MODEL HTC−8675

BOOK No. 1054

SERIAL No.

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents, and certain
vehicle components contain or emit chemicals known to the State
of California to cause cancer, birth defects, and other
reproductive harm.

CRANE SERIAL NUMBER

The crane serial number is written on the Crane Rating Manual located in the operator’s cab.
The crane serial number should always be furnished when ordering parts for the crane, or
when corresponding with the distributor or factory regarding the crane. The serial number is
the only method of ensuring that the correct parts and/or information can be furnished.
In the event the serial number is not readable, a number is stamped on top of the bumper on the
right side of the carrier and on the right side of the upper frame just below the boom hoist cylin-
der lug. This number can then be used to identify the crane.

Link-Belt Construction Equipment Company F00056

 Operator’s Manual

Crane Serial Number

The crane serial number is written on the Crane Rating In the event the serial number can not be found on the
Manual located in the lower right interior of the upper Crane Rating Manual, a number is stamped on top of
cab. The crane serial number should always be fur- the bumper on the right side of the carrier and on the
nished when ordering parts for the crane, or when cor- right side of the upper frame just above the boom hoist
responding with the distributor or factory regarding the cylinder lug and also on the Gross Axle Weight Rating
crane. The serial number is the only method the dis- plate located on the hydraulic reservoir. This number
tributor or factory has of ensuring that the correct parts can then be used to identify the crane.
will be furnished.

BOOK1054 F2012307RSW Preface

Operator’s Manual

WARNING
CONSTRUCTION EQUIPMENT CAN BE DANGEROUS
IF IMPROPERLY OPERATED OR MAINTAINED. THIS
MACHINE SHOULD BE OPERATED AND MAINTAINED
ONLY BY TRAINED AND EXPERIENCED PEOPLE WHO
HAVE READ, UNDERSTOOD, AND COMPLY WITH THE
OPERATOR’S & MAINTENANCE MANUAL.

The productive life of construction equipment depends that may occur. Any questions pertaining to the care
largely on the care and consideration given to it. This and upkeep of this crane which are not covered in this
especially holds true for hydraulic cranes. This Opera- manual should be directed to your nearest distributor.
tor’s & Maintenance Manual was compiled to explain In addition to this Operator’s & Maintenance Manual, a
the procedures and adjustments necessary for proper Parts Manual, Crane Rating Manual, and Safety Manu-
operation of this crane. al are supplied with the crane. Read and understand
A study of this manual will acquaint the operator and all safety guidelines before operating the crane. Addi-
service personnel with the construction of this crane. It tional copies of all manuals are available through your
will enable them to identify and remedy most problems distributor.

Preface
 Operator’s Manual
Throughout this manual, reference is made to the left, right, front, and rear pertaining to direction and locations.
These reference directions are relative to the operator as he is sitting in the operator’s seat of the carrier cab with the
upper directly over the front of the carrier, unless otherwise stated.

Danger, warning, and caution captions as well as special notes are used throughout this manual and on the crane to
emphasize important and critical instructions. Labels, plates, decals, etc. should be periodically inspected and
cleaned as necessary to maintain good legibility for safe viewing. If any instruction, caution, warning, or danger
labels, decals, or plates become lost, damaged, or unreadable, they must be replaced. Information contained
on such labels, decals, and plates is important and failure to follow the information they contain could result in an
accident. Replacement labels, decals, and plates can be ordered through your distributor. For the purpose of this
manual, and the labels which are placed on the crane, danger, warning, and caution captions and notes are defined
as follows:

DANGER
An operating procedure, practice, etc. which,
if not correctly followed, will result in severe
personal injury, dismemberment, or loss of
life.

WARNING
An operating procedure, practice, etc. which,
if not correctly followed, may result in
personal injury.

CAUTION
An operating procedure, practice, etc. which,
if not correctly followed, may result in damage
to or destruction of equipment or property.

NOTE
Note: An operating procedure step, condition,
etc. which is essential in order for the process to
be completed properly.

Preface
Operator’s Manual
General Index
A detailed table of contents for each section of this manual is included at the
beginning of each section. The following is a description of each section:

Section 1 − Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1−1 Thru 1−122

Section 1 includes the necessary information for safe, productive crane operation. It includes the nomenclature and
operation of all control switches, levers, pedals, and instrumentation of the crane.

Section 2 − Lubrication And Preventive Maintenance . . . . . . . . . . . . . . . .Pages 2−1 Thru 2−38

Section 2 includes the necessary information for proper lubrication and preventive maintenance for daily opera-
tions. It includes the check/change intervals and procedures for maximizing the service life of the crane under nor-
mal working conditions. It also includes lubrication types and specifications approved for use in the crane.

Section 3 − Periodic Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 3−1 Thru 3−32

Section 3 includes the adjustments which must be made periodically to keep the crane in proper, safe working order.
It includes the procedures and necessary information for adjusting the brakes, mechanical linkages, and hydraulic
pressures on the crane.

Section 4 − Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 4−1 Thru 4−18

Section 4 includes the use and operation of the crane attachments. It includes the necessary information for installa-
tion, erection, storage, and removal of the auxiliary lifting sheave and offset lattice fly sections.

Section 5 − General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 5−1 Thru 5−22

Section 5 includes general information on the Crane Rating Manual and serial number as well as wire rope specifica-
tions, inspection, replacement, connections, and reeving. General specifications for the crane are also included.

Section 6 − Fundamental Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 6−1 Thru 6−4

Section 6 includes a list of terms which are used to refer to crane functions, assembly, operation, and maintenance.
These terms are defined as to how they are used in this manual.

Preface
 Operator’s Manual
Table Of Contents
Crane Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1

On Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1

Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1

General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−2

Operator Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−2

Electrical Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−7

Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−10

Signalmen And Bystanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−10

Crane Inspections And Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−10

Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−13

Crane And Area Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−13

Weights, Lengths, And Radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−14

Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−18

Leaving The Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−19

Personnel Handling Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−19

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−19

Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−20

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−20

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−21

Additional Requirements for Offshore Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−21

Inspection and Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−21

Crane Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−22

Operation and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−22

Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−24

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−24

Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−25

Dash Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−25

Indicator Light Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−30

Steering Column, Pump Disconnect, And Foot Operated Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−31

Transmission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−33

Shifting The Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−33

Section 1 − Operating Instructions i

Operator’s Manual
Dual Switch Range Selector Style Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−33

Double−Clutching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−34

Upshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−34

Downshifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−34

Skip Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−35

Engine Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−35

Engine Brake Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−35

Engine Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−35

Descending A Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−35

Slippery Pavement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−36

Cruise Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−36

To Set The Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−36

Resetting The Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−36

Suspending And Resuming A Set Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−37

Turning The Cruise Control Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−37

Carrier Cab Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−37

Hydraulic Oil Cooler Fan Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−38

Battery Disconnect Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−38

Carrier Cab Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−38

Engine Control Module Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−38

Engine Interface Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−38

Anti-lock Brake System (ABS) (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−40

ABS Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−40

ECU Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−41

Active Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−41

Blink Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−41

Blink Code Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−41

Blink Code Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−42

Diagnostic Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−42

Active Diagnostic Trouble Code Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−42

Inactive Diagnostic Trouble Code Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−43

Clearing Active Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−43

ii Section 1 − Operating Instructions

 Operator’s Manual
System Configuration Check Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−43

Dynamometer Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−43

Reconfiguration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−43

Upper Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−48

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−49

Top Hatch Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−49

Upper Operator’s Cab Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−49

Windshield Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−49

Gauge And Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−49

Seat Console Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−53

Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−54

To Start The Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−54

To Stop The Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−54

Cab Heater Shutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−54

Air Conditioning (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−54

Main Outrigger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−56

To Extend Outrigger Beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−57

To Extend Outrigger Jacks − Raise The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−59

To Retract Outrigger Jacks − Lower The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−59

To Retract Outrigger Beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−60

Bumper Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−61

Bumper Outrigger Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−61

To Extend Bumper Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−61

To Retract Bumper Outrigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−61

Crane System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−62

Engine Throttle Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−62

Throttle Lock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−62

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−62

Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−62

Swing Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−62

Travel Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−64

Swing Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−64

Section 1 − Operating Instructions iii

Operator’s Manual
360° Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−65

Wire Rope Winch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−65

Warm-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−66

Front Winch Control Lever (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−66

Rear Winch Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−66

Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−66

Winch Control Switch(es) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−66

High Speed Hoist Or Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−66

Winch Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−66

Winch Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−66

Drum Rotation Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−67

Boom Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−67

Boom Telescope System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−67

Boom Telescope Control Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−68

Boom Telescope Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−68

Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−69

Hydraulic Oil Cooler Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−69

Crane Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−70

Anti-Two Block Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−70

Lockout Pin And Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−71

MicroGuard 534 Rated Capacity Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−73

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−73

Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−73

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−75

System Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−75

System Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−75

System Inoperative Or Malfunctioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−75

Configuration Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−76

To Select Rigging/Travel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−82

Cancel Audible Alarm And Reset Function Limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−82

Operator Settable Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−82

Angle, Length, And Height Operator Settable Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−83

iv Section 1 − Operating Instructions

 Operator’s Manual
Swing Operator Settable Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−84

Operator Defined Area Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−84

System Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−87

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−87

MicroGuard 434 Rated Capacity Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−88

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−89

Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−89

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−90

To Perform System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−90

System Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−91

System Inoperative Or Malfunctioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−91

Configuration Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−92

To Select Rigging/Travel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−96

To Cancel Audible Alarm And Reset Function Limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−96

Operator Settable Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−96

Setting Length/Angle/Height/Swing Operator Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−97

To Set Operator Defined Area Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−99

Entering And Exiting The Upper Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−103

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−104

Before Starting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−104

Engine Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−105

To Start The Engine From The Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−105

To Start The Engine From The Upper Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−105

Engine Shutdown Procedure From The Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−106

Engine Shutdown Procedure From The Upper Operator’s Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−106

Jump Starting The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−107

Cold Weather Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−108

Hydraulic Pump Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−108

Electric Engine Block Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−108

Ether Start System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−109

Changing The Ether Fuel Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−110

Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−111

Section 1 − Operating Instructions v

Operator’s Manual
Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−111

During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−112

Pick And Carry Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−113

Traveling The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−113

Job Site Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−113

Highway Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−114

Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−114

To Remove The Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−114

To Install The Counterweights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−116

Traveling With Boom Dolly/Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−116

Boom Dolly/Trailer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−117

Boom Dolly/Trailer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−118

Lifting The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−119

Towing The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−119

Transporting The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−121

Crane Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−122

Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−122

Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−122

vi Section 1 − Operating Instructions

 Operator’s Manual
1 2 3 4

11 10 9 8 7 6 5

1. Four Section Boom 4. Rear Winch 7. Turntable Bearing 10. Carrier Cab
2. Upper Operator’s Cab 5. Counterweights 8. Fuel Tank 11. Bumper Outrigger
3. Front Winch 6. Rear Outrigger 9. Front Outrigger

Figure 1−1
Crane Nomenclature

On Delivery
WARNING
When a new crane is delivered, follow the instructions Do not lift, suspend, swing or lower
loads or attachments over anyone.
outlined in the latest version of Technical Bulletin Gen- Do not allow anyone to ride on any
eral Series #213. A copy of this bulletin can be ob- part of load or attachment.

tained from your Distributor.

SAFETY INSTRUCTIONS
Operating Safety Construction equipment can be dangerous if
improperly operated or maintained. This
Remember SAFETY every day. Someone’s LIFE may crane should be operated and maintained
only by trained and experienced people
depend on it, MAYBE YOUR OWN. who have read, understood, and complied
with the Operator’s Manual.
Safe operations of a hydraulic crane requires a well Before leaving operator’s position, lower
trained, qualified operator. Crane operation is more in- load to the ground.
Do not use swing brake for swing lock.
volved than it may appear, and operation by a careless When facing over rear some functions
or unqualified person can result in a serious accident. will be reversed relative to operator.
Raise the crane on outriggers, or block the
When a hydraulic crane is maintained and used prop- wheels before working on the crane. Replace
all guards or panels before operating the crane.
erly it can be a safe, highly productive piece of equip- With the boom removed from upper, do not
ment, but if not used properly, it can be dangerous. swing over side on tires or on retracted
outriggers.
Think Safety − You, the operator, are in charge of an
important piece of equipment. It is very important that
you know what it can do. It is also important that you Do not deface or remove this label from the crane.
know what it should not do. No set of instructions can
anticipate all of the situations you will encounter. The
rules given here cover the general usage, and some of Figure 1−2
the more common specific cases. If conditions arise Read and understand all points covered in the
not covered by these rules, consult your nearest Dis- Operator’s Manual before operating the crane.
tributor. A phone call could save someone’s life.

Section 1 − Operating Instructions 1−1

Operator’s Manual
Right
Wrong

Figure 1−3
Shutdown the engine, ensure that the operator has vacated the upper operator’s cab, and
insert blocking through the diamond shaped hole closest to the base section of the boom
before putting hands or tools inside a boom section.

your shoes. Slippery shoes could cause momentary

loss of control of crucial foot operated controls.
6. Keep all walking surfaced non-skid materials on
the crane clean. Non-skid materials are placed on
the crane assist operators and service personnel
Keep clear of
moving parts to with safe access/egress to/from the crane and to/
prevent serious from adjustment and inspection areas. Do not al-
bodily injury. low non-skid materials to become contaminated
with mud, oil, paint, wax, etc. Any contamination
can cause the non-skid materials to become slick,
reducing their effectiveness for safety while walk-
Figure 1−4
ing on the crane. If any non-skid materials be-
Keep hands and tools clear of moving parts.
comes ineffective due to wear, age, or destroyed in
any way, it must be replaced.
General Safety Rules 7. Keep fingers, feet, and clothing away from
sheaves, drums, and ropes unless the crane is
The following is a list of safety rules which should be fol-
shutdown and everyone knows what you are do-
lowed during all crane operations.
ing. Do not place a hand on wire ropes when
Operator Awareness climbing on the crane. A sudden movement could
pull them into the drums or sheaves.
1. Read and understand this Operator’s Manual, all safety
8. Shutdown the engine, ensure that the operator has
manuals, and the Crane Rating Manual and heed
vacated the operator’s cab, and insert blocking
them. These manuals contain important information.
through the diamond shaped hole closest to the
2. An operator must not eat, read, or otherwise divert
boom base section, to prevent movement of the indi-
his attention while operating a crane. Remem-
vidual sections, before putting your hands or tools in-
ber−operating is a full-time job.
side the boom. Unsuspected movement of the
3. Don’t smoke when fueling, or fuel up near an open
boom section could sever fingers, hands, arms, etc.
flame. Keep the nozzle in contact with the filler
9. The operator, supervisor, or person in charge of the
neck to prevent static electric sparks. Shutdown
load must observe the following rules:
the engine when fueling.
a. Loads must be well secured before lifting. Be
4. Start and operate the engine in a well ventilated
sure that the rigging cannot slip off or pull away
area. Diesel exhaust fumes can be harmful. If it is
from the load, or get out of position on the load.
necessary to operate in an enclosed area, vent the
Be sure the load is rigged so it will not turn over.
exhaust to the outside. Properly maintain the ex-
b. Chains and slings must be of adequate size, in
haust system to its original design.
good condition, and not twisted around each
5. Keep your shoes clean. Before entering the operator’s
other.
cab, clean any mud, gravel, moisture or grease from

1−2 Section 1 − Operating Instructions

 Operator’s Manual

Right
Wrong

A 3 Degree Side Tilt Can Grade Ground Level

Reduce Capacities Or Block Under Crane.
By Over 50%. The Load Should Hang
Parallel With The Boom.

Figure 1−5
Level the crane.

c. The load must not catch on an obstruction f. Avoid sudden starts and stops. Lift carefully,
when lifting or swinging. Be sure the load, fall swing gently, brake smoothly, lower and set
lines, or any other parts of the crane do not loads carefully. Jerking the load, swinging and
snag or strike any obstruction. engaging swing brake roughly, and lowering
d. Do not allow the load to rotate out of control. the load rapidly and slamming on brakes, will
Personal injury to ground personnel, load put shock loadings and possible side loadings
damage, crane damage, or damage to anti- on the boom. Unnecessary abuse labels the
two block system may occur. operator as a beginner. Be a professional.
e. When hoisting with single part line, especially g. Do not wrap the winch rope around the load.
in long falls applications, the design of wire Do not use discarded, worn, or damaged wire
rope and hookball is crucial to minimize the po- ropes for slings. They may break and drop the
tential for uncontrolled rope and/or load rota- load.
tion. Rotation-resistant wire rope is recom- h. The crane must be level before making a lift.
mended for single part of line applications. Use the bubble level, to level the crane. Check
See Wire Rope Capacity Chart in the Crane its accuracy frequently with a carpenter’s level.
Rating Manual for the specific types of rotation Remember, a three degree side tilt can reduce
resistant wire rope recommended for your capacities by 50% or more.
crane.

Section 1 − Operating Instructions 1−3

Operator’s Manual

Just A Little Bump Can Cause This!

Like This ...........

Wrong

Figure 1−6
Do not let the load hit the boom or fly.

the boom or fly is struck, or damaged by anything,

STOP. The loading on a boom or attachments in-
creases as they are lowered, therefore their sus-
Wrong pension systems could collapse during lowering.
Use another crane to lower a damaged boom or at-
tachment.
11. Don’t pull sideways on the boom, not even a little.
Lift straight up on every load. Moving trucks, rail
cars, barges, or anything else pulling sideways on
the winch rope could buckle the boom. It could
also damage the swing mechanism. Pulling side-
ways on a boom can overturn the crane.
12. Do not
two block" (pulling the hook block into the
head machinery) as this can cause winch rope and
sheave breakage resulting in an accident.
13. After slack winch rope operation, make sure the
winch rope is properly seated in sheaves and on
drums before continuing to operate. Use a stick or
Figure 1−7 mallet to set the winch rope, not your hands.
Do not use the boom to pull sideways. 14. Do not lower the load beyond the point where less
than three full wraps of winch rope are left on the
drum. This condition could occur when lowering a
10. Don’t let the load or bucket hit the boom, fly, or jib.
load beyond ground level. If all the winch rope runs
Don’t let the boom or attachment rest, or hit, a
off the drum, the load will jerk which could break
building or any other object. A dent or other dam-
the winch rope.
age could result, which will weaken the boom or at-
15. Make sure there is a safety latch on the hook, and
tachment. If the damage is severe, the attachment
that it works properly. Without a latch, it is possible
could collapse. If a lattice or diagonal bracing
for slings or chains to come off the hook, allowing
member on the fly is broken, cracked, or bent, con-
the load to fall.
tact your local distributor for repair procedures. If

1−4 Section 1 − Operating Instructions

 Operator’s Manual

Wrong

Right

Figure 1−8 Figure 1−9

Crane level, all beams extended equally (all Watch that carrier cab!
fully extended, all intermediately extended, or
fully retracted), and tires clear of the ground. When blocking or matting under pontoons, be
sure that each pontoon is supported fully − no un-
16. Don’t alter any part of the crane. Additions to, or supported pontoon area is permissible. Be sure
changes in, any part of the equipment can create pontoons are on a smooth surface. Rough sur-
loadings for which the crane was not designed. face, rocks, etc., under pontoons will cause un-
Such changes may seriously affect the usable ca- equal loadings, and can puncture them, causing
pacities and make the entire Crane Rating Manual them to collapse.
invalid. Such changes can dangerously overload
or weaken critical parts and may cause disastrous Capacities are based on outriggers equally ex-
failure. tended; all fully extended, all intermediately ex-
17. Do not exceed the rated capacities of the crane un- tended, or all fully retracted. Working on outriggers
der any circumstances. While a crane has more that are not equally extended will reduce capaci-
stability when lifting over a corner (as compared to ties and crane stability considerably and could
straight over the side), the crane capacity is not in- cause an accident. Do not make any lifts while on
creased. Anytime the load exceeds the rated ca- outriggers without the outrigger beams equally ex-
pacities listed in the Crane Rating Manual, the tended.
crane is overloaded. Overloads can damage the 19. Before attempting to move the carrier, make sure
crane and such damage could cause failure and there is enough air pressure to operate the brakes.
accidents. Always check the brake operation before traveling
18. When operating on outriggers, all beams must be the crane.
extended equally; all fully extended, all intermedi- 20. Brake firmly in one application. Avoid fanning the
ately extended, or all fully retracted. All jacks must brakes. This could exhaust air pressure so fast that
be extended so all tires are clear of the ground, and the compressor may not supply enough air.
the crane must be level. Be sure that blocking or 21. Do not coast downhill with the transmission in neu-
pontoons are set on a firm surface, adequate to tral. It makes control of the crane more difficult and
support the blocking, pontoon, crane and load dangerous.
without settling, slipping, or collapsing. Blocking 22. Shift the transmission to neutral before operating
or matting under pontoons must form a smooth, the crane. Crane operation can cause movement
level surface under the entire pontoon. Do not which can damage the transmission or drive line.
block under outrigger beams inside the pontoons When parking, shift to neutral and engage the park
as this reduces stability. Blocking must be under brake. Block wheels if on an unlevel surface.
pontoons only. Remember−there are tremendous 23. When operating over the front, use care not to hit
loadings on pontoons and blocking − the weight of the carrier cab or front of the crane with the load or
the entire crane plus any load. boom.

Section 1 − Operating Instructions 1−5

Operator’s Manual
1
Right
Wrong

2 1

1. Use The Connecting Lugs As Lifting Points. 3. Do Not Attach Slings To Lattices, They Will Bend.
2. Use The Main Chords As Lifting Points With Nylon Straps Only

Figure 1−10
Handling The Fly Section.

24. Use care handling the fly when loading, transport-

1
ing, and unloading. Damage that occurs during
these operations can go undetected and could re-
sult in failure of the attachment, once subjected to
2 loading. Do not attach slings to the lattices, when
3 lifting the fly, as they will bend. It is recommended
that the connecting lugs and/or head machinery
6
cross shaft be used as the lifting points. However, it
4 is permissible to attach nylon straps around all four
main chords.
25. Block under and between the fly when loading
them on a transport vehicle. When securing the fly
to a transport vehicle, it is best to use synthetic
5 webs or slings. If using wire rope slings, pad the fly
to protect it from damage. Do not overtighten the
tie downs or the fly may be damaged. Do not use
1. Head Sheave 5. Connecting Lugs chain ties downs, as they may dent and damage
2. Main Chord 6. Head Machinery Cross the sections.
3. Lattices Shaft
4. Picture Frame
26. Thoroughly inspect all the elements of each fly be-
fore installing it on the crane. Check each main
Figure 1−11 chord, picture frame, diagonal, lattice, and con-
Fly Section Nomenclature
necting lug for bends, dents, and cracked or cor-
roded welds. Picture frames must be square. Do
not use any fly that is even slightly damaged. Con-
sult your local distributor for the proper repair pro-
cedures.

1−6 Section 1 − Operating Instructions

 Operator’s Manual

Wrong

Stay away from crane

if close to power lines. ELECTROCUTION HAZARD.
Keep all parts of crane and
Crane, load, and
load at least 15 ft (4.57m)
ground can become from electrical lines or as
electrified and deadly. stated in local code. Consult
Consult Operator’s Operator’s Manual for
Manual for minimum minimum required
required clearance. clearances.

Figure 1−12
Stay away from power lines.

Electrical Dangers Minimum Required Clearance For Normal

1. All Electrical Power Lines Are Dangerous. Contact Voltage In Operation Near High Voltage Power
with them, whether insulated or not, can cause Lines And Operation In Transit With No Load
death or injury. When operating near power lines, And Boom Or Mast Lowered.
the best rule is to have the power company turn off Minimum Required
the power and ground the lines. However, in some Normal Voltage, kV
Clearance, ft (m)
cases, the operator may be unable to have the (Phase to Phase)
See Note 1
power turned off. Follow these rules whether the Operation Near High Voltage Power Lines
power is turned off or not.
a. Be alert. You are working around conditions To 200 15 (4.57)
which can cause death. Over 200 To 350 20 (6.10)
b. Keep all parts of the crane, fall lines, hook Over 350 To 500 25 (7.62)
block, and load at least 15 ft (4.57m) from elec- Over 500 To 750 35 (10.67)
trical lines or as specified in the
High Voltage
Power Line Clearance Chart" or other dis- Over 750 To 1000 45 (13.72)
tances specified by applicable codes. Slow Operation in Transit with no Load and Boom or
down crane operation. Mast Lowered
c. Assume that every line is
Hot". To 345 15 (4.57)
d. Appoint a reliable person equipped with a loud Over 345 To 750 16 (4.87)
signal (whistle or horn) to warn the operator
when any part of the crane is working around Over 750 To 1000 20 (6.10)
the power line. This person should have no Note 1: Environmental conditions such as fog,
other duties while the crane is working around smoke, or precipitation may require increased
the power line. clearances.
High Voltage Power Line Clearance Chart

Section 1 − Operating Instructions 1−7

Operator’s Manual

Wrong Wrong

Shaded area shows
sensitivity zone" with full boom length Shaded area shows
sensitivity zone" with the probe near the
sensor used, and adjusted for 15 ft (4.57m) clearance. Contact boom peak and adjusted for 15 ft (4.57m) clearance. Contact
can be made outside this zone by the fall lines, winch rope, cab, can be made outside this zone by the fall lines, winch rope, cab,
etc. In such cases, the alarm will not sound, but the crane will be etc. In such cases, the alarm will not sound, but the crane will be
electrified and deadly. electrified and deadly.

Figure 1−13 Figure 1−14

Crane Equipped With Proximity Warning Crane Equipped With Proximity Warning
Device On The Entire Boom Device On The Boom Tip

e. Warn all personnel of the potential danger. transmitter or antenna. Painful, dangerous
Don’t allow unnecessary persons in the area. shocks could occur. Consult trained electronic
Don’t allow anyone to lean against or touch the personnel before operating the crane to deter-
crane. Don’t allow ground workers to hold mine how to avoid electrical hazards.
load lines, or rigging gear unless absolutely 2. What do you do if a power line is touched by a
necessary. In these cases use dry plastic crane or load?
ropes as tether lines. Make certain everyone a. Remain calm − think − a mistake can kill
stays at least 15 ft (4.57m) away from the load, someone.
or a distance specified in the
High Voltage b. Warn all personnel to keep clear.
Power Line Clearance Chart", or such distance c. If crane will still operate, try to move it away
as required by applicable codes. from contact. You, the operator are reasonably
f. The use of boom point guards, proximity de- safe in the cab unless the crane is on fire or an
vices, insulated hooks or swing limit stops do arc is cutting through the cab.
not assure safety. Even if codes or regulations d. Move away from contact in the reverse direc-
require the use of such devices, you must fol- tion to that which caused the contact. Exam-
low rules listed here. If you do not follow them, ple: If you swing left to the wire, swing to the
the result could be serious injury or death. right to break contact. Remember − once an
g. Grounding the crane can increase the danger. arc has been struck, it will stretch out much far-
Poor grounding such as a pipe driven into the ther than you think before it breaks. Keep mov-
ground, will give little or no protection. In addi- ing until the arc has been broken.
tion, a grounded crane may strike an arc so e. When the arc breaks, continue moving away
heavy that a live line may be burned down. until you are at least 15 ft (4.57m) away (or a
This could cause the crane and the area distance specified in the
High Voltage Power
around it to be electrified. Line Clearance Chart" or as specified by local
h. When operating near radio or T.V. transmitting codes). Stop the crane. Make a thorough in-
stations, high voltage can be induced in metal spection for crane damage before further use.
parts of the crane, or in the load. This can oc-
cur even if the crane is some distance from the

1−8 Section 1 − Operating Instructions

 Operator’s Manual

Wrong

Wrong

1
1

This Man Is Not Protected.

1. Insulated Link if wet or contaminated will not provide protection.

1. Insulated Link
Figure 1−16
Figure 1−15 Crane Equipped With Insulated Link And
Crane Equipped With Insulated Link Boom Point Guard

f.If you can not disengage from the electrical line

and the crane is not on fire or no arc is cutting
through the cab, stay in your seat until the
power line can be turned off.
g. If you must leave the crane, don’t step off.
Leap from the crane as far as you can, landing
with feet together, then hop away from the
crane with feet together, or shuffle feet to keep
them close together. This could help prevent
personal injury.
3. When using a magnet:
a. Lifting magnet generators produce voltage in
excess of 200 volts and present an electrical
shock hazard. Only trained personnel should
work on the magnet, controller, or wiring.
Don’t open the controller door with the genera-
tor running.
b. Do not let workmen touch magnet or load.
c. Do not let workmen get between magnet and a
metal object.
d. If necessary to position a load, use a dry,
wooden stick.
e. Open magnet disconnect switch at magnet
control panel before connecting or discon-
Figure 1−17
necting leads. If you must leave the crane, do not step off.
Leap as far as you can with feet together and
hop or shuffle away from the crane.

Section 1 − Operating Instructions 1−9

Operator’s Manual

Wrong

Wrong

Figure 1−19
Use a signalman, back safely.

Signalmen And Bystanders

1. Don’t allow crane boom or loads to pass over peo-
ple, or endanger their safety. Remove all loose ob-
jects from load. All unnecessary personnel should
Figure 1−18 leave the immediate area when crane is operating.
No hook riders! 2. Do not allow anyone to ride on the hook ball, hook
block or any part of the load or attachment for
construction work or recreational activities. (This
Protective Equipment applies to recreational activities such as
bungee
1. Always replace protective guards and panels be- jumping" or
bungee cord jumping"). Cranes are
fore operating the crane. intended to lift objects, not people. They are not
2. Always wear hard hats, safety glasses, steel toe elevators.
shoes, hearing protection, and any other safety 3. Do not carry passengers! There is only one seat
equipment required by local job conditions, and it is for the operator. A fall from the crane can
OSHA, or regulations. cause death or serious injury.
3. Always wear safety glasses when drilling, grinding 4. Always look before you back up, or better yet, post
or hammering. Flying chips could injure the eyes. a signalman to guide you. If crane is equipped with
4. Keep a dry chemical or carbon dioxide fire extin- a back up alarm, make sure it is working properly.
guisher of 5BC rating or larger in the cab or in the Use the horn as a signal. Use a code such as one
immediate area of the crane at all times. Instruct all beep − stop, two beeps − forward, and three
operating and maintenance personnel in proper beeps − backward. Make sure everyone on the
use of the extinguisher. Check periodically to job site knows the code.
make sure it is fully charged and in working order. 5. Do not make a lift which is not in plain sight without
5. Do not tamper with safety devices. Keep them in a signalman. This can lead to an accident or crane
good repair and properly adjusted. They were put damage.
on the crane for your protection.
6. When operating a crane equipped with any form of Crane Inspections And Adjustments
load indicating mechanism, overload warning sys- 1. Inspect crane daily. Do not operate a damaged or
tem, or any automatic safety device, remember poorly maintained crane. Pay particular attention
that such devices cannot replace the skill and judg- to the clutches, brakes, attachments, and wire
ment of a good operator. For instance, such de- ropes. If a component is worn or damaged, re-
vices cannot tell when a crane is located on a sup- place it before operating.
porting surface that will give away, that too few 2. Labels, plates, decals, etc. should be periodically
parts of line are being used to lift a load, cannot cor- inspected and cleaned as necessary to maintain
rect for the effects of wind, warn that the device good legibility for safe viewing. If any instruction,
may be improperly adjusted, correct for side pulls caution, warning, or danger labels, decals, or
on the boom, or for many conditions which could plates become lost, damaged, or unreadable, they
occur and create hazards. It requires all the skill, must be replaced.
experience, judgment, and safety consciousness 3. When performing repetitive lift applications, espe-
that a good operator can develop to attain safe op- cially at or near maximum strength limited capaci-
eration. Many safety devices can assist the opera- ties, an inspection of the major structural areas of
tor in performing his duties, but he should not rely the crane, for cracks or other damage, should be
on them to keep him out of trouble. conducted on a regular basis. (A non-destructive

1−10 Section 1 − Operating Instructions

 Operator’s Manual
test such as magnetic particle or dye penetrant
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
may even be considered.) Along with inspection

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
for cracks and damage, frequently check the criti-
cally loaded fasteners, such as the turntable bear-
ing mounting capscrews, to ensure they have not
been stretched. Not only does frequent inspection ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
DANGER
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
CRANE OUT OF SERVICE
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
promote safety, but it is also much easier and less

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
expensive to perform a repair when a crack is Do not operate the crane or start
small, before it has a chance to traverse through a the engine without first notifying
structural member. Any sign of cracks or damage
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
this mechanic. Personnel within

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
must be repaired before continuing operations. the crane could be hurt or killed.

