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3120933 Rev -

1. M CENTER JACK STABILIZER real A CES R 2 WAY N C SOLENOILD VALVE B EI 2792296 Rev Figure 7 16 Out and Down Stabilizers with Center Stabilizer 7 18 USTC January 15 2001 SECTION 7 HYDRAULICS 78c267c 301 N3AIJQ M399lIMLRnO NOILV2OO1 QN3 3SOH LHOIVYLS NON S310N3Q X SONULAS SYNSSAYd 991821 33S S318808 NI LNO Q3TIvO SONILLIJ O S3I9NVIMI NI LNO Q3TIVO 5 5 N G1ION310S 9 N AVM Z QlION310S O N AVM Z YAZMEVLS M3JLN3O LNO34J YSZMIGVLS gd3GNI IAS 439914110 3015 LNOY4 SOILVWSHOS GAH 804 GN35S31 SASOH 43Zl llgavLS SNILSIX3 Figure 7 17 Front Center Stabilizer 1 19 USTC 3120933 Rev SECTION 7 HYDRAULICS a A8Y 970c8c ANTWA 03345 1 os ANTWA d334S 30 159 9 NO 140d YNVL OL QN3 ISOH 1H9IVHIS NON S310N30 X N00 X3 981009 S9NILLI 3dld Wd n NO q 03H 00 I r MO H OL LOIN NO934 9 3ATVA ISOH 9NIISIX4 L23NNO
2. 56 50 47 45353839 Figure 5 5 Bearing Bolt Tightening Sequence Swing Bearing Wear Tolerance As the bearing wears the clearance will gradually increase Initially bearing clearance increases due to smoothing of the surfaces Clearance will then remain essentially constant for many years if the crane is not overloaded or subject to shock loads If the design life of the bearing has been reached pitting will occur in the contact area of the raceway Eventually the number of pittings will increase to a 5 8 USTC density where material is spalled off the raceway and the bearing becomes non functional Note The following procedure serves only to illustrate how a relative clearance measurement may be acquired to evaluate the integrity of a swing bearing The only true method to determine the integrity of the bearing is to compare the original clearance between the inner and outer race as manufactured to the current measurement on the bearing in question If the condition of the bearing is questionable based on the clearance measurements obtained from the following procedure the bearing should be January 15 2001 SECTION 5 SWING DRIVE evaluated by the bearing manufacturer to determine case by case basis if the bearing requires replacement Turntable Note Ensure bearing bolts are properly torqued before taking measurement Place the crane in an operating positi
3. r 1 1 H e 4 v gt y FEH gt Gas 1334s 21118 18 _ gana 2 8 1 _ Gas 1335 2 15 _ 337 18 15 _ LNNOW LNOY4 40 30IS 100dS NO Q31v201 18Od DOM Yu S660r9r N d dd INWA TVIDYIWWOS 10095 4 Figure 7 21 Outrigger Hydraulic Schematic with Continuous Rotation 1 23 USTC 3120933 Rev 7 24 SECTION 7 HYDRAULICS USTC January 15 2001
4. 33034 81 IVnNVW AVT3Y aly LN HOLIMS 81 O M3lNVIS ANIONS E NYOH ONL e NYOH LET 1SIOH Q33dS 1SIOH Q33dS SNOILdO 4399lIM1 nO SNOILONN4 ei QNVOUNVIS 338 dV S 338 dWV 9 9015 WALSAS MONYL NO QVO NOILINOI Monel Wo l1V8 MOL NWO33 LY s AVI3M YIMOd ANVYO WVYSVId NOILOSIMISIO J3MOd iagram D istribution Figure 6 3 Electrical Power D January 15 2001 USTC 6 4 SECTION 6 ELECTRICAL ed O 67S20 dIMLS TWNINYAL 30 GNVH LHOh JHL NO S3YIM 33HLO NY SLVNINYSL ane N3339 0323 N3349 Qu x8 QvOTH3AO 100112 ASIOH HOIH 39NV23O 8 qas ovg 39 04 ame SIOH OL aay t Ee ER SSvdA8 401
5. H t 4 4 J Gos issus N3znivis _ Gos euno N3znevis _ Gos 135415 auno YAZNIGVIS _ aaznevis _ INNOW LNOYS BATA 30 3GIS 100dS NO 031 207 1509 AYOM Vu S660r9r N d 34 J3ATVA WIDYINWO3 TOOdS Z Figure 7 13 Outrigger Schematic 1 15 USTC 3120933 Rev SECTION 7 HYDRAULICS TWO SPEED WINCH ASSY W BRAKE VALVE amp STATIC BRAKE REF 4880150 SELECTOR VALVE REF 4640123 1282489 Rev G EN Sheet 3 HOIST VALVE REF 44640982 Figure 7 14 Two Speed Hoist 7 16 USTC January 15 2001 SECTION 7 HYDRAULICS PRESSURE SWITCH REF P N 4360034 is OIL COUPLING REF A CYLINDER CYLINDER MACHINES WITH NON CONTINOUS ROTATION MACHINES WITH CONTINOUS ROTATION 1282330 Rev C Figure 7 15 Overload 3120933 Rev O USTC 7 17 SECTION 7 HYDRAULICS 2 WAY N O SOLENOILD VALVE EXISTING STABILIZER HOSES I STABILIZER STREET SIDE care STREET SIDE VALVE 2 WAY N C SOLENOILD VALVE
6. 91 Ang ze Figure 6 7 Outrigger Stabilizer Wiring January 15 2001 USTC 6 8 SECTION 6 ELECTRICAL Ne DETAIL DETAIL PANEL CUT OUT LEFT SIDE CONSOLE WIRING DIAGRAM 20 A FUSE E 12 VDC x GROUND BATT POWER NM E POIWER SUPPLY 0257474 Rev Figure 6 8 Outrigger Stabilizer Switch Wiring 3120933 Rev USTC 6 9 SECTION 6 ELECTRICAL 1norvo HOLMS 3803 Tig 801 335 338 962 620 9015 ANIONS S NOLLO3NNOO SNOLLVOllddV 133Sv8 NOLLO3NNOO OML ILNV TWNOIS do1s 3 OML UNV MOSN3S 1 7338 318vO V 68229020 W3LSAS INAM LNOHLIM WOOS NO 7334 3NAM 304 ALON WLS3dad NO 39018 3onds NIV NI SZ TWNINYAL OL 3AOW 8f IMG Jos 1303 Fas ao1s dsz avo 91 WOOS WONJ Qu AlddNS 20 98 AVT3H dOLS
7. LIFT UP Lowest to Maximum Elevation _ sec Minimum 30 sec Maximum 40 sec LIFT DOWN Maximum to Minimum Elevation _ sec Minimum 25 sec Maximum 35 sec TELESCOPE OUT Retracted to Fully Extended sec Minimum 70 sec Maximum 95 sec TELESCOPE IN Extended to Fully Retracted sec Minimum 70 sec Maximum 100 sec SWING LEFT 360 Boom 60 Elevation sec Minimum 40 sec Maximum 50 sec SWING RIGHT 360 Boom 60 Elevation sec Minimum 40 sec Maximum 50 sec HOIST UP Boom 60 Elevation sec Minimum 30 sec Maximum 45 sec HOIST DOWN Boom 60 Elevation _ sec Minimum 30 sec Maximum 45 sec 3120933 Rev WEIGHTS 94 ft 9500 Ibs 4309 kg HIS ene es 470 Ibs 213 kg Lift Cylinder 804 Ibs 365 kg Pedestal 1925 Ibs 873 kg Turntable Assembly 1300 Ibs 590 kg 26 ft Jib tone s ree 975 Ibs 442 kg 26 46 ft Jib 1500 Ibs 680 kg USTC 1 5 SECTION 1 SPECIFICATIONS Table 1 1 Torque Chart SJeuejsej pejejd o Ajdde op anbio 8s u eyoN 00ccrv L 0088 L 00S9c L 0S0t L OOL8LL OSLE L 000701 0566 00996 0 20 L 00228 069
8. Wear Ring Wear Ring Headcap Bushing Figure 7 5 Typical Cylinder 11 Remove locknut attaching piston to the rod and Cleaning and Inspection iston 1 Clean all parts thoroughly an approved 12 Remove and discard piston o ring seals and mercial cleaning solvent 2 Inspect cylinder rod for scoring tapering ovality Note Some USTC cylinders use a 3 piece seal on or other damage If necessary dress rod with the piston Others use a standard 1 piece seal Scotch Brite or equivalent Replace rod if necessary 13 If applicable remove spacer from rod 3 Inspect threaded portion of rod for damage 14 Remove rod from vise Dress threads as necessary 15 If applicable remove cylinder head and head 4 Inspect inner surface of cylinder barrel tube for cap from rod scoring or other damage Check inside diameter 16 Remove and discard head o ring back up ring for tapering or ovality Replace if necessary wear rings rod seal and wiper seal s 3120933 Rev USTC 7 7 SECTION 7 HYDRAULICS 5 Inspect threaded portion of barrel for damage Dress threads as necessary 6 Inspect piston surface for damage and scoring and for distortion Dress piston surface or re place piston if necessary 7 Inspect seal and o ring grooves in piston and head for burrs and sharp edges Dress applicable surfaces as necessary 8 Inspect cylinder head for scoring or other dam age and for ovali
9. Old L 170100 1SIOH R ree oTe AVI W3MOd 3NVSO SNOLyOriddv L3 sv8 M04 SC Wi3l OL INAYO NI 9 318v2 diis AJNO SNOLLWONdd 13 5 8 HLIM 3SN 304 e dois was sz vz cz sav ez lNNVIS 9 NYOH 3015 SY3AINd 8 08 Zz i AY T13H 8LV OZ 61 dols W3u 8l 4 OIS Blv cf u3yy3ug 91 EL OQAZ1 705 gv V 1 130 UNE dWV9 9373 o Old ASIOH 7 3015 SYAIYA S 9018 NOILONNAP 9f ONIN OL xOv18 ONY Sf ONIN OL 3MIM 3LIHM SMOTIOJ SV Q3LO3NNOO 3H OL SIYM HOLIMS STONY SNOILVOTTIddV SNONILNOO 310N ov18 z 3LIHM L 8 OVE WIL N33UD LE NI z 21 3uvas OGAZL Ol 6 NOILINDI 8 4 os ni 9 9 11S NMOHS LON SNOILdO Ov SZ S34n1v3d QJvONVIS vZ l iE NYOH 1_ 91015 IVNIN331 XO8 NIVW Y L IM 3LHW sLv 40078 aly 8 HOVE WIL 1SIOH HOIH 3L
10. 31IHM Tos giv AINO LNOLND ISN QVOTH3AO 10 AV133 81V AYTAY Loo aiv OZ 61 dOlS W3H Ms 8l 44 9NS 8lV N olS Blv cf u3 v348 318vO AWRY 81 91 1 Dio 20 21 lt diMIS 318v9 alv ANNO AV HLIM 3SN dI 110 100 HLIM 3SN 3AOW3H TVNIN331 HOLIMS 81 aly S3NIHOVW SNONILNOD 303 QvVOTJ3AO 6 7 USTC Figure 6 6 Overload Electrical Schematic 3120933 Rev SECTION 6 ELECTRICAL 8 219266 dvo MONaL NI Q31v901 9NINSVM 3ShjJ M3HSV MH AV 13M 310N 3505 Q3MOLS 38V 554399141 0 035019 38V SSHOLIMSLIATT 3LON 3NFINI OGATL NOILINOI MONML 9 3n 8 dAVOl 9 MOTISA YAZIMEGVLS ON 4 9 MOTI3A YAZNIEVLS 9 MOTISA 4399lIuLnO 9 4 9 MOTI3A ON 91 NMO38 9914 ON iis ak X 1 9i d3H
11. 16 Pitch Diameter 4 in 101 6 mm Outside Diameter 4 40 111 8 mm Swing Brake Manufacturer Eskridge Type Spring Applied Hydraulic Release Release Pressure 170 psi 11 73 bar Holding Torque 2400 Ib in 271 Nm Swing Motor Manufacturer White U E ee ee wi Gear Displacement 6 0 in 98 3 Maximum Pressure 1750 psi 120 8 bar Maximum Flow 13 gpm 49 2 L min Swing Bearing Manufacturer uu s uu al una ah u Su a PSL TYPO R ukawa apa Internal Tooth Ball Ball Bearing Circle 29 96 in 761 0 mm Ball Diameter 1 37 in 35 mm Bolt Torque 472 Ib ft 640 Nm w Loc Wel Patch Dry 3120933 Rev Control Valve Manufacturer Commercial Intertech TYP Et Dual Inlet Open Center SeCliOnS cette i Dock te 7 Manufacturer Commercial Intertech LEES Open Center SECON S och md rte bete 1 Hydraulic Pump Manufacturer Commercial Intertech divs nei rh RR UR ORE 3 Section Gear Rated Pump Speed 2400 rpm 1st Section Flow 39 gp
12. 4 15 SECTION 4 BOOM Telescope Cylinder Retract Cable Retainer Plate Cylinder Mounting Pin Figure 4 11 Telescope Cylinder TELESCOPE CYLINDER The telescope cylinder is located in the boom Through several sets of cables the cylinder extends and retracts each of the boom sections proportionally When extending the barrel end of the cylinder moves with the rod end pinned to the pedestal end of the boom base section The cylinder is double acting with cartridge style holding valve located in the port block Because the barrel end extends the port block is located on the rod end of the cylinder rather than the butt end Removal Removal of the cylinder requires the hoist to be laid back The boom can remain mounted on the truck or removed If boom remains mounted use all applicable precau tions to prevent dropping the cylinder or slipping of maintenance personnel 1 Park truck in a location with adequate room for extending cylinder out back of boom approxi mately 25 ft Set Park Brake 2 Lay back hoist Refer to hoist layback proce dure 4 16 USTC Base Section Retainer Plates 3 Evenly remove four nylon insert lock nuts from extend cables Note If a single nut is removed completely with tension on any remaining cables the free cable will retract into boom and completely boom disassembly will be required 4 Remove six socket head bolts which secure the cable retainer block to
13. 90 WOOB SNONNILNOD 30 1 301931100 90 AVI38 NMOG MOTS AINO SNOLLVOllddV 133SV8 3orids 1ng 387023 05 8 2 2 aN AVTI3H OML ILNV Wiring ion for Platform Installat ircuit Figure 6 9 A2B with Slow Down C January 15 2001 USTC 6 10 SECTION 6 ELECTRICAL zavo 91 9100901 OS a Hose USNI JULOYHL 44 5 0 335 SNLSIX3 ee H A 70s n4 4g naa 4 se Qva E dolS 3 3i E 4015 3 7WOIMIO3I3 NOLLVOl lddV 13 sv8 V ed c90 6r dn 1 cf u3uv3u8 139 20 21 0 LO SNIHOLY1 S824G20 434 1 3Ql333AO 9 dOLS W3Y Sc Tos aly cz ZZ 1 AVT3W 81V 1 OZ 61 dOlS W3N u
14. FUEL SOL 7 8 IGNITION 9 10 12VDC 11 SPARE 12 12VDC 13 16 BREAKER 2 B M CHART P N DESCRIPTION CRANE POWER RELAY 4932725 BUMPER STAB S PTO RELAY 4932726 OUT amp DOWN OUTR S A 4932727 OUT amp DOWN STAB S ERG Pro 1 BREAKER 4 4932728 OUT amp DOWN OUTR S amp STAB S 1282315 Rev C 15 CONSOLE 4932907 O amp D STAB S W SEALABLE CONNECTIONS 12VDC Figure 6 5 Outrigger Stabilizer Schematic 6 6 USTC January 15 2001 SECTION 6 ELECTRICAL SNOLLO3NNOO 1ONLNOO 310N3H M vLEC8CI TWNOILIGGY 304 174667 HO 6 4c 6v 335 Q3d 1H 038 OTO 21096 150 k dn 140 Q3d1H ONVIS GIAO Z z 6r dn ISOH NOlLdl49OS 3G N d LYVHO W 8 81 310W34 7015 lan CZ 13r 310W33 3NI9N3 MOT dnian a0 SLOWSY 3NI9N3 H9IH LSIOH 1fo313L ino 3131 NMOHS SV LOJNNOD x LORY INDIO 100 100 ISN dI S3SS3NNVH GIAO 81 LNO 310N ois ANO A V 3SN 303 3AOW3S ran 182 SSVdAB SSVdA8 X0v18 ao NM
15. eo __ 3399181no yazmigvis 3znevis _ e _ 84 e 40 3015 100dS NO Q31V201 140d AYOM Vu G660t9t N d 34 3ATVA WIOAIWNOD TO0dS Z XOIN NOLON NI Nivea HONIM Q33dS OML X04 f 133HS 33S 501 1SIOH Figure 7 12 Hydraulic Schematic January 15 2001 USTC 7 14 SECTION 7 HYDRAULICS z 1eeus eH 6872821 3015 gano 2 18 15 an 43N Gos 122815 2 8 _ 3znivis _ INNON 2015133515 3218715 3015 133415 M3zriavis 33 Qv3u nng amp 3015 aano uazniavis Sinomvo ONILLIJ Su3zrigvis 40 ASSY 335 i i IN fay x 3015 133415 M3zriiavis 3dss gyno MN3aznrievis Sinomvo SNILLIJ Su3zriavis 40 ASSY 335
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18. 6 Using suitable equipment pull fly and outer mid sections out of inner mid section approximately one foot to access wear pad bolts at nose end Remove side and lower wear pads and shims and upper wear pad from inside of outer mid section at nose end 7 Using suitable lifting equipment pull fly section from outer mid section 8 Set fly section on suitable supports 9 Extend cables and sheaves may be removed from inside of outer mid section as required Fly Section Installation 1 Hang extend cables to pedestal end of fly sec tion with mechanics wire adjuster end at top bullet end on bottom Stretch cable out for length of section and support middle of extend cables at nose end using mechanics wire Sev eral 2 ft boards laid across top of section will support the cable Wire tie ramp at pedestal end of section to prevent catching it once inside section 2 Insert fly section into boom assembly removing boards and cable supports along the way Con tinue until retract cables are inside wear pad locations 4 18 USTC 3 Insert side wear pads inside outer mid section loosely without shims Install upper and lower wear pads shimming bottom wear pads to 1 16 clearance Be sure to orient lower pads toward outside edge of section 4 Slide remainder of fly section and any other sections completely into base section 5 Lay extend cables in grooves on outside of fly section Attach cable anchor blocks on top
19. S3YIM YOLONGNOD FIONIS VO 91 3uV 4 62 SWALI ALON 3LIHM 33S A1 gW3ssv 8ns Sv Q3TIVISNI SLN3NOdWOO HLM 3Lv1dNOVB 9415 VNIWH3L 40 305 ONVH 1331 JHL NO SIHL 3LVNIWH3L Or 3uvds NOWONAr 6 8 dOLS 310W3N e Nog 1an 4 fas mmo ss v NYYNOTO df _13ITGTAQ 1 30I833AO og 915 07 0 KARELEN 62 12 190 OQNZL f u3yy3ug 9 139 OGAZL SC 5 2 72 oS gv ZZ le Av T3WBlV OZ 61 dOLS W3Y 8l L av cf uiw3u8 91 81 Do 20 21 zi 3uvds Iit Ol 6 NOLLINDI 8 4 105 uu 9 9 1BNVIS y V Old annouo dlls VNIW33L leeleleleeleleolelelolo iSieisieissisis s sisisisisisisisisis e leleleejejejelejejelejejelejjeje Lik FIWOS V oY cc 2 9015 SSYdAg an 40 JASNI OL G3HOVILY vil u3 v348 110959 f 10030 z u3 v3ug 10949 ALV1d ONILNNOW ONY TWNINYAL 69 S lslels slelsle
20. TM Incorporated A Manitowoc Company 2500 2700JBT Cranes Service Manual 76 Bowman Road York 17404 8793 Sales 717 505 8800 Sales Fax 717 505 8811 Service 800 556 8280 Service Fax 717 505 8812 USTC Inc 3000 S Austin Ave Georgetown TX 78627 1609 Sales 512 942 3000 Sales Fax 512 863 3776 Service 512 942 3022 Service Fax 512 942 3094 3120933 Rev 0 PRINTED IN U S A January 15 2001 FORWARD The purpose of this manual is to provide the customer with the operating procedures essential for the promotion of safe and proper machine operation for its intended purpose It is impor tant to over stress proper usage All information in this manual should be READ and UNDER STOOD before any attempt is made to operate the machine SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION CONFORMANCE WITH GOOD SAFETY PRACTICE IN THIS AREA IS THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL ALL PROCEDURES HEREIN ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITIONS WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN ALTER ATION AND OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN WITHOUT WRITTEN APPROVAL FROM USTC INC REMEMBER EQUIPMENT IS ONLY AS SAFE AS THOSE WHO OPERATE IT Since safety of personnel and proper use of the machine are of primary concern statements are used throughout this manual
21. 24 gpm to the hoist control valve The solenoid valve cartridges can be removed and cleaned if necessary Four check valves are also removable for cleaning 7 12 USTC The solenoids are interchangeable To test one of the solenoids they can be interchanged if the opposing solenoid is known to be working If the solenoid fails but the cartridge is operational replace the solenoid When reassembling be sure the nut is torqued to 12 17 lb ft Overtightening can result in distortion of the cartridge and a sticking spool January 15 2001 SECTION 7 HYDRAULICS HYDRAULIC FILTER The hydraulic filter is a spin on replaceable element in the return line The element provides 10 micron nominal filtration before the oil is returned into the tank The filter is equipped with a gauge which indicates the pressure differential between the entry and exit of the oil into the filter When the gauge indicates in the red it should be replaced If the element is not replaced and becomes clogged a bypass opens in the filter head to release unfiltered oil into the tank IMPORTANT Do not operate the crane with a clogged filter 3120933 Rev 0 Figure 7 11 USTC Element Hydraulic Filter 7 13 SECTION 7 HYDRAULICS SONULIS 33055359 304 591821 335 S3188n8 LNO SONULI4 S319NviML NI 100 03TIVO sso N NOLLY2O1 QN3 3SOH 1HOIVHIS NON S3lON3d X SLIM 1 SO
22. Malfunctioning counterbalance valve Hydraulic oil level low Restricted or broken supply line Malfunctioning hydraulic pump Worn or broken teeth on drive hub pinion or swing bearing gears Malfunctioning swing motor Malfunctioning swing brake Malfunctioning counterbalance valve USTC Table 3 4 Hydraulic Components continued REMEDY Add oil Remove line and clear obstruction or replace line Repair or replace pump Repair or replace control cable Check pressure delivery from control valve and repair or replace valve Repair or replace motor Repair or replace swing brake Repair or replace drive hub Adjust or replace relief valve Remove line and clear obstruction or replace line Check pressure delivery from control valve and repair or replace valve Remove obstruction and check for damage Repair as necessary Replace counterbalance valve Add oil Remove line and clear obstruction or replace line Repair or replace pump Replace pinion gear or swing bearing Repair or replace motor Repair or replace swing brake Replace counterbalance valve 3 9 TROUBLE Swing motor operation slow Boom will not telescope out Boom will not telescope in 3 10 SECTION 3 TROUBLESHOOTING PROBABLE CAUSE Hydraulic oil level low Restricted or broken supply line Malfunctioning hydraulic pump Worn control valve spool Worn or defective swing motor Swing circuit re
