

length, example 65 feet. MIN ANGLE OFF

• Access the operator alarm screen. MAX ANGLE OFF

• Press the push-button pointing to maximum MAX LENGTH 65 SET

length.
MAX HEIGHT OFF
• The display will read
MAX LENGTH 65 SET
Exit

The red warning light will now flash and the audi-
ble alarm will now sound whenever the boom
length is longer than 65 feet.

Pressing the MAX LENGTH push-button again will

cancel the alarm and the display will read: MAX
LENGTH OFF

SETTING MAXIMUM TIP HEIGHT ALARM

• Move the boom tip the desired maximum

height, example 97 feet. MIN ANGLE OFF

• Access the operator alarm screen. MAX ANGLE OFF

• Press the push-button pointing to maximum MAX LENGTH OFF

height.
MAX HEIGHT 97 SET
• The display will read
MAX HEIGHT 97 SET
Exit

The red warning light will now flash and the audi-
ble alarm will now sound whenever the boom tip
height is above 97 feet.

Pressing the MAX HEIGHT push-button again will

cancel the alarm and the display will read
MAX HEIGHT OFF

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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 TABLE OF CONTENTS
TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL

OPERATOR SETTABLE ALARMS

SETTING SWING ALARMS

NOTE THAT BOTH LEFT AND RIGHT SWING ALARMS MUST BE SET FOR THE SYSTEM TO
OPERATE CORRECTLY.

FULL OUTRIGGERS
SWING 360 o
ACCESSING THE SWING ALARMS
AUX HEAD FITTED
Access Swing Alarms from the main working
screen by pressing any one of the push buttons ERECTED
33' TELEJIB, 30 o
to the left of the 3” x 3” Information Screen.
REAR WINCH
The Information Screen will show the LIFTING FROM
available choices. MAIN BOOM

SELECT SWING ALARMS Set Operator Alarms

Press the push-button pointing to “Set Swing Set Jib Selection

Alarms” to access the Swing Alarms.
Set Swing Alarms
If no choice is made, the system will return to the
main screen after 30 seconds, or you can return
Return to main screen
to the main screen by pressing the “RETURN TO
MAIN SCREEN” push button.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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 TABLE OF CONTENTS
TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL

OPERATOR SETTABLE ALARMS

SETTING LEFT SWING ALARM

LT. SWING OFF
• Swing the boom to the desired Left Swing
Limit, e.g. 300 degrees. RT. SWING OFF

• Access the operator alarm screen. If the

alarms have not been previously set, the dis-
play will read;
LT. SWING OFF Exit
RT. SWING OFF

• Press the push-button pointing to

LEFT SWING.

• The display will read

LT. SWING 300 SET
(set both alarms) LT SWING 300 SET
(SET BOTH ALARMS)

RT SWING OFF
Both alarms must be set for the system to
operate correctly.

Pressing the LT. SWING push-button again will

cancel the alarm and the display will read:
LT. SWING OFF
Exit

SETTING RIGHT SWING ALARM

• Swing the boom to the desired Right Swing

Limit, e.g. 30 degrees.

• Press the push-button pointing to RIGHT

SWING.

• The display will read RIGHT SWING 30 SET

LT. SWING 300 SET

Pressing the RT. SWING push-button again will

cancel the alarm and the display will read RT. SWING 30 SET
RT. SWING OFF

The red warning light will flash and the audible

alarm will sound whenever the boom swings past
the pre-set limits. Exit

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL

OPERATOR SETTABLE ALARMS

WORK AREA SELECTION MODE

This alarm, when set, permits the operator to define an Operating Zone by only two set points.
The use of this method of setting results in a greatly enhanced working area and also clearly
defines the Exclusion Zone area more simply. The following diagram illustrates the Operating Zone and the
Exclusion Zone.

Operator Area Alarm and Operating Zones

Operating Zone Operating Zone

Set Point 2

Operating Zone
Safe
Working
Distance
Set Point 1
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
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 machine motion to be halted before entering the Exclusion Zone. It is the responsibility
of the operator to set points that ensure that the cranes 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 setting the left or right alarm points. When selecting the left and right alarm 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 work area alarm must be reset

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL

.
OPERATOR SETTABLE ALARMS

WORK AREA SELECTION MODE NOTE: For best results, the Left and Right points
should be separated by a minimum of 10 ft or 30
degrees.

ACCESSING WORK ALARMS

• To access the Work Area Alarms from the

main working screen press any push-button
to the left of the 3”x3” INFORMATION
SCREEN (ITEM 5). The Information Screen Set Operator Alarms
will show the available choices.
Set Jib Selection
• Press the push-button pointing to
Set Swing/Work Alarms
Set Swing/Work Alarms
• If no choice is made the system will return to
the main working screen after 30 seconds or Return to main screen
you can return to the main screen by pushing
the Return to main screen push-button.

• If the alarms have not been previously set

then the display will read;
Swing Alarms
Swing alarms LT. SWING OFF
LT. SWING OFF
RT. SWING OFF RT. SWING OFF
Work Area Select Mode Work Area Sel Mode
LT. POINT OFF
LT. POINT OFF
RT. POINT OFF
RT. POINT OFF
If no choice is made the system will return to the Exit
main working screen after 30 seconds or you can
return to the main screen by
pushing the Exit push-button.

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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TEREX RCI 500 RATED CAPACITY INDICATOR W450200
OPERATORS MANUAL Rev. A

OPERATOR SETTABLE ALARMS

WORK AREA SELECTION MODE

SETTING LEFT AND RIGHT ALARM POINTS

• Move the boom, attachment, load, rigging

etc. to the desired Left Alarm Point.

• Access the operator alarm screen. Swing Alarms

If the alarms have not been previously set, the LT. SWING OFF
display will read;
Swing alarms RT. SWING OFF
LT. SWING OFF Work Area Sel Mode
RT. SWING OFF
LT. POINT OFF
Work Area Select Mode
LT. POINT OFF
RT. POINT OFF
RT. POINT OFF Exit

• Press the push-button pointing to

LT. POINT
The display will read:

• LT. POINT SET

(set both alarms) Swing Alarms
LT. SWING OFF
Both alarms must be set for the system to
operate correctly. RT. SWING OFF
Work Area Sel Mode
Pressing the LT. POINT push-button again will
LT. POINT SET
cancel the alarm and the display will read
Set both alarms
LT. POINT OFF
RT. POINT OFF
Exit

• Move the boom, attachment, load, rigging

etc. to the desired Right Alarm Point.
Swing Alarms
• Press the push-button pointing to LT. SWING OFF
RT. POINT
The display will read: RT. SWING OFF
LT. POINT SET Work Area Sel Mode
LT. POINT SET
RT. POINT SET

Pressing the RT. POINT push-button again will RT. POINT SET
Exit
cancel the alarm and the display will read
RT. POINT OFF

GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626

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CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its con-
stituents are known to the state of California
to cause cancer, birth defects, and other
reproductive harm.

WARNING: Battery posts, terminals, and

related accesories contain lead and lead com-
pounds, chemicals known to the State of Cal-
ifornia to cause cancer and reproductive
harm. Wash hands after handling.
TABLE OF CONTENTS