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
Consult your distributor for repairs. Crane damage may also result from
4. When performing maintenance on the crane, do premature operation of systems
the following:
a. Fully retract the boom. Lower the boom to the ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
which are still under repair.

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
Signed:

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
limit of the boom hoist cylinders or on to the
boom rest.
b. Shutdown engine, disengage the main pump,
Figure 1−20
and work all control levers back and forth to re-
Remove the keys from the ignition and post a
lieve pressure and relax the attachment.
sign to make others aware of repair activity.
c. If the above instructions cannot be followed,
block securely under the attachment so it can-
not move. 9. When making repairs, which require welding, use
d. Bleed any precharge off the hydraulic reservoir proper welding procedures. Also make note of the
before opening it or disconnecting a line. following:
e. Hydraulic oil becomes hot during operation. In a. All paint in the area should be removed to pre-
some cases it becomes hot enough to cause vent burning the paint. The smoke and fumes
severe burns. Be careful not to let hydraulic oil from the burning paint can be very hazardous.
come in contact with skin. b. Turn the battery disconnect switches to the
f. Post warning signs in cab so no one will try to
OFF" position to protect any electronic equip-
start the engine. Never adjust, maintain, or re- ment on the crane which may be effected by
pair a crane while it is in operation. electric arc welding. Contact the distributor or
5. Always reduce pressure in hydraulic system to factory for proper procedures.
zero before working on any part of the system. Pin c. The welding ground cable should be attached
sized and smaller streams of hydraulic oil under to the portion of the crane being welded. If
pressure can penetrate the skin and result in seri- welding on the upper, ground on the upper. If
ous infection. Do not use your hand to check for welding on the carrier ground on the carrier.
leaks. If hydraulic oil does penetrate the skin, seek Failure to take this precaution may result in
medical treatment immediately. electrical arcs in the turntable bearing.
6. Always reduce pressure in air system to zero be- d. The welding ground cable should always be
fore working on any part of the system. Pin sized connected as close as possible to the area be-
and smaller streams of air under pressure can ing welded. This minimizes the distance that
penetrate the skin and result in serious infection. electricity must travel.
Do not use your hand to check for leaks. If air does e. Disconnect computers and other electronic
penetrate the skin, seek medical treatment imme- equipment (such as rated capacity limiters and
diately. engine computers) to prevent damage. Con-
7. Use extreme care when working with circuits with tact the distributor or for proper procedures.
accumulators. Check that hydraulic pressure is re- f. Remove all flammables from the proximity of
lieved before opening the circuit for repairs. the welding area.
8. When setting pressures, never exceed the manu-
facturer’s ratings. Always follow instructions ex-
actly. Over pressurization can cause hydraulic
component damage or failure of mechanical parts
on the crane. Either of the above can lead to an ac-
cident.

Section 1 − Operating Instructions 1−11

Operator’s Manual
Right

Figure 1−21 Figure 1−23

Use a guard when inflating tires. Do not use an open flame near the battery.

12. Use extreme caution when removing radiator

caps, hydraulic pressure caps, etc. They can fly off
and hit you, or you could be burned by hot oil,
water, or steam.
13. Check tires daily for correct pressure. Do not stand
in front of a tire when inflating it. The lock ring can
fly off and injure you. Use a clip-on inflator, and
stand aside. Use a guard in front of the tire.

WARNING
Battery posts, terminals, and related
accessories contain lead and lead
compounds. Wash hands after handling.
Figure 1−22
Allow engine to cool before removing the 14. When checking battery fluid level, use a flashlight,
radiator cap. not an open flame. If the battery explodes, you can
get acid in your eyes, which could cause blind-
10. Keep the crane clean, in good repair, and in proper ness. Don’t check battery charge by shorting
adjustment. Oil or grease on the decks may cause across posts. The resulting spark could cause the
falls. Improper adjustments can lead to crane battery to explode. Check with a tester or hy-
damage, load dropping, or other malfunctions. drometer. Don’t smoke near batteries.
11. Keep all walking surfaced non-skid materials on 15. When using jumper cables to start an engine, be
the crane clean. Non-skid materials are placed on sure to connect negative post to negative post, and
the crane assist operators and service personnel positive post to positive post. Always connect the
with safe access/egress to/from the crane and to/ two positive posts first. Any spark could cause the
from adjustment and inspection areas. Do not al- battery to explode. Refer to
Jump Starting the
low non-skid materials to become contaminated Crane" found later in this Section of this Operator’s
with mud, oil, paint, wax, etc. Any contamination Manual for the proper procedure.
can cause the non-skid materials to become slick, 16. Test the automatic winch brake by raising the load
reducing their effectiveness for safety while walk- a few inches and holding. It should hold without
slipping. It takes more braking power to hold a load
ing on the crane. If any non-skid materials be-
in the air when the drum is full of rope than when it
comes ineffective due to wear, age, or destroyed in
is a few inches above the ground with only a few
any way, it must be replaced.
wraps on the drum.

1−12 Section 1 − Operating Instructions

 Operator’s Manual
Wire Rope
Thursday . . . . .
1. Inspect all wire rope thoroughly. OSHA (Occupa-
tional Safety And Health Act) regulations state
a
I thought I could save
thorough inspection of all ropes shall be made money by running this
once a month and a full written, dated, and signed rope until Friday."
report of the rope condition be kept on file where
readily available." Replace any worn or damaged
rope. Pay particular attention to winch ropes.
Check end connections (pins, sockets, wedges,
etc.) for wear or damage.
2. Use at least the number or parts of winch line Wrong
specified on the Wire Rope Capacity Chart located
ing the Crane Rating Manual to handle the load.
Local codes may require more parts of line than is
shown. Check code requirements and use them
where applicable.
3. Non-rotating, rotation-resistant, or spin-resistant
wire ropes are recommended for single part of line
applications. This is of utmost importance for long
fall hoist line applications. Only if certain criteria are
met may a swivel hook ball be used with rotation Figure 1−24
resistant rope. Refer to
Single Part Line Hoisting’ Do not operate the crane with worn or
and
Hook Ball Usage With Rotation Resistant damaged wire rope.
Rope" found in Section 5 of this Operator’s Manu-
al. 3. Be sure the work area is clear. Make sure to have
4. Do not handle wire rope with bare hands. Always proper clearance for the crane, boom, and load.
use gloves to prevent possible injury from frayed or Don’t swing, travel, lift, or lower loads, or raise or
damaged spots in the rope. lower jacks, without first making sure no one is in
5. Inspect head machinery and hook block often as the way. If your vision is obscured, locate a signal-
damaged or deteriorating sheaves can cause man so you can see him, and he can see all areas
undo wear of the wire rope. you can’t. Follow his signals. Be sure you and the
6. When reeving wire rope on the crane, do not stand, signalman understand each other’s signals. See
walk, or climb on the boom or attachment. Use a hand signal chart found later in this Operator’s
ladder or similar device to reach necessary areas. Manual or the label located on the crane. Use the
horn to signal or warn. Make sure everyone on
Crane And Area Clearance the job site understands signals before starting
1. Know your job site conditions. Familiarize yourself operations.
with work site obstructions and other potential haz- 4. When working inside a building, check overhead
ards in the area which might lead to mishaps. clearance to avoid a collision. Check load limits on
Make any necessary arrangements to eliminate floors or ramps so as not to crash through.
any potential hazards, if possible. 5. Don’t operate close to an overhang or deep ditch.
2. Erect barricades around the immediate work area Avoid falling rocks, slides, etc. Don’t park crane
to prevent unauthorized personnel from wander- where a bank can fall on it, or it can fall in an exca-
ing onto the job site. vation. Don’t park where rain can wash out footing.
6. Watch the tail swing of the upper revolving frame
and counterweight. Even though the original set-
up may have been clear, situations change.
7. Do not store material under or near electrical
power sources. Make material handlers aware of
the dangers involved with storing material under
power lines or in the vicinity of any other hazards.

Section 1 − Operating Instructions 1−13

Operator’s Manual

It looked like

about 5 ton."
Operation under conditions which
exceed listed capacities may result in
Wrong
overturning.
Swinging, extending or lowering boom
to radii where no capacities are listed
may result in overturning even without
a load.
Figure 1−25
Safety Instruction Label

Weights, Lengths, And Radii

1. Know your load. Don’t try to guess or estimate the
load. Use a scale or a load indicating system to de-
termine exact weight. Remember the weight you
Figure 1−26
are lifting includes the weight of any lifting slings or
Know your load.
gear, the hook block, and any other weight on the
hook. If lifting off the boom with the fly installed, the
When in doubt, do not take a chance. Reduce rat-
weight of the fly and rigging must also be consid-
ings more than you think you need. Avoid working
ered as part of the load. The total load weight must
a crane in high winds. If you must work in a wind,
never exceed the rated capacity of the crane, as
reduce capacities considerably below those
listed in the Crane Rating Manual, for the position,
shown in the Crane Rating Manual. Wind blowing
boom length, load radius, and condition of opera-
against the load and the boom produces a side
tion being used. Remember − capacity chart rat-
ings in the Crane Rating Manual are based on ideal load on the boom and reduces its capacity.
conditions: When lifting loads in a wind which have large sur-
a. Standing on firm, level surface face areas, such as building panels, the movement
b. Calm wind of the load may pose a danger to workmen or
c. No side loads or out swing of load building structures. Out swing of a load will in-
d. Good visibility crease the load radius, and may overload the
e. Crane in top condition and equipped as when crane. This could lead to boom failure or the crane
leaving the factory tipping.
2. When operating off the main boom with the fly
When such conditions cannot be attained, loads erected, deductions must be made for its weight.
being handled must be reduced to compensate. The weight of the fly, pendants, etc., must be sub-
The amount loads are reduced depends upon how tracted to obtain a
NET" capacity. Failure to do so
good or how poor, the actual operating conditions could result in an overload condition and cause
are. It is a matter of judgment and experience. boom failure. Refer to the Crane Rating Manual for
Some factors which may require reduction of ca- amounts to be deducted.
pacities are: 3. When operating off the main boom with the auxil-
a. Soft or unpredictable supporting surfaces iary lifting sheave installed, the weight of the auxil-
b. Wind iary lifting sheave must be deducted. Refer to the
c. Hazardous surroundings Crane Rating Manual for amount to be deducted.
d. Inexperienced personnel
e. Poor visibility
f. Fragile loads
g. Crane in poor condition
h. Condition and inflation of tires

1−14 Section 1 − Operating Instructions

 Operator’s Manual

Wrong

Wrong

Figure 1−28
Do not push with the boom.

8. When performing repetitive lift applications, espe-

cially at or near maximum strength limited capaci-
ties, be aware that these applications may reduce
component life. These applications include re-
peated lifting (or lifting and swinging) of near 100%
strength limited capacities and repeated lifting
maximum moment loads. These applications may
fatigue the major structural portions of the crane.
Although the crane may not break during these ap-
plications, they can reduce the fatigue life and
Figure 1−27 shorten the service life of the crane. To improve the
Do not lift two loads at the same time. service life, while performing repetitive lift applica-
tions, consider reducing the capacities to 70% of
4. Do not lift two loads at the same time, even if the maximum strength limited capacities to reduce fa-
total load weight is within crane capacity. Loads on tigue cracking. Frequently perform a thorough in-
the boom and fly at the same time, stress the boom spection of all the structural areas of the crane.
and drastically reduce its ability to handle loads. Any sign of cracks or damage must be repaired be-
Your full attention cannot be given to both loads, fore continuing operations. Consult your distribu-
creating a dangerous situation. tor for repairs.
5. Some capacities on hydraulic cranes are based on 9. Always refer to the Crane Rating Manual after
strength of materials. In these cases, overloads changing the arrangement of the attachments for
may cause something on the crane to break, be- the correct lifting capacities.
fore it will tip. Do not use signs of tipping as a warn- 10. The boom must be extended in the correct manner
ing of overload. before making a lift. The capacities listed in the
6. Don’t lash a crane down. Lashing a crane down Crane Rating Manual for this crane are based on
encourages overloading. Crane damage or injury the boom sections being extended in accordance
could result. with boom mode
A" or
B".
7. Do not shock load and/or overload the crane at 11. Do not use the boom to push or pull. It is not de-
anytime. Shock loading or overloading the crane signed for this purpose. Such action can damage
will reduce the fatigue life of crane components the boom and lead to an accident.
and could result in component failure. 12. Know the load radius. Don’t guess at it. Determine
the load radius by using the boom angle indicator,
the boom length indicator and the Crane Rating
Manual, or measure it with a steel tape. Remember
− Radius is the horizontal distance from the center-
line of rotation of the upper to the center of gravity
of the load, when the load is hanging free.

Section 1 − Operating Instructions 1−15

Operator’s Manual
15. When extending or lowering a boom with a load,
the load radius increases. As the load radius in-
creases, capacity decreases. If capacity is ex-
ceeded, the boom may bend, or the crane may tip
over. Sometimes at low angles, a hydraulic crane
boom can be extended with a load, but cannot be
retracted. This is because more power is available
in the boom telescope cylinders to extend than to
retract. If an operator extends the boom under
load, he may not be able to retract the boom and
may get into a dangerous situation.
16. Know the boom length. Don’t guess. Use of an in-
correct boom length can cause an accident.
17. When lowering or retracting the boom, the load will
lower. To compensate for this, the operator must
hoist up on the winch rope. Otherwise, movement
of the load may cause an accident. When extend-
Figure 1−29
ing the boom, the load will raise. the operator must
Pinch Point Label
hoist down the winch rope to keep the load in
place. Extending the boom without winching
13. Do not operate a hydraulic crane at radii or boom
down, can lead to
two blocking". This is when the
lengths where the Crane Rating Manual shows no
hook block or the hook ball contacts the head ma-
capacity. Do not use a fly not designed for this
chinery. Two blocking can lead to sheave or rope
crane. Either of the above can tip the crane over or
damage.
cause attachment failure. In some cases, the
18. The winch rope must be vertical when starting to
crane can tip over with no load on the hook, for-
lift. If not, the load will swing in, out, or sideways
ward or backward! Also, if the boom is fully ex-
when lifted from the ground. The crane will lean to-
tended at a low angle, the crane may tip until the
ward the load when lifting heavy loads. This is
boom touches the ground. In any of these cases,
caused by elasticity of the crane and the boom.
injury or crane damage could result.
This lean will increase operating radius so the load
14. When lifting a load with any crane, the load may
will swing outward when it clears the ground. This
swing out, or sideways. The load radius will in-
out swing is dangerous to anything in the path of
crease. Due to the design of hydraulic crane
the load, and because of the increase in load ra-
booms, (cantilever boom, supported by cylinders
dius may overload the crane. To overcome this out
and overlapping sections) this increase is much
swing, boom up as the load is lifted so winch ropes
more pronounced. The increase or out swing of
remain vertical. When setting the load on the
the load can overload the boom, and lead to boom
ground, lower boom after the load touches down to
failure or tipping. Also, movement of the load can
avoid hook block swing when it is unhooked from
cause it to hit something. Make sure the load being
load.
lifted will remain within capacity as it is lifted and the
19. Pinch points, which result from relative motion be-
boom deflects.
tween mechanical parts, can cause injury. Keep
clear of the rotating upper or moving parts.

1−16 Section 1 − Operating Instructions

 Operator’s Manual
Just a little side tilt when
working over the end.
Wrong
Look what happens Wrong
over the side. . . .
LOAD RADIUS INCREASES!

1
2

1. Load Radius At Rest

2. Load Radius Increases Due To Centrifugal Force

Figure 1−30 Figure 1−31

Watch that side tilt! Watch that centrifugal force!

20. Lifting heavy loads can cause the crane to tilt or 24. Don’t increase the maximum allowable counter-
lean toward the load. When swinging a load from weight. Don’t add anything to the crane that will
over the end to over the side, the tilt of the crane will act as additional counterweight. Remember that
increase. Since tilt acts to increase load radius, it anything which has weight, if carried behind the
must be compensated for when swinging the load. crane’s center of gravity, acts as counterweight.
Swing slowly. Change boom angle (raise or lower Adding counterweight affects backward stability of
boom) while swinging, to maintain a constant ra- the crane, particularly when working over the side.
dius, and prevent in swing or out swing of load. If It also encourages overloading of the crane.
not, a dangerous condition could result. 25. Working areas for cranes are defined per the Work-
21. Watch out for centrifugal force when swinging a ing Areas Chart located in the Crane Rating Manu-
load. Swing gently. Centrifugal force tends to in- al. Permissible loads, per the Crane Rating Manu-
crease load radius. This increase in radius could al, will vary from lifting quadrant to lifting quadrant.
overload the crane and cause crane damage or tip- The operator must make sure capacity ratings are
ping. When stopping the swing, over swing of the not exceeded regardless of which quadrant he is
load can side load the boom. operating in, or when swinging from one quadrant
22. Keep the winch ropes as short as possible to pre- to another.
vent excessive swinging. Always use the shortest 26. When making lifts on tires, the tires must be inflated
boom length which will do the job. Remember − to pressures shown on the Tire Inflation label lo-
the shorter the boom, the better the capacity. cated on the carrier or in the Crane Rating Manual.
23. Do not move a crane away from the load while han-
dling near capacity loads. Due to load inertia
(weight) the load will tend to stay in position when
the crane starts to move, and then will swing in to-
wards the crane. The inertia effect will tend to in-
crease load radius and decrease stability. This
could lead to boom failure or crane tipping.

Section 1 − Operating Instructions 1−17

Operator’s Manual
Traveling k. See
Pick And Carry Operation" found later in
1. Traveling with a suspended load should be this Section of this Operator’s Manual for more
avoided if possible. It is especially hazardous details.
when terrain is rough or irregular, on a side slope, 2. Do not exceed the maximum axle load ratings as
or in a hilly area. When traveling with a load, ob- listed on the Gross Axle Weight Rating plate.
serve the following rules: 3. Road the crane safely. Watch for narrow bridges
and low clearances. Check load limits, heights,
a. Use a hand line to control the load and reduce
width and length restrictions in the area you are
load swing.
traveling. Make sure your crane complies with all
b. Travel by the smoothest, most level route. If a
regulations.
smooth, level route is not available, don’t travel 4. Do not allow anyone to ride in the upper operator’s
with a suspended load. Grade the route to pro-
cab during any highway travel. Highway travel is
vide a smooth, level path. If it is not possible to considered to be any travel of the crane over 5.0
grade the route, move the load by stepping.
mph (8.0km/h). Refer to
Highway Travel" found
Level the crane on outriggers, lift the load and
later in this Section of this Operator’s Manual for
set it down ahead of the crane. Travel the un-
more details.
loaded crane beyond the load, level the crane
5. When roading the crane, note the following:
on outriggers, lift the load, swing and set it a. Operate with lights on. Use proper warning
down farther along the route. Continue this
signs, flags, and other devices. Use an escort
procedure until the load is at its destination. service if required.
c. Carry loads as close to the ground as possible.
b. Engage travel swing lock. Release the 360°
d. Do not allow side swing of the load.
swing lock.
e. Don’t attempt to carry loads which exceed the
c. Lash down or otherwise restrain the hook
crane’s rating. Refer to On Tires and Pick And
block.
Carry capacities shown in the Crane Rating d. Check for maximum allowable travel speed,
Manual.
and any other travel limitations. Don’t exceed
f. Don’t travel with a load on soft ground. If the these maximums. Crane damage or an acci-
crane sinks into ground, stability can be af-
dent could result.
fected to the point of tipping the crane.
e. When traveling, outriggers must be fully re-
g. Keep all personnel clear of crane and load. Be
tracted.
prepared to set load down quickly at anytime.
f. Remove all pontoons from the outrigger jacks
h. Fully extend outrigger beams. Extend or re-
and store them properly.
tract jacks until pontoons just clear the ground.
g. See
Traveling the Crane" found later in this
i. Check clearance for the extra width of the Section of this Operator’s Manual for more de-
crane with the outriggers extended. Outrigger
tails.
beams or pontoons must not hang on any ob-
6. If the crane must be towed, shift the transmission
struction.
to neutral and move slowly. Slowly take up slack in
j. Inflate tires as shown on the Tire Inflation label
the rope or chain. Don’t jerk, the chain or rope may
located on the carrier or Tire Inflation chart lo-
break. Keep the chain or rope tight while towing.
cated in the Crane Rating Manual when mak-
See
Towing the Crane" found later in this Section
ing lifts on tires. of this Operator’s Manual for more details.

1−18 Section 1 − Operating Instructions

 Operator’s Manual
Leaving The Station
1. Do not get on or off a crane in motion. Use the grab
handles and ladders when climbing on or off the
crane. Remain in three point contact with the crane
at all times (two hands and one foot or two feet and Wrong
one hand).
2. Whenever an operator leaves the control station for
any reason, the following must be done:
a. Lower the load to the ground.
b. Engage the swing lock. Engage the park
brake. Shutdown engine and remove keys.
c. Do not depend on a brake to suspend a load
unless the operator is at the controls, alert and
ready to handle the load. Brake slippage, van-
dalism or mechanical malfunctions could
cause the load to drop.
3. Do not leave crane unattended with the engine run- Figure 1−32
ning. Do not leave the crane with a load suspended.
4. When changing work shifts be sure to notify the
next operator of any changes or problems with the Link-Belt cranes are designed and intended for han-
crane. dling material. They are not normally equipped with
secondary systems or other devices required by per-
Personnel Handling Guidelines sonnel lift or elevator standards and are not intended
for handling personnel for construction or amusement
Introduction purposes. Use of cranes for these purposes is hazard-
The following information is intended to provide ous and is not recommended by Link-Belt. However,
Link-Belt’s recommended minimum requirements that Link-Belt understands that circumstances may occur
must be followed when handling personnel with a (in construction work) when lifting or lowering person-
personnel basket or work platform (hereafter referred nel on a materials handling crane load line is the only or
to as a platform) suspended by wire rope from the the least hazardous method available to position per-
boom of Link-Belt cranes. These requirements are sonnel. In fact, OSHA (Occupational Safety and Health
based upon several sources and are put forth in Administration) Part 29 CFR 1926.550(g) states
The
recognition of current industry practices. However, use of a crane or derrick to hoist employees on a per-
safety, when handling personnel, remains the sonnel platform is prohibited, except when the erec-
responsibility of job site management and is tion, use, and dismantling of conventional means of
dependent upon the responsible action of every reaching the work site, such as personnel hoist, ladder,
person on the job involved in the related work. stairway, aerial lift, elevating work platform, or scaffold
would be more hazardous or is not possible because of
This information is intended to supplement and not to
structural design or work site conditions."
supercede or replace any more restrictive federal,
state, or local regulations, safety codes, or insurance Much corollary and supplementary information is con-
requirements. It is intended to serve users of personnel tained within the following resource documents per-
platforms in achieving the following objectives. taining to both cranes and personnel platforms.
1. Reduce risk of personal injuries to users and the
American National Standards Institute Reference −
public. ANSI Standards A10.28, A92.2, A92.3, B30.5, and
2. Inform users of their respective responsibilities. B30.23.
3. Provide standards of equipment requirements.
PCSA (Power Crane and Shovel Association) Bureau
4. Provide standards for tests and inspections. of the American Equipment Manufacturers Associa-
5. Provide standards of operation to promote safety. tion Reference − PCSA Standard No. 4.

A.P.I. (American Petroleum Institute) Specification
2C.

OSHA Part 29, CFR 1926.550 Cranes and Derricks.

Section 1 − Operating Instructions 1−19

Operator’s Manual
Authorization brake which is applied when the applicable
control is in neutral, or when the anti-two block
Authorized use of a work platform may be permitted device is actuated.
only after the following on-site procedures have been c. If the crane is equipped with a
free-fall" hoist,
performed: steps shall be taken to ensure its use is not
1. The person on the job site specifically responsible possible during the use of the work platform.
for the overall work function to be performed has (Note: A.P.I. applications do not permit the
determined that there is no practical alternate way crane to be equipped with free-fall.)
to perform the needed work and has authorized a d. A boom angle indicator.
personnel lifting operation.
2. For each instance of such lifting, the person
Cranes with extendable booms must utilize a
responsible for the task has attested to the need for boom angle indicator having
high and low"
the operation by issuing a statement describing set points and audible/ visual alarm(s) capa-
the operation and its time frame and itemizing that ble of activating function lock-outs.
each of the on-site authorization requirements has
Cranes with fixed boom lengths must have
been met. The statement, after being approved by an accurate and reliable boom angle indica-
the authorizer, shall be retained at the job site. tor.
3. Review of crane inspection records has been con- e. Boom length indicator
ducted to ensure the crane being used meets ap-
Cranes with extendable booms must utilize a
plicable provisions in ANSI B30.5 and B30.23. boom length indicator.
4. Review of the work platform inspection records
Cranes with fixed boom lengths do not re-
and specifications has been conducted to ensure it quire a boom length indicator.
meets applicable design standards (refer to ANSI f. Audible and visual alert systems shall be pro-
A10−28). vided to the personnel in the platform to signal
5. Review of the personnel lifting operation practices for assistance in the event of an emergency.
specified in these instructions have been g. Each crane shall have a mechanical swing
conducted with crane operator(s), foreman, signal lock capable of being set at any swing posi-
person, personnel to be lifted, safety supervisor, tion, and shall have a variable swing brake ca-
and any other person who has jurisdiction over the pable of stopping the swing motion smoothly.
operation to ensure that they are aware of the haz- The swing brake must be properly maintained
ards of the operation and they are aware of provi- at all times to ensure its holding capability.
sions of these instructions that must be adhered to 2. The platform shall be designed by a qualified engi-
before and during the personnel lifting operation. neer competent in structural design. Its mainte-
nance, and its attachment to the crane load line, is
Equipment the responsibility of the job site management.
1. The crane/platform system shall be equipped with Their arrangement shall comply with the following
the following: as a minimum:
a. The work platform harness must be of suffi-
Note: All these operational aids must be main-
cient length to prevent any portion of the work
tained in operable condition.
platform or the harness from coming in contact
a. An anti-two block device to prevent damage to with the boom at any boom angle.
the hoist rope, other crane components, or at- b. Hooks on hook ball assemblies, sheave block
tachments, and subsequent endangerment of assemblies, or other assemblies, shall be of a
personnel. type that can be closed and locked, eliminat-
ing the hook throat opening, and shall be full

It is required that the anti-two block device
load-bearing, and contain a manual trigger re-
warn both audibly and visually as well as
lease. A secondary shackle must be applied
have the capability to lock out those con-
between the platform and the lower lifting
trols/functions that may cause a two-block block to provide insurance against platform
condition. suspension/connection malfunction.
b. Boom hoist and load line shall have power low- 3. No unauthorized alterations or modifications shall
ering and raising and shall have an automatic be made to the basic crane.

1−20 Section 1 − Operating Instructions

 Operator’s Manual
Maintenance Inspection and Rigging
1. The crane operator must have a complete unders- 1. The lift crane and work platform shall be inspected
tanding of the crane’s maintenance instructions as immediately prior to commencement of operation.
outlined in this Operator’s Manual. Inspection shall include all of the equipment vital to
2. The crane shall be maintained as specified in this the safety of the operation. (Refer to ANSI A10−28
Operator’s Manual. for inspection procedures for the work platform.)
3. The crane and platform decals must be un- 2. The inspection shall be performed once daily when
derstood and maintained. the crane is being used in work platform service or
4. All decal precautions and instructions shall be each time the crane is converted from material lift-
strictly observed. ing to personnel handling operation. In the event
the operator is replaced, a new inspection is re-
Additional Requirements for Offshore Cranes quired.
1. Link-Belt offshore cranes are designed to handle 3. Any structural or functional defect which adversely
materials. affects the safe operation of the lift crane shall be
However, due to the special conditions commonly corrected before any operation utilizing a work
existing offshore, the use of cranes to transfer per- platform begins or continues.
sonnel between vessels or from a vessel to a plat- 4. The hoist drum shall have at least three wraps of
form is an established practice. The safety of the wire rope remaining on the drum at all times when
personnel, if a materials handling crane is used in using a work platform.
transferring personnel, depends upon the skill and 5. Minimum load hoist and boom hoist wire rope safe-
judgement of the crane operator and alertness of ty factors for the combined weight of the lift attach-
the personnel being transferred. Sea and weather ments, platform personnel, and tools shall be 7:1
conditions may create additional hazards beyond for manufacturer’s specified construction wire
the skill of persons involved. rope and 10:1 for rotation resistant wire rope.
(Note: A.P.I. applications require 10:1 for all rope
This operation is approved by the American Petro-
construction.)
leum Institute (A.P.I.). By adopting procedures for
6. Wire rope ends shall be seized and anchored (at-
this operation, the institute has determined that the
tached) to boom, hook balls, hook blocks, and
transfer of personnel may be performed safely un-
drums using practices and methods described in
der certain offshore conditions.
the Wire Rope Users Manual published by the
Therefore, whenever an offshore crane is used to Committee of Wire Rope Producers, American Iron
transfer personnel, all persons involved in the op- and Steel Institute.
eration must know and implement, the A.P.I. proce- 7. No platform shall be suspended from boom exten-
dures and verify that sea and weather conditions sions, auxiliary boom noses, jibs, swing away fly
are within safe limits for the transfer. sections, or luffing jibs on extendible boom cranes.
2. In addition to all previous requirements in these In- Suspension of a platform from other than the main
structions, A.P.I. 2C requires the following: boom nose is strictly prohibited on extendible

Boom and load hoists used shall be approved by boom cranes.
the hoist manufacturer for personnel handling 8. In addition to other regular inspections, visual in-
and shall be so indicated on their name plate. spection of crane and platform shall be conducted
immediately after testing and prior to lifting person-
Refer to A.P.I. 2C Section 6 for further details and nel.
procedures. 9. The crane shall be inspected in accordance with
the requirements of ANSI B30.5, Section 5−2.1.2
and 5−2.4 and ANSI B30.23.