23. WALI MAN 9 3HIM ONLLSIXA HOWLLV HOW 1 9 2 SWALI M zov 1d38 9 TVNINH31 9NLLSIX3 3AOW3H 3415 21 910 9 Olava KINO Gasn NI STYNIWYAL Figure 6 11 Clam Shell January 15 2001 USTC 6 12 SECTION 7 HYDRAULICS HYDRAULIC SYSTEM SAFETY It should be particularly noted that the machine s hydraulic systems operate at extremely high and potentially dangerous pressures Every effort should be made to relieve any system pressure prior to dis connecting or removing any portion of the system Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the return line to the reservoir Pressure supply lines to system components can then be disconnected with minimal fluid loss Awarnine NEVER CHECK FOR LEAKS USING HANDS HYDRAULIC FLUID UNDER PRESSURE CAN PENETRATE SKIN NEVER CHECK FOR LEAKS USING HANDS DRIFT TEST To determine if cylinders are leaking internally drift tests can be conducted on the telescope and lift cylin ders Telescope Cylinder 1 Activate hydraulic system properly set outrig gers and stabilizers Awarnine BEFORE EXTENDING AND RAISING BOOM ENSURE THAT AREAS ABOVE AND BEL
24. section Do not install cotter pins in sheave pins 15 Loosely attach hose clamp to bullet end of cable Lay bullet end of retract cable in grooves inside outer mid section above retract cable sheaves Tighten hose clamp against anchor block to prevent cable from coming out of groove 16 Reeve cable around sheaves and under assem bly Stretch cable out length of boom assembly and attach retainer plate to adjuster ends of cable 17 Remove mechanics wire securing extend cables and fly section ramp Attach fly extend cables to inner mid using cable anchor bars and nylon lock nuts Cable anchor bars must be oriented so cable is in center of cutout in section weldment 18 Apply anti sieze compound to extend cable adjustment threads Remove slack from retract cables keeping both cables even 19 Insert boom assembly into base section As soon as side plates are inside the base section place the bottom wear pads under the boom assembly to protect the cables Continue inserting boom assembly to within 1 ft of completion 20 At the nose end insert the top wear pad and two bottom wear pads and shims Attach cable guide assembly to top of base section opposite top wear pad Shim bottom wear pads as necessary to provide 1 16 in clearance Be sure to orient bottom wear pads toward outside edge of sec tion 3120933 Rev USTC 21 Insert four side wear pads loosely to inside of base section Shims will be added after boom
25. OUTRIGGER Street Side Main Relief TELESCOPE Pressure Checkpoint Main and Section Relief Adjustment for Pressure Checkpoint Swing Figure 7 1 Main Control Valve Pressure Relief Test Locations 2 Using all applicable safety practices start the 6 Repeat step 3 to ensure that the pressure set truck engine engage the PTO and operate the ting is correct crane at low engine speed TUE Telescope In Relief Valve 3 Completely retract one of the outriggers until the cylinder bottoms out and the main relief valve opens Note the pressure on the gauge The telescope in function has a separate relief valve on the retract side of the telescope section Refer to the table for the proper pressure set 1 Attach a 0 4000 psi 276 bar pressure gauge to ting the gauge port at the mid inlet section of the 4 If the pressure is incorrect remove the acorn nut or loosen the jam nut on the relief valve 2 Using all applicable safety practices start the cartridge to access the adjustment screw truck engine engage the PTO and set the out If the pressure is too low turn the adjustment Operate the crane at Ton speed screw clockwise to increase the pressure set 3 Retract the boom until the telescope cylinder ting If pressure is too high turn the adjustment bottoms out and the relief valve opens Note screw counterclockwise to decrease the pres the pressure on the gauge Ref
26. Testing Main Relief Valve Telescope In Relief Valve Swing Inlet Relief Valve Hoist Relief Valve Burst of Speed and Telescope Out Relief Valve Cylinders Holding Valves Dissasembly Cleaning and Inspection Assembly Control Valve Hoist Valve iv USTC January 15 2001 FIGURE LIST Lubrication Points Wire Rope Components Measuring Wire Rope Hoist Cable Spooling Cable Socket and Wedge Installation Cable Reeving Snatch Block Hoist Layback Internal Boom Cable Reeving Boom Removal Inner Mid Outer Mid and Fly Sections Telescope Cylinder Swing Drive Components Swing Motor Assembly Swing Brake Assembly Gear Reducer Hub Assembly Bearing Bolt Tightening Sequences Swing Bearing Clearance Measurement Bearing Tolerance Check Anti Two Block Positions Electrical Schematic Electrical Power Distribution Diagram Electrical Box Schematic Outrigger Stabilizer Schematic Overload Electrical Schematic Outrigger Stabilizer Wiring Outrigger Stabilizer Switch Wiring A2B with Slow Down Circuit for Platform Installation WIring Radio Remote Control Clam Shell Main Control Valve Pressure Relief Test Locations Hoist Valve Relief Cartridges In Line Relief Valve Manifold Block Valve Typical Cylinder Control Linkage Linkage Control Valve Control Valve Section 3120933 Rev O USTC y FIGURE LIST Continued Hoist Control Valve Manifold Valve Hydraulic Filter Hydraulic Schematic Outrigger Schematic Two Speed
27. Torque Chart 4 12 USTC Boom Disassembly The boom has four sections which extend proportion ally using a telescope cylinder connected to each of the sections through a series of extend and retract cables Wear pads are provided inside the nose end and on the outside of the pedestal end of each section Refer to the shimming procedures earlier in this section A boom requires complete disassembly for inspec tions extend cable replacement or if a section is overloaded and damaged 1 Using suitable lifting equipment adequately support hoist assembly Remove bolts nuts and washers attaching hoist assembly to rear of base boom section 2 Using all safety precautions lift hoist clear of boom assembly and move to suitable supported workstand or bench 3 Remove telescope cylinder Refer to telescope cylinder removal procedure 4 Remove wear pads inside base section at nose end 5 Pullinner mid outer mid fly assembly from the base section 6 Remove nuts and retainer plates securing the fly extend cables 7 Remove hose clamps on outer mid retract cables Remove cable retract mount at nose end 8 Remove top and side wear pads from inside nose end of inner mid section 9 Pull outer mid fly assembly from inner mid section Be careful not to pinch cables Remove bottom cable anchor when section has been pulled out approximately six feet 10 Remove hose clamps on fly retract cables Remove cable anchor
28. bolt holding fly retract cable and remove anchor block Note number of shims under each anchor for reinstallation 11 Remove fly extend cables from each anchor on fly section January 15 2001 SECTION 4 BOOM 12 Remove top and side wear pads from inside Boom Inspection nose end of outer mid section Inspect upper and lower boom nose sheave pins 13 Pull fly section from outer mid section for tapering ovality and scoring Ensure that pin surfaces are protected prior to installation Re 14 Inspect each boom section for straightness place pins as necessary rubbing cracks at welds Inspect cables per the cable inspection procedure Inspect upper and lower boom nose sheaves for wear ovality scoring or other damage Replace 15 If necessary remove boom nose sheave retaining sheaves as necessary rings and pins Remove sheaves and inspect sheaves and bushings for damage Inspect all sheaves boom nose extend and re tract cables for excessive groove wear burrs or other damage Replace sheaves as necessary Inspect extend and retract cable sheave pins for scoring tapering ovality and evidence of correct lubrication Replace pins as necessary Fly Extend Cables Fly Retract e Cables Cable Anchor cQ ZA T 5 Fly Retract Cables Fly Section Outer Mid Section Inner Mid Section Cables Plates Fly Extend 4 Cables La gt Retainer Z i Fly Retract 2 Cables re eN Outer M
29. clean work surface in a dirt free environment Dissasembly 1 Connect a suitable auxiliary hydraulic power source to the cylinder ports Awarnine DO NOT FULLY EXTEND CYLINDER RETRACT CYLINDER SLIGHTLY TO PREVENT TRAPPING PRESSURE 2 Operate hydraulic power source and extend cylinder 3 Ifapplicable remove holding valve s and fittings from cylinder port block Discard o rings 4 Remove bleeder blugs and seal washers from cylinder port block 5 Secure cylinder barrel in a suitable holding device Clamp butt end of barrel to prevent distortion and barrel damage 6 Remove nylon plug if installed and set screw from cylinder head cap 7 Use a spanner wrench to loosen the cylinder head cap Tap with a hammer if necessary Remove head cap from cylinder barrel IMPORTANT Take care not to damage the chrome plating on the rod 8 Attach a suitable pulling device to the cylinder rod IMPORTANT Extreme care should be taken when removing cylinder rod head and piston Avoid pulling rod off center which could damage the piston or cylinder barrel surfaces 9 With barrel clamped securely apply pressure to the rod pulling device and carefully withdraw complete rod assembly from barrel 10 Using suitable protection for the rod clamp cylinder rod in a vise or holding fixture as close to the piston as possible January 15 2001 SECTION 7 HYDRAULICS Valve Check Plug Bushing 2
30. correct Burst Of Speed and Telescope Out Relief Valve On older models two inline relief valves are used to protect the burst of speed and telescope out func tions Newer models use a manifold block valve with cartridges to protect these two circuits Test methods are similar for each circuit 1 Attach a 0 4000 psi 0 276 bar pressure gauge to the gauge port on inline valves or manifold Note Block valves have gauge ports labelled G 1 for the burst of speed circuit and G 2 for the telescope out circuit 2 For burst of speed tests remove one end of the hydraulic line between the main control valve and the hoist control valve and plug 3 Using all applicable safety practices start the truck engine engage the PTO and set the outrig gers Operate the crane at low engine speed 4 Operate the appropriate control lever and note the pressure reading on the gauge IMPORTANT For telescope out relief valve testing be sure the outriggers and stabilizers are set The boom must be fully extended and bottomed out to cause the relief valve to operate Figure 7 4 Manifold Block Valve 3120933 Rev 0 USTC 7 5 SECTION 7 HYDRAULICS 5 If the pressure is incorrect remove the acorn nut or loosen the jam nut on the relief valve cartridge to access the adjustment screw If the pressure is too low turn the adjustment screw clockwise to increase the pressure setting If pressure is too high turn the adjustm
31. head gland IMPORTANT Ensure piston seals are installed properly Improper seal installation could result in cylinder leakage and improper cylinder operation 9 nstall new seal assembly into the applicable outside diameter groove 10 Install wear rings in applicable grooves in pis ton 11 Position cylinder barrel in a suitable holding fixture 12 With barrel clamped securely and while ad equately supporting the rod carefully insert piston end into cylinder barrel Ensure piston wear rings and 3 piece seal assembly are not damaged or dislodged 13 Continue pushing rod into barrel until the cylin der head cap can be inserted into the cylinder barrel 14 Install cylinder head cap and secure using a suitable spanner wrench Keep wrench toward outside of head cap to avoid distorting threads 15 Install set screw in cylinder head cap 16 Retract the rod into the barrel fully Install holding valve s and fittings using new o rings Torque holding valves according to table January 15 2001 SECTION 7 HYDRAULICS ae NSRERRE SE ess er cr T cem s ELEM MOT Teh js Nor ELIT 3 pil sj wee Figure 7 6 Control Valve Linkage 3120933 Rev USTC 7 9 SECTION 7 HYDRAULICS CONTROL VALVE The main control valve operates the lift telescope swing functions and the outrigger functions The swing section receives oil at the inlet from the small 8 gpm pump se
32. headache ball hookblock combination in headache ball configuration Reinstall anti two block counterweight around the hoist cable and adjust counterweight chain length to activate cut off switch before two blocking occurs January 15 2001 SECTION 4 BOOM Two Part Line Reeving Note The following procedure must be followed and used before lifting any load with two part line 1 Lower boom to allow access to boom nose 2 Ifthe headache ball is installed lower onto the ground or suitable capacity stand Remove hair pins and straight pin securing cable socket to the headache ball 3 Remove anti two block counterweight from around the hoist cable Let hang 4 Configure headache ball hookblock assembly Note Cable socket does not need to be removed Lay hoist cable into hookblock single sheave wheel groove before installing sheave wheel into headache ball hookblock assembly body 5 Attach cable socket to the lug behind lower sheave wheel on the boom nose using the pin and pin clip provided 6 Reinstall anti two block counterweight around the hoist cable and adjust counterweight chain length to activate cut off switch before two blocking occurs Three Part Line Reeving Note Reference to right and left is made with the operator facing the controls on the console Note The following procedure must be followed and used before lifting any load with three part line 1 Lower boom to allow access
33. in 6553 mm Overall Stowed Width 95 6 in 2228 mm Extension per side 90 0 in 2286 mm Pad Dimensions 17 63 x 11 50 in 447 x 2922 mm Below Ground Penetration 8 00 in 203 mm Out and Down Stabilizers Extended Width Jack Centerline 164 8 in 4 23 m Overall Stowed Width 96 in 2438 mm Extension per side 38 in 965 2 mm Pad Diameter 14 in 356 mm Below Ground Penetration 12 31 in 320 mm CYLINDERS Telescope Bore 6 00 in 152 mm Stoke ce seein aedi 261 00 in 6629 mm Rod Diameter 4 97 in 126 mm Nut Torque esse Weld On Lift BOG e ee 8 00 in 208 mm Stroken oodd 58 44 in 1484 mm Rod 4 00 102 Nut 1900 2400 lb ft 2576 3254 Nm A Frame Outrigger B le oues 4 00 in 102 mm SYOK Errelea ius 56 13 in 1426 mm Rod 2 75 70 Nut 1125 1375 Ib ft 1525 1864 Nm 1 4 USTC Out and Down Stabilizer Extend BOO 2 00 in 51 mm SItOke ide 76 00 in 1930 mm Rod 1 25 32 Nut Torque
34. ined Refer to the Cable Inspection Procedures earlier in this section HOIST LAYBACK Awarnine ENSURE MACHINE IS ON A FIRM AND LEVEL SURFACE IMPORTANT Before adjusting boom extend and retract cables remove boom stop on top of fly section just behind boom nose After cables have been adjusted fully retract boom install boom stop and shim as necessary until boom stop is snug against inner mid or outer mid section top plate 1 Using all safety precautions operate crane and properly set outriggers and stabilizers 2 Lower boom to allow access to boom nose 3 Extend boom far enough to remove boom stops and shims from fly section just behind boom nose USTC n SECTION 4 BOOM Lube Ports and Alignment Holes Figure 4 7 Hoist Layback 4 Retract boom to ensure telescope cylinder is fully retracted bottomed Note Open wedge socket may need to be removed to unreeve cable from around lower boom nose sheave wheels in next step if crane is configured for 3 or 4 part line If socket is removed it will need to be reinstalled to help lower hoist out of way as in the following steps 5 With boom still in lowered position remove headache ball hook block assembly from hoist cable and unreeve cable from boom nose sheaves Also remove upper and lower hoist cable retaining pins from boom head 6 Using all applicable safety precautions operate the hoist and retract cable onto drum until cable socket
35. oil causing excessive temperature buildup Incorrect valve mounting causing warping of the unit Valve spool scored Return spring weak or broken Relief valve malfunctioning causing excessive pressure within valve Control rod or lever binding Dirt or other foreign material under seal Valve spool scored Excessive back pressure caused by restricted return line to reservoir Damaged valve seals Swing bearing attaching hardware loose or missing Swing bearing worn or requires lubrication Flow control valve dirty or out of adjustment Flow control valve out of adjustment USTC SECTION 3 TROUBLESHOOTING REMEDY Change oil using recommended viscosity and flush system Loosen valve and check mounting Replace mounting if bent Remove valve and repair or replace Remove valve and repair or replace Check pressure delivery to and from valve and repair or replace Repair or replace control rod or lever Remove and repair valve Remove valve and repair or replace Remove line and clear obstruction or replace line Remove valve and repair or replace Replace all bearing bolts and torque properly Replace swing bearing or lubricate bearing Clean flow control valve and adjust open to increase brake action Adjust flow control valve closed as necessary to apply brake slowly 3 3 TROUBLE PTO jumping out of gear Noisy PTO Oil leaking from PTO Hydrau