Section 1 − Operating Instructions 1−21

Operator’s Manual
Crane Test Procedures Operation and Safety
The test procedures listed below shall be conducted at 1. This Operator’s Manual for the crane shall be read
the following intervals: and understood by operating personnel. It shall be

Daily, available to them at all times.

When an operator is replaced, and 2. Safety when handling personnel remains the re-

When, in the judgement of responsible job site sponsibility of job site management and is depen-
management, there has been a significant change dent upon the responsible action of every person
in the conditions of the personnel lifting operation. on the job involved in the related work.
3. Mobile lift cranes shall be erected to obtain maxi-
Note: No personnel shall ride the work platform dur- mum crane stability. The crane must be level and
ing any of the tests recommended in this section. on firm ground with the outriggers fully extended
and the tires clear of the ground before beginning
1. The work platform shall be loaded with ballast at any operation.
two times the intended load. This load shall not ex- 4. The operator shall not leave the operator’s station
ceed the rated capacity of the work platform. when the work platform is occupied. The operator
a. This test load shall be tested for stability. shall remain alert in a position of readiness at the

The operator and signal person shall con- work station with the engine running and the mas-
duct this test. ter clutch engaged, if crane is so equipped.

This test shall include movement of the 5. Unauthorized personnel shall not be in the opera-
platform through its entire intended range tor’s cab on the lift crane, or near the lift crane while
of motion, simulating the specific opera- a work platform is suspended from the load line.
tion to be undertaken. 6. Any operation in which a work platform is to be sus-

A successful stability test will not produce pended from the load line shall be carefully
instability of the crane or cause permanent planned by the operator, supervisory personnel,
deformation of any component. signal person, and personnel to be lifted prior to
b. This test load shall be raised and lowered at commencement of such operation. They are to be
maximum power controlled line speed (NOT advised:
FREE-FALL). The acceleration must be a. That the crane does not have safety devices
smooth and the deceleration capability of the normally used on personnel handling equip-
control/braking system shall be confirmed by ment.
bringing the work platform to a smooth stop. b. That the safety of the operation depends on
(This experience is intended to sharpen the the skill and judgement of the crane operator
skill of the operator in handling the platform and others present.
and to give the operator an opportunity to eval- c. Of procedures to enter and leave the work plat-
uate the crane’s performance.) The work plat- form and other safety procedures.
form shall then be inspected for any evident 7. After positioning of the work platform, all brakes
sign of damage or defect. and locks on the lift crane shall be set before per-
2. All limiting and warning devices shall be tested by sonnel perform any work.
activation of each appropriate control function.

1−22 Section 1 − Operating Instructions

 Operator’s Manual
8. A work platform attached to load line of lift cranes person shall have no other duties to perform when
shall not be used for working on any energized personnel are on the platform.
electric power line, or any energized device or facil- 17. Voice communication between platform person-
ity used for electric power generation or transmis- nel, the crane operator, and signal person, if as-
sion. Minimum working clearance shall be at least signed, shall be maintained.
twice that recommended for material handling op- 18. If other cranes or equipment may interfere with the
erations in ANSI B30.5b section 503.4.5 and ANSI lifting of personnel, signals or other means of com-
B30.23. munication between all crane or equipment opera-
9. The combined weight of the work platform, any at- tors shall be maintained to avoid interference with
tachment device, personnel, tools and other individual operations.
equipment shall not exceed 50% of the lifting ca- 19. If the work platform is not landed, it shall be tied to a
pacity of the applicable lift crane load chart. (Note: structure before personnel mount or dismount.
A.P.I. applications require 25% of lifting capacity as 20. Personnel on the platform shall wear personal fall
the limit.) arrest systems. Anchors used for attachment of
10. Cranes shall not travel while personnel are on the personal fall arrest equipment shall be indepen-
work platform. dent of any anchors being used to support or sus-
11. No lifts shall be made on another of crane’s load pend platforms. Personnel shall keep all parts of
lines with personnel suspended in a work platform. body, tools, and equipment inside work platform
12. No external load shall be lifted by attaching to the during raising, lowering, and positioning.
work platform. 21. Personnel shall always stand firmly on the floor of
13. Work platform lifts shall be a single crane oper- the platform and shall not sit or climb on the edge of
ation. A work platform shall not be lifted using two the platform or use planks, ladders, or other de-
cranes. vices for attaining a work position. (This does not
14. Hoisting of personnel shall be discontinued upon apply to offshore personnel transfer baskets. Per-
indication of any dangerous weather conditions or sonnel must ride on the exterior of this type of per-
other impending danger. sonnel handling device to assure greater safety of
15. Movement of the work platform with personnel the operation.)
shall be done in a slow, controlled, cautious man- 22. When welding is done by personnel on the plat-
ner with no sudden movements of the crane or form, the electrode holders shall be protected from
work platform. contact with metal components of the platform. If
16. Clear, unobstructed visibility between personnel electrically connected electrode holders contact
on the platform and the crane operator shall be work platform, work platform could be dropped
maintained at all times except where a special sig- due to burning/melting of wire ropes suspending
nal person shall have been assigned and posi- the work platform.
tioned such that he is visible to both. Such signal

Section 1 − Operating Instructions 1−23

Operator’s Manual
2

3
1

10

9
8
7 6
1. Carrier Cab Dash 5. Electrical Control Center 8. Service Brake Pedal
2. Steering Wheel 6. Carrier Cab Seat 9. Clutch Pedal
3. Transmission Shifter 7. Throttle Pedal 10. Windshield Washer Reservoir
4. Fire Extinguisher

Figure 1−33
Carrier Cab Layout

Carrier Cab Fire Extinguisher

The carrier cab contains various controls needed to A fire extinguisher is located directly behind the driver’s
drive the crane. Figure 1−33 illustrates the general seat in the carrier cab. Refer Figure 1−33. It is an A B C
location of the these controls. type fire extinguisher, meaning it is capable of extin-
guishing most types of fires. The operator should be
familiar with its location, the clamp mechanism used to
secure it in place, and foremost the operation of the de-
WARNING vice. Specific instructions, regarding operation, are
This manual must be thoroughly read and given on the label attached on the fire extinguisher. A
understood by the operator before driving the charge indicator on the fire extinguisher monitors the
crane. Crane damage or personal injury pressure within the tank. Check the indicator daily to
could result from improper operating ensure the fire extinguisher is adequately charged and
procedures. ready for use.

1−24 Section 1 − Operating Instructions

 Operator’s Manual
Windshield Washer Reservoir pear in the LCD area of the speedometer/odome-
ter message center.
Check the windshield washer reservoir daily. The res-
ervoir for washer fluid is located in the lower left of the 2. Coolant Temperature Gauge
cab. Refer to Figure 1−33. Visual inspection can de- This gauge registers engine cooling system tem-
termine if the washer fluid is adequate. Do not operate perature. For proper cooling system operating
the washer when the reservoir is empty. Use specially temperature range, refer to the engine manufactur-
formulated windshield washer fluid rather than water er’s manual. If cooling system overheats, reduce
because specialty washer fluids contain additives that engine speed, shift to a lower gear, or both, until
dissolve road grime. the temperature returns to normal operating
range. If engine temperature does not return to
Dash Panel normal temperature, refer to engine manufactur-
Located directly in front of the operator is the dash pan- er’s manual. When coolant temperature exceeds
el. It contains the following controls and is shown in normal operating range, an indicator light within
Figure 1−34. the gauge will illuminate, an alarm buzzer will
sound, the stop engine light will illuminate, and the
Note: When the key is turned on, the gauges will go message
H20 TEMP" will appear in the LCD area
through an initialization sequence to allow the oper- of the speedometer/odometer message center.
ator to verify correct operation of the gauges and in-
dicator lights. The gauge needle will move counter- 3. Engine Oil Pressure Gauge
clockwise to just below minimum scale for a 1/2
This gauge registers the engine oil pressure. For
second, then clockwise to minimum scale and the
proper oil pressure operating range, refer to the
indicator light within each gauge will flash. When
engine manufacturer’s manual. If there is no en-
initialization sequence is complete, all indicator
gine oil pressure after 10−15 seconds of running
lights will distinguish, gauge needles will indicate
time, shutdown the engine immediately and repair
actual readings, and the odometer will display in
the problem to avoid engine damage. When the oil
the speedometer gauge.
pressure is not within normal operating range, an
If a gauge is not monitoring its respective function: indicator light within the gauge will illuminate, an
(1) the indicator light will flash slowly and the gauge alarm buzzer will sound, the stop engine light will
needle will stay at minimum scale. This indicates illuminate, and the message
OILPSI" will appear
the gauge is not receiving data from the data bus. in the LCD area of the speedometer/odometer
(2) the indicator light will flash rapidly and the message center.
gauge needle will go to full or minimum scale. This
indicates the gauge has received invalid or out-of- 4. Battery Gauge
range data. (3) the indicator light will flash slowly
This gauge registers the charge in the battery and
(about once per second) and the gauge needle will
the output of the alternator through the regulator. It
go to full or minimum scale. This indicates the
should read 12 volts with the key on, and 12.5 to 14
gauge is not receiving any data from the system
volts with the engine running. When the charge or
control unit (SCU). Repair the problem before driv-
the voltage in the battery is not within normal oper-
ing crane.
ating range an indicator light within the gauge will
1. Fuel Gauge illuminate and the message
VOLTS" will appear in
the LCD area of the speedometer/odometer mes-
This gauge registers the level of fuel in the fuel tank.
sage center.
The fuel tank capacity is 100 gal (378.5L). Refer to
the engine manufacturer’s manual for the correct 5. Tachometer
grade of diesel fuel. When the fuel level reaches an
eighth of a tank, an indicator light within the gauge The tachometer registers engine speed in revolu-
will illuminate and the message
LOFUEL" will ap- tions per minute (rpm). Refer to the engine manu-
facturer’s manual for suggested operating speeds.

Section 1 − Operating Instructions 1−25

Operator’s Manual
8
7
9
6
4 5
3 10
2
1
11

15
18 17 16
19
21 20
22 14

13
12
1. Fuel Gauge 9. Park Brake Control Knob 16. Fan Switch (Defroster)
2. Coolant Temperature Gauge 10. Boom Dolly/Trailer Air Control Valve (If 17. Climate Control Switch
3. Engine Oil Pressure Gauge Equipped) 18. Pump Engagement/Throttle Selector
4. Battery Gauge 11. Cigarette Lighter Switch
5. Tachometer 12. 12V DC Accessory Outlet 19. Fan Control Override Switch
6. Speedometer/Odometer Message Center 13. Inter-Axle Differential Lock Switch 20. Engine Diagnostic Request Switch
7. Air System Pressure Gauges 14. Air Ride Suspension Switch 21. Dash Lights Dimmer Switch
8. Heat Control Switch 15. Indicator Light Cluster 22. Headlight Switch

Figure 1−34
Carrier Cab Dash Panel

6. Speedometer/Odometer Message Center
Odometer − reads in miles and tenths (for exam-
The speedometer registers crane travel speed in ple, 123456.7). The odometer is not resettable.
miles per hour (mph) or kilometers per hour (km/h)
Trip 1 Odometer − reads in miles and tenths,
The Message Center portion of the gauge is used preceded by a 1 (for example, 1 TRIP 123456.7 ).
MI
most often to display the odometer. The Message
Trip 2 Odometer − reads in miles and tenths, fol-
Center display disappears when the ignition is lowed by a T2 (for example, 2 TRIP123456.7 ).
MI
turned off. To view the display when the ignition is
Hour meter − reads in hours, followed by the let-
off, press the Mode button in the bottom portion of ters HR (for example, 123456HR).
the gauge. It remains activated for ten seconds af-
If a warning alarm is triggered, a warning message
ter the button is pushed.
will override all other Message Center displays until
To view a different function, press and release the the alarm condition is corrected. The warning
Mode button until one of the following functions ap- message may be temporarily overridden for twenty
pears: seconds as described in
Warning Alarms" found
later in this Section of this Operators Manual.

1−26 Section 1 − Operating Instructions

 Operator’s Manual
Setting and Resetting Functions in the Message Note: The System Diagnostics Test mode is
Center only enabled when the ignition is on.
Trip Odometers
The System Diagnostic Test has three functions
To Display The Trip 1 or 2 Odometer available:
Press and release the Mode button until the de-

Auto − A fully automatic test of all modules, dis-
sired trip odometer is displayed.
plays, and indicators.
To Reset A Trip Odometer To Zero
1. Display odometer to be reset (Trip 1 or Trip 2).
Manual − Manual selection of individual mod-
2. Press and hold the Set button until the mileage ules and telltales to test.
is reset to zero (about three seconds).
Fault Display − Recalls up to 128 device fault.
Warning Alarms Auto Test Sequence
If a condition that requires attention develops dur- Pressing the Set button while
AUTO" is displayed
ing operation, a warning will be displayed in one of starts the Auto Test sequence. During the Auto
three ways: Test, the system control unit (SCU) generates its
own gauge needle positioning data and warning

A warning message can appear in the Speedom- LED data. The sequence begins with all gauge
eter Message Center display. needles at zero scale and a blank Message Center

The red warning light in the associated gauge Display. The SCU moves the gauge needle in uni-
will turn on. son to mid-scale, full scale, back to mid-scale,

An audible warning tone will sound (for select back to zero, and then exits to the Normal Opera-
functions only). tion mode.
Once a warning alarm is triggered, it will continue Pressing the Mode or Set button during the se-
until the condition that caused it is corrected. At quence halts the sequence and returns the display
that time, the visual and audible alarms will stop to
AUTO".
and the Speedometer Message Center will display If the instrumentation passes the Auto Test, it is a
a Reset message for twenty seconds. Pressing the good indication that the entire instrumentation sys-
Set button clears the Reset message sooner. tem is functioning properly.
Temporarily Overriding a Warning Message Manual Test Function
1. Press the Set button. Pressing the Mode button while
AUTO" is dis-
2. Press the Mode button to display another func- played activates the Manual Test function and
tion. After twenty seconds, the warning mes- causes
MANUAL" to be displayed. The Manual
sage will reappear. Test is the same as the Auto Test except that the
The red warning light in the gauge and the warning user can select which modules to test.
tone cannot be overridden and will continue until a. Use the Set button while MANUAL is displayed
the condition is corrected. to select the module to be tested. The mod-
The following identifies the possible warning mes- ule’s name will appear in the display, starting
sages and the conditions that cause them. with SCU.
b. Press the Set button to start the test, or press
Function Message Alarm the Mode button to select a different module.
Low Fuel Warning LO FUEL No c. To end the test and display the module name,
Engine Oil Temp Warning OIL TEMP Yes press the Mode button at any time during the
Coolant Temp Alarm H2O TEMP Yes sequence. The Manual Test sequence is iden-
Hydraulic Oil Temp Alarm HYD TEMP Yes tical to the Auto Test sequence except that the
Front Air Pressure Alarm LO AIR1 Yes user must press the Set button to move from
Rear Air Pressure Alarm LO AIR2 Yes one phase to the next.
Battery Voltage Warning VOLTS No
Fault Codes
System Diagnostic Test Mode When a device (or ECU) attached to the crane data
To access the System Diagnostic Test mode, turn bus detects a fault, it can place an active fault code
the ignition on and press the Mode button until on the data bus. The active fault code describes a

DIAGTST" appears in the display. Then press the specific type of failure (for example, low oil pres-
Set button to enter the System Diagnostics Test sure). Each fault code includes a device fault code
mode.
AUTO" will be displayed.

Section 1 − Operating Instructions 1−27

Operator’s Manual
that identifies the device which detected the fault. c. Pull the knob out.
Pressing the Set button when
FAULTS" is dis-
played tells the SCU to send a request over the To Release Park Brake
crane data bus for all devices to send their active a. Apply the service brakes.
fault codes. During this time the SCU displays b. Push the knob in.

POLLING". After all the active fault codes have
been received, the SCU displays the device fault Note: If the park brake knob will not stay in the
codes one-at-a-time in 3-second intervals. Up to released position, check the air system pres-
128 device fault codes can be displayed. Pressing sure. It must be at least 60 psi (414kPa) before
the Mode or Set button during this time exits the the brake will release. The emergency park
Fault mode. brake will also begin to apply, and will fully en-
gage if pressure decreases below 40 psi
Note: A device fault code does not contain actu- (276kPa).
al failure data, only the identification of the de-
vice that detected the fault. 10. Boom Dolly/Trailer Air Control Valve
(If Equipped)
7. Air System Pressure Gauges This valve is used on cranes which are equipped
These gauges register the air pressure in the front with a boom dolly/trailer, to pressurize the system
and rear systems. The front gauge registers the which supplies air to the dolly/trailer brake circuit.
pressure of the front brake system. The rear gauge See the operating instructions for
Traveling With
registers the pressure of the rear brake system. Boom Dolly/Trailer" found later in this Section of
Normal operating range on both systems is this Operator’s Manual for operating procedures.
100−120 psi (690−827 kPa). If they do not register
11. Cigarette Lighter
within this range, correct the problem before oper-
ating. When the air pressure is not within the nor- Push knob in to heat element. The knob will pop-
mal operating range, an indicator light within the up when the element is hot.
gauge will illuminate, an alarm buzzer will sound,
and the message
LO AIR1" or
LO AIR2" will ap- 12. 12V DC Accessory Outlet
pear in the LCD area of the speedometer/odome- Use this outlet for electrical accessories.
ter message center.

8. Heater Control Switch CAUTION

This switch controls the temperature of the carrier Do not connect an accessory to any part of the
cab heater. Rotate the switch clockwise to in- crane other than the accessory outlets or
crease the temperature; counterclockwise to de- cigarette lighter. Damage to the crane’s
crease the temperature. electrical system may result. If it is necessary
to do so, contact your Link-Belt distributor.
9. Park Brake Control Knob
This knob controls engaging and releasing the 13. Differential Lock Switch
park brake.
This switch is used to increase rear wheel traction
on slippery roads or soft ground. Under normal
WARNING driving conditions the differential lock switch
should remain in the
UNLOCK" position. This will
Avoid using the park brake to stop the crane in provide differential action between the front-rear
motion (as a service brake) except in cases of and rear-rear axles. To provide maximum pulling
extreme emergency. Brake wear will not be power when wheels are likely to slip, use the
distributed evenly and application cannot be
LOCK" position to limit slipping.
controlled.
To Engage The Differential
To Engage Park Brake a. Maintain a constant crane speed.
b. Move the Differential Lock switch to the
a. Bring the crane to a full stop.
LOCK" position.
b. Shift the transmission to neutral.

1−28 Section 1 − Operating Instructions

 Operator’s Manual
c. Let up on the throttle pedal momentarily to al- 18. Pump Engagement/Throttle Selector Switch
low the differential lock to engage.
This switch is used to select from which cab the
d. Proceed with caution.
throttle pedal will function. When driving from the
Note: A buzzer will sound continuously while carrier cab, this switch must be in the
Lower" posi-
the main differentials are locked as a reminder tion. When performing crane operations, this
to unlock them as soon as slippery surface con- switch must be in the
Upper" position.
ditions have ceased.
19. Fan Control Override Switch
The fan control override switch is used to help con-
CAUTION trol engine temperature. With the switch in the

Off" position (top part of switch), the fan will auto-
Do not actuate the differential lock when the matically come on when the temperature reaches
wheels are slipping or spinning without
195°F (90°C) and will shut off at 175°F (80°C).
traction. Do not allow wheels to spin with
With the switch in the
On" position (bottom part of
differential lock in the
UNLOCKED" position.
switch), the fan will run continuously. Normally the
Either situation can damage the differential
switch should remain in the
Off" position except
gears.
for example when climbing a grade. Before climb-
ing the grade, turn the switch to the
On" to prevent
To Disengage The Differential Lock an unexpected power reduction of the engine.
a. Maintain a constant crane speed. 20. Engine Diagnostic Request Switch
b. Move the Differential Lock switch to the
UN-
LOCK" position. This switch is used to activate the check engine in-
c. Let up on the throttle pedal momentarily to al- dicator light to flash active and inactive engine fault
low the differential lock to disengage. codes. The switch is used to flash codes in the fol-
d. Proceed with caution. lowing circumstances:
a. When the engine is not running and with the
14. Air Ride Suspension ignition on, pressing and holding the bottom
part of the switch will flash out engine fault
This crane is equipped with an air ride suspension
codes.
which utilizes air bags to absorb shock. This con-
b. When the engine is idling and not in a pro-
trol is used to adjust the crane’s suspension de-
tected condition, pressing and holding the bot-
pending on operating conditions. Under normal
tom part of the switch will flash out engine fault
conditions, this switch should be in the
UP" (in-
codes.
flated) position. Use the
DOWN" (deflated) posi-
tion before raising the crane on outriggers. Refer to engine manufacturer’s manual for the en-
gine fault code descriptions.
15. Indicator Light Cluster
Note: On cranes equipped with the anti-lock
Nine individual indicator lights are contained in this braking system (ABS), the switch is also used to
one location. Refer to
Indicator Light Cluster" flash ABS fault codes. Refer to
Anti-lock Brake
found later in this Operator’s Manual for a descrip- System (ABS)" found later in this Section of the
tion of each indicator light. Operator’s Manual for additional information.
16. Fan Switch (Defroster)
21. Dash Lights Dimmer Switch
This switch controls the defroster fan. Press the
switch to operate the defroster fan. This switch is used to dim the dash lights. Rotate
the switch down to dim the lights and rotate up to
17. Climate Control Switch illuminate dash lights.
This control is used to operate the cab heater and 22. Headlight Switch
air conditioner (if equipped). Once the desired sys-
Press the bottom half of this switch to turn head-
tem is selected, use the heat control switch to regu-
lights, park lights, and instrument panel lights on.
late the temperature inside the cab.
Press the top half to turn them off.

Section 1 − Operating Instructions 1−29

Operator’s Manual
1 6. Stop Engine Indicator Light
3 4 This red indicator light will illuminate along with an
2
1 alarm buzzer to make the operator aware of critical
engine problems. When this light illuminates, stop
operations immediately and shutdown the engine.
Consult the engine manufacturer’s manual and
determine the problem before any further opera-
tion of the engine.

Note: The stop engine light will illuminate mo-

mentarily when the ignition is turned on as a
means of testing the indicator light. The light
should go out after a short period of time.
9 8 7 6 5
1. Turn Signal Indicator Light 6. Stop Engine Indicator Light 7. Check Engine Indicator Light
2. Cruise Enabled Indicator 7. Check Engine Indicator
This amber indicator light will illuminate along with
Light Light
3. Engine Torque Limit 8. Boom Trailer Anti-lock an alarm buzzer to make the operator aware of mi-
Indicator Light Brake System (ABS) Warn- nor engine problems. When this light illuminates,
4. High Beam Indicator Light ing Light engine operation may continue. However, consult
5. Carrier Anti-lock Brake 9. Park Brake Indicator Light
the engine manufacturer’s manual and determine
System (ABS) Warning
Light the problem as soon as possible to avoid pro-
longed operation of the malfunctioning engine
Figure 1−35 which could develop into a major problem. This
Indicator Light Cluster light will also flash when using the engine diagnos-
tic request switch to retrieve engine fault codes
stored in the electronic control module (ECM).
Indicator Light Cluster
Note: The check engine light will illuminate mo-
1. Turn Signal Indicator Light mentarily when the ignition is turned on as a
This light will blink to indicate that a turn signal is on means of testing the indicator light. The light
or the hazard lights are flashing. should go out after a short period of time.

2. Cruise Enable Indicator Light

5. Boom Trailer Anti-lock Brake System (ABS)
This indicator light will illuminate to alert the opera- Warning Light (If Equipped)
tor that the cruise control system is enabled.
If the crane is equipped with boom trailer and anti-
3. Engine Torque Limit Indicator Light lock brakes, this amber indicator light will illumi-
This indicator light will illuminate to alert the opera- nate to alert the operator that a malfunction in the
tor that the engine torque limiter is activated. trailer ABS has occurred and the system is dis-
abled. Normal braking should not be affected,
4. High Beam Indicator Light however, the ABS should be serviced immediately.
Refer to Anti-lock Brake System (ABS) found later
This indicator light will illuminate to indicate when
in this Operator’s Manual.
the headlights are on high beam.

5. Carrier Anti-lock Brake System (ABS) 9. Park Brake Indicator Light

Warning Light (If Equipped) This light will come on any time the park brake is
If the crane is equipped with anti-lock brakes, this engaged and the ignition is on.
amber indicator light will illuminate to alert the opera-
Note: When the park brake control knob is
tor that a malfunction in the ABS has occurred and pushed in (released), the park brake remains
the system is disabled. Normal braking should not engaged until the indicator light goes off.
be affected, however, the ABS should be serviced
immediately. Refer to Anti-lock Brake System (ABS)
found later in this Operator’s Manual.

1−30 Section 1 − Operating Instructions

 Operator’s Manual

5
1 6

12

11

10 9
1. Tilt Lever 5. Ignition Switch 9. Service Brake Pedal
2. Turn Signal Lever 6. Ignition Lock 10. Clutch Pedal
3. Steering Wheel 7. Hazard Flasher Switch 11. Engine Diagnostic Connector
4. Horn 8. Throttle Pedal 12. Pump Disconnect Control Handle
Figure 1−36
Steering Column, Pump Disconnect, And Foot Operated Controls

Steering Column, Pump Disconnect, e. Check all steering wheel functions before con-
tinuing operation.
And Foot Operated Controls
The steering column and wheel are the conventional 2. Turn Signal Lever
automotive type equipped with a tilt function. The fol-
The turn signal lever controls the following func-
lowing is a description of the switches and controls on
tions:
the steering column, along with an explanation of their
function and/or operation. Refer to Figure 1−36. a. Turn Signals: Push the lever down for left turn
signal, pull the lever up for right turn signal.
1. Tilt Lever b. Headlight Beam Control: Pull the lever toward
This lever controls the tilt (angle) function of the the steering wheel and then release to change
steering wheel. To change steering wheel tilt: beam.
c. Windshield Wiper: Rotate the turn signal lever
a. Bring the crane to a complete stop.
counterclockwise to activate the windshield
b. Engage the park brake and shift the transmis-
wiper. Rotate the lever forward to the first
sion to neutral.
detent for low speed wiper, to the second
c. Pull the tilt control lever toward the steering
detent for high speed wiper. Rotate clockwise
wheel and hold.
to turn wiper off.
d. Position the steering wheel at the desired an-
d. Windshield Washer: Push in on the end of the
gle and release the lever.
lever to spray washer fluid onto the windshield.

Section 1 − Operating Instructions 1−31

Operator’s Manual
3. Steering Wheel Do not fan the service brake pedal. This wastes
Turn the steering wheel clockwise for right turns compressed air and increases stopping distance.
and counterclockwise for left turns. Depress the pedal fully only in cases of emergency
as this makes control of the crane difficult.
4. Horn If the air system pressure drops far below the nor-
The button in the center of the steering wheel acti- mal operating range of 100−120 psi
vates the horn. Press the button to sound the horn. (690−827kPa), stop the crane and repair the prob-
lem. As the air system pressure decreases below
5. Ignition Switch 60 psi (414kPa), the park brake will automatically
The ignition switch is the key operated, conven- begin to apply.
tional, automotive type. It controls engine
off/run/start and energizes the instrument panel 10. Clutch Pedal
gauges in the carrier cab. On cranes equipped with a manual transmission,
the clutch pedal controls engaging/disengaging
6. Ignition Lock the clutch. Release the clutch pedal to engage the
This button locks the key in the ignition switch. clutch. Depress the clutch pedal to disengage the
Turn the key to the
LOCK" position and push the clutch.
lever down to remove key and lock the steering The clutch is equipped with a brake to stop the
wheel in position. transmission gears from rotating. This aids in shift-
ing smoothly from neutral to first and reverse. The
7. Hazard Flasher Switch brake also aids in smooth upshift under adverse
This switch controls the hazard warning flashers. conditions where vehicle road speed rapidly slows
Press the switch to turn the flashers on. Pull the down. For instance, when accelerating up a hill
switch to turn the flashers off. from a standing start. To engage the clutch brake,
shift the transmission to neutral and push the
8. Throttle Pedal clutch pedal down to the limit of its travel.
Engine speed is controlled by the throttle pedal.
Press down on the throttle pedal to increase en-
gine speed. Release the throttle pedal to decrease
CAUTION
engine speed. Do not apply the clutch brake when down
shifting. Do not apply clutch brake before
9. Service Brake Pedal transmission is in neutral. Either of these
applications will cause rapid wear of the
The air brakes are controlled by the brake pedal.
clutch brake.
Press the pedal down to apply the brakes. Release
the pedal to release the brakes.
Air Brake Operation 11. Engine Diagnostic Connector
The distance the service brake pedal is moved The engine diagnostic connector is located under the
regulates the amount of air delivered to the brake carrier cab dash to the left of the steering column. Re-
chamber, which determines the braking force. fer to Figure 1−36. The connector allows the engine
The smoothest stop results when the brake appli- service technician to attach the engine diagnostic data
cation is as hard at first as crane speed and road reader (DDR) for diagnosing engine problems. When
conditions will permit. Then gradually release the the check or stop engine light illuminates, contact the
pedal as crane speed decreases. As the crane engine service technician to retrieve the fault codes
stop is completed, the brake application should and repair the engine.
only be enough to hold the crane stationary. A
rough stop will occur if the application is light at first
and increased as crane speed decreases.

1−32 Section 1 − Operating Instructions

 Operator’s Manual
12. Pump Disconnect Control Handle
Dual Switch
The hydraulic pump disconnect is used to engage and
Range Selector
disengage the main hydraulic pump. Disengaging the
main pump aids in engine start−up by reducing crank-
ing resistance. It also allows for disengaging the pump
for highway travel. Refer to Figure 1−36.