36. on the end of cable is up over the boom nose and next to cable socket attach lug on top of base boom 7 Using cable socket pin hoist cable to cable socket attach lug on top of base boom and re move any excess slack in hoist cable 8 Using all applicable safety precautions operate crane and move the boom to the horizontal position 9 Remove upper two bolts on the hoist mount that go through the side plates of base boom 10 Using all safety precautions start crane and operate hoist lower lever and gradually lower hoist till it comes to rest on the turntable 4 8 USTC 11 With hoist in resting position operate hoist to allow slack in hoist cable to move cable to side out of way 12 Shut down crane 13 Reverse process to reinstall the hoist for opera tion Awarnine NEVER OPERATE CRANE WITHOUT PLEXIGLASS SHIELDING IN PLACE Extend Retract Cable Adjustment Procedure IMPORTANT If locking nuts bottom out on threaded cable adjustment ends on both the extend and retract cables no threads remain before adjustment dimension or torque can be obtained cables are stretched and require replacement Always replace cables for each boom section in sets i e all fly and outer mid section extend cables or all fly and outer mid section retract cables It is acceptable to cut one inch off of cable adjust ment stud with an abrasive cutting saw if extend cable stud interferes with hoist mounting plate Note Do no
37. relief valve Disassemble hoist and repair or replace brake system Repair or replace anti two block solenoid valve Reduce load Refer to Load Capacity Chart Add oil Remove line and clear obstruction or replace line Repair or replace pump Repair or replace control cable Clean or replace sticking valve Check pressure delivery to valve and clean or replace section Adjust or replace relief valve Clean or replace defective valve Repair or replace cylinder 3 7 SECTION 3 TROUBLESHOOTING Table 3 4 Hydraulic Components continued TROUBLE Boom will not lower Boom raises and lowers erratically Boom lowers with control lever in neutral 3 8 PROBABLE CAUSE Hydraulic oil level low Restricted or broken supply line Malfunctioning hydraulic pump section Control cable broken kinked or disconnected Check valve in control valve section inlet stuck in closed position Excessive oil leak past cylinder piston seal Worn control valve spool Hydraulic lines incorrectly connected at control valve Holding valve in lift cylinder stuck in closed position Hydraulic oil level low Restricted or broken supply line Malfunctioning hydraulic pump section Excessive oil leak past lift cylinder piston seal Worn control valve spool Boom pivot pin seized or otherwise damaged Malfunctioning holding valve on cylinder Defective cylinder packing Worn control valve
38. spool Malfunctioning holding valve on cylinder USTC REMEDY Add oil Remove line and clear obstruction or replace line Repair or replace pump Repair or replace control cable Repair or replace check valve Repair or replace cylinder Check pressure delivery from control valve and repair or replace valve Connect hydraulic lines properly Check for presence of pilot pressure at return valve and repair or replace Add oil Remove line and clear obstruction or replace line Repair or replace pump Repair or replace cylinder Check pressure delivery from control valve and repair or replace valve Replace pivot pin and bushings Replace holding valve Repair or replace cylinder Check pressure delivery from control valve and repair or replace valve Replace holding valve January 15 2001 TROUBLE No turntable swing in either direction Turntable swings in only one direction Swing motion erratic 3120933 Rev SECTION 3 TROUBLESHOOTING PROBABLE CAUSE Hydraulic oil level low Restricted or broken supply line Malfunctioning hydraulic pump section Control cable broken kinked or disconnected Worn control valve spool Malfunctioning swing motor Malfunctioning swing brake Malfunctioning drive hub Relief valve in control valve inlet set too low Restricted or broken supply line Worn control valve spool Foreign object wedged in swing gear teeth
39. the base section 5 Using truck hydraulics extend cylinder approxi mately 2 ft This will extend the rod end of the cylinder with the cable retainer block to provide access to hoses connections It may be necessary to lift cylinder to extend trunnion ears through retainer blocks inside base section 6 Disconnect hydraulic hoses and cap hoses and cylinder ports 7 Remove retaining ring and pin securing cable retainer block to rod end of cylinder 8 Remove cotter pins on four lower retract cable sheaves and push sheave pins back flush with January 15 2001 SECTION 4 BOOM inside of retract cable sheave holders to provide clearance for cylinder 9 Using an adequate lifting device such as an overhead crane pull telescope cylinder approxi mately 6 in Raise cylinder up and remove lower cable retainer block Acaution WHEN USING SLING TO LIFT CYLINDER USE BLOCKS TO PREVENT PINCHING AND DEFORMATION OF CABLE WHEN REPOSITIONING SLING USE BLOCKING TO PREVENT LAYING CYLINDER ON CABLES 10 Wire tie extend cable ends to cylinder and pull cylinder and retract cables from boom assembly 11 Set cylinder assembly on supports Installation 1 If not already done attach hydraulic power source to telescope cylinder ports and extend cable approximately 2 ft Position cylinder so that cable retaining tabs are up Note Mark both ends of the cables to ensure that they do not cross inside of the boom 2 Lay four exte
40. to emphasize certain areas The following definitions indicate how a statement will appear in this manual Whenever this symbol is seen in this manual or on the machine personnel safety is a concern Take time to read and understand these statements INDICATES IMMINENTLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN DEATH OR SERIOUS INJURY Awarnine INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN DEATH OR SERIOUS INJURY Acaution INDICATES A POTENTIALLY HAZARDOUS SITUATIONS WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES IMPORTANT Indicates a situation which may cause machine damage if not correctly followed Note Provides information which may be of special interest TABLE OF CONTENTS SECTION 1 SPECIFICATIONS General Hydraulic System Safety Maintenance Swing Brake Swing Motor Swing Bearing Control Valve Hoist Valve Hydraulic Pump Hydraulic Filter Hydraulic Tank Boom Specifications Jibs Optional Outriggers And Stabilizers A Frame Outriggers Out and Down Stabilizers A Frame Outrigger Out and Down Stabilizer Extend Out and Down Stabilizer Jack Pressure Settings Capacities Performance Data Functional Speed Specifications Weights 3120933 Rev O USTC i TABLE OF CONTENTS Cont SECTION 2 LUBRICATION Machine Inspection Requirements Preparation For U
41. weldment has been removed adjust the linkages before mounting the console weldment to the pedestal MID INLET January 15 2001 SECTION 7 HYDRAULICS 3 Wes 3 Retainer Plate Screws Figure 7 8 Control Valve Section HOIST VALVE The hoist valve controls oil flow to the hoist Oil enters from the third pump section 39 gal and the power beyond port of the main control valve The valve is a sectional valve with one section and inlet and outlet sections A relief valve cartridge is located on the inlet section The hoist valve is located on the inside of the console weldment above the main control valve The hoist valve can be accessed by removing the side covers from the pedestal To remove the valve disconnect the hoses and the linkage from the valve Remove the bolts securing the valve to the console weldment IMPORTANT Clean area around valve and valve to prevent dirt and contamination from entering hydraulic lines and valve ports Figure 7 9 Hoist Control Valve 3120933 Rev USTC 7 11 SECTION 7 HYDRAULICS Figure 7 10 Manifold Valve MANIFOLD VALVE The manifold valve is a block valve with two solenoid cartridges It is located on the rear of the turntable One solenoid stops operation of the hoist up boom up boom down and telescope out functions when the anti two block switch is tripped The other solenoid opens the burst of speed circuit adding an additional
42. 34v3u8 91 Eb DO 20 21 si GAZI u NOLIN ol 6 8 24 05 n4 dius ONNONO ANNONO TVNINS3L QONnO39 2H N dolS 3 VOIMLOJI3 1300N n 318VO 9 NI O3NIVLNOO 544 NHOH NO 31V0013389 AVTI3N NOILdO 3HL 3MIM S 3HL 3AOW 3LON FN 9 z lt 7 AV OI AC Pa NMOG dn 13137 LSV THAT LISV EP s dn 131 30188300 Waal LNOO WNOILYOdOYd AlddNS 33MOd Figure 6 10 Radio Remote Control 6 11 USTC 3120933 Rev SECTION 6 ELECTRICAL 3015 21 V 2 008 1 109 OIQYY M KINO 4351 Xog 1 5 19 404 dAL HO LIMS NYOH ONILSIX4 dAL 9 Z SWALI OL 1
43. 50 Ib ft 68 Nm Out and Down Stabilizer Jack nl 5 00 in 127 mm Stroke 22 25 565 Rod Diameter 3 50 in 89 mm Nut Torque 1600 2000 Ib ft 2169 2712 Nm PRESSURE SETTINGS Main Relief 3500 psi 241 3 bar Lift Up 3500 psi 241 3 bar Lift Down siiri 3500 psi 241 3 bar Telescope In 2500 psi 172 3 bar Telescope Out 3300 psi 227 5 bar Outriggers 3500 psi 241 3 bar Stabilizers 3500 psi 241 3 bar SWING cerit 2100 psi 144 8 bar Hoist eive etre ines 3200 psi 220 6 bar Burst of Speed 2000 psi 137 9 bar Adjustable Relief Valve CAPACITIES Hydraulic 90 gal 340 L Hoist 94 ft Boom 3 5 qt 3 3 L Gear Reducer Hub 1 25 qt 1 2 L January 15 2001 SECTION 1 SPECIFICATIONS PERFORMANCE DATA Hoist Performance IMPORTANT Line pull ratings are based on hoist capabilities Refer to Hoist Specification Decal on machine to determine permissible line pull of wire rope Acaution MINIMUM OF 5 WRAPS TO REMAIN ON DRUM AT ALL TIMES IMPORTANT Non swivel hookblock must be used with low rotation wire rope Functional Speed Specifications
44. 6 0 00027 09S8 0 00289 0 9 0 00 66 0 99 0 00919 09090 0086 06090 00917 0c9v O 009 06260 00106 0 00082 09S 0 05606 09cc 0 0Sc8l 0 0c 0 00 9 0280 6690 05 21 6Lv 0 00201 281 0 0996 900 0064 82800 0001 92200 029 08900 Oct 13 97 90 0 0826 v9E0 0 098 8100 0081 000200 0891 092100 OZEL VZvt0 O 09cL 00 10 0 026 SL0LO O 0c8 60600 0 009 L9900 0 NI 8 LZZ HO eva 311201 3NOYOL 96 ALILOOT 3n0uOL SM3HOS QV3H 13520S 8 SLNN 8 3aVH9 9 51709 8 aqvu5 AVS NI 97 901 3nO0uO0L 9c 31lLOO1 HO Aud 3n0uO0L LZZ HO eva 3111001 dWv19 3nouol 91 90 111901 3 OtO L 3nO0HOL AINO SH3N31SVd GALV 1d ONIZ S3f YIVA 91 92 3111201 HO 1 SLNN c 3QVuH95 51109 S aqVt9 AVS t0900 0 NI vid 1108 January 15 2001 USTC 1 6 SECTION 1 SPECIFICATIONS Sieuejsej pejejd uniupeo o Ajdde jou op senjeA anbio 8 ON 000861 008S L 0090r L OSOr l 009161 09161 009911 09911 008201 062071 00696 06960 00998 0998 0 00892 06920
45. Add only clean distilled water as necessary warne DO NOT USE AN OPEN FLAME TO PROVIDE ILLUMINATION FOR BATTERY CHECKS GASES GIVEN OFF BY BATTERY ARE EXPLOSIVE AND THEREFORE POTENTIALLY DANGEROUS TO PERSONNEL Awarnine ALWAYS WEAR APPROPRIATE EYE PROTECTION WHEN SERVICING BATTERIES 11 Check integral swing gear bearing bolts and nuts for damage and proper torque uneven wear patterns correct lubrication and proper meshing of torque hub pinion gear 12 Inspect turntable and pedestal for obvious damage such as cracked welds loose or missing hardware 13 Check lift cylinder and hydraulic lines for damage evidence of leakage and security of attachment 14 Check boom pivot bushing for evidence of correct lubrication and shaft retainers for damage and security Lubricate as necessary 15 Check hoist for damage evidence of leakage and security of attachment Check for correct lay of cable on drum Check hydraulic lines to hoist for damage evidence of leakage and security of attachment Check cable attachment to hoist drum 16 Inspect hydraulic electric swivel assembly for obstructions damage and security of attachment Check for pinched wires or hoses and leakage 3120933 Rev USTC 17 18 19 21 22 23 24 25 27 28 29 30 3 Check telescope cylinder and lines for damage evidence of leakage and security of attachment Check boom structure for damage missing or loo
46. BOOM WITHOUT OUTRIGGERS SET ON A FIRM SURFACE 1 Park the machine in an open area and set the outriggers 2 Place a 4000 psi pressure gauge in each of the hoses going into the counterbalance valve 3 Using all applicable safety practices operate the boom and monitor the pressures on each gauge The higher pressure should be three times that of the lower pressure 4 If gauge readings are not properly set replace the counterbalance valve USTC 5 1 SECTION 5 SWING DRIVE SWING MOTOR The swing motor mounts directly to the swing brake A seal kit is available for the swing motor Refer to the Parts Manual for component information SWING BRAKE The swing brake is a static brake It is engaged after pressure drops in the swing motor and remains en gaged until pressure rises Compression springs clamp friction disks and hydraulic pressure over comes the spring load and releases the brake Adjustment A flow control valve is located on the brake inlet line It meters the flow out of the brake The brake should engage and stop rotation in one to two seconds To adjust loosen the set screw on flow control valve If the turntable continues to rotate turn the adjust ment knob counterclockwise If the turntable stops abruptly less than one second turn the adjustment knob clockwise After adjusting tighten the set screw Disassembly Acaution DO NOT CLAMP OR OTHERWISE RESTRAIN COVER FROM MOVING WHILE REM
47. Control cable broken kinked or disconnected Worn control valve spool USTC REMEDY Add oil Remove line and clear obstruction or replace line Repair or replace pump Check pressure delivery from control valve and repair or replace valve Add oil Remove line and clear obstruction or replace line Repair or replace pump Repair or replace control cable Check pressure delivery from control valve and repair or replace valve Repair or replace sticking valve Repair or replace hoist motor Disassemble hoist and check for pressure of pilot pressure at hoist brake Repair as necessary Disassemble hoist and repair or replace valve Disassemble hoist and repair or replace primary drive Adjust or replace relief valve Reduce load Refer to Load Capacity Chart Repair or replace anti two block Add oil Remove line and clear obstruction or replace lines Repair or replace pump Repair or replace control cable Check pressure delivery from control valve and repair or replace valve January 15 2001 TROUBLE Hoist will not raise load or load handling device Hoist will not raise load or load handling device continued Hoist lowers load with control lever in neutral Hoist chatters while raising or lowering load Boom will not elevate 3120933 Rev 0 SECTION 3 TROUBLESHOOTING PROBABLE CAUSE Hoist drive motor defective Check valve in hoist sticking in closed pos
48. HICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL KEEP OIL GREASE WATER ETC OFF STANDING SURFACES AND HAND HOLDS USTC USE CAUTION WHEN CHECKING A HOT PRESSURIZED COOLANT SYSTEM NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING BEFORE MAKING ADJUSTMENTS LU BRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF THE ENGINE BATTERY SHOULD ALWAYS BE DISCON NECTED DURING REPLACEMENT OF ELECTRICAL COMPONENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAM MABLE CLEANING SOLVENTS January 15 2001 SECTION 1 SPECIFICATIONS COMPONENT DATA Hoist Manufacturer Braden Model nne Mn PD12C TYPO tai etn rb Hydraulic Drive Planetary Drum Diameter 9 75 in 247 6 mm Drum Length 13 57 in 344 7 mm Flange Diameter 16 38 in 416 1 mm Brake eR Integral Multi Disc Maximum Rope Capacity 400 ft 121 9 m Rope Diameter 9 16 in 14 3 mm Gear Reduction Hub Manufacturer Eskridge TYPO ice Double Reduction Planetary Hallo aide das nd 36 1 Number of Teeth
49. Hoist Overload Out and Down Stabilizers with Center Stabilizer Front Center Stabilizer Clam Shell Circuit Emergency Down Hydraulic Schematic with Continuous Rotation Hydraulic Schematic with Continuous Rotation TABLE LIST Torque Chart Lubrication Points and Intervals Boom Assembly Pedestal Chassis Components Hydraulic Components Electrical System Pressure Settings vi USTC January 15 2001 SECTION 1 SPECIFICATIONS GENERAL This section contains the general safety precautions which must be observed during maintenance of the crane It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe to operate Awarnine MODIFICATION OF MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION The specific precautions to be observed during ma chine maintenance are inserted at the appropriate point in the manual These precautions are those that apply when servicing hydraulic and larger machine component parts The safety of the maintenance and operating person nel must be the first consideration when engaging in the maintenance of equipment 3120933 Rev Always be conscious of
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52. OQ Lan iu os XS XO8 NOlLdO NI SL3320S AV I33 JO 73437 N3MO1 NMOG 13l1 3LIHM QAO SLOWS SS3NNVH 103135 SS3NUVH guo xov18 Wo N3349 Mov 8 SS3NUVH S3HOLIMS aly ammi NOLON 0 0 Ee aly ONIN YOLOITION NMOHS S3MIM TIY LON vO ZL MOVIE SSANYVH NOlLdO mM SNOILO3NNOO 3NIHOVA GYWONVLS 3onas 10S NYOH Moan NOLON ALNO 4E NMOQ Lan 9 S AO QTAO WNOLLIGGV ZIEZ8ZL 33S maa SLHON 21519313 QVOT43A0 Qv31 aly 30 HL9N31 ee San 39NV3O 0 QVOT43AO 3uvas o4 dn LATINO N3385 es Ie 3QI83 0 dn 141 SSvdA8 z i OL 9015 I WANN Qv31 3LIHM UL Lil of O STWO 30 2 1 OL 2 0 NI v u3yy3ug NA unn 5131005 62 12 IAI 9QAZi 4 oo 8 LNO LNO 3Sn d33W REENEN XOVI8 HoLWS X OWE LM AINO A V 3SN 303 3AON3Y 92 1X0 DGAZI 1531 xg 6830900 1 ON NY Xv xavo s T S 38 OL HOLIMS waves Ta x Im WOOB ols z z OSAV 98 S8 ano dS 3uvds N3389 N3349
53. OSIQ Figure 7 18 Clamshell Circuit January 15 2001 USTC 7 20 SECTION 7 HYDRAULICS eu v8vc6Zc Q i i i 1 1 4 j Libby N d SATWA LINN Y3MOd AON3933W3 t I EH Ed 3015 133418 Gas suno YIZMIGVLS __ 4 390953131 N3oomi no _ _ 3ATVA 40 3QIS 10095 NO Q31V201 LYOd AYOM V G660t9t N d 444 TVIDYINWWOI TOOdS Z zseoo9 _N d LINN N3MOd AON3ON3W3 lt WALL 30v1d3H ONY 91022 ONILSIXS SAOWSY vf W3ll 30v1d3N ONY 1180222 ONILSIXS 3AOW3H 180d NYNLIY v L 1 1NOd NYNL3Y Z L L 130d L3NI 2 1 1 1409 LAN v 140d 131NI IdN Z L 1 7 21 USTC Figure 7 19 Emergency Down 3120933 Rev SECTION 7 HYDRAULICS d ed 20902821 SONLLL3S 3N SS3Nd N04 591821 335 S3188n8 LNO AINY SONULIJ Q S319NVIML NI 100 Q3TIVO sason N NOLLV2O1 3SOH 1HOIVALS NON S3LON3Q X SLIM LNMOW SONILLH P S3SOH
54. OVING COVER BOLTS HIGH COMPRESSIVE SPRING LOAD WILL CAUSE COVER TO FLY ONCE RELEASED 1 Loosen four capscrews from the input end of the brake Alternately unscrew bolts 1 2 turn at a time until all internal spring force is relieved Remove the cover Check for broken springs and replace if necessary Figure 5 2 Swing Motor Assembly 5 2 USTC January 15 2001 SECTION 5 SWING DRIVE Figure 5 3 Swing Brake Assembly 2 Apply low air pressure 20 30 psi to the brake Installation release port while holding one hand on top of the piston and springs The air will force the piston out of the case Note Unless otherwise specified use automatic transmission fluid ATF Type F as a lubricant for the swing brake 3 Remove friction pack Friction pack consists of friction discs seperator plates and spacers Replace any items that are burned or scored 1 If removed install shaft seal and bearing in the case 2 Install shaft in brake case Tap shaft into place 4 Remove shaft from brake case by tapping out with a soft hammer the output end with a soft hammer 3 Install friction pack in the brake case Install spacer first and friction discs and spacers Note Be careful not to contaminate friction surfaces with dirt grease or fluids other than those specified for the brake 3120933 Rev USTC 5 3 SECTION 5 SWING DRIVE 4 Pour approximately 1 tablespoon of ATF Type F over the friction plates or u
55. OW BOOM AND HOOK BLOCK AND AHEAD OF HOOK BLOCK ARE CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL 2 With boom in the stowed position move tele scope control lever forward until boom extends approximately four feet Use tape or chalk line to mark outer mid section at end of base section 3 Raise boom to maximum elevation 80 4 Shut down hydraulic system by disengaging Power Take Off PTO and turning off truck engine 3120933 Rev 5 With engine off move telescope control lever to retract boom If boom starts to retract holding valve is defective and requires replacement 6 If boom does not retract complete steps 7 through 10 Acaution HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM 7 Tag and carefully disconnect the hydraulic lines to telescope cylinder Use a suitable container to retain any residual hydraulic fluid Immediately cap lines and ports 8 Leave boom elevated in test position for ap proximately one hour Awarnine BEFORE LOWERING BOOM ENSURE THAT AREAS BELOW BOOM AND HOOK BLOCK ARE CLEAR OF ALL PERSONNEL AND OBSTRUCTIONS 9 Start engine and using truck hydraulics lower boom to horizontal position 10 Check boom length against original measure ment If boom has retracted more than one inch and oil is leaking around rod end of telescope cylinder check with light and inspection mirror seals a
56. asure inside dimension of outer mid inner mid and base sections Install wear pads and shims to side top and outside of each section allowing 1 16 in clearance between inner and outer dimensions of each section Note Mark both ends of the cables to ensure that they do not cross inside of the boom USTC 2 Place sheaves on pins inside outer mid section Attach adjuster end of fly section retract cables to fly section using clamps at the pedestal end Use mechanic s wire to hold middle of cable in approximate location of sheaves inside outer mid section Lay bullet end of extend cables in approximate position at pedestal end 3 Attach ramp to fly section Using mechanic s wire hold ramp up as high as possible Pull cable ends top and bottom in towards center of fly section to prevent catching inner sheaves 4 Insert fly section into outer mid section Be sure ramp stays in position Remove mechanic s wire holding middle of extend cable before cable is completely inserted Slide in until approximately 12 in of retract remains 5 At the nose end insert the top wear pad and two bottom wear pads and shims Shim as necessary to provide 1 16 in clearance Be sure to orient wear pads toward outside edge of section 6 Insert four side wear pads loosely to inside of outer mid section Shims will be added after boom is assembled 7 Attach cable anchor blocks on top of extend cables at pedestal end of fly section Do no
57. attachment proper swivel lubrication and for nicks cracks gouges deformation or evidence of any other damage Check for proper operation of hook safety latch Inspect the hookblock for security of attachments proper lubrication and for nicks cracks gouges deformation or evidence of any other damage Check wedge socket for proper size and proper cable installation Ensure all components requiring lubrication are serviced as necessary i e wear pads wire rope sheaves etc Ensure that all control placards are located adjacent to the corresponding control device and safety warning and instruction placards are securely attached and legible Inspect steps handholds deck operator platform and controls to ensure they are free of oil grease mud water debris and foreign objects tools material rags etc Check entire machine for debris which may interfere with operation Using all applicable safety precautions start engine and with PTO engaged check indicator on top of hydraulic filter mounted adjacent to oil tank for condition of element Change element as required With the unit operating and before starting actual job site applications inspect the following a Smooth and proper operation of all crane and outrigger functions Check that Outrigger in Motion Alarm system is working properly b Check that boom and jib cable sheaves rotate freely and ensure that they are in good condition c Inspect al
58. c8 9 Old AW13a 13IHS LOH HSVQ HONYL ONIH38 AV133 1VNOILLIOOV 90 21 VO ZL NONA N Navo ams Tama S Lt 3LIHM 301195 705 YIMOd NOILIN9I t AN3WLYVdWOD 3NI9N3 NI AVT33 1vNOILIGO NMOHS SV AYTAY TWNOLLIGGY TIVISNI SdWv 9 NVHL 3HOW W3LSAS AONYL JHL NO a LON S3801V33 GYVGNVLS ST YOs Figure 6 2 Electrical Schematic 6 3 USTC 3120933 Rev SECTION 6 ELECTRICAL z N ZLEZ8ZL JI9NY SS33d AV ldSIQ SdWV 0 WALSAS INT LVd TaN AVTI3M 81 ro AVT3N SLY t INN NI 1SIOH et 3r38 81 IWAN TON 34 QVOTH3AO WAY LN 34 QVOTH3AO WAY 43034 NMOQ 14 FT voc AV738 NMOO 13A31 NMOG 13A31 ro LNy Av38 13A31 dn 13A71 ro AV 3H N3MOd Xhv 9 M43MOd xnv TOL AV LYVLS 00 Wd JOMINOO MOTA TOULNOD o Vo LN OL L183AIQ HOLIMS 193135 NOILONN4 Sc 310W3H Ol LYSAId p d oe Ov NMOG 13A31 AVT3H NMOQ 13A31 HOLIMS O
59. cessary to maintain conditions until cables do not hit as established in step above 9 Repeat steps 7 and 8 as necessary Extend cable nylon collar adjusting nuts should be torqued to 30 Ib ft 40 6 Nm dry 10 Install boom stop and shim as necessary so stop is snug against outer mid section top plate when boom is fully retracted 11 Check for proper operation of boom 12 Operate hoist and carefully remove slack in cable be sure cable is in direct line with cable socket attached to lug on end of base boom 13 Carefully operate hoist to pivot and raise hoist until mounting plate holes line up with holes in base boom side plates 14 Install the 3 4 10UNC x 3 1 2 long grade 8 bolts washers spacers and nuts Torque to 301 Ib ft 408 Nm using Loctite 262 15 Remove open wedge cable socket from base boom lug and reeve cable for the configuration required i e one part line two part line etc Refer to reeving instructions earlier in this manual 16 Reinstall hoist 4 10 USTC Extend Retract Cable Replacement When the extend cables require replacement and the boom is not scheduled to be completely disassembled it is possible to attach a wire to one end of the old cable before pulling the cable out Once the old cable is removed the new cable can be attached to the wire and threaded through To replace the retract cables the telescope cylinder and fly section must be removed To remove the tele
60. ction The remaining sections receive oil at the mid inlet from the middle 24 gpm pump section The valve sections are three position valves A relief valve cartridge is located in the swing inlet and mid inlet sections and in the telescope section on the retract side On the bottom of each outrigger stabilizer section is a small switch which activates the outigger stabilizer in motion alarm The control valve 15 located inside the console weld ment Sections are operated through linkages to the control handles STABILIZER Curb Side STABILIZER Street Side OUTRIGGER Curb Side OUTRIGGER Street Side IEEE ORE Outrigger Stabilizer In Motion Alarm Switches Figure 7 7 Control Valve 1 10 USTC The control valve can be accessed inside the pedes tal through the pedestal side covers for adjustments and hose replacement If the valve must be replaced or other components require access the console weldment can be removed To remove the console weldment the hoses must be disconnected from the valves mounted on the inside of the console weld ment IMPORTANT Always clean area around valve and valve to prevent dirt and contamination from entering hydraulic lines and valve ports Always mark hydraulic lines according to port loca tion before disconnecting hoses Cap or plug hoses to prevent contamination When installing the valve and linkages attach the linkages before aligning the control levers If the console
61. ction or replace Repair or replace pump Replace pump drive shaft January 15 2001 TROUBLE Outrigger will not extend Outrigger will not retract 3120933 Rev SECTION 3 TROUBLESHOOTING Table 3 4 Hydraulic Components PROBABLE CAUSE Control rod or lever broken or disconnected Low hydraulic oil level Restricted or broken supply line Malfunctioning hydraulic pump Worn control valve spool Hydraulic lines incorrectly connected to outrigger control valve Hydraulic lines incorrectly connected to cylinder Outrigger holding valve stuck in closed position Relief valve in control valve set too low Malfunctioning outrigger valve Holding valve stuck in closed position Control rod or lever broken or disconnected Low hydraulic oil level Restricted or broken supply line Malfunctioning hydraulic pump Hydraulic lines incorrectly connected to outrigger control valve Hydraulic lines incorrectly connected to cylinder Malfunctioning crossover valve Malfunctioning outrigger valve Excessive oil leak past piston seal Relief valve in control valve set too low USTC REMEDY Replace switch Add oil Remove line and clear obstruction or replace line Repair or replace pump Check pressure delivery from control valve and repair or replace valve Connect hydraulic lines properly Connect hydraulic lines properly Repair or replace holding valve Adjust o
62. d the hoist cable and adjust counterweight chain length to activate cut off switch before two blocking occurs Four Part Line Reeving Note Reference to right and left is made with the operator facing the controls on the console Note The following procedure must be followed and used before lifting any load with four part line 1 Lower boom to allow access to boom nose 2 Remove anti two block counterweight from around the hoist cable let hang 3 Ifthe headache ball hookblock combination is installed lower to the ground and pay out ap proximately 25 ft of cable Note Four part load line requires the boom head lower sheave wheel position to be configured for double sheave wheel operation USTC 4 5 SECTION 4 BOOM 4 Remove hair pin from the wedge socket pin securing the wedge socket to the boom nose lug or hookblock headache ball assembly 5 Remove lower hoist cable retaining pin from the boom nose 6 The headache ball hookblock assembly must be configured as a double sheave hookblock assem bly The hoist cable can either be reeved through the headache ball hookblock assembly with the open wedge cable socket removed as in Step 7 or hookblock sheave wheels can be removed from the headache ball hookblock assembly by removing center sheave wheel pin spacers and sheave wheels 7 Remove open wedge cable socket from end of hoist cable if attached and reeve hoist cable m through boom nos
63. d section distorted Insufficient lubricant on boom nose sheaves Wire rope broken or bird caged Wire rope binding or incorrectly positioned on sheaves Boom retract and extend cables out of adjustment Attach pins damaged Boom nose lugs damaged Jib attach lugs damaged Jib stowage attach bracket out of adjustment Defective bearing Upper lift cylinder pin damaged or worn Boom pivot pin or bushings damaged or worn USTC SECTION 3 TROUBLESHOOTING REMEDY Replace applicable cables Replace anchor weldment Replace applicable sheaves or attach pins Adjust cables Replace nuts and applicable cables Adjust cable systems Replace and lubricate sheaves Lubricate as required Adjust or replace pads Repair or replace sections Lubricate sheaves refer to Lubrication Chart Replace wire rope Check and align hoist and correctly position wire rope over sheaves Adjust boom cables Replace attach pin Repair or replace lugs Repair or replace jib Adjust bracket Lubricate or replace bearing as necessary Replace lift cylinder pin Replace pivot pin or bushings January 15 2001 TROUBLE Control valve spool sticking Control valve leaking Turntable swing motion erratic Turntable coasts with control lever in neutral Turntable stops abruptly when control lever is moved to neutral 3120933 Rev Table 3 2 Pedestal PROBABLE CAUSE Dirt in
64. e functions on and off Usually a signal wire from the PTO switch ground operates the power solenoid through a relay This can vary depending upon the type of PTO installed Stacked terminal strips distribute power between the various components located in the main electrical box 6 2 USTC OVERLOAD SYSTEM The overload system includes an optional shut down function on some models The shut down function operates by activating a solenoid valve that dumps oil to the reservoir The overload system monitors the pressure difference between the extend and retract ports If the machine is overloaded the system will not allow the machine to boom down boom up telescope out or hoist up An override switch is provided to allow the boom up function to operate which may be needed in certain situations LOAD MOMENT INDICATOR Some models may be equipped with an additional Load Moment Indicator LMI The LMI provides load information such as load weight load radius and boom angle Refer to the LMI documentation for additional information January 15 2001 SECTION 6 ELECTRICAL N ed ZLEZ8ZL O3d LH Q38 LNW 221096 10313 0 1 LNA rr 10313 0NVIS LNW 1NOMJ OZLZC6v NOILdINS3G N d LYVHO W 8 SNOLLVUNDIINOD 3NI9N3 531415 AINUL 9NIASVA OL 3nd SNOLVOrlddY 7v2lH123 13 NO S3ONVYSIOL GYVNOSYSIC 3LON
65. e gauge cartridge to access the adjustment screw to the gauge port at the mid inlet section of the control valve Remove the hydraulic line to the swing brake and plug the line Using all applicable safety practices start the truck engine engage the PTO and operate the crane at low engine speed Move the swing control lever in either direction and note the pressure reading on the gauge If the pressure is incorrect remove the acorn nut or loosen the jam nut on the relief valve cartridge to access the adjustment screw If the pressure is too low turn the adjustment screw clockwise to increase the pressure setting If pressure is too high turn the adjustment screw counterclockwise to decrease the pres sure setting Tighten jam nut while holding the adjusting screw or install the acorn nut Repeat step 4 to ensure that the pressure set ting is correct USTC If the pressure is too low turn the adjustment screw clockwise to increase the pressure set Adjustment for Figure 7 2 Hoist Valve Relief Cartridge January 15 2001 SECTION 7 HYDRAULICS Pressure Check Point Quick Connect Pressure Adjustment Screw Figure 7 3 In Line Relief Valve ting If pressure is too high turn the adjustment screw counterclockwise to decrease the pres sure setting 6 Tighten jam nut while holding the adjusting screw or install the acorn nut 7 Repeat step 4 to ensure that the pressure set ting is
66. e left lower sheave wheel SNATCH 8 After reeving cable through boom nose sheave s and headache ball hookblock assembly sheaves e ud to ae hoist ee A COUNTER cable socket to boom nose lug wedge socke Z lt WEIGHT hole using the wedge socket pin and hair pin provided 9 Reinstall lower hoist cable retaining pin in boom nose 10 Reinstall anti two block counterweight around the hoist cable and adjust counterweight chain length to activate cut off switch before two blocking occurs Figure 4 6 Snatch Block Five and Six Part Line Reeving If it is desired to handle higher loads than the four part lined is rated for the crane can be equipped with a single sheave snatch block to allow for five and six part line reeving The snatch block hangs from the 3 Remove anti two block counterweight from boom nose lug and functions as an additional lower around hoist cable and let hang sheave on the boom nose able capacity stand Remove cable socket from the load handling device 4 Remove lower hoist cable retainer pin from Note Five part line requires a two sheave boom nose hookblock Six part line requires a three sheave hookblock 5 Securely attach snatch block to boom nose lug sure block is oriented properly ss t BOOM DOSY 6 Reeve hoist cable through hookblock and lower 2 Lower installed headache ball hookblock or boom sheaves as if for four part line Continue oth