To Engage The Main Pump: 1

a. Warm up the engine using the normal start−up
and warm−up procedure.
b. Park the crane and engage the park brake.
c. Shift the transmission to neutral and shutdown the
2
engine.
d. As the engine stops, apply light pressure and pull
the pump disconnect control handle out, to the
limit of its travel. 1. Range Preselection Lever
Up Position − Hi Range
Down Position − LO Range
CAUTION 2. Deep Reduction Button

In"/Forward Position − Deep Reduction
Do not attempt to engage or disengage the
Out"/Rearward Position − Deep Reduction
pump with the engine running. Damage could Figure 1−37
occur to the pump and/or pump drive. Manual Transmission Shift Control

Note: In extremely cold weather, it is recom-

mended that the pump be allowed to cycle with-
CAUTION
out a load for 3−5 minutes at low engine speed. Do not preselect. When making the shift from
Throttle engine to half throttle and cycle the a deep reduction ratio to low range, move the
boom telescope for another 3−5 minutes. This deep reduction valve from
IN" to
OUT"
will help prevent cold oil from damaging the immediately before making the shift. This is
main pump. not a preselect valve and only torque will hold
the deep reduction gear after the button is
moved to the
OUT" position. The shift
To Disengage The Main Pump:
cylinder will make the shift by air as soon as
a. Park the crane and engage the park brake.
torque is released.
b. Shift the transmission to neutral and shutdown the
engine.
c. Push the handle all the way in. Shifting The Transmission
Note: Disengage the main pump for all highway In the following instructions, it is assumed that the op-
travel. This will prevent unnecessary wear on erator is familiar with and can coordinate the necessary
the pump and hydraulic components. movements of the shift lever and clutch pedal to make
progressive and selective gear engagements in either
direction, up or down.
Transmission Controls
Dual Switch Range Selector Style Shifter
The transmission has a 5 speed front section and a
high−low range section which allows the operator to This style shifter uses two dual position switches to se-
select 8 evenly spaced forward speeds and one
LO" lect the shift range of the transmission. Refer to
speed using a single control lever and a two position Figure 1−37 . Three ranges are available: Deep Re-
range control switch. Refer to Figure 1−38. Additional duction (LO−LO), Low Range, and High Range. Refer

LO−LO" deep reduction speeds may be selected by to Figure 1−38 and Figure 1−39 for the associated
using a deep reduction button. The
LO" and
LO−LO" shift pattern for each range.
speeds are for off highway use. The transmission also
has 3 reverse speeds.

Section 1 − Operating Instructions 1−33

Operator’s Manual

With Deep Reduction

Lever/Button in the

OUT"/REARWARD WHILE IN LOW RANGE
position . . . ONLY and shift lever in
LO . . .
Shift LO−1−2−3−4 in
LOW RANGE. LL1 & LL2 can be ob-
tained by moving Deep
Range Shift . . Reduction Lever/Button
Shift 5−6−7−8 in HIGH to the
IN"/FORWARD
RANGE. position.

Figure 1−38 Figure 1−39

Transmission High And Low Range Shift Pattern Transmission Deep Reduction Shift Pattern

Double−Clutching 4. Fully depress the clutch pedal to apply the clutch

Smooth upshifting and downshifting of the main trans- brake and disengage the clutch. Shift the trans-
mission requires double−clutching. When the opera- mission into the
LO" gear position.
tor is ready to make a shift: 5. Release the clutch pedal to start the crane moving.
1. Depress the clutch pedal, to disengage the clutch. Upshift, double−clutching, from
LO" through 1st,
2. Move the gear shift lever to neutral. 2nd, and 3rd to 4th while in the low range.
3. Release the clutch pedal to engage the clutch. 6. While in 4th and ready for the next upshift, pull up
a. Upshifts: Decelerate the engine until the en- the range preselection lever and move the shift
gine rpm and road speed match. lever, double−clutching, to the 5th speed gear po-
b. Downshifts: Accelerate the engine until the en- sition. As the shift lever passes through neutral,
gine rpm and road speed match. the transmission will automatically shift from low
range to high range.
Note: By engaging the clutch with the gear shift
lever in the neutral position, the operator is able
to control the rpm of the transmission since it is
CAUTION
regulated by the engine rpm. This procedure Never move the gear shift lever to the
LO"
enables the operator to match the speed of the speed gear position after high range
transmission with the road speed. preselection, or at anytime transmission is in
high range.
4. Quickly depress the clutch pedal to disengage the
clutch and move the gear shift lever to the next gear 7. Continue upshifting, double−clutching, from 5th
speed position. through 6th and 7th to 8th while in high range.
5. Release the clutch pedal, to engage the clutch.
Downshifting
Upshifting 1. Move the gear shift lever, double−clutching, from
1. Move the deep reduction valve to the
OUT" posi- 8th through 7th and 6th to 5th, while in high range.
tion to disengage the deep reduction gears.
2. With the transmission in neutral, start the engine
and bring the air system pressure to its normal op- CAUTION
erating range. Apply the service brake. Release Limit clutch pedal travel when downshifting to
the park brake. prevent application of the clutch brake. Use of
3. Make sure the range preselection lever is in the the clutch brake during downshifting will

LOW RANGE" position. cause excessive wear to the clutch brake
discs.
CAUTION
Do not apply the clutch brake before the
transmission is in neutral. Excessive wear of
the clutch brake will occur.

1−34 Section 1 − Operating Instructions

 Operator’s Manual
2. While in 5th and ready for the next downshift, push
down the range preselection lever and move the
shift lever, double−clutching, to the 4th speed 1
gear position. As the shift lever passes through
neutral, the transmission will automatically shift
from high range to low range.
3. Continue downshifting, double−clutching, from 2
4th through 3rd, 2nd, and 1st to
LO" while in low
range.

Skip Shifting
3
After becoming proficient in shifting the transmission, 4
the operator may want to skip some shifts. Skip shift- 1. Shift Lever 3. Cruise On/Off/Pause
ing may be done while up shifting providing the range 2. Cruise Set/Resume Switch 4. Engine Brake Switch
lever is pulled up before the shift which passes 4th Figure 1−40
gear. Skip shifting is possible while down shifting, pro- Engine Brake Switch And Cruise Controls
vided the range lever is pushed down to the low range
position before the shift which passes 5th gear. To activate the engine brake, simply remove your foot
from the throttle pedal. Note that the engine brake re-
Engine Brake mains activated even after the brake pedal has been
depressed, giving the combined power of both the en-
The engine brake is a device which uses the engine it-
gine and service brakes. The engine brake alone will
self to aid in slowing and controlling the carrier. When
slow the carrier. However, it is essential that the service
activated, the engine brake alters the operation of the
brakes be used to bring the carrier to a complete stop.
engine’s exhaust valves so the engine works as a
power−absorbing air compressor. This provides a re- To deactivate the engine brake, reapply the throttle
tarding action to the wheels. pedal, depress the clutch pedal, or move the control
switch to the
OFF" position. Always be sure to turn off
engine brake switch when you shutdown the engine.
WARNING Descending A Grade
The engine brake is a vehicle slowing device. An explanation of
control speed" is helpful in under-
It is not a substitute for the service braking standing how to use the engine brake while descend-
system. The carrier’s service brakes must be ing a grade. Control speed is the constant speed at
used to bring the crane to a complete stop. which the forces pushing the carrier forward on a grade
are equal to the forces holding it back, without using
the service brakes. For example, you may be able to
Engine Brake Controls
descend a grade safely at 10 mph (16km/h), without an
The engine brake control switch is located on the shift engine brake. With the engine brake, you might be
lever. The switch has three retarding levels to regulate able to descend that same grade at 25 mph (40km/h),
the amount of braking force made available: 1 (Low), 2 and still remain under control.
(Med), and 3 (High). Refer to Figure 1−40. Another
Under some circumstances, you may want to come
switch used to give the engine brake its fully automatic
down a grade at a faster rate than the control speed.
feature is the clutch pedal activated by its position.
This can be done by selecting a higher gear, or the
1"
Engine Brake Operation position on the engine brake switch. However, you
may have to apply your service brakes intermittently to
Once the engine brake switch is moved to the
1" posi- prevent over speeding the engine and to keep the vehi-
tion, operation of the engine brake is fully automatic. cle at a safe speed.
Since the engine brake depends on the free flow of en-
gine oil for operation, be sure to let the engine warm up
before switching it on. The engine brake can be left on
whenever driving, providing the weather and road con-
ditions are favorable.

Section 1 − Operating Instructions 1−35

Operator’s Manual
tend to lock, immediately switch the engine brake
switch into the number
1" position. Do not attempt to
WARNING use the
2" or
3" position until road conditions im-
Frequent use of the service brakes, while prove.
descending a grade, will cause them to heat
In changing weather conditions, check the proper po-
up and reduce their stopping ability. The
sitioning of the control switch often. Remember: do
result can be dangerous
brake fade".
not skip a step when operating the engine brake
switch. Always go from the
1" position, then to the
2"
Since the engine brake is most effective at rated engine position, and then to the
3" position.
speeds, gear selection is very important. You obtain
maximum retarding power when you use the lowest Cruise Controls
possible gear without exceeding the recommended
engine speed. Refer to the engine manufacturer’s The crane is equipped with cruise control that allows
manual for rated engine speeds. the crane to automatically maintain a constant speed at
or above 30 mph (48km/h). The controls are located on
There are other circumstances in which you might want the transmission shift lever. Refer to Figure 1−40.
to descend a grade at a rate slower than the control
speed. This is done by selecting a lower gear, one that
will not over speed the engine. You may have to apply
the service brake to obtain the desired lower speed. WARNING
As a general rule for maintaining control speed, esti- Do not use the cruise control in heavy traffic or
on roads that are winding, slippery, or
mate the gear that you would use to climb the grade.
unpaved.
Usually this is the same gear that can be used for a con-
trolled descent with an engine brake.
It’s always a good idea to determine if your engine To Set The Cruise Control
brake is operational before beginning a long steep de- 1. Press and release the
On" switch.
scent. This can be done by briefly lifting your foot off the 2. Accelerate to the desired speed above 30 mph
throttle. You will feel the engine brake going into action. (48km/h) using the accelerator pedal.
3. Press and release the
Set" switch. This will set the
Slippery Pavement
speed. Holding the
Set" switch will allow the
If the engine brake operation is unfamiliar, it is recom- crane speed to decrease. Release of the switch
mended that it not be used on slick roads until you gain sets cruise to the lower speed.
some experience with it on dry pavement. 4. Remove your foot from the accelerator. The crane
Since the operation of any vehicle under slippery con- will maintain the set speed.
ditions is unpredictable, be sure you have plenty of dis-
Note: Pressing the accelerator pedal will allow
tance when testing service brakes or your engine
the crane speed to increase. Taking your foot
brake.
off the accelerator pedal allows the crane to re-
When driving on wet or icy pavement, start with the en- turn to the set speed.
gine brake switch in the
OFF" position and use the
same gear you would normally use under these condi-
tions. Resetting The Cruise Control
Before activating the engine brake be sure that the ve- To reset the cruise control to a lower speed, do any of
hicle is maintaining traction and stability using the natu- the following:
ral retarding of the engine alone.
Press and hold the
Set" switch.Let the crane slow
If the vehicle is maintaining traction, you may then acti- down to the desired speed and release the
Set"
vate the engine brake by moving the switch to the
1" switch. The speed is now set at the lower speed.
position. If the drive wheels begin to lock or there is a

fishtail" motion, immediately turn off the engine brake


Tap down" − this that allows the current speed to
switch. Don’t turn the engine brake on until road condi- decrease in increments of 1 mph (1.6km/h) by a mo-
tions improve. mentary tap of the
Set" switch. Multiple taps of the

Set" switch will decrease the speed 1 mph
If there was no tendency for the drive wheels to lose (1.6km/h) for each tap.
traction and you desire greater slowing power, move
the control switch to the
2" position. If the drive wheels

1−36 Section 1 − Operating Instructions

 Operator’s Manual
To reset the cruise control to a higher speed, do any of
the following:

Accelerate to the desired speed, then press and re-
lease the
Set" switch.

Press and hold the
Res" switch, allow the crane to
accelerate and release the switch.


Tap up" − this allows the current speed to increase
in increments of 1 mph (1.6km/h) by a momentary 4
tap of the
Res" switch. Multiple taps of the
Res"
switch will increase the speed 1 mph (1.6km/h) for
each tap.
1 5
Suspending And Resuming A Set Speed
To suspend the cruise control, do any of the following: 2

Press the
Pause" switch or depress the brake or 3

clutch pedal. The cruise controls are suspended, but
1. Air Control Valve 4. Seat Back Adjustment
can be reset by pressing the
Set" switch or return to 2. Height Adjustment Latch Knob
the previous set speed with the
Res" switch. 3. Seat Release Lever 5. Seat Belt

Note: Double clutching will not suspend the Figure 1−41

cruise control. After a double clutch shift is made, Carrier Cab Seat
the crane will maintain the previously set speed.

The engine speed drops below the set point (1,000 Note: For optimum comfort and proper seat adjust-
rpm) or the crane speed drops below the mph set ment, the operator should
sit back in the seat" and
point (30 mph [48km/h]). The cruise controls are sit erect while making any adjustment.
suspended, but can be reset by pressing the
Set"
switch or return to the previous set speed with the

Res" switch.
WARNING
Turning The Cruise Control Off Do not make seat adjustments while crane is
in motion. Properly park crane before making
To deactivate cruise controls, do any of the following: seat adjustments.

Press the
Off" switch.All cruise control switches are
off. To resume cruise control, press the
On" switch
and reset the speed control by pressing the
Set"
1. Air Control Valve
switch. The air control valve is used to adjust the cushion

The cruise control switches are also turned off each angle and weight resistance for maximum driver
comfort. Increase the cushion angle and weight
time the crane’s engine is turned off. resistance for a heavier operator or bumpy road
conditions; decrease for light, smooth road condi-
Carrier Cab Seat tions by using the air control valve. Push the valve
The operator’s seat in the carrier cab is fully adjustable. in to increase the resistance; pull out to decrease it.
For average conditions, the seat cushion surface
should be level while the operator is seated. The seat
2. Height Adjustment Latch
should ride freely up and down, without bottoming out, To Raise The Seat:
during normal crane movement. a. Pull out on the air control valve to exhaust all
Seat back angle and the forward and backward posi- the air.
tion of the seat should be adjusted to provide operator
comfort. The seat is adjusted by manual controls. Re-
fer to Figure 1−41.

Section 1 − Operating Instructions 1−37

Operator’s Manual
b. While holding the height adjustment latch in The fan switch is located above the battery disconnect
the released position, push the air control switches and can be accessed from the left side engine
valve in to raise the seat to the desired height. access door. Refer to Figure 1−42.
c. Once the desired height is reached, release
the air control valve and the height adjustment Battery Disconnect
latch.
d. Adjust the air pressure as needed to obtain the Switches
desired ride.
Located behind the left engine access door is the bat-
To Lower The Seat: tery disconnect switches. Refer to Figure 1−42. Move
a. Firmly pull up on the height adjustment latch the disconnect switches to the
Off" position any time
while pulling out on the air control valve, ex- welding is being done on the crane to protect the cranes
hausting air until the latch releases. electronic components from damage due to an electric
b. Once the desired height is reached, release arc type welder.
the air control valve and the height adjustment
latch.
c. Adjust the air pressure as needed to obtain the
CAUTION
desired ride. Serious damage may occur to the ECM, DDEC
components, and electronic equipment from
3. Seat Release Lever welding on the crane prior to turning
disconnect switches to the
OFF" position.
To move the seat forward or backward, pull the
seat release lever outward and hold. Position the Ignition switch should be shut off at least 30
seat as desired and release the lever to lock the seconds prior to turning disconnect switches
seat in place. to the
OFF" position.

4. Seat Back Adjustment Knob

To recline the seat back, turn the seat back adjust- Carrier Cab Fuse Box
ment knob clockwise. To bring the seat back for-
The carrier cab fuse box is located behind the driver’s
ward, turn the knob counterclockwise.
seat. Remove the access panel to gain access to the
5. Seat Belt fuse box. Located on the back of the box cover is a label
which designates the carrier electrical circuit protected
A seat belt is provided for operator safety while by each fuse. Refer to Figure 1−42. Use a fuse puller
driving the crane. The seat belt must be used at all when replacing a fuse.
times while driving the crane.
Engine Control Module Fuses
WARNING Located below the battery disconnect switches are two
15 amp fuses which protect the ECM’s main power. If
Always wear the seat belt while driving the
the ECM is not functioning, check these fuses and re-
crane. The seat belt must be snug and low
place if required. Refer to Figure 1−42.
across the hips.

Engine Interface Box

Hydraulic Oil Cooler Fan When the transmission is in the lower gears, a torque
limiter is used to protect the power train components
Override Switch by reducing maximum engine output torque. This al-
The hydraulic oil cooler fan is used to help keep the oil lows the use of low ratio transmissions for slow job site
cool during warm weather operations. The fan should creep speeds without over torquing components. The
remain on except in cold weather. When the oil cooler torque limiter is controlled by the engine interface box
override switch is in the ON position, the engine fan will located in the electrical control center. Refer to
run at full speed. When the oil cooler override switch is Figure 1−42.
in the OFF position, the engine fan is controlled by the
engine ECM.

1−38 Section 1 − Operating Instructions

 Operator’s Manual
A B

1 2

3
6

A B

1. Engine Interface Box 3. Carrier Cab Fuse Box 5. Battery Disconnect Switches
2. Coolant Level Module 4. Hydraulic Oil Cooler Fan Override Switch 6. Engine Control Module Fuses

Figure 1−42
Electrical Center And Battery Disconnect Switches

Section 1 − Operating Instructions 1−39

Operator’s Manual

1 2 3

Front

1. ABS Controller 2. ABS Power Relay 3. ABS Warning Light Relays

Figure 1−43
ABS Controller Location

Anti-lock Brake System (ABS) ABS Controller

When a system malfunction has occurred a warning
(If Equipped) light on the carrier cab dash will illuminate. When this
light illuminates, a malfunction has been detected with
This crane may be equipped with an anti-lock braking
the ABS system. Depending on which component has
system. This system helps the driver maintain control
malfunctioned, the ABS may be fully or partially dis-
by preventing wheel lockup during hard braking.
abled. To determine the malfunction the engine diag-
The system operates with a computer that is able to op- nostic request switch is used to place the controller
timize crane control during braking on varying tire and (ECU) in diagnostic blink code mode where the ABS
road conditions by modulating the brake pressure at warning light will display a sequence of flashes. When
each wheel. During an anti-lock stop, the modulating the ABS warning light illuminates, the controller should
pressure will not allow the wheels to lock-up. This is an be serviced as soon as possible.
indication that the ABS is working correctly.

CAUTION
The ABS may not assist the crane in stopping
quickly on wet or icy surfaces. Heavy braking
combined with poor road conditions could
cause loss of steering control.

1−40 Section 1 − Operating Instructions

 Operator’s Manual

2
1. ABS Warning Light
2. Diagnostic Request Switch
3. ABS Electronic Control Unit (ECU) Carrier Cab Dash
Figure 1−44
ABS Controller

ECU Diagnostics Note: The ECU will not enter the diagnostic blink
The controller contains self-testing diagnostic circuitry code mode if the wheel speed sensors show that
that continuously checks for the normal operation of in- the crane is in motion. If the ECU is in the diagnostic
ternal components and circuitry, as well as external blink code mode and then detects crane motion, it
ABS components and wiring. will exit the blink code mode.
In addition, by operating the diagnostic request switch
Active Diagnostic Trouble Codes as described below, one of several diagnostic modes
When an erroneous system condition is detected, the can be entered. Refer Diagnostic Modes found later in
controller: this Section of the Operator’s Manual.
1. Illuminates the appropriate indicator light(s) and dis-
engages part or all of the ABS and ATC functions. Blink Code Activation
2. Places the appropriate trouble code information in Activate blink codes with the diagnostic request switch:
the ECU memory. 1. Wait at least two seconds after ignition on. (Except
3. Communicates the appropriate trouble code infor- when entering Reconfiguration Mode − refer to
mation over the serial communications diagnostic Reconfiguration Mode found later in this Section of
link as required. Hand-held or PC-based diagnos- the Operator’s Manual.
tic tools attach to the diagnostic connector located 2. For the ECU to recognize that the switch is acti-
under the carrier cab dash. vated
on", the technician must press for at least
0.1 seconds, but less than 5 seconds. (If the switch
Blink Codes is held for more than 5 seconds, the ECU will regis-
Blink codes allow a technician to troubleshoot ABS ter a malfunctioning switch.)
problems without using a hand-held or PC-based diag- 3. Pauses between pressing the switch when a se-
nostic tool. Instead, information about the ABS system quence is required, (e.g. when changing mode)
is communicated by the ECU using the ABS warning must not be longer than 2 seconds.
light to display sequences of blinks. 4. After a pause of 3.5 seconds, the ECU will begin re-
sponding with output information blinks. Refer
Figure 1−45 for an example.

Section 1 − Operating Instructions 1−41

Operator’s Manual

Time in Seconds

2.5 second pause between messages

3.5 second
initial pause
Lamp stays illuminated
for 5 seconds showing
Switch end of messages
Activation 1.5 second pause between digits

Figure 1−45
Blink Code Message Example

Blink Code Timing To enter the various diagnostic modes, refer to the
The ECU responds with a sequence of blink codes.
Diagnostic Mode Activation" chart below.
The overall blink code response from the ECU is called
a
message". Each message includes, depending on Diagnostic Mode Activation
the mode selected, a sequence of one or more groups No. of
of blinks. Simply record the number of blinks for each Times to
sequence and then use the
Blink Code Identification" Press the
chart to identify the active or inactive trouble codes. System Mode Entered
Diagnostic
Request
1. Sequences of blinks illuminate the ABS warning Switch
light for half a second, with half-second pauses be-
tween them. 1 Active diagnostic trouble code retrieval
2. Pauses between blink code digits are 1.5 seconds. 2 Inactive diagnostic trouble code retrieval
3. Pauses between blink code messages are 2.5 sec-
3 Clear active diagnostic trouble codes
onds.
4. The light remains on for 5 seconds at the end of 4 System configuration check
messages. 5 Dynamometer Test Mode
Once the ABS warning light begins displaying a se- 7* Reconfigure ECU
quence of codes, it continues until all blink code mes-
sages have been displayed and then returns to the nor- * To enter the Reconfiguration Mode, the switch must
mal operating mode. During this time, the ECU will ig- be held in before the application of ignition power.
nore any additional diagnostic switch activation. Once the power is supplied, the switch is released
and then pressed seven times.
All trouble codes, with the exception of voltage and
J1939 trouble codes, will remain in an active state for
the remainder of the power cycle. Voltage trouble Active Diagnostic Trouble Code Mode
codes will clear automatically when the voltage returns For troubleshooting, typically the Active and Inactive
within the required limits. All ABS functions will be re- Diagnostic Trouble Retrieval Modes are used. Press-
engaged. ing the diagnostic request switch once and the ABS
J1939 trouble codes will clear automatically when com- warning light blinks the first group of two codes, and if
munications are re-established. there are more trouble codes recorded, this is followed
by a second set of codes, etc. (refer to
Blink Code
Diagnostic Modes Identification" chart to identify the codes). All active
trouble codes may also be retrieved using a hand-held
In order to communicate with the ECU, the controller or PC-based diagnostic tool.
has several modes that can be selected, allowing infor-
mation to be retrieved or other ECU functions to be ac- To clear active diagnostic trouble codes (as problems
cessed. are fixed), simply clear by removing and re-applying

1−42 Section 1 − Operating Instructions

 Operator’s Manual
ignition power. The only exception is for wheel speed Reconfiguration Mode
sensor trouble codes, which clear when power is re- Reconfiguration is carried out by using the Reconfigure
moved, re-applied, and the ECU detects valid wheel ECU Mode. To enter the Reconfiguration Mode, the
speed from all wheel speed sensors. Alternately, blink code switch must be held in before the applica-
codes may be cleared by pressing the diagnostic re- tion of ignition power. Once the power is supplied, the
quest switch 3 times (to enter the Clear Active Diagnos- switch is released and then pressed seven times.
tic Trouble Code Mode) or by using a hand-held or PC-
based diagnostic tool. Handheld or PC-based diag- Note: During the reconfiguration process, and inde-
nostic tools are able to clear wheel speed sensor pendently from any reconfiguration being carried out
trouble codes without the crane being driven. by the technician, the ECU automatically checks the
J1939 serial link and communicates with other con-
Inactive Diagnostic Trouble Code Mode trol modules. In particular, if the serial link shows
The ECU stores past trouble codes and comments (su- that the crane has a retarder device present, the
ch as configuration changes) in its memory. This re- ECU will configure itself to communicate with the
cord is commonly referred to as
event history". When retarder device for improved ABS performance.
an active trouble code is cleared, the ECU stores it in For example, if the ECU detects the presence of a
the event history memory as an inactive trouble code. retarder disable relay during a reconfiguration, it
Using blink codes, the technician may review all inacti- will configure itself to control the relay to disable
ve trouble codes stored on the ECU. The ABS warning the retarding device as needed.
light will display inactive diagnostic blink codes when
the diagnostic request switch is pressed and released System Configuration Check
two times.
1st Number System Power
Inactive trouble codes, and event history, may be retrie-
ved and cleared by using a hand-held or PC-based 1 12 Volts
diagnostic tool. 2 24 Volts
2nd Number Wheel Speed Sensors
Clearing Active Diagnostic Trouble Codes
4 4 Sensors
The ECU will clear active trouble codes when the diag-
nostic request switch is depressed and released three 6 6 Sensors
times. 3rd Number Pressure Modulator Valves
System Configuration Check Mode 4 4 Modulators
The ABS warning light will display system configura- 5 5 Modulators
tion information when the diagnostic request switch is 6 6 Modulators
depressed and released four times. The light will blink 4th Number ABS Configuration
out configuration information codes using the patterns
1 4S/4M or 6S/6M
shown in the
System Configuration Check" chart. In
this mode the ECU tells the technician, by means of a 2 6S/4M
series of six blink codes, the type of ABS system that 3 6S/5M
the ECU has been set up to expect. For example, if the
5th Number Traction Control Configuration
fourth blink code is a three, the technician knows that a
6S/5M sensor/modulator configuration has been set. 2 No ATC
3 ATC Engine Control Only
Dynamometer Test Mode
4 ATC Brake Control Only
The Dynamometer Test Mode is used to disable auto-
matic traction control (ATC) when needed (e.g. when Full ATC (Engine Control & Brake
5
performing any crane maintenance where the wheels Control)
are lifted off the ground and moving, including dyno 6th Number Retarder Configuration
testing). This mode is not reset by power off, power on, 1 No Retarder
cycling. Instead a hand-held or PC-based diagnostic
tool must be used to change the setting. Alternatively, 2 J1939 Retarder
pressing and releasing the diagnostic request switch 3 Retarder Relay
three times will cause the ECU to exit the blink code 4 J1939 Retarder, Retarder Relay
mode.