67. e of the sections Note When assembling a new boom it is beneficial to measure the clearance inside each section and install the wear pads at pedestal end before assembling sections Side Wear Pads The side wear pads in addition to being shimmed to eliminate any gap must also be adjusted to make the boom extend straight When the boom is fully ex tended the boom must be within 1 2 in of straight when measured side to side 3120933 Rev Fully extend the boom Attach one end of a string centered on top of the boom at the pedestal end and the other at the nose end If the boom string does not trace along the center of the boom add or remove shims under side wear pads at nose end to cause the boom to be straight If boom curves to the right remove shims from left side of the section that seems to be causing the bend and reinstall them on the right side Continue to adjust shims until the boom is straight within 1 2 in EXTEND RETRACT BOOM CABLES Cable Inspection Procedures Acaution WEAR GLOVES TO PROTECT HANDS WHEN HANDLING CABLE Boom extend and retract cables must receive periodic inspections by a qualified person Inspections should occur annually or every 2000 hours which ever occurs first and more often when deemed necessary based on experience In order to inspect the cables the telescope cylinder and fly section must be removed from the boom The cables can then be removed and the full length exam
68. ent screw counterclockwise to decrease the pres sure setting 6 Tighten jam nut while holding the adjusting screw or install the acorn nut 7 Repeat step 4 to ensure that the pressure set ting is correct CYLINDERS Holding Valves Each hydraulic cylinder on the crane except the outrigger extend cylinder has an integral holding valve to prevent the cylinder from retracting if a line breaks or is accidentally punctured The holding valves use small orifices which can become clogged if dirt enters the hydraulic system Holding valves prevent movement in one direction only such as retraction Some applications require holding valves for both directions When multiple holding valves are used it is possible to trap oil in the cylinder between the holding valves To avoid this do not remove the holding valves when the cylinder is fully extended or retracted To remove a holding valve 1 Loosen the hoses into the cylinder to relieve any pressure 2 Fitthe wrench on the cartridge and cover with a rag to prevent hydraulic spray 3 Remove the cartridge Acaution NEVER ADJUST HOLDING VALVES Note Cylinders vary depending upon the application The procedures described herein are general If specific questions arise contact the USTC Customer Service Department If not equipped with cylinder disassembly tools refer to a specialty hydraulic shop 7 6 USTC IMPORTANT Perform cylinder disassembly and assembly on a
69. er load handling device onto ground or suit reeving through the snatch block and attach to 4 6 USTC January 15 2001 SECTION 4 BOOM the hook block lug five part line or the snatch block lug six part line 7 Reinstall lower hoist cable retaining pin 8 Reinstall anti two block counterweight around hoist cable It may be necessary to add addi tional length to the counterweight chain The counterweight must hang at least 14 in below the snatch block For five part line install the counterweight on dead end line going to the hook block For six part line install the counterweight on dead end line going to the snatch block WEAR PADS Wear pads are located at the ends of each boom section Shim wear pads to allow 1 16 in gap be tween wear pad and adjacent surface Replace wear pads when worn to within 1 8 in of insert or screw head Top and bottom wear pads are located inside each section on the nose end Vertical clearance is adjusted using the two bottom wear pads and the appropriate amount of shims Two top wear pads are located at the pedestal end of the outer sections Wear pad adjustment is made by adding shims through access holes on the top of the base at the pedestal end Side wear pads are also used and are adjustable On the nose end of each section four nylatron wear pads are placed inside the section two per side At the pedestal end of the boom metal wear pads and shims are welded to the outsid
70. er time for cable replacement a dated cable condition report from each periodic inspection shall be kept on file Per ANSI specifications replacement parts shall have a strength rating at least as great as the original any deviation from the original must be specified by the manufacturer a wire ripe manufacturer or a qualified person Note Cable must be spooled onto hoist in same direction as removal from spool HOIST CABLE Installation and Attachment Procedure 1 From top of spool route cable over top idler sheave 2 Continue routing cable along base boom and anchor to hoist drum 3 Keeping cable tight as possible operate hoist and spool cable onto drum using a brass mallet to assure cable wraps properly 4 If using multi part line properly reeve cable through sheave wheels of boom nose and hook block assembly 5 Attach cable to wedge socket Attach wedge socket assembly to attaching link on bottom of boom nose January 15 2001 SECTION 4 BOOM ANCHORING WIRE ROPE Take the free end of the wire rope and insert it through the small opening of the anchor pocket Loop the wire rope and push the free end about 3 4 of the way through the pocket Install the wedge then pull the slack out of the wire rope The wedge will slip into the pocket and secure the wire rope into the drum HORT PIECE F WIRE ROPE SIZE in EXCEED LENGTH g OF WEDGE TORQUE INSERT SMALL Wire ro
71. er to the table for sure setting the proper pressure setting 5 Tighten jam nut while holding the adjusting screw or install the acorn nut 3120933 Rev USTC 7 3 SECTION 7 HYDRAULICS If the pressure is incorrect remove the acorn nut or loosen the jam nut on the relief valve cartridge to access the adjustment screw If the pressure is too low turn the adjustment screw clockwise to increase the pressure setting If pressure is too high turn the adjustment screw counterclockwise to decrease the pres sure setting Hoist Relief Valve The hoist relief valve is located on the hoist control valve 1 Attach 0 4000 psi 0 276 bar pressure gauge to the gauge port on the hoist control valve inlet Remove the hydraulic lines to the hoist and plug both lines Tighten jam nut while holding the adjusting 3 Using all applicable safety practices start the screw or install the acorn nut truck engine engage the PTO and set the outrig Repeat step 3 to ensure that the pressure setting ges Ope tile tHe is correct 4 Move hoist control valve in either direction and note pressure gauge reading Refer to the table Swing Inlet Relief Valve for the correct pressure setting The swing section has a separate relief valve in the ME 5 If the pressure is incorrect remove the acorn swing inlet section nut or loosen the jam nut on the relief valve 1 Attach a 0 4000 psi 0 276 bar pressur
72. for locating and correcting most of the oper ating problems which may develop in the crane If a problem should develop which is not presented in this section of which is not corrected by listed corrective actions technically qualified guidance should be obtained before proceeding with any maintenance Troubleshooting and maintenance information per taining to the truck rear axle suspension and drive train components are contained in the applicable maintenance manual 3120933 Rev 0 TROUBLESHOOTING INFORMATION The troubleshooting procedures applicable to the crane are listed and defined in Tables 3 1 through 3 5 As an aid to table use the crane is divided into five major groups or systems each covered within a separate section in this section These groups or systems are as follows boom assembly pedestal chassis hydraulic system and electrical system Each malfunction or trouble within an individual group or system is followed by a listing of probable causes which will enable determination of the appli cable remedial action The probable causes and the remedial actions should where possible be checked in the order listed in the tables It should be noted that there is no substitute for a thorough knowledge of the equipment and related system Reference should be made to the applicable maintenance portion of the manual for instructions pertaining to the remedies listed in the troubleshoot ing tables It should be reco
73. gnized that the majority of the prob lems arising in the crane will be centered in the hy draulic and electrical systems For this reason every effort has been made to ensure that all likely mal functions in these areas are given the fullest possible treatment In the remaining crane systems only those malfunctions which are symptomatic of greater prob lems or which have more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section USTC 3 1 TROUBLE Fly or outer mid section s will not extend or retract Extension and retraction of fly or outer mid section is erratic Hoist cable movement erratic Jib attach pins will not install Boom angle indicator inoperative Boom raises and lowers noisily and erratically 3 2 Table 3 1 Boom Assembly PROBABLE CAUSE Broken extend or retract cable for fly and outer mid section Broken cable anchor weldment Broken telescope cylinder or inner outer mid section sheaves or sheave attach pins Extend or retract cables require adjustment Cable nylon collar locking nuts or threaded end of cable stripped causing excessive cable slack Cable sheave bushings defective as a result of cable overtightening Lack of lubricant on fly or outer mid section 85 and 94 ft booms or cable sheaves Wear pads out of adjustment or worn Fly or outer mi
74. h and for excessive or uneven wear patterns 5 Inspect primary and secondary planet carriers for damage especially in roll pin and planet pin hole areas Ensure that gear apertures are not damaged Replace as necessary 6 Inspect all planet pins for scoring or other dam age Replace as necessary January 15 2001 SECTION 5 SWING DRIVE 8 Inspect seal mounting area in case for burrs or sharp edges Dress applicable surfaces or re place components as necessary Inspect cover for cracks or other damage and o ring sealing area for burrs or sharp edges Dress applicable surfaces or replace cover as neces sary Carrier Disassembly Sun Gear Retainer Secondary Planet Assembly 25 3 4 5 6 Shaft Seal 1 Both the primary and secondary carrier assemblies Primary can be disassembled if necessary Planet Assembly Place the primary planet carrier into a suitable hand operated hydraulic press with the roll pins securing the planet pins to the carrier housing Place blocks beneath the planet carrier such that they clear the planet pin Blocks should be approximately six in high to provide adequate clearance for removeal of the planet pins Press the planet pin from the carrier Be sure to protect the pin from damage Slowly and carefully press the pin from the carrier shearing the attaching roll pin Remove the planet gear and washers from the carrier and if necessary remove and disca
75. he large diameter up Using the press install bearing into planet gear making sure that the bearing cage is installed squarely Apply a coating of multi purpose grease to the planet mounted bearing rollers and carefully insert planet gear and washers into the carrier gear aperture Align carrier and gear bearing holes and insert planet pin into the carrier with the chamfered end of the roll pin hole on the same side as the carrier roll pin hole Ifnecessary gently tap planet pin into position with a soft mallet ensuring that the rol pin is flush with the carrier surface Again ensure that the planet gear rotates freely Repeat steps 1 through 5 for remaining planet gears Hub Assembly 1 5 6 Replace shaft seal Lubricate inner lip of new seal and turn so open side is facing upward Slide seal down output shaft to gear teeth It must fit snug over seal diameter on shaft With large end down press outer bearing cone onto output shaft Be sure it is seated properly USTC Using a suitable press install upper and lower bearing cups into hub case Apply a layer of lithium grease to outer bearing cup and surface Set case assembly over shaft until shaft s outer tapered bearing cone is seated in cases s outer bearing cup Carefully place shim over shaft making sure the three holes in shim are properly aligned with those on the shaft Use same number of shims that came ou
76. hould be 50 80 Ib in 13 Remove press load from secondarhy carrier Install bolts and torque to 70 75 Ib ft 14 Press splined end of sun gear into spline on bottom side of primary carrier 15 Turn primary carrier assembly over sun gear down Install assembly into unit until sun gear teeth mesh with secondary planet gears Primary carrier assembly will slide down to where pri mary planet gears touch top of gear teeth in case Hold inside diameter of carrier and rotate until planet gears line up with case gear teeth Assembly will drop down 16 Install input thrust washer over step of input gear Insert input gear into unit so teeth mesh with primary planet gears 17 Replace o ring seal on bottom of cover 18 Set cover on top of unit and rotate until oil fill hole is in proper orienteation to oil drain hole in case Install cover bolts and loackwashers Torque bolts to 32 Ib ft 19 Ensure magnetic plug is secured in case 20 Fill unit with 2 5 pints of extreme pressure gear lubricant Correct oil level will measuer to middle of primary planet gear 2 Put pipe sealant on magnetic plug and install into oil fill hole in cover 22 Stick a shaft into input gear and turn by hand to be sure unit runs smoothly and easily 3120933 Rev SWING BEARING The swing bearing carries all the load from the boom The bearing is manufactured with a certain clearance which must be maintained to obtain a smooth rotation with
77. id Retract Cables Figure 4 10 Inner Mid Outer Mid and Fly Sections 3120933 Rev 0 USTC 4 13 SECTION 4 BOOM Inspect boom pivot pin for wear scoring or other damage and for tapering or ovality replace pin as necessary Inspect upper lift cylinder attach pin for tapering ovality scoring wear or other damage Ensure pin surfaces are protected prior to installation Replace pin as necessary Inspect extend cable anchor plates for wear of other damage Replace anchor plates as neces sary Inspect inner diameter of boom pivot bushing for scoring distortion wear or other damage Re place bushing as necessary Inspect all wear pads for excessive wear or damage Replace wear pads when worn to within 1 16 in of insert Inspect extend and retract cables for stretching distortion or other damage Replace components as necessary Inspect all threaded components for damage including stretching thread deformation or twist ing Replace as necessary Inspect structural units of boom assembly for bending cracking separation of welds or other damage Replace boom sections as necessary Boom Assembly 4 14 The boom assembly procedure covers installation of a complete new boom including new wear pads Some steps may not be necessary if reusing existing parts Always shim wear pads correctly after assem Awarnine NEVER ALLOW SECTIONS TO REST ON CABLES WHILE ASSEMBLING CABLES MAY BE DAMAGED 1 Me
78. ing common sense coupled with a series of visual inspection guidelines A warnine SINCE THE MACHINE MANUFACTURER HAS NO CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR LUBRICATION The lubrication points to be covered periodically are illustrated and defined in Figure 2 1 USTC Inc recommends using high quality hydraulic oil such as AW68 If operating in cold climates AW46 may be substituted USTC 2 1 SECTION 2 INSPECTION Figure 2 1 Lubrication Points TABLE 2 1 Lubrication Points and Intervals LUBRICANT FITTINGS DESCRIPTION Hook Bearing Hookblock Sheave Lower Boom Nose Sheaves Upper Boom Nose Sheave Fly Extend Cable Sheave Align holes in mid and fly Boom Assembly Extend boom Brush on wear pad travel area Fly Cable Retract Sheave 50 Align access hole in base boom Boom Pivot Bushing 50 Hoist Oil Level Check w boom at 0 by using the 100 1000 Change oil after first 100 hours and every large oil level plug located in center of support 1000 hrs thereafter Upper Lift Cylinder Pin 50 Lower Lift Cylinder Pin 50 Swing Bearing 50 Apply MPG rotate turntable 90 and Pi
79. is assembled 22 Install lower boom nose sheaves Use vaseline to hold spacer in place between sheaves Insert pin through sheaves and secure with tube spacer bolt and hardened washer 23 Insert upper boom nose sheave assembly with spacers on each side Insert pin through sheave assembly and secure with cotter pin 24 Insert telescope cylinder according to Telescope Cylinder Installation procedure 25 Attach hydraulic lines to telescope cylinder Install retract cable retainer plate to cylinder with pin Secure with retaining rings on each side 26 Using hydraulic power retract telescope cylin der until retainer plate is seated against cylinder mounting bar inside base section Secure re tainer plate with six socket head bolts Tighten per Torque Chart 27 Apply anti sieze to extend cable threads Secure with nylon insert lock nuts Remove slack from cables tightening lock nuts evenly Torque lock nuts to 40 Ib ft with cables even 28 Rotate cable so that flats at base of threads are horizontal Attach bars on top and bottom of cables using five bolts to prevent cable rotation 29 Adjust cables using standard cable adjustment procedure 29 Shim side wear pads of each section using standard wear pads dimensions Use string to straight line boom Awarnine SINCE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR
80. ition Return relief valve in hoist stuck in closed position Hoist primary drive assembly damaged Relief valve in hoist control valve inlet section set too low Hoist brake clutch defective Uneven hoist mounting Excessive back pressure at hoist motor manifold Hoist brake defective Hoist control valve spool stuck in open position Relief valve in hoist control valve opening and closing Hoist friction brake intermittently engaging and releasing Anti two block valve not opening completely Load capacity exceeded Hydraulic oil level low Restricted or broken hydraulic line Malfunctioning hydraulic pump Control cable broken kinked or disconnected Check valve in lift control valve inlet stuck in closed position Worn control valve spool Main relief valve spool too low Holding valve in lift cylinder stuck in closed position Excessive oil leak past lift cylinder piston seal USTC Table 3 4 Hydraulic Components continued REMEDY Repair or replace hoist motor Repair or replace sticking valve Disassemble hoist and repair or replace relief valve Disassemble hoist and repair replace primary drive Adjust or replace relief valve Disassemble hoist and repair or replace clutch Check hoist for correct mounting Check hoist counterbalance valves and repair Disassemble hoist and repair or replace brake Clean or replace valve section Clean or replace