Section 1 − Operating Instructions 1−43

Operator’s Manual
Blink Code Identification
1st Digit 2nd Digit
Blink Blink Description
Code Code
2 1 Left Steer Axle Wheel Speed Sensor Excessive Air Gap
2 2 Left Steer Axle Wheel Speed Sensor Output Low @ Drive-Off
2 3 Left Steer Axle Wheel Speed Sensor Open or Shorted
2 4 Left Steer Axle Wheel Speed Sensor Loss of Sensor Signal
2 5 Left Steer Axle Wheel Speed Sensor Wheel End
2 6 Left Steer Axle Wheel Speed Sensor Erratic Sensor Signal
2 7 Left Steer Axle Wheel Speed Sensor Tire Size Calibration
2 8 Left Steer Axle Wheel Speed Sensor Configuration Error
3 1 Right Steer Axle Wheel Speed Sensor Excessive Air Gap
3 2 Right Steer Axle Wheel Speed Sensor Output Low @ Drive-Off
3 3 Right Steer Axle Wheel Speed Sensor Open or Shorted
3 4 Right Steer Axle Wheel Speed Sensor Loss of Sensor Signal
3 5 Right Steer Axle Wheel Speed Sensor Wheel End
3 6 Right Steer Axle Wheel Speed Sensor Erratic Sensor Signal
3 7 Right Steer Axle Wheel Speed Sensor Tire Size Calibration
3 8 Right Steer Axle Wheel Speed Sensor Configuration Error
4 1 Left Drive Axle Wheel Speed Sensor Excessive Air Gap
4 2 Left Drive Axle Wheel Speed Sensor Output Low @ Drive-Off
4 3 Left Drive Axle Wheel Speed Sensor Open or Shorted
4 4 Left Drive Axle Wheel Speed Sensor Loss of Sensor Signal
4 5 Left Drive Axle Wheel Speed Sensor Wheel End
4 6 Left Drive Axle Wheel Speed Sensor Erratic Sensor Signal
4 7 Left Drive Axle Wheel Speed Sensor Tire Size Calibration
4 8 Left Drive Axle Wheel Speed Sensor Configuration Error
5 1 Right Drive Axle Wheel Speed Sensor Excessive Air Gap
5 2 Right Drive Axle Wheel Speed Sensor Output Low @ Drive-Off
5 3 Right Drive Axle Wheel Speed Sensor Open or Shorted
5 4 Right Drive Axle Wheel Speed Sensor Loss of Sensor Signal
5 5 Right Drive Axle Wheel Speed Sensor Wheel End
5 6 Right Drive Axle Wheel Speed Sensor Erratic Sensor Signal
5 7 Right Drive Axle Wheel Speed Sensor Tire Size Calibration
5 8 Right Drive Axle Wheel Speed Sensor Configuration Error
6 1 Battery Voltage Too Low
6 2 Battery Voltage Too High
6 3 Battery Voltage Too Low During ABS
6 4 Battery Voltage Input Open Circuit

1−44 Section 1 − Operating Instructions

 Operator’s Manual
Blink Code Identification
1st Digit 2nd Digit
Blink Blink Description
Code Code
6 5 Ignition Voltage Too Low
6 6 Ignition Voltage Too High
6 7 Ignition Voltage Too Low During ABS
6 8 Input Voltage Has Excessive Noise (Temporary)
6 9 Input Voltage Has Excessive Noise
7 1 Left Steer Axle Pressure Modulator Valve Release Solenoid Shorted to Ground
7 2 Left Steer Axle Pressure Modulator Valve Release Solenoid Shorted to Voltage
7 3 Left Steer Axle Pressure Modulator Valve Release Solenoid Open Circuit
7 4 Left Steer Axle Pressure Modulator Valve Hold Solenoid Shorted to Ground
7 5 Left Steer Axle Pressure Modulator Valve Hold Solenoid Shorted to Voltage
7 6 Left Steer Axle Pressure Modulator Valve Hold Solenoid Open Circuit
7 7 Left Steer Axle Pressure Modulator Valve CMN Open Circuit
7 8 Left Steer Axle Pressure Modulator Valve Configuration Error
8 1 Right Steer Axle Pressure Modulator Valve Release Solenoid Shorted to Ground
8 2 Right Steer Axle Pressure Modulator Valve Release Solenoid Shorted to Voltage
8 3 Right Steer Axle Pressure Modulator Valve Release Solenoid Open Circuit
8 4 Right Steer Axle Pressure Modulator Valve Hold Solenoid Shorted to Ground
8 5 Right Steer Axle Pressure Modulator Valve Hold Solenoid Shorted to Voltage
8 6 Right Steer Axle Pressure Modulator Valve Hold Solenoid Open Circuit
8 7 Right Steer Axle Pressure Modulator Valve CMN Open Circuit
8 8 Right Steer Axle Pressure Modulator Valve Configuration Error
9 1 Left Drive Axle Pressure Modulator Valve Release Solenoid Shorted to Ground
9 2 Left Drive Axle Pressure Modulator Valve Release Solenoid Shorted to Voltage
9 3 Left Drive Axle Pressure Modulator Valve Release Solenoid Open Circuit
9 4 Left Drive Axle Pressure Modulator Valve Hold Solenoid Shorted to Ground
9 5 Left Drive Axle Pressure Modulator Valve Hold Solenoid Shorted to Voltage
9 6 Left Drive Axle Pressure Modulator Valve Hold Solenoid Open Circuit
9 7 Left Drive Axle Pressure Modulator Valve CMN Open Circuit
9 8 Left Drive Axle Pressure Modulator Valve Configuration Error
10 1 Right Drive Axle Pressure Modulator Valve Release Solenoid Shorted to Ground
10 2 Right Drive Axle Pressure Modulator Valve Release Solenoid Shorted to Voltage
10 3 Right Drive Axle Pressure Modulator Valve Release Solenoid Open Circuit
10 4 Right Drive Axle Pressure Modulator Valve Hold Solenoid Shorted to Ground
10 5 Right Drive Axle Pressure Modulator Valve Hold Solenoid Shorted to Voltage
10 6 Right Drive Axle Pressure Modulator Valve Hold Solenoid Open Circuit
10 7 Right Drive Axle Pressure Modulator Valve CMN Open Circuit

Section 1 − Operating Instructions 1−45

Operator’s Manual
Blink Code Identification
1st Digit 2nd Digit
Blink Blink Description
Code Code
10 8 Right Drive Axle Pressure Modulator Valve Configuration Error
11 1 J1939 Serial Link
11 2 J1939 Retarder
11 3 J1939 Engine Communications
12 1 Stop Lamp Switch Not Detected
12 2 Stop Lamp Switch Defective
12 3 Dynamometer Test Mode
12 4 Retarder Relay Open Circuit or Shorted to Ground
12 5 Retarder Relay Circuit Shorted to Voltage
12 6 ABS Warning Lamp Circuit Fault
12 7 Pressure Modulator Valve/Traction Control Valve/Diff Lock Common Shorted to Ground
12 8 Pressure Modulator Valve/Traction Control Valve/Diff Lock Common Shorted to Voltage
12 9 ATC Disabled to Prevent Brake Fade
12 10 Tire Size Out of Range (Front to Rear)
12 11 Wheel Speed Sensors Reversed on an Axle
12 12 Diff Lock Solenoid Shorted to Ground or Open Circuit
12 13 Diff Lock Solenoid Shorted to Voltage
13 2 ECU (10)
13 3 ECU (11)
13 4 ECU (12)
13 5 ECU (13)
13 6 ECU (14)
13 7 ECU (15)
13 8 ECU (16)
13 9 ECU (17)
13 10 ECU (18)
13 11 ECU (1A)
13 12 ECU (1B)
13 13 ECU (80)
14 1 Left Additional Axle Wheel Speed Sensor Excessive Air Gap
14 2 Left Additional Axle Wheel Speed Sensor Output Low @ Drive-Off
14 3 Left Additional Axle Wheel Speed Sensor Open or Shorted
14 4 Left Additional Axle Wheel Speed Sensor Loss of Sensor Signal
14 5 Left Additional Axle Wheel Speed Sensor Wheel End
14 6 Left Additional Axle Wheel Speed Sensor Erratic Sensor Signal
14 7 Left Additional Axle Wheel Speed Sensor Tire Size Calibration

1−46 Section 1 − Operating Instructions

 Operator’s Manual
Blink Code Identification
1st Digit 2nd Digit
Blink Blink Description
Code Code
14 8 Left Additional Axle Wheel Speed Sensor Configuration Error
15 1 Right Additional Axle Wheel Speed Sensor Excessive Air Gap
15 2 Right Additional Axle Wheel Speed Sensor Output Low @ Drive-Off
15 3 Right Additional Axle Wheel Speed Sensor Open or Shorted
15 4 Right Additional Axle Wheel Speed Sensor Loss of Sensor Signal
15 5 Right Additional Axle Wheel Speed Sensor Wheel End
15 6 Right Additional Axle Wheel Speed Sensor Erratic Sensor Signal
15 7 Right Additional Axle Wheel Speed Sensor Tire Size Calibration
15 8 Right Additional Axle Wheel Speed Sensor Configuration Error
16 1 Left Additional Axle Pressure Modulator Valve Release Solenoid Shorted to Ground
16 2 Left Additional Axle Pressure Modulator Valve Release Solenoid Shorted to Voltage
16 3 Left Additional Axle Pressure Modulator Valve Release Solenoid Open Circuit
16 4 Left Additional Axle Pressure Modulator Valve Hold Solenoid Shorted to Ground
16 5 Left Additional Axle Pressure Modulator Valve Hold Solenoid Shorted to Voltage
16 6 Left Additional Axle Pressure Modulator Valve Hold Solenoid Open Circuit
16 7 Left Additional Axle Pressure Modulator Valve CMN Open Circuit
16 8 Left Additional Axle Pressure Modulator Valve Configuration Error
17 1 Right Additional Axle Pressure Modulator Valve Release Solenoid Shorted to Ground
17 2 Right Additional Axle Pressure Modulator Valve Release Solenoid Shorted to Voltage
17 3 Right Additional Axle Pressure Modulator Valve Release Solenoid Open Circuit
17 4 Right Additional Axle Pressure Modulator Valve Hold Solenoid Shorted to Ground
17 5 Right Additional Axle Pressure Modulator Valve Hold Solenoid Shorted to Voltage
17 6 Right Additional Axle Pressure Modulator Valve Hold Solenoid Open Circuit
17 7 Right Additional Axle Pressure Modulator Valve CMN Open Circuit
17 8 Right Additional Axle Pressure Modulator Valve Configuration Error
18 1 Traction Control Valve Solenoid Shorted to Ground
18 2 Traction Control Valve Solenoid Shorted to Voltage
18 3 Traction Control Valve Solenoid Open Circuit
18 4 Traction Control Valve Configuration Error

Section 1 − Operating Instructions 1−47

Operator’s Manual

4
3 5

2
6

14
13
7

12
11
10

8
9
1. Throttle Pedal 6. Outrigger Control Box 11. Console Control Switches
2. Crane Rating Manual Holder 7. Windshield Washer Reservoir 12. Swing Brake Pedal
3. Gauge And Control Panel 8. Operator’s Manual Holder 13. Boom Telescope Pedal
4. Rated Capacity Limiter Display 9. Fire Extinguisher 14. Fuse Panel
5. Bubble Level 10. Seat And Console Assembly

Figure 1−46
Upper Operator’s Cab

gauges to operate and monitor crane operations. Re-

Upper Operator’s Cab fer to Figure 1−46. The following is a description of
Located throughout the upper operator’s cab are sev- each gauge, switch, or control in each panel, along
eral panels which contain the controls, switches, and with an explanation of their function and/or operation.

1−48 Section 1 − Operating Instructions

 Operator’s Manual

U−25

HH−10 GG−10 FF−7.5 EE−5

N−10

Z−5
PUMP RCL
HEATER ENABLE BYPASS SPARE FUSES
FAN ALARM RELAY RUN
RELAY RELAY CAVITY RATING

V−10
RELAY

CC−10 BB−10 AA−

P−5
1 C 5 AMP
L 7.5 AMP
M 10 AMP
BOOM REAR DD 15 AMP

A−10
WINCH JJ 25 AMP

D−5
G−5

R−5
K−5
PIN

W−
RELAY UP K/O
RELAY

B−15
E−10

X−10
L−10

S−5
RUN

H−
BOOM FRONT RELAY
LATCH WINCH 2
2 UP K/O

J−25
RELAY

DD−
T−5

JJ−
C−

M−
RELAY

Y−
F−
1. Control Switch A−RUN RELAYS, GAUGES,
START RELAY
L−OIL FAN COOLER
M−
Y−
Z−FUNCTION LOCKOUT
B−UPPER LIGHTS N− WIPER, WASHER AA−
2. Wiper Motor C−
D−DOME LIGHT, HORN
P−SWING ALARM, FAN
R−DRI
BB−12 VOLT ACCESSORY
CC−EXTERNAL LIGHT BAR (OPT)
E−BOOM LIGHT S−HEATER RELAY, HEAT CONTROL DD−
F− T−3RD WRAP INDICATOR (OPT) EE−RCL BYPASS
G−STROBE LIGHT U−OUTRIGGERS FF−RCL BYPASS
Figure 1−47 H−
J−HEATER FAN
V−TOP HATCH WIPER
W−
GG−WINCH SELECTOR
HH−WINCH CONTROL
Top Hatch Wiper K−BUZZER X−TELESCOPE OVERRIDE JJ−

Figure 1−48
Fire Extinguisher Fuse Panel Label
A fire extinguisher is located in the operator’s cab be-
low the left console. Raise the left console to gain ac- Gauge And Control Panel
cess to the extinguisher. It is an A B C type fire extin-
guisher, meaning it is capable of extinguishing most Located to the right front corner of the operator’s cab is
types of fires. The operator should be familiar with its a panel that contains the following controls, gauges,
location, the clamp mechanism used to secure it in and indicators. Refer to Figure 1−49.
place, and foremost the operation of the device. Spe-
cific instructions, regarding operation, are given on the
1. Windshield Wiper/Washer Switch
label attached on the fire extinguisher. A charge indica- Rotate the wiper/washer knob clockwise
tor on the fire extinguisher monitors the pressure within to activate the windshield wiper. Rotate
the tank. Check the indicator daily to ensure the fire ex- the knob to the first detent for low speed
tinguisher is adequately charged and ready for use. wiper and to the second detent for high speed wip-
er. Pushing the wiper/washer knob sprays washer
Top Hatch Wiper fluid on the windshield to clean the window.
The top hatch wiper is located on the top hatch win- 2. Stop Engine Indicator Light
dow. Refer to Figure 1−47. The switch for the top
This red indicator light will illuminate along
hatch wiper is located on the wiper motor. Move the
with an alarm buzzer to make the operator
switch to the
ON" or
OFF" position as desired.
aware of major engine problems. When
this light illuminates, stop operations immediately
Upper Operator’s Cab Fuse Panel and shutdown the engine. Consult the engine
The fuse panel is located in the lower left front corner of manufacturer’s manual and determine the prob-
the upper operator’s cab. Refer to Figure 1−46. Lo- lem before any further operation of the engine. Use
cated behind the fuse panel cover is a label which des- the engine diagnostic request switch located in the
ignates the electrical circuit protected by each fuse. carrier cab to retrieve active engine fault codes
Refer to Figure 1−48. Each fuse has a letter designa- stored in the engine control module (ECM).
tion which corresponds to the upper electrical system
as shown on the fuse identification label. Note: The stop engine light will illuminate mo-
mentarily when the ignition is turned on as a
Windshield Washer Reservoir means of testing the indicator light. The light
should go out after a short period of time.
Check the windshield washer reservoir daily. The res-
ervoir for washer fluid is located in the lower right rear of 3. Check Engine Indicator Light
the cab. Refer to Figure 1−46. Visual inspection can
determine if the washer fluid is adequate. Do not oper- This amber indicator light will illuminate
ate the washer when the reservoir is empty. Use spe- along with an alarm buzzer to make the op-
cially formulated windshield washer fluid rather than erator aware of minor engine problems.
water because specialty washer fluids contain addi- When this light illuminates engine operation may
tives that dissolve road grime. continue. However, consult the engine manufac-
turer’s manual and determine the problem as soon
as possible to avoid prolonged operation of the

Section 1 − Operating Instructions 1−49

Operator’s Manual
malfunctioning engine which could develop into a 9. Hydraulic Oil Temperature Gauge
major problem. Use the engine diagnostic request
switch located on the carrier cab dash to retrieve This gauge registers the hydraulic oil tem-
inactive engine fault codes stored in the engine perature in the main return line. Normal op-
control module (ECM). erating ranges vary with the oils used in dif-
ferent climates. Refer to Section 2 of this Opera-
Note: The check engine light will illuminate mo- tor’s Manual for proper oil viscosities and operat-
mentarily when the ignition is turned on as a ing temperature ranges. If the hydraulic oil ex-
means of testing the indicator light. The light ceeds the maximum operating temperature, an in-
should go out after a short period of time. dicator light within the gauge will illuminate and an
alarm buzzer will sound. Shutdown the crane im-
4. Ignition Switch Indicator Light mediately and correct the problem.
This light will illuminate to alert the operator 10. Fuel Level Gauge
when the ignition switch is in the
ON" posi-
tion. This gauge registers the level of fuel in the
fuel tank. The fuel tank capacity is 95 gal
5. Upper Lights Switch (359.6L). Refer to the engine manufactur-
This switch operates upper floodlights. er’s manual for the correct grade of diesel fuel.
Push the left side of the switch to turn flood- When the fuel level reaches an eighth of a tank, an
lights on, right side to turn them off. indicator light within the gauge will illuminate.

6. Boom Floodlight Switch 11. Coolant Temperature Gauge

This switch operates the boom floodlight. This gauge registers the engine cooling
Push the left side of the switch to turn flood- system temperature. For proper cooling
light on, right side to turn it off. system operating temperature range, refer
to the engine manufacturer’s manual. If the cool-
7. Rotating Beacon or Strobe Light Switch ing system overheats, reduce engine speed or
(If Equipped) shift to a lower gear, or both, until the temperature
This switch controls the cab rotating bea- returns to normal operating range. If engine tem-
con or strobe light. Push the left side of the perature does not return to normal temperature,
switch to turn it on, right side to turn it off. shutdown the engine and refer to engine manufac-
turer’s manual. When the coolant temperature ex-
8. Gauge Lights Dimmer Switch ceeds normal operating range an indicator light
This switch is used to control the gauge lights. Ro- within the gauge will illuminate, an alarm buzzer
tate the switch down to dim the gauge lights and will sound, and the stop engine light will illuminate.
rotate up to brighten gauge lights.
12. Tachometer
Note: When the key is turned on, the gauge
The tachometer registers engine speed in revolu-
needle on the coolant temperature, hydraulic oil
tions per minute (rpm). Refer to the engine manu-
temperature, tachometer, and fuel gauges will go
facturer’s manual for suggested operating speeds.
to the 12 o’clock position and an indicator light
within each gauge will flash as a means of testing 13. Winch Selector Switch
the gauge. The needle will return to the normal
operating position and the light should go out af- On cranes equipped with both a front (aux-
ter a short period of time. If the gauge is not moni- iliary) and rear (main) winch, a winch cir-
toring its respective function, the indicator light cuit switch is provided to allow an equal
will illuminate and the needle will sweep back and amount of oil to flow to both winches for simulta-
forth then move and remain at the 10 o’clock posi- neous operation or a combined flow for single
tion. Repair the problem before operating the winch operation. Press the bottom part of the
crane. switch to the position for single winch opera-
tion or the top part of the switch to the position
for simultaneous winch operation.

1−50 Section 1 − Operating Instructions

 Operator’s Manual

1
2
3

4
5
6
7
8

10
1. Windshield Wiper/Washer Switch
2. Stop Engine Indicator Light
3. Check Engine Indicator Light
4. Ignition Switch Indicator Light
11 5. Upper Light Switch
6. Boom Floodlight Switch
7. Rotating Beacon or Strobe Light Switch
8. Gauge Lights Dimmer Switch
9. Hydraulic Oil Temperature Gauge
12 10. Fuel Level Gauge
11. Coolant Temperature Gauge
25 12. Tachometer
24 13 13. Winch Selector Switch
14. RCL Display
23 15. Ignition Switch
16. Horn Button
17. 12V DC Accessory Outlet
22 14
18. Heater/Air Conditioner Selector Switch
19. Heater or Fan Speed Switch
20. Climate Control Knob
21 21. Check Gauges Audio Alarm
22. Throttle Lock Switch
15 23. Function Lockout Switch
20 24. Third Wrap Warning Light
25. First Layer Warning Light
16
19

18 17

Figure 1−49
Gauge And Control Panel

Section 1 − Operating Instructions 1−51

Operator’s Manual
14. Rated Capacity Limiter Display range. The check engine or stop engine light will
also illuminate where applicable. The problem
This displays the boom length, boom angle, load
should be repaired before operating the crane.
weight, etc. See
Crane Monitoring System" found
later in this Section of the Operator’s Manual for 22. Throttle Lock Switch
complete operating instructions.
This switch is used to hold the engine at a
15. Ignition Switch constant speed. This provides the opera-
tor with more flexibility for certain job re-
The ignition switch is the conventional, key oper- quirements. The bottom part of the switch will illu-
ated, automotive type. It controls engine minate to indicate switch in the ON position. Refer
off/on/start, accessories, and energizes the instru- to
Throttle Lock System" found later in this Opera-
ment panel in the upper operator’s cab. tor’s Manual.
16. Horn Button 23. Function Lockout Switch
Press this button to sound the horn. This switch is used to disable hydraulic
functions which are operated by the con-
trol levers and boom telescope foot pedal.
17. 12V DC Accessory Outlet Press the top part of the switch to disable hydraulic
Use this outlet for electrical accessories. function and to prevent inadvertent operation of
these controls. To allow normal operation of the
control levers and boom telescope foot pedal,
CAUTION press the bottom part of the function lockout
Do not connect an accessory to any part of the switch. The bottom part of the switch will illuminate
crane other than the accessory outlets or to indicate switch is in the ON position.
cigarette lighter. Damage to the crane’s
electrical system may result. If it is necessary 24. Third Wrap Warning Light
to do so, contact your Link-Belt distributor. The crane may be equipped with the third
wrap indicator option. When the third
wrap indicator switch is ON, this red warn-
18. Heater/Air Conditioner Selector Switch (If ing light will illuminate and a buzzer will sound to
Equipped) alert the operator that the wire rope is down to the
If cab is equipped with air conditioning, third wrap on the winch drum(s).
this three position switch selects which
system to operate. Press the top part of
the switch to turn the heater on, bottom part to turn WARNING
the air conditioning on. Locate the switch to the Three (3) full wraps of wire rope must be
center position to turn either system off. maintained on the winch drum at all times
during operation. Rope failure may occur.
19. Heater or Fan Speed Switch
This switch controls the cab heater if cab is
not equipped with air conditioning. Press 25. First Layer Warning Light (If Equipped)
the top part of the switch to turn the unit on, The crane may be equipped with a first lay-
bottom part to turn it off. If cab is equipped with air er warning light option. When the third
conditioning, this switch controls the fan speed. wrap indicator switch is ON, this red warn-
ing light will illuminate to alert the operator that
20. Climate Control Knob there is only one layer of wire rope remaining on the
Turn the climate control knob to adjust the temper- winch drum(s).
ature in the cab.
21. Check Gauges Audio Alarm
This buzzer alarm will sound to alert the operator
that a gauge is detecting an abnormal operating

1−52 Section 1 − Operating Instructions

 Operator’s Manual
Left Right

1 2 3 4 5 6
1. Boom Telescope Override Switch 3. Third Wrap Indicator Switches 5. Drum Rotation Indicator Switch
2. Swing Park Brake Switch 4. Horn Button 6. Winch Control Switches

Figure 1−50
Seat Console Control Switches

Seat Console Control Switches on the winch drum. Refer to Figure 1−49 for warn-
ing light location.
Control switches are located on the left and right
consoles of the operator’s seat. Refer to Figure 1−46
and Figure 1−50. WARNING
1. Boom Telescope Override Switch Three (3) full wraps of wire rope must be
maintained on the winch drum at all times
This switch is provided to manually over- during operation. Rope failure may occur.
ride the telescope system when the boom
is not extending/retracting proportionally
in boom mode
B". Use this switch for that pur- 4. Horn Button
pose only. While in boom mode
B", press the top Press this button to sound the horn.
part of the switch to stop the outer mid and tip sec-
tions or the bottom part to stop the inner mid sec-
tion so the boom can be extended/retracted pro-
portionally.
5. Drum Rotation Indicator Switch
This switch is used to activate the drum ro-
2. Swing Park Brake Switch tation indicator system. To activate the
This switch is used to operate the swing system, press the bottom part of the
park brake to hold the upper in any posi- switch. Press the top part of the switch to deacti-
tion over the carrier. The bottom part of the vate the system. The bottom part of the switch will
switch will illuminate to indicate switch in the ON illuminate to indicate switch is in the ON position.
position. Refer to
Swing System" found later in Refer to
Drum Rotation Indicators" found later in
this Section of the Operator’s Manual for complete this Section of the Operator’s Manual for complete
operating procedures. operating procedures.

3. Third Wrap Indicator Switch (If Equipped) 6. Winch Control Switches

These switches operate the third wrap/first These switches are used to control engag-
layer indicator system for the winch ing/disengaging the high speed hoist and
drum(s). When this switch is in the
ON" disabling the front and/or rear winch. Re-
position, a red warning light will illuminate and a fer to
Wire Rope Winch System" found later in this
buzzer will sound to alert the operator when the Section of the Operator’s Manual for complete op-
wire rope is down to the first layer and/or third wrap erating procedures.

Section 1 − Operating Instructions 1−53

Operator’s Manual
Cab Heater Cab Heater Shutoff
A cab heater is used to heat the upper cab. Refer to
Figure 1−51. The cab heater uses engine coolant cir-
culating through the unit to provide heat. Normally the
WARNING
Shutdown the engine and allow it to cool
engine coolant circulates through the heater in the cab
before operating the heater shutoff valves.
regardless of whether the heater switch is turned on or
The valves may be hot and could cause
not. During warm weather conditions, the operator
serious burns.
may wish to shutoff the flow of hot engine coolant to the
heater to reduce the temperature in the operator’s cab. 1. Shutdown the engine and rotate the handles on
Shutoff valves are located on the engine to perform this the shutoff valves clockwise to stop the flow of en-
function. Refer to Figure 1−52. gine coolant to the heater; Counterclockwise to re-
store it. Refer to Figure 1−52.
To Start The Cab Heater
1. With the engine running, press the heater switch or
if crane is equipped with air conditioning, press the
Air Conditioning (If Equipped)
top part of the heater/air conditioner selector The operator’s cab may be equipped with an air condi-
switch to turn the heater on. tioning unit. Use the following instructions to operate
2. Turn the climate control knob to the desired set- the unit. Refer to Figure 1−51.
ting. 1. Start the engine and allow all operating tempera-
3. If cab is equipped with air conditioning, use the fan tures and pressures to reach their normal range.
speed switch to control the air flow into the cab. If 2. Press the bottom part of the heater/air conditioner
cab is not equipped with air conditioning, use the selector switch to activate the air conditioning unit.
heater/fan speed switch to control the air flow into 3. Press the fan speed switch to control the amount of
the cab. air blown into the cab.
4. Turn the climate control knob to the desired set-
To Stop The Cab Heater ting.
1. Press the heater switch to the off position. 5. To turn the unit off, press the heater/air conditioner
2. During warm weather conditions or if the heater is selector switch to the off position.
not going to be used for an extended period of
time, rotate the temperature control knob to the
coolest setting.

1−54 Section 1 − Operating Instructions

 Operator’s Manual

1
2

1. Heater/Air Conditioner Selector Switch (If Equipped)

2. Heater And/Or Fan Speed Switch
3. Climate Control Knob

Figure 1−51
Cab Heater And Air Conditioner Controls

1. Shutoff Valve − Heater Return 2. Shutoff Valve − Heater Supply

Figure 1−52
Cab Heater Shutoff

Section 1 − Operating Instructions 1−55

Operator’s Manual

1
12

11
10 2

3
9

Right Side
8 4

1
5
7
6

1. Bumper Jack Extend 7. Beam − Left Rear

2. Beam − Right Front 8. Retract Mode − Beam/Jack
3. Jack − Right Front 9. Extend Mode − Beam/Jack
4. Beam − Right Rear 10.Jack − Left Front
5. Jack − Right Rear 11.Beam − Left Front
6. Jack − Left Rear 12.Bumper Jack Retract

Figure 1−53 Left Side

Outrigger Switches − Hand Held Control Box

Main Outrigger Operation 1. Bubble Level

The outriggers can be used in any one of three Figure 1−54

positions; fully retracted, intermediate, or fully Outrigger Switches − Ground Controlled
extended. The outriggers are controlled from the hand
All of the outrigger pontoons must set on a smooth,
held control box, located in the upper operator’s cab,
solid surface flush with the ground with no hills or val-
or one of two ground control stations located at the rear
leys under them or they may be damaged or de-
outriggers, and the extend position pin located at each
stroyed. If there is any doubt as to the ground condi-
outrigger station.
tions, use mats under the pontoons. Check pontoons
Note: The throttle lock switch located in the upper before and during operations. If they are allowed to
cab must be in the OFF position to activate the settle, they may lose their effectiveness, and make con-
ground control stations. tinued operations unsafe.
A bubble level is provided on the right side wall of the
The outrigger switches, at each station, control both upper operator’s cab and at each ground control sta-
outrigger functions. Each individual outrigger switch tion to assist in determining when crane is level.
controls all functions of that outrigger beam and jack Included in the ground control outrigger stations is a
cylinder. The mode switch controls outrigger direction, throttle switch which can be used to increase engine
extend/retract. Refer to Figure 1−53, Figure 1−54, speed during outrigger operation and an axle lift switch
and Figure 1−56. Each extend position pin controls that can be used to raise the rear axles while on outrig-
the extend length of the beam. When the pin is gers.
installed, it allows the beam to be extended to its inter-
mediate position or the fully retracted position.

1−56 Section 1 − Operating Instructions

 Operator’s Manual

A B A

2 B
1 1

Self Stored Position Working Position

1. Hitch Pin With Hair Pin

2. Hair Pin
3. Lock Pin

Figure 1−55
Pontoon Storage

To Extend Outrigger Beams 3. Determine the outrigger position desired. Install

1. Park the crane in the desired location. Engage the extend position pins, as required. Refer to
park brake and shift transmission to neutral. Figure 1−56.
2. If the pontoons are stored on the crane, remove
them from storage and attach one to each outrig-
ger jack in the working position. If the pontoons WARNING
are in the self stored position, move them to the When making lifts on outriggers, all outrigger
working position. Install all hitch pins in their prop- beams must be equally extended; all fully
er position and secure with hair pins. Refer to retracted, all intermediate extended, or all
Figure 1−55. fully extended. Failure to do so will cause a
loss of stability and possible crane damage
and/or personal injury.

WARNING 4. Start the engine.

Pontoons must be attached to outrigger jacks
Note: To operate the outriggers from the hand
before crane is set on outriggers. If the
held control box in the upper operator’s cab, the
pontoons should settle, the jacks could
upper operator’s cab ignition switch must be in
disengage from the pontoons, causing a loss
of stability. the
ON" position.

Section 1 − Operating Instructions 1−57

Operator’s Manual

1 2 3

1. Extend Position Pin In The Retracted Position

2. Extend Position Pin In The Intermediate Position
3. Extend Position Pin In The Fully Extended Or Stored Position

Figure 1−56
Outrigger Extend Positions

9. Set the Rated Capacity Limiter to the proper setting

to match the position of the outrigger beams.
WARNING
Do not extend or retract an outrigger beam or
jack unless it is in full view of the operator or
signalman. Make sure all personnel and
WARNING
When making lifts on outriggers, all outrigger
obstructions are clear from the path of the
beams must be equally extended; all fully
machinery. Unsuspected movement may
retracted, all intermediate extended, or all
occur.
fully extended. Failure to do so will cause a
loss of stability and possible crane damage
5. Push an individual outrigger switch to the
BEAM"
and/or personal injury.
position and hold. Push the center mode
switch to
EXTEND MODE ON" position and When making lifts with the outrigger beams in
hold. the intermediate position, the extend position
6. When the beam reaches the selected position, re- pins must be installed in the beams. Visually
lease both switches. check that all beams are properly positioned
7. Repeat Steps 5−6, for each outrigger beam, until in the intermediate position by observing the
all the beams are in the selected position. decals on the side of the beams. All beams
must be extended until the hydraulic system
Note: As conditions warrant, a proficient crane goes over relief before beginning operations.
operator may operate multiple beams such as Check that the Rated Capacity Limiter is set to
one end or side at the same time. the correct outrigger position before
8. If the intermediate beam position is to be used, beginning operation.
visually check that all beams are properly posi- Failure to perform any of the above may cause
tioned in the intermediate position by observing crane damage and/or serious personal injury.
the decals on the side of the beams. All beams
must be extended until the hydraulic system goes
over relief.

1−58 Section 1 − Operating Instructions

 Operator’s Manual
To Extend Outrigger Jacks − Raise
The Crane WARNING
1. If the crane is equipped with the axle lift system, en- All capacities listed on the capacity charts in
sure the air ride suspension switch in the carrier the Crane Rating Manual, when on outriggers,
cab is in the
DOWN" position. are based on all tires clear of the ground, all
outrigger beams equally extended (fully
retracted, intermediate extended, or fully
CAUTION extended), using the proper chart for the
When the hoist line is tied off to the crane or outrigger beam position, and the crane setting
any solid object, the winch system can be on all pontoons on a firm, level, solid surface,
and the front bumper outrigger properly
overloaded causing major winch, wire rope,
extended. Major reductions in the crane lifting
or crane damage. Do not extend boom, raise
capacity and unsafe operating conditions can
or lower the boom, or raise the crane on
result if these conditions are not met.
outriggers unless wire rope is spooled off the
drum to prevent tension on the wire rope. 9. Properly extend the front bumper outrigger. Refer
to
Bumper Outrigger" found later in this Section of
2. With the beams extended to the selected position this Operator’s Manual.
(fully extended, intermediate extended, or fully re-
tracted), push an individual outrigger switch to the To Retract Outrigger Jacks − Lower

JACK" position and hold.
The Crane
It is recommended that lowering the crane be done
WARNING from the ground control stations.
1. Retract boom fully. Swing the upper over the front
Do not extend or retract an outrigger beam or
of the carrier and engage the travel swing lock.
jack unless it is in full view of the operator or
2. Boom down and set boom on boom rest.
signalman. Make sure all personnel and
obstructions are clear from the path of the 3. Engage the park brake.
machinery. Unsuspected movement may
occur.
WARNING
3. Push center mode switch to
EXTEND MODE ON" If the rear air suspension is allowed to hang in
and hold until the pontoon just contacts the its fully extended (lowered) position, the
ground. action of the suspension compressing will
4. Release both switches. cause the crane to move slightly forward as
5. Repeat Steps 2−4 for each outrigger jack. the weight transfers from the outriggers to the
tires. The suspension lift system will minimize
Note: As conditions warrant, a proficient crane
this if the axles are lifted to the highest
operator may operate multiple jack cylinders
possible position before lowering the crane
such as one end or side at the same time.
onto the tires.
6. Extend the jack cylinders until all tires are clear of
the ground. 4. If the crane is equipped with the axle lift system, en-
sure that the air ride suspension switch in the carri-
Note: A bubble level is provided on the side er cab is in the
Down" position and that the rear
panel, in the upper operator’s cab, and at each axles are lifted to their highest position.
ground control station to assist in determining
when the crane is level.
7. Raise or lower jacks as required to level the crane.
8. Check that all tires are clear of the ground and pon-
toons are not settling.

Section 1 − Operating Instructions 1−59

Operator’s Manual
To Retract Outrigger Beams
WARNING
Do not extend or retract an outrigger beam or
jack unless it is in full view of the operator or WARNING
signalman. Make sure all personnel and Do not extend or retract an outrigger beam or
obstructions are clear from the path of the jack unless it is in full view of the operator or
machinery. Unsuspected movement may signalman. Make sure all personnel and
occur. obstructions are clear from the path of the
machinery. Unsuspected movement may
5. Properly retract the front bumper outrigger. Refer occur.
to
Bumper Outrigger" found later in this Section of
this Operator’s Manual. 1. Push an individual outrigger switch to the
BEAM"
6. Push an individual outrigger switch to the
JACK" position and hold.
position and hold. 2. Push the center mode switch to the
RETRACT
7. Push the center mode switch to
RETRACT MODE MODE ON" position and hold until the beam is
ON" position and hold. Carefully retract jack fully retracted.
until the pontoon just clears the ground. 3. Release both switches.
8. Release both switches. 4. Repeat Steps 1−3 for each beam.
9. Repeat Steps 6−8 for each outrigger jack. 5. Store all pontoons in the brackets provided.
6. Store the extend position pins, as required.
Note: As conditions warrant, a proficient crane
operator may operate multiple jack cylinders
such as one end or side at the same time.
10. Fully retract all jacks.

1−60 Section 1 − Operating Instructions

 Operator’s Manual

INFORMATION
Front Bumper Jack Control
Front bumper jack must be last jack extended
and first jack retracted. Crane must be
leveled with other four jacks before front jack
is extended.

1. Bumper Outrigger Switch Left Headlight

Figure 1−57
Bumper Outrigger Switch

the pontoon rests firmly on a solid surface and the

Bumper Outrigger hydraulic system goes over relief.
The bumper outrigger is provided to permit the same
lifting capacities over the front as over the side when it
is used with the main outriggers. Refer to the Crane WARNING
Rating Manual for specific capacities.
Do not extend or retract an outrigger jack
unless it is in full view of the operator or
Bumper Outrigger Control Switch signalman. Make sure all personnel and
The bumper outrigger can be controlled from the hand obstructions are clear from the path of the
held control box in the upper operator’s cab or from the machinery. Unsuspected movement may
ground control switch (toggle type) located on the front occur.
bumper, just above the left headlight.
4. Release the switch.
To Extend Bumper Outrigger
1. Level the crane on the main outriggers. To Retract Bumper Outrigger
1. Push the bumper outrigger switch up (or the left
side of the switch on the hand held control box)
CAUTION and hold until cylinder is fully retracted.
Always level the crane on the main outriggers
before extending the bumper outrigger.
Failure to do so could result in structural CAUTION
damage to the crane as the bumper outrigger The bumper outrigger must be retracted
alone will not properly support the weight of before the main outriggers. It alone will not
the crane. properly support the weight of the crane.

2. The bumper outrigger pontoon must set on a

smooth, solid surface flush with the ground with no
hills or valleys under it or it may be damaged or de-
stroyed. If there is any doubt as to the ground con-
ditions, use a mat under the pontoon. Check pon-
toon before and during operations. If it is allowed
to settle, it may lose its effectiveness and make
continued operations unsafe.
3. Push the bumper outrigger switch down (or the
right side of the switch on the hand held control
box) to extend the cylinder. Hold the switch until

Section 1 − Operating Instructions 1−61

Operator’s Manual

Figure 1−58
Keep Clear Of Pinch Points
Figure 1−59
Crane System Controls Back Stability Label
The following pages, along with Figure 1−60 and/or rocker switch, located on the gauge and control panel,
Figure 1−61, give detailed instructions of individual will illuminate when the throttle lock is engaged.
controls related to crane operation. It is essential that
To increase engine speed with the throttle lock set,
the operator knows the function of each control and its
press the throttle pedal until the desired engine speed
duty in the overall operation of the crane.
is reached and press the top then the bottom part of the
throttle lock switch again.
WARNING To turn off the throttle lock setting and return to idle,
Read and understand all
Operating Safety" press the top part of the throttle lock switch.
procedures as well as all other operating
instructions in this Operator’s Manual before Swing System
attempting to operate the crane. Operation of Rotation of the upper, over the carrier, is controlled by
the crane by unqualified personnel may result the swing system. Use the following controls to operate
in an accident. the swing function of the crane:

Swing Brake Pedal

Engine Throttle Controls The swing brake pedal is used to stop rotation of the
A foot throttle is located on the upper operator’s cab floor. upper over the carrier. To apply the swing brake, push
Refer to Figure 1−60. Before operating the throttle, en- down on the swing brake foot pedal. To release the
sure that the pump engagement/throttle selector switch swing brake, release the swing brake foot pedal.
in the carrier cab is in the
Upper" position. To operate
the foot throttle, press down to increase engine speed; Swing Control Lever
release to decrease engine speed. The control lever, on the left side of the operator’s seat,
Note: Switching the pump engagement/throttle se- is used to operate the swing function of the upper.
Move the control lever to the appropriate position to
lector switch to the
Upper" position also engages
swing the upper.
the main pump.

Throttle Lock System

The throttle lock system gives the operator the ability to WARNING
set and hold a specific engine speed. Refer to Do not exceed maximum boom angles listed
Figure 1−49. This provides the operator with more on the back stability label located in the upper
flexibility for certain job requirements. operator’s cab. This crane can tip over
To lock the throttle, press the throttle pedal until the de- backwards when on tires or retracted
sired engine speed is reached and press the bottom outriggers.
part of the throttle lock switch. The engine should con-
tinue to run at a constant speed when the throttle pedal
is released. An indicator light on the bottom part of the

1−62 Section 1 − Operating Instructions

 Operator’s Manual
Console Control Switches

Left Right

10

9 11 12 13 14 15 16 17

7
6
5

18

19

1. Fire Extinguisher 7. RCL Display 13.Third Wrap Indicator Switch

2. Hydraulic Control Lever 8. 360° Swing Lock (If Equipped) 14.Horn Button
(Swing, Front Winch) 9. Bubble Level 15.Drum Rotation Indicator
3. Swing Brake Pedal 10.Hydraulic Control Lever 16.Front Winch Control Switch
4. Boom Telescope Pedal (Boom Hoist, Rear Winch) 17.Rear Winch Control Switch
5. Throttle Pedal 11.Boom Telescope Override Switch 18.Outrigger Remote Control Box
6. Crane Rating Manual Holder 12.Swing Park Brake Switch 19.Travel Swing Lock

Figure 1−60
Crane Controls

Section 1 − Operating Instructions 1−63

Operator’s Manual
Travel Swing Lock
Use the travel swing lock to lock the upper directly over
2 1 either the front or rear of the carrier. The travel swing
4 3 lock will engage in these two positions only. Use of the
travel swing lock is mandatory when traveling, towing,
or transporting the crane and during pick and carry op-
erations.

To Release The Travel Swing Lock

1. Fully apply the swing brake pedal.
2. Pull the travel swing lock lever up.
Note: In order to disengage the travel swing lock,
it may be necessary to swing the upper slightly to
relieve the pressure on the swing lock pin.
Left Right
1. Hydraulic Control Lever 3. Hydraulic Control Lever 3. Move the lever to the right and release. The lever
(Boom Hoist) (Rear Winch) should remain in the released position.
2. Hydraulic Control Lever 4. Hydraulic Control Lever
(Front Winch) (Swing) To Engage The Travel Swing Lock
Figure 1−61 1. Position the upper directly over either the front or
Single Axis Controls (If Equipped) rear of the carrier. Fully apply swing brake pedal.
2. Pull the travel swing lock lever up and to the left.
Then push the lever down.
To Swing The Upper
Note: In order to engage the travel swing lock, it
1. Compare the boom configuration and length to the
may be necessary to swing the upper slightly to
capacity chart in the Crane Rating Manual. Posi-
align the swing lock pin and retaining ring on the
tion the boom safely within the limits specified on
carrier deck.
the capacity chart.
3. Check the engagement of the travel swing lock by
trying to swing the upper right, then left. The upper
DANGER should not swing.
Swing slowly and cautiously. Watch for
centrifugal force. Out swing of a load Swing Park Brake
increases the load radius and thus decreases The swing park brake is a multiple disc type brake and
capacity. Load out swing may result in tipping is used for holding the upper, in any position, over the
or damaging the crane. carrier during normal, stationary crane operations. En-
All personnel and equipment must be out of gage the travel swing lock and release the swing park
the path of the rotating upper. Do not allow brake anytime the crane is traveled, towed, trans-
boom or load to pass over personnel. Failure ported, or during pick and carry operations. An indica-
to do so could result in severe personnel tor light on the bottom part of the rocker switch, located
injury or equipment damage. on the left arm rest or gauge and control panel, will illu-
minate when the swing park brake is applied.
2. Fully apply the swing brake pedal and release the
swing park brake and/or swing lock(s).
3. Release the swing brake pedal as you begin to en-
CAUTION
gage the swing control lever. Do not leave the swing park brake applied
during pick and carry operations or when
To Stop Upper Swing traveling, towing or transporting the crane.
1. Ease swing control lever into the neutral position. Use the travel swing lock. Failure to release
2. Apply the swing brake to bring the upper to a com- the swing park brake during these operations
plete stop. may result in damage to the swing
3. Engage the swing park brake and/or swing lock(s) mechanism.
as required.
4. Check engagement of the swing park brake by try-
To Release The Swing Park Brake
ing to swing right, then left. The upper should not
1. Fully apply the swing brake pedal.
swing.

1−64 Section 1 − Operating Instructions

 Operator’s Manual
2. Push the top part of the swing park brake rocker To Engage The 360° Swing Lock:
switch on the gauge and control panel to release 1. Rotate the upper to the desired position over the
the park brake. The indicator light will go out. Re- carrier. Apply the swing brake pedal to bring the
fer to Figure 1−49 for switch location. upper to a complete stop.
To Apply The Swing Park Brake
1. Rotate the upper to the desired position over the CAUTION
carrier. Apply the swing brake pedal to bring the Do not attempt to engage 360°swing lock with
upper to a complete stop. the upper in motion. This practice will result in
2. Push the bottom part of the swing park brake rock- damage to the swing mechanism. Use swing
er switch on the gauge and control panel to apply brake pedal to stop rotation of the upper.
the park brake. Indicator light will illuminate. Refer
to Figure 1−49 for rocker switch location. 2. Move the 360°swing lock lever to the
Engage"
position.
CAUTION Note: In order to engage the 360° swing lock, it
Do not attempt to apply swing park brake with may be necessary to swing the upper slightly to
the upper in motion. This practice will result in allow the swing lock pawl to engage in the turn-
damage to the swing mechanism. Use the table gear teeth.
swing brake pedal to stop rotation of upper. 3. Check engagement of 360°swing lock by trying to
swing upper right, then left. Upper should not swing.
3. Check engagement of swing park brake by trying to
swing upper right, then left. Upper should not swing. Wire Rope Winch System
360° Swing Lock This system controls raising and lowering the winch
The 360° swing lock, if equipped, is a positive lock lines. The system is equipped with a two speed motor
against rotation of the upper over the carrier. The up- that, when activated, will approximately double winch
per is mechanically locked by a manually operated line speed. The controls for the system are shown in
pawl that engages the gear teeth in the turntable bear- Figure 1−60 and/or Figure 1−61. Review the follow-
ing. Use this swing lock during normal, stationary ing for control descriptions and brief summary of op-
crane operations. Engage the travel swing lock and re- eration.
lease the 360°swing lock anytime the crane is traveled,
transported, or during pick and carry operations.
CAUTION
When the hoist line is tied off to the crane or
CAUTION any solid object, the winch system can be
Do not leave the 360° swing lock engaged overloaded causing major winch, wire rope,
during pick and carry operations or when or crane damage. Do not extend boom, raise
traveling, towing, or transporting the crane. or lower the boom, or raise the crane on
Use the travel swing lock. Failure to release outriggers unless wire rope is spooled off the
the 360° swing lock during these operations drum to prevent tension on the wire rope.
may result in damage to the swing
mechanism.

To Release The 360°Swing Lock: WARNING

1. Fully apply the swing brake pedal. Cold weather operation of the winch requires
2. Move the 360° swing lock lever to the
Disengage" a warm-up procedure. Failure to properly
position. Refer to Figure 1−60 for location. warm-up the winch may result in brake
slippage. Warm-up the winch before
Note: In order to disengage the 360° swing
beginning crane operations.
lock, it may be necessary to swing the upper
slightly to allow the swing lock pawl to disen-
gage from the turntable gear teeth

Section 1 − Operating Instructions 1−65

Operator’s Manual
Warm-Up Procedure who has read and fully understands the entire content
of this manual.
A warm-up procedure is recommended at each start-
up and is essential at ambient temperatures below To Lift A Load: Attach hook block or hook ball to the
40°F (4°C). Allow the engine to run at idle speed, with load. Position head machinery directly above the load
the main hydraulic pump engaged and the winch con- and pull the control lever back, toward the operator.
trol lever(s) in neutral, for several minutes. Once the hy-
Note: When both winch levers are activated simul-
draulic oil begins to warm, operate the winch at low
taneously, the winch line requiring the most line pull
speed, with no load, lifting and lowering only the hook-
may not function.
block or hook ball until warm oil circulates throughout
the winch.
To Hold A Load: Return the control lever to the neutral
position. The automatic brake in the winch system will
hold the load in position.
WARNING To Lower A Load: Push the control lever forward. Re-
The weight of the load must be known before
turn the control lever to neutral to stop the load.
making a lift. Compare the load weight to the
appropriate capacity chart in the Crane Rating Winch Control Switch(es)
Manual to ensure compliance with capacity
This switch is used to control engaging/disengaging the
ratings. Compare the load weight to the wire
high/low speed hoist and disabling the front or rear
rope capacity chart in the Crane Rating
winch. Refer to Figure 1−60 or Figure 1−61.
Manual to determine the number of parts of
line required to lift the load. Rig and set up the High Speed Hoist Or Lower
crane to ensure compliance with both the
Press the winch control switch to the high speed
appropriate crane capacity chart and wire
( ) position. Move the control lever to the winch
rope capacity chart in the Crane Rating
up or winch down position. The high speed
Manual. Properly set the Rated Capacity
hoist will activate after engaging the control lever.
Limiter to the correct crane configuration.
Do not lift a load to the point where the hook Note: Using the high speed hoist reduces the maxi-
block or hook ball contacts the head mum line pull by approximately half. The high
machinery.
Two blocking" could damage the speed hoist button can be activated at anytime dur-
hook block or hook ball, wire rope, and/or the ing either winch mode. Switching the high speed
head machinery. Always keep load and hook hoist button before engaging the winch control
block or hook ball a safe distance from the lever will make the system work smoother.
boom.
To Return To Standard Winch Mode: Press winch
control switch to the low speed ( ) position.
Front Winch Control Lever (If Equipped) Winch will immediately return to standard speed.
This lever controls the front winch drum. Pull this con-
Winch Disable
trol lever back, toward the operator to lift the load. Push
this control lever forward, away from the operator to Press the winch control switch(es) to the disable ( )
lower the load. Refer to
Winch Operation" for more position to disable the winch(es) to prevent inadvertent
specific instructions. operation of the winch(es) while using the control le-
vers to perform other operations.
Rear Winch Control Lever
Winch Selector Switch
This lever controls the rear winch drum. Pull this con-
trol lever back, toward the operator to lift the load. Push On cranes equipped with both a front (auxiliary) and
this control lever forward, away from the operator to rear (main) winch, a winch circuit switch is provided to
lower the load. Refer to
Winch Operation" for more allow an equal amount of oil to flow to both winches for
specific instructions. simultaneous operation or a combined flow for single
winch operation. Press the bottom part of the switch to
Winch Operation the position for single winch operation or the top
The following is a brief description of the basic proce- part of the switch to the position for simultaneous
winch operation.
dure for operating the wire rope winch. Crane opera-
tions are to be performed only by a qualified operator

1−66 Section 1 − Operating Instructions

 Operator’s Manual

1 2 3 4 5
1. Boom Head Machinery 4. Inner Mid Section
2. Tip Section 5. Base Section
3. Outer Mid Section

Figure 1−62
Boom Nomenclature

Drum Rotation Indicators To Lower The Boom (Boom Down): Move the right
This system is used to monitor winch drum speeds control lever to the position.
through the use of a mechanical signaling device
mounted inside each of the winch control levers. To acti- CAUTION
vate the system, push the bottom part of the drum rota-
tion indicator switch located on the right armrest con- Wire rope must be spooled off the winch drum
as the boom is lowered. Failure to do so may
trol console (Figure 1−60). Place your thumb over the
cause two blocking.
end of the control lever being used. As the winch drum
rotates, a mechanical signal will be felt with your thumb.
The frequency of the mechanical signal is a direct in- To Stop The Boom: Ease the right control lever into
dication of the winch drum speed. Push the top part of the neutral position.
the drum rotation switch to deactivate system.
Boom Telescope System
Boom Hoist System The crane is equipped with a four section full power
Raising and lowering the boom is controlled by the boom. The four section boom consists of a base sec-
boom hoist control lever located on the right arm rest. tion, inner mid section, outer mid section, and a tip sec-
Refer to Figure 1−60. tion. Refer to Figure 1−62.
The telescoping feature, of the boom sections, is oper-
ated through the use of two hydraulic cylinders and a
WARNING cable/sheave mechanism which are an integral part of
Do not exceed maximum boom angles listed the boom assembly. The boom can be extended or re-
tracted to any desired length using the control pedal in
on the back stability label located in the upper
the upper operator’s cab. The telescope feature has
operator’s cab. This crane can tip over
two modes of operation. Refer to Figure 1−63.
backwards when on tires or retracted
outriggers. Boom Mode
A": When using boom mode
A" only the
inner mid boom section extends/retracts. This mode
offers increased strength capacities. Select this mode
To Raise The Boom (Boom Up): Move the right con-
through the Rated Capacity Limiter system.
trol lever to the position.
Boom Mode
B": When using boom mode
B" all
CAUTION boom sections extend/retract simultaneously. This
mode offers increased stability capacities. Select this
When the hoist line is tied off to the crane or mode through the Rated Capacity Limiter system.
any solid object, the winch system can be
overloaded causing major winch, wire rope, Note: Boom must be fully retracted before chang-
or crane damage. Do not extend boom, raise ing boom modes.
or lower the boom, or raise the crane on
outriggers unless wire rope is spooled off the
drum to prevent tension on the wire rope.

Section 1 − Operating Instructions 1−67

Operator’s Manual
Boom Length
Boom Mode
A" Ft Boom Mode
B"
(m)
38
(11.6)
45
(13.7)
55
(16.8)
63.6
(19.4)
65
(19.8)

75
(22.9)

85
(25.9)
95
(28.9)
105
(32.0)

115
(35.0)
Figure 1−63
Boom Telescope Mode

Boom Telescope Control Pedal 3. Review the appropriate capacity chart in the Crane
Rating Manual to establish boom length, angle,
Figure 1−60 shows the location of the telescope con-
and load limitations.
trol pedal in the upper operator’s cab. Depress the toe
4. Set the Rated Capacity Limiter to the desired tele-
of the telescope control pedal to extend the boom. De-
scope mode.
press the heel of the telescope control pedal to retract
5. Depress the toe of the telescope control pedal.
the boom. Use the telescope mode in conjunction with
the telescope control pedal to extend the boom sec-
tions to the desired length. CAUTION
Boom Telescope Override Switch Wire rope must be spooled off the winch
drum(s) as the boom is extended. Failure to
This switch is provided to manually override the tele- do so may cause two blocking.
scope system when the boom is not extending/retract-
ing proportionally. Use this switch for that purpose 6. Stop the boom sections by releasing the telescope
only. While in boom mode
B", the switch will stop one control pedal.
of the boom sections so the boom can be extended/re-
tracted proportionally. Refer to Figure 1−60 for switch Note: The telescope control pedal is spring
location in the upper operator’s cab. loaded and will return to the neutral position
when released.
To Extend The Boom Sections
1. Park the crane on a firm, level surface, engage the To Retract The Boom Sections
park brake, and shift the transmission to neutral. 1. Depress the heel of the telescope control pedal.
2. Compare the crane setup to the appropriate ca- 2. Stop the boom sections by releasing the telescope
pacity chart in the Crane Rating Manual. Position control pedal.
the boom safely within the limits specified on the
capacity chart.

1−68 Section 1 − Operating Instructions

 Operator’s Manual
1 2
5
CONSTRUCTION EQUIPMENT

2
4
3

1. Access Door
1 6 2. Hydraulic Oil Cooler Fan Switch
7
1. Seat & Console 5. Seat Back
Figure 1−65
Release Lever Adjustment Lever
2. Seat Release Lever 6. Seat Belt
Hydraulic Oil Cooler Fan Switch
3. Seat Height 7. Tool Box
Adjustment Lever 5. Seat Back Adjustment Lever
4. Arm Rest Height
Adjustment Knob Raise the lever and lean back in the seat to adjust
Figure 1−64 the seat back to the desired position.
Upper Operator’s Seat
6. Seat Belt
A seat belt is provided and must be worn during all
Operator’s Seat operations. To fasten the seat belt pull the belt out
This 6-way adjustable seat is controlled by manual of the retractor and insert the tongue into the
controls. Refer to Figure 1−64. buckle until you hear a snap and feel the latch en-
gage. Be sure the belt is not twisted and is fitting
snugly around the hips, not around the waist.
WARNING
Do not make seat or console adjustments
while operating the crane or while crane is in
motion. Discontinue operations and properly
WARNING
park crane before making adjustments. Always wear the seat belt while operating the
crane. The seat belt must be snug and low
across the hips.
1. Seat & Console Release Lever
Move the seat & console release lever to the left
and hold. Position the seat as desired and release 7. Tool Box
the lever to lock the seat in place. A tool box is provided under the operator’s seat to
store tools and other crane accessories.
2. Seat Release Lever
Move the seat release lever to the left and hold. Po- Hydraulic Oil Cooler Fan
sition the seat as desired and release the lever to
lock the seat in place.
Switch
The hydraulic oil cooler fan is used to help keep the oil
3. Seat Height Adjustment Lever cool during warm weather operations. The fan should
Move the height adjustment lever to the left and remain on except in cold weather. The fan switch is lo-
hold. Position the seat as desired and release the cated by the oil cooler fan and can be accessed from
lever to lock the seat in place. the door on top of the oil cooler housing behind the up-
per operator’s cab. Refer to Figure 1−65.
4. Arm Rest Height Adjustment Knob
Loosen the knob on the inside of the arm rest. Posi-
tion the arm rest as desired and tighten knob screw.

Section 1 − Operating Instructions 1−69

Operator’s Manual
6
1 2

Lockout Pin Installed

3
WARNING
MAIN BOOM ATB IS DISABLED
WHEN LOCK OUT PIN IS IN
HOLE. TO OPERATE MAIN BOOM
ATB, REMOVE PIN AND STORE
IN STORAGE HOLE BEHIND
SWITCH. FAILURE TO HAVE
FULLY OPERATIONAL ATB SYSTEM
COULD RESULT IN SERIOUS
INJURY OR DEATH.
LOCK OUT PIN HOLE

1. Jumper Assembly 3. Anti-Two Block Switch 5. Lockout Pin & Flag

2. Plug Assembly 4. Anti-Two Block Weight 6. Lockout Pin Storage Hole

Figure 1−66
Anti-Two Block Weights And Switches

situation is imminent, an audio/visual alarm is activated

Crane Monitoring System to alert the operator of the pending danger. When the
Crane monitoring systems are available for monitoring alarm activates, it is essential that the operator discon-
boom length, boom angle, load weight and two block tinue operations immediately and correct the two-
situations. Figure 1−67 shows the display units, for block situation.
the monitoring systems, which may be used on this Three basic components are used to make up the anti-
crane model. two block system. The anti-two block weight, anti-two
Your crane may be equipped with one of the systems block switch with lockout pin, and the display unit in the
available for this crane. Use Figure 1−67 to determine operator’s cab. Refer to Figure 1−66 and Figure 1−67.
which system you have and where to find the appropri-
ate operating instructions. CAUTION
Anti-Two Block Warning System Do not allow the load to spin out of control
when hoisting. The anti-two block weight may
Integrated into the Rated Capacity Limiter System is an become entangled with the wire rope and
anti-two block warning system. An anti-two block could damage the anti-two block system, wire
warning system is an electromechanical system de- rope, or boom. Use rotation resistant rope
signed to alert the operator before the hook block or during single part line hoisting applications,
hook ball contacts the head machinery of the main especially when long fall lifts are involved.
boom, auxiliary lifting sheave, or fly. When a two block

1−70 Section 1 − Operating Instructions

 Operator’s Manual

MicroGuard 534 MicroGuard 434

Refer to Page 1−72 Refer to Page 1−88

Figure 1−67
Crane Monitoring Systems

The added feature of hydraulic function limiters, pre- fore beginning operations. Test the system by manual-
vents the operator from continuing crane functions ly lifting the ATB weight and verifying that the function of
which will cause a two block situation to occur. The winch up, boom down, and boom extend are disabled.
crane functions of winch up, boom down, and boom
extend are disabled when the anti-two block weight is Lockout Pin And Flag
lifted. These functions will remain disabled until the two The lockout pin is used to hold the main boom anti-two
block situation is corrected or the
cancel alarm" block switch in the
working" position, the same as
switch on the display unit is utilized. having a two block weight suspended from the switch.
The main boom head must always have an anti-two When operating from the main boom the lockout pin
block switch. Each of the added attachments used on and flag must be in the stored position. When operat-
the crane must employ a similar head machinery ing from an attachment only, the lockout pin must be
switch as well, in order for that particular attachment to installed in the main boom head anti-two block switch.
be monitored by the system.
When both main boom and attachment are reeved for
The plug assembly is connected to the jumper assem- operation, lockout pin and flag must be removed from
bly on the boom head when operating from the main switch and properly stored.
boom. It is connected to the jumper assembly on the
attachment when operating from that attachment. Note: When using main boom and attachment, anti-
Check that all the harness connections between the at- two block weights must be suspended from each
tachments are properly joined and test the system be- anti-two block switch.

Section 1 − Operating Instructions 1−71

Operator’s Manual

1 2 3

4
5

17 6
9.7 X 1000 LBS MAX

36.5’ 0.5 1
2_

16
61.0

15

60.0ft 7

14
90.0ft

13 !! TWO BLOCK !!

12
12000

11 10 8 8
1. Bar-Graph 7. Configuration Selection Buttons 13. Boom Length Display
2. Pre-Alarm Indicator 8. Cancel Alarm Button 14. Brightness Buttons
3. Overload Indicator 9. Operator Alarms Button 15. Load Radius Display
4. Maximum Rated Capacity Display 10. Crane Setup Button 16. Boom Angle Display
5. Actual Load Display 11. Display/Select Button 17. Erected Attachment Display
6. Parts-of-Line Display 12. Warning Message Area

Figure 1−68
Microguard 534 Rated Capacity Limiter

1−72 Section 1 − Operating Instructions

 Operator’s Manual
MicroGuard 534 Rated Capacity
Limiter
3
The following describes the function and operation of
the Microguard 534 Rated Capacity Limiter. The sys- 2
tem is intended to aid the operator in the efficient op-
eration of the crane by continually monitoring the load
and warning of an approach to an overload or unsafe
condition. 1

WARNING
Although the system will alert the operator of
an approaching overload or unsafe condition,
it remains the responsibility of the operator to
operate the crane safely at all times.
This system must never be substituted for the
good judgment of the crane operator using safe
1 2 3
operating procedures. The operator is solely
responsible for safe operation of the crane.
!!THIS SYSTEM IS AN OPERATOR’S AID − 1. Green Lights − Percent- 2. Amber Lights − Ap-
NOT A SAFETY DEVICE!! age of Rated Load proaching Overload
3. Red Lights − Overload

System Description Figure 1−69

Overhead Bar Graph And External Light Bar
The system monitors crane functions by means of high (If Equipped)
accuracy sensors and continuously compares the load
with a copy of the crane capacity chart which is stored
in the computer memory. If an overload is approached, Display Unit
the system warns by means of audible and visual The following is a description of the control buttons, in-
alarms and is configured to cause function limitation. dicators, and windows on the display unit. Use them
The MicroGuard 534 Rated Capacity Limiter provides along with Figure 1−68.
the operator with a continuous display of:
 Rated Capacity 1. Bar-Graph
 Actual Load The Bar-Graph is a series of twelve colored lights which
 Percentage of Rated Capacity gives a visual indication of how much of the crane’s ca-
 Radius of the Load pacity is being used and the rate at which an overload
 Angle of the Main Boom is being approached. Each green light represents 10%
 Crane Configuration of the crane’s rated capacity is being used. Yellow indi-
 Length of the Main Boom cates 90−99.9%, and the red lights indicate an over-
An additional feature of the system is the provision of load.
operator settable alarms. These alarms, when proper- Note: System may be equipped with an overhead
ly set, provide a method of obstacle avoidance. This is bar graph or an external light bar which operates
achieved by means of maximum boom angle, maxi- similar to the bar graph on the display. Refer to
mum load radius, maximum boom head height, left
Figure 1−69.
and right swing, and defined area alarms. These
alarms can be programmed for each job site and set
rapidly for the prevailing site conditions thereby aiding 2. Pre-Alarm indicator
the operator in safe operation of the crane. The Pre-Alarm (yellow) Indicator illuminates at a pre-
set value of 90% of Maximum Rated Capacity and pro-
vides a visual indication of an approach to an overload.