81. l control levers switches and accelera tor pedal for proper installation and operation d Check for proper operation of all lights and reflectors 2 3 SECTION 2 INSPECTION e Check anti two block device for proper operation The hookblock must stop when it contacts the anti two block counterweight while winching up or telescoping out Telescope out hoist up and boom down must not function when in an anti two block condition f Check anti two block device for proper operation The load handling device must stop when it contacts the anti two block counterweight while hoisting up or telescoping out g If equipped with Overload Audio Visual Warning or Overload Cut off test the system by activating the toggle switch labeled Capacity Alert Test Switch located on the console When the test switch is activated the warning light must flash the warning horn sound and the following crane controls must be disabled Hoist Up Telescope Out Boom Up and Boom Down Next lift and hold the Override Switch for Lift Up Only and attempt to lift the boom from its current position If the boom elevates the system is working properly Awarnine DAMAGE TO EQUIPMENT OR PERSONNEL MAY OCCUR IF THE FOLLOWING IS NOT ADHERED TO Note The overload warning overload cut off and the LMI systems are an operational aid only and shall not be a substitute for good operator judgement experience and use of safe crane operating procedu
82. lay rod end of lift cylinder down on truck bed to provide clearance for boom removal 9 Tag and disconnect lines to telescope cylinder and hoist Use suitable containers to retain any residual hydraulic fluid which may leak out Plug and cap hydraulic lines to prevent addi tional leakage Dispose of residual oil in ac cordance with all federal state and local laws 10 With boom assembly adequately supported remove rod keeper and boom pivot pin and pivot pin sleeve Use a brass drift tool if necessary to remove pin 11 Carefully lift boom assembly clear of crane and lower to suitable work surface Boom Installation 1 Using suitable lifting equipment position assembled boom on turntable so that boom pivot holes in both boom and turntable are aligned 2 Insert boom pivot pin through turn table boom and pivot pin sleeve Be sure that locat ing holes in pin are aligned so keeper rod can be attached to holes in turntable If necessary gently tap pin into position with a soft headed mallet Secure pin with rod keeper and rod keeper to turntable Torque keeper bolt per Torque Chart 3 Connect hydraulic lines to hoist and telescope cylinder 4 Using suitable lifting equipment raise rod end of lift cylinder to align with mounting holes in boom It may be necessary to extend or retract lift cylinder using crane hydraulics Insert pin through boom and lift cylinder Secure pin with rod keeper Torque keeper bolt per
83. ld TO 134 AVTI3H SSVdA8 9015 ANIONS Ov dn 13431 AYTAY dN 13A31 OL MN3MOd xnv H3MOd xnv ol S 3NION3 AV133 LYVLS u NOLLONNS 9 40 oz NOILONNS AYTAY oz 705 3NION3 HOIH e 3NION3 HO SNOILdO TWANWW OL LY3AIG 193135 ov OL 183M0 o QN3LX3 8v1S S _ AV 134 dO1S 3 HOLIMS 50193135 9 9015 3 gT et 331133 dn 14N SLOW zo N HOLIMS BYNSS3Yd AV I34 QVO IH3AO QVOTM3AO 1ndino QVO IH3AO 1 SNOLdO 4 IW1 QVO TH3AO AV I34 M3MOd OlQV3 310W38 ov OL 183M0 o QN3LX3 8V1S Ov OL LYSAIG o QN31X3 YLNO 0 OL 183M0 QN31X3 Nino TOS 3NION3 amp 14 SI SNOILdO 3SIMOMVH OIOV 9 AV I3N 3NION3 MOT fuya sH E ov OL LYIMO MOvr EE NA 1101d 7 GIONIIOS 1303 IRA 5311 NOLLOW YLNO NYOH dt aed S3HOLIMS NOLON 31100 43034 3NN NI LSIOH
84. lear obstruction or replace line Repair or replace pump Check pressure delivery from control valve and repair or replace valve Adjust cables Replace nuts and applicable cables Adjust cables Replace sheaves and lubricate Adjust cables Lubricate boom sections Adjust or replace wear pads Repair or replace boom sections 3 11 SECTION 3 TROUBLESHOOTING Table 3 5 Electrical System TROUBLE PROBABLE CAUSE REMEDY Warning horn inoperative Fuse in horn circuit blown Determine cause of circuit overload or short and correct before replace fuse Malfunctioning horn button Check switch for correct switch or loose terminal operation with test meter connections Replace or repair as necessary Malfunctioning horn Check for defective horn with Relay in ground electrical box test meter Replace as defective necessary Replace relay 3 12 USTC January 15 2001 SECTION 4 BOOM GENERAL This manual covers the 94 ft boom which is mounted on 2500JBT and 2700JBT cranes The boom consists of four sections a telescope cylinder inside of the boom and the hoist For the purposes of this manual the lift cylinder is also to be considered part of the boom The boom must be maintained properly to provide long life and proper operation Wear pads are con sumable items which must be adjusted through shims or replaced when necessary Cables inside the boom will stretch and require adjustment The wire rope o
85. lels Sl Seis e ls Islsisisis s slsls lelelelelejelelejeje lelejelelelejeje saya SSnH LNaovray N33W138 G3TIVISNI S3LYId 9NILV3Vd3S 438 NMOHS SV Q3TIVISNI ONY NOlLISOd NOILISOd Z OLNI suve SSnH 434 Figure 6 4 Electrical Box Schematic 6 5 USTC 3120933 Rev SECTION 6 ELECTRICAL PASSENGER SIDE CONTROL CONSOLE DRIVERS SIDE HORN amp E STOP SWITCHES START seio AND CONNECTIONS NOT SHOWN START WHITE YELLOW HIGH HOIST GREEN 7 WIRE CABLE YELLOW OPTIONAL OUTRIGGER STABILIZER COMBINATIONS eee SPLICE ENGINE COMPARTMENT geek Sack HORN START EN TION x Se STARTER amp FUEL_SOL CONNECTIONS EXTEND EXTEND SOLINOID NOT SHOWN 2 No PASS SIDE STAB STAB OUTR EXTEND EXTEND EXTEND us an DRIVER SIDE HSoAMP PASS OUTR EXTEND BREAKER STAB EXTEND BLACK SPLICE BLACK BE BK 7 WIRE CABLE OUTR EXTEND STAB EXTEND PASS SIDE OUTR EXTEND PASS SIDE STAB EXTEND DRIVER SIDE DRIVER SIDE MAIN BOX TERMINAL SEE 1282312 FOR STRIP ADDITIONAL STANDARD MACHINE CONNECTIONS GREEN SPARE GREEN BLACK BLACK 1 PTO SPARE 1 BROWN HORN 3 414 BROWN YELLOW START 5 6 YELLOW BUMPER JACK 7 WRE CABLE 7 WIRE CABLE
86. lic pump noisy No oil delivery from pump 3 4 SECTION 3 TROUBLESHOOTING Table 3 3 Chassis Components PROBABLE CAUSE Shift rail poppet spring broken Shift rail poppet notch worn Shift fork sprung or loose on shift rail Gear teeth worn Gears not shifted fully in mesh Shift linkage too short Improper number of gaskets Gears worn and pitted Bearings worn due to high loads or chips Oil seal failure Broken gaskets Crack or hole in housing Air entering system through a broken hydraulic suction line or fitting Air bubbles in oil caused by depleted reservoir oil level Contaminated oil filters Worn or chipped pump gears Worn or broken pump drive shaft Low hydraulic oil level Restricted or broken suction line Worn or chipped pump gears Worn or broken pump drive shaft USTC REMEDY Replace poppet spring Replace shift rail Replace shift fork or tighten set screw in shift fork Replace worn gears Check shift linkage for proper adjustments Adjust shift linkage to permit full shift Check backlash and refer to setting the backlash Replace worn gears Reduce load Replace worn and rough bearings and change oil Replace worn seal Replace gasket s Replace housing Check suction side of hydraulic system for defects and repair Add oil Replace oil filter Repair or replace pump Replace pump drive shaft Add oil Remove line and clear obstru
87. lief vale set too low Check valve in telescope section stuck in closed position Control cable broken kinked or disconnected Hydraulic oil level low Malfunctioning hydraulic pump Worn control valve spool Hydraulic lines incorrectly connected at control valve Excessive oil leaking past cylinder piston seal Check valve in telescope cylinder stuck in closed position Main relief valve set too low Anti two block valve defective or switch stuck Check valve in telescope section stuck in closed position Control cable broken kinked or disconnected Hydraulic oil level low Restricted or broken supply line Malfunctioning hydraulic pump Excessive oil leak past cylinder piston seal USTC Table 3 4 Hydraulic Components continued REMEDY Add oil Remove line and clear obstruction or replace line Repair or replace pump Check pressure delivery from control valve and repair or replace valve Repair or replace motor Adjust or replace relief valve Repair or replace sticking valve Repair or replace control cable Add oil Repair or replace pump Check pressure delivery from control valve and repair or replace valve Connect hydraulic lines properly Repair or replace cylinder Repair or replace valve Adjust or replace relief valve Replace valve or switch Repair or replace sticking valve Repair or replace control cable Add oil Remove line and clear obstr
88. low torque requirements Bearing mounting bolts must also be monitored to ensure safe operation of the crane Bolt Replacement Torque Procedure Awarnine DO NOT REUSE TURNTABLE BEARING BOLTS ALWAYS REPLACE ALL BOLTS AND HARDENED WASHERS ANYTIME A BOLT HAS BEEN REMOVED USE ONLY UNBRAKO LOC WEL PATCH BOLTS AND SPECIAL HARDENED WASHERS OBTAINED FROM USTC INC IMPORTANT Re torque swing bearing bolts after the first 200 hours of operation and then at 500 hour intervals thereafter New bearing bolts are required when the bearing is removed or if bolts are found to be stretched If bolts are found to be missing all bolts should be replaced The recommended bolts are a special hardness and include a patch with a thread locker As the bolt is turned into the hole the patch opens distributing the correct amount of thread locker on the threads It is not necessary to lubricate or use any other type of thread locker on the bolts To prevent twisting the bearing to one side the bear ing bolts need to be tightened in a specific sequence Use a torque multiplier to effectively access and torque all bolts When new bearing bolts are installed 1 Insert bolts in holes 2 Following sequence in Figure 5 5 tighten all bolts to 180 lb ft 244 Nm in sequence 3 Repeat step 2 tightening to 472 lb ft 640 Nm USTC 5 7 SECTION 5 SWING DRIVE 40 37 36 45 48 49 59
89. m 148 L min 2nd Section Flow 24 gpm 91 L min 3rd Section Flow 8 gpm 30 L min Hydraulic Filter Inline Return Filtration sss 10 Micron Nominal Flow Rating 60 gpm 227 L min Hydraulic Tank Manufacturer USTC Type sua una eee All Steel with Lockable Cap Capacity qu u nutes vel 90 gal 341 L BOOM SPECIFICATIONS Manufacturer Manitowoc Boom Trucks Type 4 Section Proportional Telescope Retracted Length 29 ft 8 84 m Extended Length 94 ft 28 65 m Boom 8 to 80 Extend Cable Type 5 8 in RRL Outer Mid Length 609 in 15 47 m Fly Length 626 in 15 90 m Retract Cable Type RRL Outer Mid Retract 5 16 in dia 345 in 8 76 m Fly Retract 3 8 in dia 349 in 8 86 m USTC 1 3 SECTION 1 SPECIFICATIONS Jibs Optional Non Extendable Length 26 ft 7 92 m Extendable Length 26 46 ft 7 92 14 02 m OUTRIGGERS AND STABILIZERS A Frame Outriggers Extended Width Pin to Pin 258 00
90. me attach points and outriggers 2 Inspect outrigger assemblies for evidence of leakage and security pressure lines for evidence of abnor mal chafing 3 Inspect power take off assemblies for security wear and damage 4 Inspect main hydraulic pumps and lines for damage evidence of leakage and security of attachment 5 Check hydraulic fluid reservoir and lines for damage evidence of leakage and security of attachment Check filter indicators for element condition Clean or replace elements as necessary 6 Check control levers in cab and linkage under operator platform for visible damage loose or missing parts and proper lubrication Assure that levers function properly 7 Check control switches at outrigger control station and in cab for visible damage loose or missing parts security electrical connections for corrosion and tightness and wiring for proper routing Assure that switches function properly January 15 2001 SECTION 2 INSPECTION 8 Check instruments in truck cab for damage and security of installation Check PTO knob and cable and indicator light for damage and security 9 Inspect Load Capacity Charts Hook Height Chart Area of Operation Chart and corresponding Lifting Notes decals and Instruction Chart for legibility and security 10 Check batteries for damage loose or missing cell caps security and condition of cable connections and hold down brackets and electrolyte for proper level
91. n on the ground Mark as necessary Leave boom elevated in test position for approximately one hour 7 2 USTC 9 Check to see whether boom has lowered more than eight inches If boom has lowered and oil is leaking around rod end cap of cylinder seals in cylinder are defective and require replacement If boom has lowered and oil is leaking from the holding valve the valve is either improperly adjusted or defective and requires replacement Acaution ENSURE THAT HYDRAULIC LINES ARE CONNECTED PROPERLY 10 Connect hydraulic lines to lift cylinder PRESSURE TESTING Several relief valves protect against overloading different hydraulic circuits Each relief valve should be checked when setting up the machine or if lift power seems too high or too low Refer to the table for specific settings for each relief valve Main Relief Valve The main relief valve protects the lift telescope out outrigger and stabilizer circuits 1 Attach a 0 4000 psi 0 276 bar pressure gauge to the gauge port at the mid inlet section of the control valve Table 7 1 Pressure Settings PRESSURE SETTING PSI BAR COMPONENT MAIN RELIEF HOIST 3200 220 6 BURST OF SPEED IN LINE RELIEF 2000 137 9 MAIN RELIEF VALVE BANK 3500 241 3 LIFT UP 3500 241 3 January 15 2001 SECTION 7 HYDRAULICS STABILIZER Curb Side Power Beyond STABILIZER Street Side icd lt gt OUTRIGGER Curb Side Adjustment for A
92. nd cables though sheave holder plates on telescope cylinder Bullet ends should lay down under cylinder and adjuster threads are on top Tabs provided on the cylinder are for retaining the cables on top of cylinder Number both ends of each extend cable 1 2 3 4 to prevent crisscrossing cables after cylinder is installed 3 Install sheave and sheave pin in nose end but end of cylinder Each cable must be placed in the appropriate sheave groove 1 2 3 4 Se cure sheave pin with retaining ring When in place insert cable retainer pin through sheave pin tear drop and sheave plates If new installa tion weld bar stock on each side of tear drop to prevent turning of sheave pin 4 Install cylinder and retract cables inside boom assembly Be sure cylinder sheaves stay vertical no twisting as cylinder is inserted into boom assembly 3120933 Rev USTC Acaution WHEN USING SLING TO LIFT CYLINDER USE BLOCKS TO PREVENT PINCHING AND DEFORMATION OF CABLE WHEN REPOSITIONING SLING USE BLOCKING TO PREVENT LAYING CYLINDER ON CABLES 5 When telescope cylinder is approximately six feet from being completely in boom assembly place lower retract cable retainer over cables making sure cables are properly oriented 1 2 3 4 Lower retract sheave pins must be flush to allow clearance for the lower retract cable re tainer 6 Align cylinder ears in grooves inside inner mid section Cylinder must be positioned completely i
93. nion and Swing Bearing Teeth 500 return reapply MPG and rotate 90 in opposite direction Swing Gear Box 250 1000 Change oil after first 250 hrs and every 1000 hrs thereafter Oil level to be 1 1 2 from top of hub Jib Sheave Optional 50 Outrigger Stabilizer Wear Pads 500 Extend beam Brush on wear pad travel area Hydraulic Oil Reservoir 10 2000 Check level every 10 hrs Change oil annually Hydraulic Oil Filter 50 250 Change filters after first 50 hrs and every 250 hrs thereafter Hoist Wire Rope 100 Brush on Platform Pivot Optional 200 Platform Door Hinges 200 LMI Dynamometer If Equipped 50 Not Shown Use Texaco Meropa 150 or Equivalent 2 2 USTC January 15 2001 SECTION 2 INSPECTION OPERATOR S DAILY CHECKLIST This paragraph provides a listing of those inspection procedures which must be performed before placing the unit in operation each day Careful attention should be paid during actual operation of the unit to observe any conditions which might occur between regular inspec tions that could possibly be a safety hazard Proper inspection of the crane is also of extreme impor tance and reference must be made to the appropriate vehicle components warne DO NOT OPERATE MACHINE UNTIL CORRECTIVE MEASURES HAVE BEEN TAKEN AND ALL MALFUNCTIONS HAVE BEEN CORRECTED 1 Visually inspect machine for loose or missing parts foreign object
94. ntil the fluid level is even with the top friction plate 5 If replacing piston o rings be sure the two o rings are nearest each other with the two backup rings to the outside 6 Gently slide piston into case until the large o ring tuoches the case Press down firmly on piston with the heel of both hands to squeeze o rings into the case and seat piston against the friction plates 7 If removed insert the ten springs into the piston 8 Lay the cover gasket on the case and align the holes 9 Set cover over the input end of the shaft The bearing should start over the shaft before the cover touches the spring 10 Start four cover bolts through the cover and gasket and into case by hand Alternately tighten the cover bolts 1 2 turn at a time until cover is tight against the case Torque bolts to 110 Ib ft IMPORTANT Either bolt motor to the brake or plug the input pilot in the cover before turning brake upside down or excess fluid will run out GEAR REDUCER HUB The gear reducer transfers power from the motor to the swing bearing Motor output speed is reduced from 36 1 ratio Motor output torque is consequently increased by the same ratio Hub Disassembly 1 Position reducer over suitable container and remove magnetic drain plugs from cover and case Allow oil to completely drain Then re install drain plugs 2 Remove cover bolts and lock washers Carefully remove cover ensuring that mating surfaces are no