Section 1 − Operating Instructions 1−73

Operator’s Manual
3. Overload Indicator 10. Crane Setup Button
The Overload Indicator (red) illuminates at a pre-set This button is used to start the configuration selection
value of 100% of Maximum Rated Capacity and pro- routine. Refer to
Configuration Selection" found later
vides a visual indication of Maximum Allowed Load. It in this Section of the Operator’s Manual.
will also illuminate whenever a wire rope limit is exceed-
ed. Function limiters will occur simultaneously for an 11. Display/Select Button
Overload, Wire Rope Limit or a Two Block condition, This button is used to access the Calibration And Diag-
but function limiters will not occur when exceeding an nostic Screen. Refer to
System Fault Codes" and
operator settable alarm. An audible alarm will sound
Calibration" found later in this Section of the Opera-
and a message will appear in the warning message tor’s Manual.
area for all 4 conditions.
12. Warning Message Area
4. Maximum Rated Capacity Display
The Warning Message Area displays text messages of
The Maximum Rated Capacity is a digital display of the various alarms which may occur during normal opera-
maximum permitted capacity. It is derived from a copy tion of the system. When an alarm occurs, the rectan-
of the crane’s capacity chart which is stored in the com- gular area fills in red.
puter memory and is the reference capacity for any lift-
ing operation. It is dependent on the configuration cur- 13. Boom Length Display
rently selected, which is shown in the crane setup
The Boom Length Display gives a continuous indica-
screen, and which determines the section of the ca-
tion of the boom length in feet (m). It is the distance
pacity chart to be used as the rated capacity reference.
from the centerline of the boom foot pin to the center
5. Actual Load Display line of the boom head machinery.

The Actual Load Display is a digital display which 14. Brightness Buttons
shows total load suspended below the boom or fly
These buttons are used to adjust the display bright-
head. It includes the load, any slings, pins, or tackle
ness.
used to secure the load and the hook block or ball.
15. Load Radius Display
6. Parts-of-Line Display
The Load Radius Display gives a continuous indication
Parts-of-Line displays the parts of line currently se-
of the radius of the load in feet (m). It is the horizontal
lected for the winch in use.
distance from the centerline of rotation to the centerline
7. Configuration Selection Buttons of the hook.

These buttons are used during the crane configuration 16. Boom Angle Display
selection routine. Refer to
Configuration Selection"
The Boom Angle Display gives a continuous indication
found later in this Section of the Operator’s Manual.
of the angle of the main boom relative to horizontal.
8. Cancel Alarm Button 17. Erected Attachment Display
This button is used to silence the audible alarm when
The Erected Attachment Display gives a continuous
the alarm has occurred as a result of either an Over-
display of the erected attachment with the top number
load, a Two Block, Wire Rope Limit, or an Operator Set-
indicating the actual fly length and the bottom number
table alarm. It is also used to reset the function limit
indicating the offset angle if applicable.
relay when it is necessary to by-pass function limit
which has occurred as a result of either an Overload,
Wire Rope Limit or a Two Block alarm.

9. Operator Alarms Button

This button is used to start the operator settable alarms
routines. Refer to
Operator Settable Alarms" found
later in this Section of the Operator’s Manual.

1−74 Section 1 − Operating Instructions

 Operator’s Manual
System Operation
The following is a list of procedures which are used to
operate the multiple features of the Rated Capacity
Limiter. Use these procedures in conjunction with the
previous display unit control descriptions. 1

System Self-Test
At start-up the system automatically performs a self test
after which all lamps, audible alarms, and digital dis- 2
plays will be functionally tested and all memory areas
checked for accuracy. If faults in the system are de-
tected during a test, the warning message area will
show the words SYSTEM FAULT. If the words SYSTEM
FAULT occur, press the Display/Select button to dis-
play the diagnostic screen. The diagnostic screen lists
information about the fault condition by means of an er-
ror code. Contact your local distributor for details of the
fault codes.
1. RCL Status Keyswitch 2. Computer
Note: If the batteries have been disconnected, in- Figure 1−70
terrupting power to the computor, the start-up time Rated Capacity Limiter Computer
for on-board computer systems will be longer than
normal. 2. When the rated capacity limiter is inoperative or
malfunctioning, the designated person responsi-
System Bypass ble for supervising the lifting operations shall es-
In emergency situations, the Rated Capacity Limiter tablish procedures for determining load weights
computer can be bypassed. The computer is located and shall ascertain that the weight of the load does
on the back of the operator’s cab. Refer to not exceed the crane ratings at the radius where
Figure 1−70. There is a RCL Status keyswitch adja- the load is to be handled.
cent to the computer to bypass the system. Move the 3. When a boom angle or radius indicator is inopera-
key to the
Bypass" position to bypass the system. For tive or malfunctioning, the radius or boom angle
emergency use while the system is bypassed, refer to shall be determined by measurement.

System Inoperative or Malfunctioning" that follows. 4. When the anti-two block warning device is inopera-
tive or malfunctioning, the designated person re-
sponsible for supervising the lifting operations
shall establish procedures, such as assigning an
WARNING additional signal person, to furnish equivalent
The Microguard 534 is not operational when protection. This does not apply when lifting per-
the computer is bypassed. Bypass the sonnel in load line supported baskets. Personnel
system in emergency situations only. shall not be lifted in load line supported baskets
when the anti-two block devices are not function-
System Inoperative Or Malfunctioning ing properly.
When operational aids are inoperative or malfunction- 5. When a boom length indicator is inoperative or
ing, the following recommendations for continued use malfunctioning, the designated person responsi-
of the crane should be followed or the crane should be ble for supervising the lifting operations shall es-
shutdown. tablish the boom length at which the lift will be
1. Steps shall be taken to schedule repairs and recal- made by actual measurement or markings on the
ibration immediately. The operational aids shall be boom.
put back into service as soon as replacement 6. When a level indicator is inoperative or malfunc-
parts, if required, are available and the repairs and tioning, other means shall be used to level the
recalibration can be carried out. Every reasonable crane.
effort must be made to expedite the repairs and re- 7. In situations where inconsistency exists, verified
calibration. weights, measured radii, boom lengths, and au-
thorized crane capacities must always take prece-
dence over indicator readings.

Section 1 − Operating Instructions 1−75

Operator’s Manual
Configuration Selection
In the normal operational mode the system is programmed to remember the last configuration selected. Each time
the system is powered up it will automatically default to that configuration. Only when the crane is rigged differently
must a new configuration be selected. Use the following procedure to select the crane configuration.

Note: When selecting configurations allowed on outriggers, all beams must be equally extended; all fully
retracted, intermediate extended, or fully extended.
Depending on how the crane is equipped or which selections have been made, some screens shown may not
appear or may not appear as illustrated. The system cannot be programmed for configurations not allowed
by the capacity charts listed in the Crane Rating Manual.

Figure 1−71
Carrier Selection
1. From the normal working screen press the CRANE SETUP button. The normal working screen will change and
graphically display the carrier options. Press the corresponding configuration selection button to select the
desired carrier configuration. If rigging is desired, refer to
To Select Rigging/Travel Mode" found later in this
Section of the Operator’s Manual.

WARNING
The Microguard 534 is not operational when in the RIGGING/TRAVEL Mode. Return the Microguard 534
to normal operation before operating the crane.

1−76 Section 1 − Operating Instructions

 Operator’s Manual

4 000

8 000

12000

16000

Figure 1−72 Figure 1−74

Counterweight Selection Auxiliary Head Selection

2. The carrier selection screen will change and 4. The boom mode selection screen will change and
graphically display the counterweight options. graphically display the auxiliary lifting sheave fitted
Press the corresponding configuration selection or not fitted. Press the corresponding configura-
button to select the installed counterweight. tion selection button to select the actual auxiliary
lifting sheave configuration.

36.5’ Fly

61’ Fly

Figure 1−73 Figure 1−75

Boom Extend Mode Selection Erected Attachment Selection

3. The counterweight selection screen will change 5. If the crane is equipped with a fly, the auxiliary
and graphically display the boom mode options. sheave selection screen will change and graphi-
Press the corresponding configuration selection cally display an erected attachment. Press the cor-
button to select the desired boom mode. responding configuration selection button to se-
lect the installed erected attachment if required.
Note: Consult the Crane Rating Manual to de-
termine the best boom mode to maximize lift ca-
pacity at working radius. Boom mode options
will only be displayed when the boom is fully re-
tracted.

Section 1 − Operating Instructions 1−77

Operator’s Manual

20

40

Figure 1−76 Figure 1−78

Erected Attachment Offset Selection Front Winch Lifting Point Selection
6. If an offset fly was previously selected, the erected 8. If the crane is equipped with a front winch, the rear
attachment selection screen will change and winch lifting point screen will change and graphical-
graphically display the available offset angles. ly display the front winch lifting point. Press the cor-
Press the corresponding configuration selection responding configuration selection button to select
button to select the installed offset angle if re- the actual front winch lifting point as indicated by
quired. the arrows. Or press the corresponding configura-
tion selection button to select the front winch not in
use.

24.5’

36.5’

61’

Figure 1−77 Figure 1−79

Rear Winch Lifting Point Selection Stowed Attachment Selection

7. The erected attachment or erected attachment off- 9. If the crane is equipped with a fly and was not se-
set selection screen will change and graphically lected as an erected attachment, the winch lifting
display the rear winch lifting point. Press the corre- point screen will change and graphically display
sponding configuration selection button to select the stowed attachment. Press the corresponding
the actual rear winch lifting point as indicated by configuration selection button to select the actual
the arrows. Or press the corresponding configura- stowed attachment if required.
tion selection button to select the rear winch not in
use.

1−78 Section 1 − Operating Instructions

 Operator’s Manual

Figure 1−80 Figure 1−81

Rear Winch Parts Of Line Selection Front Winch Parts Of Line Selection

10. The crane setup screen will change to the normal 11. If the crane is equipped with a front winch and it
working screen and graphically display the crane was selected, press the corresponding configura-
configuration as previously selected. Press the tion selection button to select the front winch.
corresponding configuration selection button to Press the corresponding configuration selection
select the actual parts of line for the rear winch. button to select the actual parts of line for the front
winch.

Note: From the normal working screen, after

crane setup has been established, only two
selection buttons are active; the winch select
button and the parts of line button.
To change winches, push the winch select but-
ton to toggle between winches. The winch lift-
ing points cannot be changed without going
through the crane setup routine.
The parts of line can be changed for the se-
lected winch by pressing the parts of line button
to scroll through the available options for that
winch.
Refer to Figure 1−82 and Figure 1−83 for ex-
amples of some normal working screens.

Section 1 − Operating Instructions 1−79

Operator’s Manual
8
4

7 6

5
3
1

In this example the crane is setup on fully extended outriggers (1), boom mode B (2), 12,000 lb
counterweight (3), 36.5’ fly base erected at 2 degree offset (4), fly tip stowed (5), the rear winch
available with the main boom head and the front winch selected (6), with the winch rope reeved
over the fly base (7), with one part of line (8), and an operator settable alarm enabled (9).

6 5

4
3
1

In this example the crane is setup on intermediate extended out-

riggers (1), boom mode B (2), 12,000 lb counterweight (3) 61’ fly
stowed (4), the front winch available with the auxiliary head and
the rear winch selected (5), with the winch rope reeved over the
main boom head (6) with three parts of line (7).

Figure 1−82
Normal Working Screen Examples

1−80 Section 1 − Operating Instructions

 Operator’s Manual

5 4

7 3

1
In this example the crane is setup for stationary on tires (1), boom mode
B (2), 12,000 lb of counterweight (3), front winch not in use and the rear
winch selected (4), winch rope reeved over the main boom (5), with
three parts of line (6), and the 61’ fly stowed (7).

4 6

5
3
1

In this example the crane is setup on fully retracted outriggers (1),

boom mode B (2), 12,000 lb of counterweight (3), winch rope
reeved over the main boom (4), 61’ fly stowed (5), rear winch not
in use and the front winch selected (6), with three parts of line (7).

Figure 1−83
Normal Working Screen Examples

Section 1 − Operating Instructions 1−81

Operator’s Manual
Cancel Audible Alarm And Reset Function Limiters
The CANCEL ALARM button is used to cancel the
audible alarm when the alarm has occurred as a result
of either an Overload, a Two Block alarm, or an Opera-
tor settable alarm. The audible alarm may be canceled
by pressing and releasing the CANCEL ALARM button.
The audible alarm remains canceled until the condition
which caused the alarm has been removed. For exam-
ple, if the audible alarm was canceled because of an
overload condition, it will remain canceled until the
overload condition is removed. However, if a different
alarm, e.g. two block condition, was to occur when the
audible alarm was still canceled for an earlier overload
condition, the new alarm condition would cause the au-
dible alarm to be re-started.

 WARNING
Once the function limiters have been
by-passed, the crane is no longer protected
against the condition that initially caused the
Figure 1−84 function limiters to occur.
Rigging/Travel Mode Screen
Note: The CANCEL ALARM feature is a temporary
To Select Rigging/Travel Mode
function. The audible alarm or function limit is auto-
The CRANE SETUP push button is also used to select matically reset when the condition which caused
RIGGING/TRAVEL MODE. This mode is used to facili- the alarm is no longer present.
tate rigging and travel of the crane by inhibiting func-
The CANCEL ALARM is also used to reset the function
tion limiters and the audible alarm while selected. To
limiters when it is necessary to by-pass the function lim-
resume crane operation, select proper outrigger or tire
iters which has occurred as a result of either an over-
configuration per the proper procedure.
load, a two block alarm, or a rope limit. Function limit-
ers are reset by first canceling the audible alarm (as de-
scribed above) and then pressing and holding the
WARNING CANCEL ALARM button for about 3 seconds, after
The Microguard 534 is not operational when in which the function limiters will be reset to allow normal
the RIGGING/TRAVEL Mode. Return the Mi- operation. However, should another different alarm
croguard 534 to normal operation before op- condition occur when the function limiters had pre-
erating the crane. viously been over-ridden, then the newly occurring
alarm condition would cause the function limiters to oc-
1. From the normal working screen press the CRANE cur again.
SETUP button. The crane setup screen will
Operator Settable Alarms
change and graphically display the carrier options.
2. Select for stationary rigging or when trav- Some alarms occur automatically as a result of limita-
eling the crane. Refer to Figure 1−84. tions imposed by the capacity chart. The operator has
control over additional alarms which can be set to oper-
Note: Boom must be fully retracted to enter rig- ate within the normal chart limitations and which are, in
ging/travel mode. addition to, those already set by the chart.
Operator settable alarms will be stored in the computer
memory, even if the crane is shutdown, until they are
cleared. Refer to Figure 1−85.
Alarms available for operator use are:
Minimum Boom Angle Maximum Boom Length
Maximum Boom Angle Left and Right Swing
Maximum Tip Height Operator Defined Area

1−82 Section 1 − Operating Instructions

 Operator’s Manual

EXIT

EXIT 75.0

LENGTH HEIGHT ANGLE

SETTABLE ALARMS 75.0 75.0 60.0

BOOM LIMITS  75.0

SWING LIMITS 60.0

AREA LIMITS 30.0

Figure 1−85
Boom Limit Alarms

4. Press the corresponding selection button to set the

WARNING desired alarm value as defined below. Press the
button again to turn alarm off.
The operator settable alarms are a warning
device. All functions remain operational when
entering the operator defined bad area. For Maximum Boom Length
safe operation, adequate distance must be
maintained to allow for operator reaction time Maximum Tip Height
to avoid entering the bad area. It is the
responsibility of the operator to set points
which ensure that the crane’s boom, Maximum Boom Angle
attachment, load, rigging, etc. maintains a
safe working distance and complies with local Minimum Boom Angle
safety regulations.
5. When all alarm values are set, press the EXIT but-
Angle, Length, And Height Operator Settable Alarms ton to return to the alarm screen. At the Settable
1. From the normal working screen press OPERA-
Alarm screen, press the EXIT button again to return
TOR ALARM button to access the Settable
to the normal working screen.
Alarms screen.
6. Test the alarm, with no load, to ensure the alarm
2. Press the corresponding button for Boom Limits
points have been properly set. When approaching
.
the alarm set point, the audible will sound intermit-
tently and a warning message will appear in the
WARNING warning message area. When exceeding the
alarm set point, the audible alarm will sound con-
Avoid positioning the boom, attachment, load,
tinuously and a warning message will appear in
rigging, etc. into the bad area when setting the
warning message area.
alarm values.
When selecting the alarm values, ensure that Note: An alarm icon will appear on the nor-
the load will maintain a safe distance from the mal working screen to alert the operator that an
obstacle. operator alarm has been set.

3. Position the boom in the desired position depend-

ing upon the alarm to be set. The numerical value
displayed will be the current position of the boom. WARNING
If crane or obstacle is moved or if a different
size load is lifted, the alarm(s) must be reset.

Section 1 − Operating Instructions 1−83

Operator’s Manual

265.0
SET

SWING ANGLE
EXIT
95.0

SETTABLE ALARMS EXIT

BOOM LIMITS 95.0

SET

SWING LIMITS 
AREA LIMITS

Figure 1−86
Swing Alarm

Swing Operator Settable Alarm Operator Defined Area Alarm

To have an alarm whenever the left swing and right The operator defined area alarm, when set, will define
swing exceed pre-determined alarm points, use the fol- an imaginary vertical plane between two set points to
lowing procedure: optimize the working area. When approaching the
1. From the normal working screen press OPERA- plane, the audio alarm will sound intermittently, and the
TOR ALARM button to access the Settable message
Bad Working Area" will appear in the warn-
Alarms screen. ing message area. When passing the plane, the audio
2. Press the corresponding button for Swing Limits alarm will sound continuously and the message
Bad
. Working Area" will appear on the warning message
3. Swing the boom to the left alarm point . area. Use the following procedure, Figure 1−87, and
4. Press the corresponding button for Left Swing Figure 1−88 to set the operator defined area alarm.
to enter the left alarm point. The displayed value
will be the left alarm setting.
5. Swing the boom to the right alarm point. WARNING
6. Press the corresponding button for Right Swing The operator defined area alarm is a warning
to enter the right alarm point. The displayed device. All functions remain operational when
value will be the right alarm setting. entering the operator defined bad area. For
7. Press the EXIT button to return to the settable safe operation, adequate distance must be
alarm screen. Press the EXIT button on the set- maintained to allow for operator reaction time
table alarms screen to return to the normal working to avoid entering the bad area. It is the
screen. responsibility of the operator to set points
8. Test the alarm, with no load, to ensure the alarm which ensure that the crane’s boom,
points have been properly set. When approaching attachment, load, rigging, etc. maintains a
the set alarm point, the audible alarm will sound in- safe working distance and complies with local
termittently and
Swing Alarm" will appear in the safety regulations.
warning message area. The audible alarm will acti-
vate whenever the swing exceeds the alarm points
and
Swing Alarm" will appear in warning message
area.
Note: Both the left and right swing alarms must
be set for the system to determine the operator
set working area.
Note: An alarm icon will appear on the nor-
mal working screen to alert the operator that an
operator alarm has been set.

1−84 Section 1 − Operating Instructions

 Operator’s Manual

EXIT

SWING ANGLE
EXIT
97.2

SETTABLE ALARMS

BOOM LIMITS

SWING LIMITS

AREA LIMITS 
Figure 1−87
Operator Defined Area Alarm

Setting Operator Defined Area Alarm button to enter the left alarm point. The dis-
1. From the normal working screen press OPERA- played value will be the left alarm setting.
TOR ALARM button to access the Settable
Alarms screen. Note: For best results, the two points should be
separated by a minimum of 10 ft (3m) or 30 de-
2. Disable any previously set left and right swing
grees.
alarms if required.
6. When both alarm points are set, press the EXIT
Note: The left and right swing alarms must be
button to return to the settable alarms screen.
cleared prior to setting the defined area alarm.
Press the EXIT button on the settable alarms to re-
3. Press the corresponding button for Area Limit . turn to the normal working screen.
7. Test the alarm, with no load, to ensure the alarm
points have been properly set. When approaching
WARNING the plane, the audible alarm will sound intermittent-
Avoid positioning the boom, attachment, load, ly and the message
Bad Working Area" will ap-
rigging, etc. into the bad area when setting the pear on the warning message area. When passing
left or right alarm points. the plane, the audible alarm will sound continuous-
ly and the message
Bad Working Area" will ap-
When selecting the left and right alarm points,
pear on the warning message area.
ensure that the load will maintain a safe
distance from the obstacle. Also ensure that
the two points are set so that the tailswing of
the crane will not enter the bad area. WARNING
If crane or obstacle is moved or if a different
4. Position the boom, attachment, load, rigging, etc. size load is lifted, the area alarm must be
to the right alarm point and press the correspond- reset.
ing button to enter the right alarm point. The
displayed value will be the right alarm setting. Note: An alarm icon will appear on the nor-
5. Position the boom, attachment, load, rigging, etc. mal working screen to alert the operator that an
to the left alarm point and press the corresponding operator alarm has been set.

Section 1 − Operating Instructions 1−85

Operator’s Manual

Figure 1−88
Operator Defined Area Alarm

1−86 Section 1 − Operating Instructions

 Operator’s Manual
CALIBRATION AND DIAGNOSTICS
A00 B0 C00 D00

ERROR CODES

ENTER CALIBRATION

Message Data Count

Figure 1−89
Calibration And Diagnostic Screen

System Fault Codes Calibration

If faults in the system are detected during a test, the If the system requires calibration, contact you distribu-
warning message area will show the words SYSTEM tor for assistance. Calibration must be done by a quali-
FAULT. If the words SYSTEM FAULT occur, press the fied technician. Press the Display/Select button to dis-
Display/Select button to display the Calibration And play the Calibration And Diagnostic screen. On the
Diagnostic screen. On the Calibration And Diagnostic Calibration And Diagnostic screen, press the Enter
screen, press the Error Code button to display error Calibration button. The calibration screen will be dis-
codes in the box at the top of the screen. This informa- played and prompt a calibration key sequence to begin
tion can then be used to assist the service technician in the calibration routine.
determining the fault. Contact your distributor for as-
sistance with the fault codes.

Section 1 − Operating Instructions 1−87

Operator’s Manual

16
1
15
2

14 3

13
4

12

5 5

11

10 9 8 7
1. Bar-Graph 7. Cancel Alarm 12. Load Radius Display
2. Two Block Alarm Indicator 8. Operator Alarms Button 13. Boom Angle Display
3. Maximum Rated Capacity Display 9. Crane Setup Button 14. Boom Length Display
4. Actual Load Display 10. Test Button 15. Pre-Alarm Indicator
5. Configuration Selection Buttons 11. Crane Set-up Screen 16. Overload Indicator
6. Contrast Button

Figure 1−90
Microguard 434 Rated Capacity Limiter

MicroGuard 434 Rated Capacity

Limiter WARNING
Although the system will alert the operator of
The following describes the function and operation of
an approaching overload or unsafe condition,
the Microguard 434 Rated Capacity Limiter. The sys-
it remains the responsibility of the operator to
tem is intended to aid the operator in the efficient op-
operate the crane safely at all times.
eration of the crane by continually monitoring the load
and warning of an approach to an overload or unsafe This system must never be substituted for the
condition. good judgment of the crane operator using safe
operating procedures. The operator is solely
responsible for safe operation of the crane.
!!THIS SYSTEM IS AN OPERATOR’S AID −
NOT A SAFETY DEVICE!!

1−88 Section 1 − Operating Instructions

 Operator’s Manual
System Description 1 2 3 4
The system monitors crane functions by means of high
accuracy sensors and continuously compares the load
with a copy of the crane capacity chart which is stored
in the computer memory. If an overload is approached,
the system warns by means of audible and visual
alarms and is configured to cause function limitation.
The MicroGuard 434 Rated Capacity Limiter provides
the operator with a continuous display of:
 Rated Capacity 1 2 3
 Actual Load
 Percentage of Rated Capacity
 Radius of the Load
 Angle of the Main Boom 1. Green Lights − Percent- 3. Red Lights − Overload
 Crane Configuration age of Rated Load 4. Brightness Control
2. Yellow Lights − Approach-
 Length of the Main Boom ing Overload

Note: The head height may be displayed by access- Figure 1−91

ing the angle/length/height operator settable alarm Overhead Bar Graph And External Light Bar
screen. (If Equipped)

An additional feature of the system is the provision of

operator settable alarms. These alarms, when proper-
2. Two Block Alarm Indicator
ly set, provide a method of obstacle avoidance. This is The Two Block Alarm Indicator illuminates anytime a
achieved by means of minimum and maximum boom two block situation is imminent. An audible alarm and
angle, maximum boom length, maximum height, left function limiters will also activate when a two block situ-
and right swing, and defined area alarms. These ation is imminent. Once the two block situation is cor-
alarms can be programmed for each job site and set rected the system will return to normal working mode.
rapidly for the prevailing site conditions thereby aiding
the operator in safe operation of the crane. 3. Maximum Rated Capacity Display
The Maximum Rated Capacity is a digital display of the
Display Unit maximum permitted capacity. It is derived from a copy
The following is a description of the control buttons, in- of the crane’s capacity chart which is stored in the com-
dicators, and windows on the display unit. Use them puter memory and is the reference capacity for any lift-
along with Figure 1−90. ing operation. It is dependent on the configuration cur-
rently selected, which is shown in the crane set-up
1. Bar-Graph screen, and which determines the section of the ca-
The Bar-Graph is an analog bar-graph which gives a pacity chart to be used as the rated capacity reference.
visual indication of how much of the crane’s capacity is
Note: All maximum rated load data shown is X 1,000
being used and the rate at which an overload is being
lb (kg), e.g. 12.6=12,600 lb (kg).
approached. The 100% RATED CAPACITY indicator
above the bar-graph marks the point at which 100% of
the rated capacity of the crane has been reached. The 4. Actual Load Display
leading edge of the bar-graph aligns with three colored
The Actual Load Display is a digital display which
bands around the bar-graph window. Red indicates an
shows total load suspended below the boom or fly
overload. Between the red and yellow is a black notch
head. It includes the load, any slings, pins, or tackle
which indicates 100% of rated capacity. Yellow indi-
used to secure the load and the hook block.
cates 90−99.9%, and green indicates below 90% rated
capacity. Note: All actual load data shown is X 1,000 lb (kg),
e.g. 12.6=12,600 lb (kg).
Note: System may be equipped with an overhead
bar graph or an external light bar which operates
similar to the bar graph on the display. Refer to
Figure 1−91.

Section 1 − Operating Instructions 1−89

Operator’s Manual
5. Configuration Selection Buttons 14. Boom Length Display
These buttons are used during the crane configuration The Boom Length Display gives a continuous indica-
selection routine. Refer to
Configuration Selection" tion of the boom length in feet (m). It is the distance
found later in this Section of the Operator’s Manual. from the centerline of the boom foot pin to the center
line of the boom head machinery.
6. Contrast Button
This button is used to adjust the display contrast.
15. The Pre-Alarm indicator
The Pre-Alarm (amber) Indicator illuminates at a pre-
7. Cancel Alarm Button set value of 90% of Maximum Rated Capacity and pro-
This button is used to silence the audible alarm when vides a visual indication of an approach to an overload.
the alarm has occurred as a result of either an Over- The pre-alarm indicator will also illuminate when an op-
load, a Two Block or an Operator Settable alarm. It is erator settable alarm value is approached.
also used to reset the function limit relay when it is nec-
essary to by-pass function limit which has occurred as 16. Overload Indicator
a result of either an Overload or a Two Block alarm. The Overload Indicator (red) illuminates at a pre-set
value of 100% of Maximum Rated Capacity and pro-
8. Operator Alarms Button vides a visual indication of Maximum Allowed Load. It
This button is used to start the operator settable alarms will also illuminate whenever a wire rope limit is exceed-
routines. Refer to
Operator Settable Alarms" found ed or an operator settable alarm has been reached or
later in this Operator’s Manual. exceeded. Function limiters will occur simultaneously
for an Overload, Wire Rope Limit or a Two-Block condi-
9. Crane Set Up Button tion, but function limiters will not occur when exceeding
This button is used to start the configuration selection an operator settable alarm. An audible alarm will
routine. Refer to
Configuration Selection" found later sound for all 4 conditions.
in this Section of the Operator’s Manual.
System Operation
10. Test Button The following is a list of procedures which are used to
This button is used to initiate a system self test and also operate the multiple features of the Rated Capacity
used to display fault codes. Refer to
To Perform Sys- Limiter. Use these procedures in conjunction with the
tem Test" found later in this Section of the Operator’s previous display unit control descriptions.
Manual.
To Perform System Test
11. Crane Set-Up Screen At start-up the system automatically performs a self test
The Crane Set-Up Screen provides the operator with a after which it goes directly to the normal working
graphical representation of the crane’s current config- screen. The self-test can be initiated any time during
uration during the normal working mode. It also pro- normal operation of the system by using the TEST but-
vides graphical icons used during the crane configura- ton.
tion selection routine. One press (press and release) will cause the system to
execute a self test routine during which all lamps, audi-
12. Load Radius Display ble alarms, and digital displays will be functionally
The Radius Display gives a continuous indication of the tested and all memory areas checked for accuracy. If
radius of the load in feet (m). It is the horizontal dis- faults in the system are detected during a test, the
tance from the centerline of rotation to the centerline of crane set-up screen will show the words FAULT DE-
the hook. TECTED. If the words FAULT DETECTED occur, press
and hold the TEST button. This will cause the display to
13. Boom Angle Display change to the FAULT mode. In this mode, information
The Boom Angle Display gives a continuous indication about the fault condition will be displayed in the crane
of the angle of the main boom relative to horizontal. set-up screen by means of an error code. Contact your
local distributor for details of the fault codes.

1−90 Section 1 − Operating Instructions

 Operator’s Manual
System Bypass
In emergency situations, the Rated Capacity Limiter
computer can be bypassed. The computer is located
on the back of the operator’s cab. There is a RCL Sta- 1
tus keyswitch adjacent to the computer to bypass the
system. Move the key to the
Bypass" position to by-
pass the system. For emergency use while the system
is bypassed, refer to
System Inoperative or Malfunc- 2
tioning" found in this Operator’s Manual.