95. nto grooves to allow retainer blocks to be placed Secure retainer blocks with retainer plates 7 Secure each of the lower retract cable sheaves with a cotter pin 8 Attach cable anchor plate to base section and insert adjuster ends of the four extend cables Use nylon lock nut and adjust cables according to the cable adjustment procedure FLY SECTION When cable inspection and replacement is necessary the fly section can be removed without complete disassembly of the boom Removal of the fly section provides access to the fly section extend cables and sheaves for inspection or replacement Removal 1 Park truck in an open area with suitable clear ance It is recommended that the boom is re moved from the truck to provide accessibility to components Refer to the boom removal proce dure earlier in this section If suitable lifting equipment is available the fly section may be removed with the boom installed on the truck 2 Remove the telescope cylinder Refer to the telescope cylinder removal procedure earlier in this section 4 17 SECTION 4 BOOM 3 Remove extend upper cable nuts from outer mid section at pedestal end of boom 4 Loosen hose clamps on fly section retract cables and raise cables Remove bolts securing cable anchor to outside of fly section Raise bullet end of fly extend cables 5 Atnose end of boom loosen fly section retract cables and unbolt anchor plate from under outer mid section
96. o hy draulic system utilizes a single solenoid valve and One and Three Part Line Hang weight 18 in from boom nose derives electrical power from the positive termi nal of the power relay Power is cut to the telescope out and hoist up func tions in the event that the sheave block contacts the anti two block counterweight suspended on the hoist cable beneath the boom nose The normally open NO switch mounted to the boom nose is held closed by the counterweight This switch opens when the hookblock comes into contact with and raises the counterweight The switch opens the circuit to the solenoid valve thus directing fluid flow back to the tank A spring loaded cable reel mounted on the side of the base section permits extension and retraction of the electrical cable Roller guides prevent damage to Two Four Five and Six Part Line Hang weight 25 in from boom nose Counterweigh Assembly Pins Figure 6 1 Anti Two Block Positions 3120933 Rev USTC 6 1 SECTION 6 ELECTRICAL the cable while permitting smooth cable extension and retraction The counterweight suspension chain will have to be adjusted according to the number of parts of lines being used ELECTRICAL SYSTEM The electrical system consists of a main electrical box located at the rear of the pedestal Power enters the crane electrical system from the battery A power solenoid turns power to the cran
97. of extend cables Shim as necessary to center the fly section within the outer mid section 6 Loosely attach hose clamp to bullet end of cable Lay bullet end of retract cable in cable anchor block Slide hose clamp against anchor block and tighten to prevent cable from coming out of groove 7 Install telescope cylinder TWO SPEED HOIST OPERATION The two speed hoist is a planetary drive unit with direct hydraulic drive An integral brake supports one side of the hoist and the other side is supported on a ball bearing The two speed function is achieved by supplying additional hydraulic oil flow to the hoist motor from the hydraulic system One section of the hydraulic pump supplies 39 gpm at 3200 psi to the hoist motor The Burst of Speed valve when activated pro vides an additional 24 gpm to the hoist motor from the second pump section However if another func tion is activated while in Burst of Speed mode the Burst of Speed mode is automatically deactivated Refer to the Braden PD12C hydraulic winch manual shipped with the crane January 15 2001 SECTION 5 SWING DRIVE GENERAL The rotation capability of the crane is also referred to as the swing A hydraulically driven gear motor drives a speed reducer gearbox which outputs into a large internal tooth ball bearing The static brake mounted between the motor and gear reducer pre vents rotation until the swing motor is pressurized The swing motor is d
98. on with the outriggers set 2 With the boom horizontal and fully extended use a dial indicator to measure and record the distance between the outer race of the swing bearing and pedestal Measure at the opposite side of the boom 3 With the boom at horizontal and fully retracted Pedestal Inner place a suitable 5 ton hydraulic jack between the deck and the boom Raise the boom enough Figure 5 6 Swing Bearing Clearance Measurement to reverse the load on the swing bearing 4 Attherear center of the pedestal measure and record the distance between the swing bearing and pedestal If the distance is greater than 0 072 in 1 829 mm then it may be necessary to replace the bearing Contact the Service Department for additional instructions regarding the evaluation process BOOM FULLY RETRACTED AT HORIZONTAL Figure 5 7 Bearing Tolerance Check 3120933 Rev O USTC 5 9 SECTION 5 SWING DRIVE 5 10 USTC January 15 2001 SECTION 6 ELECTRICAL GENERAL The electrical system is an integral part of the ma chine and should not be tampered or modified in any way Awarnine MODIFICATION OF MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLATION ANTI TWO BLOCK SYSTEM OPERATION The anti two block system prevents the hook sheave block from contacting the boom nose with consequent structural and hoist cable damage The electr
99. pe clip must be used with all open wedge socket fittings Do not clamp free end of wire rope to LOAD LINE LIVE END of wire rope WARNING FAILURE TO USE WIRE lb ft ROPE CLIP MAY RESULT IN SERIOUS 65 PERSONAL INJURY OR PROPERTY DAMAGE SEIZING ON FREE END LOAD LINE LIVE END MUST BE OF ROPE ON THIS SIDE OF SOCKET Figure 4 4 Cable Socket and Wedge Installation Break In Procedure A new wire rope requires careful installation and proper break in Initial operation should include several run throughs of the normal operational cycle under light load 1000 Ibs and at reduced speed During this trial operation a very close watch should be kept on all working parts sheaves drums and rollers to make certain that the wire ripe runs freely and without any possible obstruction This procedure allows the component parts of the new rope to make a gradual adjustment to the actual operating condi tions 3120933 Rev 95 Properly torque wire rope clip after first hour of operation and every 50 hours thereafter CABLE REEVING In addition to reeving the cable from boom nose to hook block the standard hookblock converts from a headache ball to either a single sheave or two sheave hookblock The single sheave hookblock is capable of handling up to three part line and the two sheave hookblock is capable of four part line The number of parts of line determines the lift capac ity of the hoist The crane i
100. r hoist cable must be wrapped prop erly on the hoist CABLE INSPECTION PROCEDURES All cables must be inspected on a daily basis In addition to the daily inspection a qualified person should do a complete and thorough inspection annu ally or every 2000 hours whichever occurs first Wire Rope Figure 4 1 Wire Rope Components 3120933 Rev Acaution WEAR GLOVES TO PROTECT HANDS WHEN HANDLING CABLE The periodic inspection shall cover the entire length of cable The inspection frequency shall be based on such factors as expected cable life as determined by experience with similar installations severity of environment percentage of capacity lifts frequency rates of operation and exposure to shock loads Inspection should be more frequent as cables ap proach the end of their useful lives Only the surface wires of the cable require inspec tion Do not attempt to open the cable Any deteriora tion resulting in an appreciable loss of original strength such as described below shall be noted and then a determination made if further use would con stitute a hazard No precise rules can be given for determination of the exact time for replacement of the cables This de pends largely on good judgment by a qualified person evaluating the cable USTC 4 1 SECTION 4 BOOM The American National Standard for crane safety ANSI B30 5b 1991 states Conditions such as the following shall be sufficient reason for que
101. r replace relief valve Repair or replace outrigger control valves Clean or replace holding valve Repair or replace control rod or lever Add oil Remove line and clear obstruction or replace line Repair or replace pump Connect hydraulic lines properly Connect hydraulic lines properly Repair or replace crossover valve Repair or replace outrigger control valves Repair or replace cylinder Adjust or replace relief valve 3 5 SECTION 3 TROUBLESHOOTING Table 3 4 Hydraulic Components continued TROUBLE Outrigger cylinder retracts during crane operation Cylinders extend or retract erratically Hoist will not lower load or load handling device 3 6 PROBABLE CAUSE Low hydraulic oil level Restricted or broken supply line Malfunctioning hydraulic pump Worn valve spool Low hydraulic oil level Restricted or broken hydraulic line Malfunctioning hydraulic pump Control cable broken kinked or disconnected Worn control valve spool Check valve in hoist sticking in closed position Hoist drive motor defective Hoist brake not releasing Return relief valve in hoist stuck in closed position Hoist primary drive assembly damaged Relief valve in hoist control valve inlet section set too low Load capacity exceeded Anti two block valve closed Low hydraulic oil level Restricted or broken hydraulic line Malfunctioning hydraulic pump section
102. rd the bearing from the planet gear Using a suitable punch gently tap roll pin from planet pin and carrier housing Repeat steps 1 through 5 for remaining planet gears Primary Carrier Assembly 2 Figure 5 4 Gear Reducer Hub Assembly 7 Inspect all threaded components for damage including stretching thread deformation or twisting and ensure that output shaft studs installed properly with no shank material visible above inner end of shaft 3120933 Rev USTC 1 Using the press install bearing into planet gear making sure teh bearing cage is installed squarely Apply a coating of multi purpose grease to the planet mounted bearing rollers and carefully insert planet gear and washers into the carrier gear aperture Align carrier and gear bearing holes and insert planet pin into carrier with chamfered end of the roll pin on the same side as the carrier hole 5 5 SECTION 5 SWING DRIVE If necessary gently tap planet pin into position with a soft mallet ensuring that roll in holes are aligned and planet gear rotates freely Position a new roll pin in the carrier hole and drive the pin into the hole until the end of the pin is flush with carrier surface Again ensure that planet gear rotates freely Repeat steps 1 through 5 for the remaining planet gears Secondary Carrier Assembly 1 Install the bearing retainer plate into the second ary carrier with t
103. re defective Replace the seals and check the cylinder rod for scoring If boom has retracted and oil is leaking from holding valve the valve is either improperly adjusted or defective and requires replacement 11 Connect hydraulic lines to telescope cylinder USTC 7 1 SECTION 7 HYDRAULICS Lift Cylinder 1 Activate hydraulic system and set outriggers and stabilizers 2 Position boom in horizontal position over rear of truck Note Tape measure or cord should be at least seven 7 feet long for use in this test 3 Attach tape measure or cord at least 30 feet long to bottom of hook block Awarnine BEFORE RAISING AND EXTENDING BOOM ENSURE THAT AREAS ABOVE AND BELOW BOOM AND HOOK BLOCK ARE CLEAR OF ALL OBSTRUCTIONS AND PERSONNEL 4 Raise boom to a 15 elevation Fully extend boom 5 Shut down hydraulic system by disengaging Power Take Off PTO and turn off truck en gine 6 With engine off move boom control lever for ward If boom starts to lower holding valve is defec tive and requires replacement If boom does not lower complete steps 7 through 10 Acaution HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDIATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO THE SYSTEM 7 Tag and carefully disconnect hydraulic lines to lift cylinder Use a suitable container to retain any residual hydraulic fluid Cap lines and ports 8 Note position of tape or cord and its positio
104. res The responsibility for the safe crane operation shall remain with the crane operator who shall ensure that all warnings and instructions supplied are fully understood and observed h If equipped with an LMI refer to the manufactur ers operation manual for daily and pre operational checks to be performed The manual is supplied with the crane and should be kept with the crane at all times 2 4 USTC PERIODIC INSPECTION Note This machine requires annual inspections by an authorized dealer A decal located on the turntable behind the cab affords a place to record stamp inspection dates Notify dealer if inspection is overdue The crane must be thoroughly inspected periodically so as to detect in a timely manner the possibility of damaged or improperly installed parts Frequency of inspection will to a large extent depend upon crane activity and severity of service but under no circumstances should the interval for the below listed inspections exceed one month These inspections should also include those listed in the Daily Inspection Checklist The appropriate truck manual should be consulted for those inspection procedures which pertain to the carrier and the recommendations of the manufacturer must be strictly adhered to 1 Inspect crane for any signs of deformation damage and attaching hardware for security and missing items Particular attention should be paid to areas of high potential stress such as crane truck fra
105. riven by the end section of the pump with a maximum of 8 gpm The swing drive may be removed as a unit from the turntable or components may be removed as neces sary starting with the motor brake and gear reducer An optional swivel assembly provides full 360 rotation of the turntable by allowing hoses and wires to rotate The top portion of the swivel is a slip ring The lower portion is a hydraulic swivel Recommended rotation speed is one revolution per minute attain that speed the PTO ratio is selected Swing Motor Swing Brake Swing Hub Figure 5 1 Swing Drive Components 3120933 Rev to provide pump output at or near maximum engine speed If an incorrect PTO is installed one rpm rotation speed will not be attainable Refer to the Operating and Safety Manual for information on PTO selection COUNTERBALANCE VALVE A dual counterbalance valve mounted on the inside of the turntable balances the pressure between left and right swing Without the counterbalance valve the swing motor would drive the pump backwards until the boom stopped rotating When one side is pressurized the off side recieves a small amount of pressure to prevent cavitation The counterbalance cartridge maintains the offside pres sure at one third of the pressure side If rotation of the crane is jerky or one direction of rotation is faster than the other the counterbalance valve may be suspect Awarnine NEVER OPERATE
106. s hydraulic leaks from lines or components and structural damage 2 Ensure that tires are inflated to the proper pressure Refer to tire sidewall or contact tire manufacturer for proper tire inflation pressure 3 With all systems shut down and machine in stowed or travel position check oil level in hydraulic fluid reservoir If necessary fill to FULL mark on tank sight gauge Note On new or recently overhauled machines or after changing hydraulic oil operate all systems a minimum of two complete cycles and recheck oil in reservoir Acaution NEVER HANDLE CABLES OR WIRE ROPE WITH BARE HANDS BROKEN OR FRAYED STRANDS CAN CAUSE SEVERE CUTS ALWAYS WEAR PROTECTIVE GLOVES IF IT IS NECESSARY TO HANDLE CABLE OR WIRE ROPE 4 Inspect cable for defects as follows a Corrosion b More than one broken wire in any one strand c More than one broken wire near an attach fitting d Excessive wear or broken wires in cable sections under sheaves where cable travel is limited e Evidence of noticeable reduction in original cable diameter after allowance for normal stretch 3120933 Rev USTC 10 11 12 and diameter reductions of newly rigged cable f Excessive abrasion scrubbing and peeling of outer wires pitting deformation kinking bird caging or other damage resulting in physical changes to the cable structure g Cracked bent worn or improperly installed wedge socket Inspect hook for security of
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108. s capable of handling from 1 to 6 parts of line To obtain the maximum amount of permissible rope pull multiple parts of line must be run See the Permissible Main Rope Pull section of the Load Capacity Chart for different ratings for each configuration USTC 4 3 SECTION 4 BOOM ONE PART LINE TWO PART LINE Figure 4 5 Cable Reeving The following sections define how to reeve the wire rope for the different parts of line assuming the ap propriately sized hookblock is installed with the correct number and size of sheaves Single Part Line Reeving Note The following procedure must be followed and used before lifting any load with single part line 1 Lower boom to allow access to boom nose upper and lower sheave wheels and hoist cable retaining pins 2 Pay out enough hoist cable so end of cable extends beyond boom nose 3 If not already done reeve hoist cable through base and mid boom cable guides on top of boom 4 Remove upper and lower hoist cable retaining pins on boom nose 4 4 USTC 7 THREE PART LINE FOUR PART LINE Reeve hoist cable through the boom nose over the upper sheave wheel and lower right sheave wheel If not already done install cable socket onto the end of the hoist cable Attach cable socket to the headache ball assem bly using the 1 1 4 in diameter straight pin and secure with clip pins provided Use center lower pin hole of
109. scope cylinder and fly section refer to the procedures later in this section BOOM ASSEMBLY When disassembly of the boom is required it should be removed from the truck for easier access to the sections A crane is required to handle the various sections Refer to the specifications section for the weight of the boom and components Boom Removal 1 Park the truck in an open area Set the park brake 2 If boom is equipped with a jib remove pins and detach jib assembly from boom assembly using suitable lifting equipment 3 Remove pin attaching hoist cable wedge socket to headache ball hookblock 4 Remove cable retainer pins on forward side of boom nose 5 Using all applicable safety precautions operate hoist to wind all cable onto hoist drum and retract boom fully 6 Shut down crane systems and turn off truck engine With ignition on and PTO engaged cycle all boom functions to relieve any pressure Turn off truck ignition and disengage PTO 7 Using suitable lifting equipment adequately support boom weight along entire length of retracted boom January 15 2001 SECTION 4 BOOM Rod Keeper Rod Keeper Lift Cylinder Figure 4 9 Boom Removal 3120933 Rev USTC 4 11 SECTION 4 BOOM 8 With the lift cylinder adequately supported remove rod keeper and lift cylinder pin from rod end of lift cylinder Use a brass drift tool if necessary to remove pin Using an adequate lifting device
110. se Lubrication Operator s Daily Checklist Periodic Inspection SECTION TROUBLESHOOTING General Troubleshooting Information SECTION 4 BOOM AND HOIST General Cable Inspection Procedures Hoist Cable Installation and Attachment Procedure Break In Procedure Cable Reeving Single Part Line Reeving Two Part Line Reeving Three Part Line Reeving Four Part Line Reeving Five and Six Part Line Reeving Wear Pads Side Wear Pads Extend Retract Boom Cables Cable Inspection Procedures Hoist Layback Extend Retract Cable Adjustment Procedure Extend Retract Cable Replacement Boom Assembly Boom Removal Boom Disassembly Boom Inspection Boom Assembly ii USTC January 15 2001 TABLE OF CONTENTS Cont Telescope Cylinder Removal Fly Section Removal Fly Section Installation Two Speed Hoist Operation SECTION 5 SWING DRIVE General Counterbalance Valve Swing Motor Swing Brake Adjustment Disassembly Installation Hub Disassembly Cleaning And Inspection Carrier Disassembly Primary Carrier Assembly Secondary Carrier Assembly Hub Assembly Swing Bearing Bolt Replacement Torque Procedure Swing Bearing Wear Tolerance SECTION 6 ELECTRICAL General Anti Two Block System Operation Electrical System Overload System Load Moment Indicator 3120933 Rev O USTC iii TABLE OF CONTENTS Cont SECTION 7 HYDRAULICS Hydraulic System Safety Drift Test Telescope Cylinder Lift Cylinder Pressure
111. se parts hardware and security of attachment Check visible wear pads for damage excessive wear and security of attachment Check jib extension for structural damage security of attachment and evidence of sheave lubrication Check boom nose sheaves for damage security of attachment evidence of lubrication and correct cable seating in sheave grooves Check all cable guards and guides for damage and security of attachments Check anti two block device and any load monitor ing hardware if equipped for damage and security of attachments Check jib stowage pins an extendable jib pin for security of attachment Check hookblock sheave s for damage correct routing of cable around sheave grooves and evidence of proper lubrication at sheaves and hook swivel Check hook for damage security of attachment and correct hook latch operation Check lift cylinder boom attach pivot points for evidence of lubrication Check boom rest for damage and security Check that all components requiring lubrication are serviced as necessary Check that no unauthorized modifications have been made to machine Check platform if equipped for damage security of attachment and functionality if equipped See Platform Safety Manual for further information 2 5 2 6 SECTION 2 INSPECTION USTC January 15 2001 SECTION 3 TROUBLESHOOTING GENERAL This section contains troubleshooting information to be used
112. stioning continual use of the cable or increasing the frequency of inspection 1 In running ropes six randomly distributed broken wires in one lay or three broken wires in one strand in one lay 2 One outer wire broken at the point of contact with the core of the rope which has worked its way out of the rope structure and protrudes or loops out from the rope structure Additional in spection of this section is required 3 Wear of one third the original diameter of out side individual wires 4 Kinking crushing bird caging or any other damage resulting in distortion of the rope struc ture 5 Evidence of any heat damage from any cause 6 Reductions from nominal diameter of more than a 1 64 in 0 4 mm for diameters up to and including 5 16 in 8 0 mm b 1 32 in 0 8 mm for cable diameters of 3 8 in 9 5 mm to and including 1 2 in 13 0 mm c 3 64 in 1 2 mm for diameters 9 16 in 14 5 mm to and including 3 4 in 19 0 mm Note A good indicator of stretched extend retract cables is if the adjusting nuts are bottomed out If no adjustment remains the cables have stretched and need replacement INCORRECT CORRECT Figure 4 2 Measuring Wire Rope 4 2 USTC Figure 4 3 Hoist Cable Spooling Also check for cracked bent worn severely cor roded or improperly installed cable ends Inspect sheave grooves for excessive wear IMPORTANT To establish a basis for judging the prop
113. t damaged Discard o ring seal 3 Remove input thrust washer and carefully re move input gear segment Discard thrust washer 5 4 USTC 4 Remove primary carrier assembly together with sun gear Be careful not to damage gear teeth 5 Remove and discard bolts retaining bearing retainer plate to output shaft 6 Place hub ina suitable hydraulic press with the pinion gear portion of the output shaft down and blocks supporting the case 7 Using a suitable drift carefully press output shaft from the secondary carrier by applying pressure to the output shaft Ensure that the output shaft is not damaged 8 Remove roller bearing cone and oil seal from the output shaft Discard seal If applicable remove shims from output shaft 9 Carefully lift secondary carrier assembly out of case ensuring that planet and case gear teeth are not damaged 10 If necessary remove roller bearing cone from secondary carrier 11 If necessary remove roller beraring cups from hub case ensuring that bearing surfaces on case are not damaged Cleaning and Inspection 1 Thoroughly clean all parts in an approved cleaning solvent 2 Inspect bearing cups and cones for damage pitting corrosion or excessive wear If necessary replace bearings as a complete set 3 Inspect bearing mounting surfaces on case output shaft and secondary carrier Replace components as necessary 4 Inspect all geared components for chipped or broken teet
114. t of unit to allow for correct shaft bearing preload IMPORTANT Holes in shaft retainer plate and shims must be aligned to ensure bolts can be installed correctly 7 Rotate bearing retainer plate inside secondary carrier assembly so counterbored holes are centered between planet gears Apply a layer of lithium grease to inner bearing cup and surface Install inner bearing cone over splined end of output shaft small end down Press bearing down slowly until it is just seated against inner bearing cup With a slight press load still ap plied rotate case by hand to ensure that roller bearings are rotating evenly and smoothly 10 Install secondary carier assembly into case Rotate seconedary carrier assembly back and forth until planet gear teeth mesh with gear teeth in case Let carrier assembly down until carrier spline touches output shaft spline View down through top os secondary carrier assembly thorogh counterbored holes in retainer plate If needed align holes in retainer plate directly over holes in shaft and shims January 15 2001 SECTION 5 SWING DRIVE 11 Counterbored holes should be centerd between planet gears Slowly press secondary carrier assembly down tightly against output shaft 12 While secondary carrier assembly is under press load approximately 2 tons rotate case by hand If correct number of shims are in unit to give proper shaft bearing preload torque re quired to turn case s
115. t torque retract cable ends on boom nose end of base boom Torque only extend cables on hoist end of base boom The boom has six extend cables and four retract cables Two extend cables extend the fly section and four extend cables extend the outer mid section The outer mid and fly sections each use two retract cables 1 Lay back hoist Refer to procedure earlier in this section 2 Adjust outer mid retract cables so lube port holes at pedestal end of the boom line up with grease fittings and all slack is removed from cables 3 Adjust outer mid extend cables to remove all slack January 15 2001 SECTION 4 BOOM 9 qe2 e194 e qeo e24 ld pi N Ie1nO oQ S J puoejx3 pIW 191nO puer Figure 4 8 Internal Boom Cable Reeving 4 9 USTC 3120933 Rev SECTION 4 BOOM 4 Adjust fly retract cables outer mid to retract fly section and remove all slack from cables 5 Adjust fly extend cables to remove all slack 6 Continue to adjust extend and retract cables to obtain a dimension of approximately 6 1 2 in from the front edge of the outer mid section to the center of the boom nose upper sheave and to maintain the grease hole alignment 7 Using all applicable safety precautions start crane and cycle boom extend at least three feet Listen for any cables hitting the inside of a boom section which indicates slack in cables 8 If the cables are hitting readjust as ne
116. t use lock washers on block bolts due to clearance Shim as necessary to center the fly section within the outer mid section 8 Install lower retract cable sheaves in outer mid section Do not install cotter pins in sheave pins 9 Loosely attach hose clamp to bullet end of cable Lay bullet end of retract cable in cable anchor block Slide hose clamp against anchor block and tighten to prevent cable from coming out of seat 10 Reeve cable around sheaves and under fly sec tion Be sure to go over cross bar underneath sheaves Stretch cable out for the length of section and attach cable mount to adjuster end of cables Leave cable lay under fly section 1 Insert fly outer mid assembly into inner mid section After side wear pads are inside inner mid section locate bottom wear pads under assembly to protect retract cables With ap January 15 2001 SECTION 4 BOOM proximately 6 ft remaining place retract cable anchor block over cables under assembly Con tinue inserting inner mid until cable anchor block slides into place under fly outer mid assembly 12 At the nose end insert the top wear pad and two bottom wear pads and shims Shim as necessary to provide 1 16 in clearance Be sure to orient wear pads toward outside edge of section 13 Insert four side wear pads loosely to inside of inner mid section Shims will be added after boom is assembled 14 Install lower retract cable sheaves in inner mid
117. te record of the inspection dates and results be maintained These legal requirements are from OSHA Regulations 29CFR Parts 1910 180 and 1926 550 They are also specified in American National Standards Institute ANSI standard B30 5 1994 Safety Code For Cranes Derricks Hoists Jacks and Slings USTC Inc recommends that inspection procedures outlined in this and other manuals pertaining to this unit be followed and that a written record be maintained and available for review by Department of Labor personnel should the need arise Further requirements are depen dent upon state and local ordinances which govern the particular area in which the equipment operates warne DO NOT MODIFY IN ANY WAY OR USE UNAUTHORIZED PARTS ON THE MACHINE WITHOUT THE EXPRESS WRITTEN CONSENT OF USTC INC 3120933 Rev O PREPARATION FOR USE To ensure that the equipment is ready for operation at all times it should be inspected systematically so that de fects may be discovered and corrected before any result in serious damage or failure Defects discovered during operation should be noted for future correction to be made as soon as operation has ceased Stop operation immediately when a deficiency is noted which would damage equipment if operation were continued All visual inspections necessary to keep the unit in a state of operational readiness is the responsibility of manage ment personnel Most requirements are relatively simple involv
118. to boom nose 2 Remove anti two block counterweight from around the hoist cable Let hang 3 Ifthe headache ball hookblock combination is installed lower to the ground and pay out ap proximately 25 ft of cable Note Three part load line requires the boom head lower sheave wheel position to be configured for double sheave wheel operation 4 Remove hair pin from the wedge socket pin securing the wedge socket to the boom nose lug or hookblock headache ball assembly 3120933 Rev 5 Remove lower hoist cable retaining pin from the boom nose 6 The headache ball hookblock assembly must be configured as a single or double sheave hook block assembly The hoist cable can either be reeved through the headache ball hookblock assembly after removing the open wedge cable socket as in Step 7 or sheave wheel can be removed from the headache ball hookblock assembly by removing center sheave wheel pin spacers and sheave wheel 7 Remove open wedge cable socket from end of hoist cable if attached and reeve hoist cable through boom nose left lower sheave wheel 8 After reeving cable through boom nose sheave reattach the cable socket to the hoist cable Attach cable socket to headache ball hookblock assembly s wedge socket pin hole at the top center of the block using the wedge socket pin and hair pin provided 9 Reinstall lower hoist cable retaining pin in boom nose 10 Reinstall anti two block counterweight aroun
119. ty and tapering Check inside and outside diameters 9 Inspect port block fittings and holding valve Replace as necessary 10 Inspect oil ports for blockage or the presence of dirt or other foreign material Repair as neces sary Assembly Note Prior to cylinder assembly ensure that proper seal kit is used Contact the USTC Customer Service Dept if unsure IMPORTANT Apply a light film of hydraulic oil to all components prior to assembly 1 Install grease fitting in cylinder barrel or rod end as necessary 2 Install new wiper seal rod U cup seal lips facing up and wear rings into the applicable cylinder head gland grooves 3 Ifapplicable carefully install cylinder head cap and cylinder head on rod ensuring that wiper rod seals and wear rings are not damaged or dislodged 4 If applicable carefully slide piston spacer on rod 5 Install a new o ring in the inner piston diameter groove Ensure correct orientation 7 8 USTC 6 Place the piston on the cylinder rod ensuring that o ring is not damaged or dislodged 7 Using suitable protection for the rod clamp cylinder rod in a vise or holding fixture as close to the piston as possible Push piston onto rod until it contacts the spacer end and install lock nut Torque lock nut according to table 8 Remove the cylinder rod from the holding fix ture install new o ring and back up ring in the applicable outside diameter groove of the cylin der
120. uction or replace line Repair or replace pump Repair or replace cylinder January 15 2001 TROUBLE Boom will not telescope in continued Boom retracts with control lever in neutral Boom telescoping action erratic 3120933 Rev SECTION 3 TROUBLESHOOTING PROBABLE CAUSE Worn control valve Hydraulic lines incorrectly connected at control valve Holding valve in telescope cylinder stuck in open position Relief valve in telescope section of control valve set too low Malfunctioning holding valve Defective cylinder packing Worn control valve spool Hydraulic oil level low Restricted or broken supply line Malfunctioning hydraulic pump section Worn control valve spool Extend and retract cables require adjustment Cable nylon collar locking nuts or threaded end of cables stripped Cable sheave bushings defective because of cable overtightening Lack of lubricant on boom sections Wear pads out of adjustment or worn One or more boom sections distorted USTC Table 3 4 Hydraulic Components continued REMEDY Check pressure delivery from control valve and repair or replace valve Connect hydraulic lines properly Check for presence of pilot pressure at return valve and repair or replace Adjust or replace relief valve Remove and repair telescope cylinder Remove and repair cylinder Repair or replace valve section Add oil Remove line and c
121. weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided Awarnine SINCE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER OPERATOR HYDRAULIC SYSTEM SAFETY It should be particularly noted that the machine s hydraulic systems operate at extremely high and potentially dangerous pressures Every effort should be made to relieve any system pressure prior to dis connecting or removing any portion of the system Relieve system pressure by moving the boom control levers several times with the engine stopped and ignition on to direct any line pressure back into the return line and to the reservoir Pressure feed lines to system components can then be disconnected with minimal fluid loss USTC 1 1 SECTION 1 SPECIFICATIONS MAINTENANCE Awarnine FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION 1 2 NO SMOKING IS MANDATORY NEVER REFUEL DURING ELECTRICAL STORMS ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRE STRAINED OR LOOSE FITTING CLOTH ING AND NECKTIES W

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