WARNING
The Microguard 434 is not operational when
the computer is bypassed. Bypass the
system in emergency situations only.

System Inoperative Or Malfunctioning 1. Computer

When operational aids are inoperative or 2. RCL Status Keyswitch
malfunctioning, the following recommendations for
continued use of the crane should be followed or the Figure 1−92
crane should be shutdown. Rated Capacity Limiter Computer

1. Steps shall be taken to schedule repairs and recal- 4. When the anti-two block warning device is inopera-
ibration immediately. The operational aids shall be tive or malfunctioning, the designated person re-
put back into service as soon as replacement sponsible for supervising the lifting operations
parts, if required, are available and the repairs and shall establish procedures, such as assigning an
recalibration can be carried out. Every reasonable additional signal person, to furnish equivalent
effort must be made to expedite the repairs and re- protection. This does not apply when lifting per-
calibration. sonnel in load line supported baskets. Personnel
2. When the rated capacity limiter is inoperative or shall not be lifted in load line supported baskets
malfunctioning, the designated person responsi- when the anti-two block devices are not function-
ble for supervising the lifting operations shall es- ing properly.
tablish procedures for determining load weights 5. When a boom length indicator is inoperative or
and shall ascertain that the weight of the load does malfunctioning, the designated person responsi-
not exceed the crane ratings at the radius where ble for supervising the lifting operations shall es-
the load is to be handled. tablish the boom length at which the lift will be
3. When a boom angle or radius indicator is inopera- made by actual measurement or marking on the
tive or malfunctioning, the radius or boom angle boom.
shall be determined by measurement. 6. When a level indicator is inoperative or malfunc-
tioning, other means shall be used to level the
crane.
7. In situations where inconsistency exists, verified
weights, measured radii, boom lengths, and au-
thorized crane capacities must always take prece-
dence over indicator readings.

Section 1 − Operating Instructions 1−91

Operator’s Manual
Configuration Selection 6. If an offset fly was previously selected, the crane
In the normal operational mode the system is pro- set-up screen will change and graphically display
grammed to remember the last configuration selected. the available offset angles. Press the correspond-
Each time the system is powered up it will automatically ing configuration selection button to select the de-
choose that configuration. Only when the crane is sired offset angle if required.
rigged differently must a new configuration be se- 7. The crane set-up screen will change and graphi-
lected. Use the following procedure along with cally display the rear winch lifting point. Press the
Figure 1−93 to select the crane configuration (the fol- corresponding configuration selection button to
lowing step numbers correspond with the numbered select the desired rear winch lifting point as indi-
screens in Figure 1−93). cated by the flashing arrows. Or press the corre-
sponding configuration selection button to select
Note: When selecting configurations allowed on the rear winch not in use.
outriggers all beams must be equally extended; all 8. If the crane is equipped with a front winch, the crane
fully retracted, intermediate extended or fully ex- set-up screen will change and graphically display
tended. the front winch lifting point. Press the correspond-
Depending on how the crane is equipped or which ing configuration selection button to select the de-
selections have been made, some screens shown sired front winch lifting point as indicated by the
in Figure 1−93 may not appear or may not appear flashing arrows. Or press the corresponding con-
as illustrated. The system cannot be programmed figuration selection button to select the front winch
for configurations not allowed by the capacity not in use.
charts listed in the Crane Rating Manual. 9. If the crane is equipped with a fly and was not se-
lected as an erected attachment, the crane set-up
1. From the normal working screen press the CRANE screen will change and graphically display the
SET UP button. The crane set-up screen will stowed deduct. Press the corresponding configu-
change and graphically display the carrier options. ration selection button to select the desired stowed
Press the corresponding configuration selection deduct if required.
button to select the desired carrier configuration. 10. The crane set-up screen will change to the normal
working screen and graphically display the crane
configuration as previously selected. Press the
WARNING corresponding configuration selection button to
The Microguard 434 is not operational when in select the desired parts of line for the rear winch.
the RIGGING/TRAVEL Mode. Return the 11. If the crane is equipped with a front winch and it
Microguard 434 to normal operation before was selected, press the corresponding configura-
operating the crane. tion selection button to select the front winch.
Press the corresponding configuration selection
2. The crane set-up screen will change and graphi- button to select the desired parts of line for the front
cally display the counterweight options. Press the winch.
corresponding configuration selection button to
Note: From the normal working screen, after
select the desired counterweight.
crane setup has been established, only two
3. The crane set-up screen will change and graphi-
selection buttons are active; the winch select
cally display the boom mode options. Press the
button and the parts of line button.
corresponding configuration selection button to
select the desired boom mode. Note: To change winches, push the winch select
4. The crane set-up screen will change and graphi- button to toggle between winches. The winch
cally display the auxiliary lifting sheave fitted or not lifting points cannot be changed without going
fitted. Press the corresponding configuration through the crane setup routine.
selection button to select the desired auxiliary lift- Note: The parts of line can be changed for the
ing sheave. selected winch by pressing the parts of line but-
5. If the crane is equipped with a fly, the crane set-up ton to scroll through the available options for
screen will change and graphically display an that winch.
erected attachment. Press the corresponding Note: Refer to Figure 1−94 and Figure 1−95 for
configuration selection button to select the desired examples of some normal working screens.
erected attachment if required.

1−92 Section 1 − Operating Instructions

 Operator’s Manual
Crane Set Up Crane Set Up Crane Set Up

0 lb A
12000 lb
4000 lb B
16000 lb
8000 lb

1 2 3
Crane Set Up Crane Set Up

No Fly

5 4
36.5’

61’

Crane Set Up Crane Set Up

6 7
20

40

Crane Set Up Crane Set Up

None 61’

9 8
24.5’

36.5’

 1
61’ Fly
20  5
61’ Fly
20

11  4
 4
10
B B

Figure 1−93
Configuration Selection Flow Chart

Section 1 − Operating Instructions 1−93

Operator’s Manual

8 5 7

4
6

3 8 A 5

1 2
9

In this example the crane is setup on intermediate extended outriggers

(1), boom mode A (2), 8,000 lb counterweight (3), auxiliary head fitted (4),
fly base and tip stowed (5), the front winch available with the aux head
and the rear winch selected (6) with the winch rope reeved over the main
boom (7), with five parts of line (8), two operator alarms have been set (9).

1
36.5’ Ofst
7
20  6

3 12 B
2
1

In this example the crane is setup on fully extended outriggers

(1), boom mode B (2), 12,000 lb counterweight (3) 36.5’ offset
fly erected with 20° offset (4), the rear winch available with the
main boom and the front winch selected (5), with the winch rope
reeved over the 36.5’ offset fly (6), with one part of line (7).

Figure 1−94
Normal Working Screen Examples

1−94 Section 1 − Operating Instructions

 Operator’s Manual

6 3 5

3 8 A

2
In this example the crane is setup for stationary on tires (1),
boom mode A (2), 8,000 lb of counterweight (3) front winch
not in use and the rear winch selected (4), winch rope reeved
over the main boom (5), with three parts of line (6).

6 1

5
4

3 8 B 2

In this example the crane is setup on fully retracted outrig-

gers (1), boom mode B (2), 8,000 lb of counterweight (3)
fly base and tip stowed (4), front winch not in use and the
rear winch selected (5), with one part of line (6).

Figure 1−95
Normal Working Screen Examples

Section 1 − Operating Instructions 1−95

Operator’s Manual
either an Overload, a Two Block alarm, or an Operator
settable alarm. The audible alarm may be canceled by
pressing and releasing the CANCEL ALARM button.
The audible alarm remains canceled until the condition
which caused the alarm has been removed. For exam-
ple, if the audible alarm was canceled because of an
overload condition, it will remain canceled until the
 overload condition is removed. However, if a different
alarm, e.g. two block condition, was to occur when the
audible alarm was still canceled for an earlier overload
condition, the new alarm condition would cause the au-
dible alarm to be re-started.

WARNING
Once the function limiters have been
by-passed, the crane is no longer protected
against the condition that initially caused the
function limiters to occur.

Figure 1−96 Note: The CANCEL ALARM feature is a temporary

Rigging/Travel Mode Screen function. The audible alarm or function limit is auto-
matically reset when the condition which caused
To Select Rigging/Travel Mode the alarm is no longer present.
The CRANE SET UP push-button is also used to select The CANCEL ALARM is also used to reset the function
RIGGING/TRAVEL MODE. This mode is used to facili- limiters when it is necessary to by-pass the function lim-
tate rigging and travel of the crane by inhibiting func- iters which has occurred as a result of either an over-
tion limiters and the audible alarm while selected. To load, a two block alarm, or a rope limit. Function limit-
resume crane operation, select proper outrigger or tire ers are reset by first canceling the audible alarm (as de-
configuration per the proper procedure. scribed above) and then pressing and holding the
CANCEL ALARM button for about 3 seconds, after
which the function limiters will be reset to allow normal
operation. However, should another different alarm
WARNING condition occur when the function limiters had pre-
The Microguard 434 is not operational when in viously been over-ridden, then the newly occurring
the RIGGING/TRAVEL Mode. Return the alarm condition would cause the function limiters to oc-
Microguard 434 to normal operation before cur again.
operating the crane.
Operator Settable Alarms
1. From the normal working screen press the CRANE Some alarms occur automatically as a result of limita-
SET UP button. The crane set-up screen will tions imposed by the capacity chart. The operator has
change and graphically display the carrier options. control over additional alarms which can be set to oper-
2. Press the corresponding configuration selection ate within the normal chart limitations and which are, in
button to select RIGGING/TRAVEL MODE. Refer addition to, those already set by the chart.
to Figure 1−96. Operator settable alarms will be stored in the computer
3. The crane set-up screen will change and graphi- memory, even if the crane is shutdown, until they are
cally display the RIGGING/TRAVEL MODE icon. cleared. Refer to Figure 1−97.
To Cancel Audible Alarm And Reset Function Six alarms are available for operator use.
Limiters Minimum Angle Maximum Length
The CANCEL ALARM button is used to cancel the audi- Maximum Angle Left and Right Swing
ble alarm when the alarm has occurred as a result of Maximum Height Operator Defined Area

1−96 Section 1 − Operating Instructions

 Operator’s Manual

Settable
Alarms
MAX
0 MIN
 Settable
Alarms
MAX
0 MIN

Exit Exit 

OFF OFF
Exit MAX
OFF
00.0

OFF OFF
MAX MAX

00.0
0 OFF
MIN Exit Menu

Figure 1−97
Operator Settable Alarms

3. Place the crane in the desired position depending

WARNING upon the alarm to be set. The numerical value dis-
played will be the current position of the crane.
The operator settable alarms are a warning
device. All functions remain operational when Note: If an alarm had been previously set, the
entering the operator defined bad area. For numerical value displayed will be the previous-
safe operation, adequate distance must be ly set alarm value. The previous alarm must first
maintained to allow for operator reaction time be cleared, then set the new alarm. Alarms
to avoid entering the bad area. It is the which are not set are indicated by the word OFF.
responsibility of the operator to set points
4. Press the corresponding selection button to set the
which ensure that the crane’s boom,
alarm value.
attachment, load, rigging, etc. maintains a
5. When all alarms are set press the EXIT button to re-
safe working distance and complies with local
turn to the normal working screen or press the
safety regulations.
MENU (Operator Alarm) button to return to the pre-
Setting Length/Angle/Height/Swing Operator Alarms vious menu screen.
1. From the normal working screen press OPERA- 6. Test the alarm, with no load, to ensure the alarm
TOR ALARM button to access the Operator Set- points have been properly set. When approaching
table Alarm screen. the alarm set point the pre-alarm (amber) indicator
2. Press the corresponding selection button to select lamp will illuminate, the audio will sound intermit-
the desired alarm to be set. tently, and a warning message will appear in the
Crane Set-up Screen. When exceeding the alarm
Note: The bottom value displayed in the max set point the red lamp will illuminate, the audible
height alarm box is the current head height. alarm will sound continuously, and a warning mes-
sage will appear in Crane Set-Up Screen.

Note: An alarm icon will appear on the normal

WARNING working screen to alert the operator that an op-
Avoid positioning the boom, attachment, load, erator alarm has been set. The number of icons
rigging, etc. into the bad area when setting the shown indicate how many operator alarms have
alarm values. been set.
When selecting the alarm values, ensure that 7. Use the following examples to understand the use
the load will maintain a safe distance from the
of the procedure.
obstacle.

Section 1 − Operating Instructions 1−97

Operator’s Manual
To Set Maximum Angle Alarm
WARNING Example: To have an alarm whenever the boom is
If crane or obstacle is moved or if a different above a 60 degree angle use the following
size load is lifted, the alarm(s) must be reset. procedure:
1. From the normal working screen press the OPER-
ATOR ALARM button to access the alarm screen.
2. Press the corresponding button for maximum
WARNING angle (top right).
3. Move the boom to a 60 degree angle.
Check the crane’s current configuration, 4. Press the corresponding button (middle right) to
capacity chart, and working area chart in the enter the alarm. The displayed value will be the
Crane Rating Manual to ensure safe, stable alarm setting.
operation under conditions described in the 5. Press the EXIT button to return to the normal work-
following examples. ing screen or press the MENU (Operator Alarm)
button to return to the previous menu screen.
To Set Minimum Angle Alarm 6. Test the alarm, with no load, to ensure the alarm
points have been properly set. When approaching
Example: To have an alarm whenever the boom is 60 degree boom angle the pre-alarm (amber) indi-
below a 30 degree angle, use the following cator lamp will illuminate, the audio will sound inter-
procedure: mittently, and
!Maximum Angle" will appear in the
1. From the normal working screen Press the OPER- Crane Set-up Screen. The red lamp will illuminate
ATOR ALARM button to access the alarm screen. and the audible alarm will sound continuously
2. Press the corresponding button for minimum whenever the boom is raised above 60 degrees
angle (top right). and
!Maximum Angle" will appear in Crane Set-
3. Move the boom to a 30 degree angle. Up Screen.
4. Press the corresponding button (bottom right) to
enter the alarm. The displayed value will be the To Set Maximum Length Alarm
alarm setting.
Example: To have an alarm whenever the boom length
5. Press the EXIT button to return to the normal work-
exceeds 50 feet, use the following
ing screen or the MENU (Operator Alarm) button to procedure:
return to the previous menu screen. 1. From the normal working screen press the OPER-
6. Test the alarm, with no load, to ensure the alarm ATOR ALARM button to access the alarm screen.
points have been properly set. When approaching 2. Press the corresponding button for maximum
30 degree boom angle the pre-alarm (amber) indi-
length (top right).
cator lamp will illuminate, the audio will sound inter- 3. Extend the boom to 50 feet.
mittently, and
!Minimum Angle" will appear in the 4. Press the corresponding button (middle left) to en-
Crane Set-up Screen. The red lamp will illuminate, ter the alarm. The displayed value will be the alarm
the audible alarm will sound continuously, and setting.

!Minimum Angle" will appear in Crane Set-Up
5. Press the EXIT button to return to the normal work-
Screen whenever the boom is lowered below 30
ing screen or press the MENU (Operator Alarm)
degrees. button to return to the previous menu screen.
6. Test the alarm, with no load, to ensure the alarm
points have been properly set. When approaching
50 foot boom length the pre-alarm (amber) indica-
tor lamp will illuminate, the audio will sound inter-
mittently, and
!Maximum Length" will appear in
the Crane Set-up Screen. The red lamp will illumi-
nate and the audible alarm will sound continuously
whenever the boom is extended beyond 50 feet
and
!Maximum Length" will appear in Crane Set-
Up Screen.

1−98 Section 1 − Operating Instructions

 Operator’s Manual
To Set Maximum Height Alarm 7. Press the EXIT button to return to the normal work-
Example: To have an alarm whenever the boom tip ing screen or the MENU (Operator Alarm) button to
height exceeds 75 feet, use the following return to the previous menu screen.
procedure: 8. Test the alarm, with no load, to ensure the alarm
1. Press the OPERATOR ALARM button to access the points have been properly set. When approaching
alarm screen. the set alarm point the pre-alarm (amber) indicator
2. Press the corresponding button for maximum lamp will illuminate, the audio will sound intermit-
height (top right). tently, and
!Swing Alarm" will appear in the Crane
Set-up Screen. The red lamp and the audible
Note: The bottom value displayed in the max alarm will be activated whenever the swing ex-
height alarm box is the current head height. ceeds the alarm points and
!Swing Alarm" will ap-
pear in Crane Set-Up Screen.
3. Extend the boom and/or adjust the boom angle so
that the tip height is 75 feet. Note: Both the left and right swing alarms must
4. Press the corresponding button (top right) to enter be set for the system to determine the operator
the alarm. The displayed value will be the alarm set working area.
setting.
5. Press the EXIT button to return to the normal work- To Set Operator Defined Area Alarm
ing screen or press the MENU (Operator Alarm) The operator defined area alarm, when set, will define
button to return to the previous menu screen. an imaginary vertical plane between two set points to
6. Test the alarm, with no load, to ensure the alarm optimize the working area. When approaching the
points have been properly set. When approaching plane the pre-alarm (amber) indicator lamp will illumi-
75 foot boom tip height the pre-alarm (amber) indi- nate, the audio will sound intermittently, and the mes-
cator lamp will illuminate, the audio will sound inter- sage
Bad Area" will appear on the Crane Set-Up
mittently, and
!Maximum Length" will appear in Screen. When passing the plane the overload (red)
the Crane Set-up Screen. The red lamp will illumi- warning lamp will illuminate, the audio alarm will sound
nate and the audible alarm will sound continuously continuously, and the message
Bad Area" will appear
whenever the boom tip height exceeds 75 feet and on the Crane Set-Up Screen. Use the following proce-

!Maximum Height" will appear in Crane Set-Up dure, Figure 1−98, and Figure 1−99 to set the opera-
Screen. tor defined area alarm.

To Set Left And Right Swing Alarms

Example: To have an alarm whenever the LEFT WARNING
SWING AND RIGHT SWING exceed The operator defined area alarm is a warning
pre-determined alarm points, use the device. All functions remain operational when
following procedure: entering the operator defined bad area. For
1. Press the OPERATOR ALARM button to access the safe operation, adequate distance must be
alarm screen. maintained to allow for operator reaction time
2. Press the corresponding button for the swing to avoid entering the bad area. It is the
alarm (middle right). responsibility of the operator to set points
3. Swing the boom to the left alarm point. which ensure that the crane’s boom,
4. Press the corresponding button (top left) to enter attachment, load, rigging, etc. maintains a
the left alarm point. The displayed value will be the safe working distance and complies with local
left alarm setting. safety regulations.
5. Swing the boom to the right alarm point.
6. Press the corresponding button (top right) to enter
the right alarm point. The displayed value will be
the right alarm setting.

Section 1 − Operating Instructions 1−99

Operator’s Manual
4. Position the boom, attachment, load, rigging, etc.
Settable MAX
to the left alarm point and press the corresponding
Alarms 0
MIN button (bottom left) to enter the left alarm point.
The displayed value will be the left alarm setting.
5. Position the boom, attachment, load, rigging, etc.
Exit to the right alarm point and press the correspond-
ing button (top right) to enter the right alarm point.
The displayed value will be the right alarm setting.

 Note: For best results, the two points should be

separated by a minimum of 10 ft (3 m) or 30 de-
grees.
6. When both alarm points are set, press the EXIT
button to return to the normal working screen or
Exit OFF the MENU button to return to the previous menu
screen.
7. Test the alarm, with no load, to ensure the alarm
points have been properly set. When approaching
the plane the pre-alarm (amber) indicator lamp will
illuminate, the audio will sound intermittently, and
the message
Bad Area" will appear on the Crane
OFF 00.0
Set-Up Screen. When passing the plane the over-
Menu load (red) warning lamp will illuminate, the audio
alarm will sound continuously, and the message
Figure 1−98
Bad Area" will appear on the Crane Set-Up
Operator Defined Area Alarm Screens Screen.

Setting Operator Defined Area Alarm

1. From the normal working screen press the OPER- WARNING
ATOR ALARM button to access the Operator Alarm If crane or obstacle is moved or if a different
screen. size load is lifted, the area alarm must be
2. Clear any previously set left and right swing alarms reset.
if required. Refer to
To Clear Operator Settable
Alarms" found later in this Section of the Operator’s To Clear Operator Settable Alarms
Manual. 1. From the normal working screen press the OPER-
ATOR ALARM button to access the Operator Alarm
Note: The left and right swing alarms must be screen.
cleared prior to setting the defined area alarm. 2. Press the corresponding selection button to select
the desired alarm to be cleared.
3. Press the corresponding button for Area Alarm
3. Press the corresponding button for each alarm un-
(bottom right). Refer to Figure 1−98.
til the value is replaced with the word OFF.
4. When all alarms are cleared press the EXIT button
to return to the alarm screen or press the MENU
WARNING button to return to the previous menu screen.
Avoid positioning the boom, attachment, load,
rigging, etc. into the bad area when setting the
left or right alarm points.
When selecting the left and right alarm points,
ensure that the load will maintain a safe
distance from the obstacle. Also ensure that
the two points are set so that the tailswing of
the crane will not enter the bad area.

1−100 Section 1 − Operating Instructions

 Operator’s Manual

Figure 1−99
Operator Defined Area Alarm

Section 1 − Operating Instructions 1−101

Operator’s Manual

5 6

1. Offset Lattice Fly Tip Section

2. Offset Lattice Fly Base Section
3. Auxiliary Lifting Sheave
4. Four Section Boom
5. Front Winch
6. Rear Winch

Figure 1−100
Typical Crane Attachment Setup (Provided for correct identification of attachments)

1−102 Section 1 − Operating Instructions

 Operator’s Manual
Entering And Exiting The
Upper Cab WARNING
Entering or leaving the upper cab could be hazardous if To prevent personal injury do not attempt
certain aspects are not taken into consideration. The to enter the operator’s cab prior to raising
elevation of the carrier deck and upper cab alone could the left console stand.
cause serious injury if someone was to fall. For this rea-
son a ladder is mounted on each side of the carrier to Figure 1−101
provide easy access to the carrier deck and upper cab. Left Console Warning Label
Numerous hand grips are also attached to the upper cab
as well as textured tread areas on the surface of the car-
2. Movable Left Hand Side Console
rier deck, to provide safe entry to the cab. Use these fea-
tures to make climbing on the crane as safe as possible. The left hand side console is hinged at the rear to
Remain in three point contact with the crane at all times allow the operator to pivot the console up, out of
(two hands and one foot or two feet and one hand). the way while entering or exiting the upper cab. A
counterbalance spring holds the console securely
Inside the cab, two separate features are provided to
in position during normal operation and makes
prevent accidental operation of the hydraulic controls
movement of it as effortless as possible.
while entering or leaving the operator’s seat.

1. Function Lockout Switch

This switch is used to disable the hydraulic
WARNING
functions which are operated by the control levers To prevent personal injury do not attempt to
and boom telescope foot pedal. Move the switch enter the operator’s cab prior to raising the left
to the disable position to prevent inadvertent console stand.
operation of these controls. To allow normal
operation of the swing, winch, boom hoist, and Lifting the left arm rest enables the console to pivot
telescope functions, move the function lockout up, out of the way for ease of entry and exit. It also
switch to the operate position. This switch must performs the same duty as the function lockout
always be moved to the disable position before switch, described previously, disabling all hydrau-
entering or leaving the operator’s seat. lic functions related to the control levers and boom
telescope foot pedal. Make sure the side console
is rotated up, out of the way before attempting to
enter or exit the upper cab.
One more feature which is available to ease entry
and exit of the upper cab, is the adjustable opera-
tor’s seat. Lift the left hand arm rest up out of the
way and move the seat and/or console back as re-
quired to allow safe entry. This feature also pro-
vides operator comfort during crane operation as
well. Refer to
Operator’s Seat" found earlier in this
Section of the Operator’s Manual for complete seat
operating instructions.

Section 1 Operating Instructions 1−103

Operator’s Manual
Break-In Period General Inspection
Visually inspect the entire crane for loose or missing
Operate a new crane at half throttle for the first twenty
cotter pins or bolts, or damaged fly chords or lattices.
(20) hours of operation. A break-in period under mod-
Check for oil or fluid leaks. Make repairs as needed.
erate loads will assist in providing long, trouble-free
performance. Electrical System
Check the operation of all lights, windshield wipers,
Before Starting Operations horns, turn signals, etc. Repair as needed.
Before starting daily operations, make the following
checks and inspections. Brakes
Start the engine and allow the air system pressure to
Engine reach its normal operating range, 100−120 psi
Check fuel, oil, and cooling systems for proper fluid lev- (690−827kPa). Check park brake and service brake
els. Check for leaks. Repair or fill as required. Refer to operations. Adjust or repair as needed.
engine manufacturer’s manual for additional details.
Controls
Gear Cases Check all controls for proper operation and adjust-
Visually inspect all gear cases for leaks or damage. If ment. Repair as needed.
leaks or damage exist, repair and fill case to proper lu-
brication level.

Hydraulic System
WARNING
This Operator’s Manual must be thoroughly
Check all hoses for chafing, bulging, or other damage.
read and understood by the operator before
Replace as necessary. Inspect hydraulic system for ex-
starting the engine. Crane damage or
ternal leaks. Repair as needed. Check hydraulic reser-
personal injury could result from improper
voir oil level. Add oil if necessary. Refer to Section 2 of
operating procedures.
this Operator’s Manual for additional information.

Lubrication
Fire Extinguisher
Lubricate the crane as outlined in Section 2 of this Op-
erator’s Manual. A fire extinguisher is located under left control console
of the upper operator’s cab and directly behind the
Note: Operators may have nothing to do with lubri- driver’s seat in the carrier cab. Refer to Figure 1−33
cation or maintenance of the crane, but it could be and Figure 1−60. They are A B C type fire extinguish-
advantageous for them to be familiar with it. Knowl- ers, meaning they are capable of extinguishing most
edge of preventive maintenance makes the opera- types of fires. The operator should be familiar with their
tor more aware of malfunctions in the crane so re- location, the clamp mechanism used to secure them in
pairs can be made with a minimum of downtime. place, and foremost the operation of the devices. Spe-
cific instructions, regarding operation, are given on the
label attached on the fire extinguisher. A charge indica-
Tires And Wheels tor on the fire extinguisher monitors the pressure within
Check tire inflation. Inflate to pressures per the Gross the tank. Check the indicator daily to ensure the fire ex-
Axle Weight Rating plate for highway travel, or per the tinguisher is adequately charged and ready for use.
Crane Rating Manual for pick and carry operations.
Check wheel lug nut torque, each day, for the first five
(5) days of operation, and periodically thereafter. Refer
to Section 3 of this Operator’s Manual for additional in-
formation.

Wire Rope And Sheaves

Inspect all wire rope and sheaves for damage or dete-
rioration. Replace as necessary. Refer to Section 5 of
this Operator’s Manual for additional information.

1−104
 Operator’s Manual
lease the ignition switch and allow the starter motor
Engine Starting Procedure to cool a few minutes before trying to start again. If
engine fails to start after four attempts, refer to en-
gine manufacturer’s manual for instructions.
WARNING 8. Warm Up − Run the engine at low throttle with no
load while engine is warming up. Observe the fol-
This manual must be thoroughly read and
lowing instruments for proper indications.
understood by the operator before starting
a. Engine Oil Pressure − If there is no engine oil
the engine. Crane damage or personal injury
pressure after 10−15 seconds of running time,
could result from improper operating
shutdown the engine immediately and repair
procedures.
the problem to avoid major engine damage.
Refer to engine manufacturer’s manual for
Before attempting to start the engine, the operator proper oil pressure operating range.
should carefully read and understand the engine start- b. Battery Gauge − Observe indicator to ensure
ing instructions in the engine manufacturer’s manual battery and electrical system is working prop-
and this Operator’s Manual. Attempting to start or run erly. The gauge should indicate 12.5 to 14.0
the engine before studying these instructions may re- volts while engine is running. (It should read
sult in engine damage. The operator should learn and 12.0 volts when the key is on, without the en-
obey all applicable
Rules of the Road" and if not al- gine running.)
ready a competent driver, obtain instructions to attain
c. Air Pressure Warning Light − Normal operat-
these necessary skills. With the crane fully serviced
ing range is 100−120 psi (690−827kPa).
and the operator familiar with all gauges, switches,
When air pressure is sufficient for safe carrier
controls and having read and fully understood this en-
operations, the low air pressure warning light
tire manual, start the engine using one of the following
and alarm will turn off. Do not attempt to oper-
procedures:
ate crane until air pressure warning light and
alarm are off.
9. When the engine has thoroughly warmed up, after
WARNING all pressures and temperatures are within operat-
Diesel exhaust fumes can be ing ranges, and all daily checks have been made,
harmful. Start and operate the crane is ready for operation.
engine in a well ventilated area.
If it is necessary to operate in an To Start The Engine From The Upper
enclosed area, vent the exhaust Operator’s Cab
to the outside. Properly
1. Walk around the crane to verify that there are no
maintain the exhaust system to
persons under, or in close proximity to the crane.
its original design.
2. Check the carrier cab to assure that the transmis-
sion is in neutral, the park brake is engaged, the
main hydraulic pump is engaged, and the ignition
To Start The Engine From The switch is in the
LOCK" position.
Carrier Cab 3. Move the throttle selector switch to the
Upper"
1. Walk around the crane to verify that there are no position.
persons under, or in close proximity to the crane. 4. In the upper operator’s cab, sound the horn twice
2. Engage the park brake. in succession, wait 10−15 seconds while making a
3. Shift the transmission to neutral. (The engine will visual check to verify that there are no persons un-
not start unless the transmission is in neutral.) der, or in close proximity to the crane.
4. Move throttle selector switch to
Lower" position. 5. Turn the ignition switch to the
On" position to ener-
5. Sound the horn twice in succession, wait 10−15 gize the engine electrical system and allow the
seconds while making a visual check to verify that gauges to go through their self test routine.
there are no persons under, or in close proximity to 6. Turn the ignition switch to the
Start" position. Re-
the crane. lease the ignition switch when the engine starts. If
6. Turn the ignition switch to the
On" position to ener- the engine fails to start in 30 seconds, release the
gize the engine electrical system and allow the ignition switch and allow the starter motor to cool a
gauges to go through their self test routine. few minutes before trying to start the engine again.
7. Turn the ignition switch to the
Start" position. Re- If the engine fails to start after four attempts, refer to
lease the ignition switch immediately after the en- the engine manufacturer’s manual for instructions.
gine starts. If engine fails to start in 30 seconds, re-

Section 1 Operating Instructions 1−105

Operator’s Manual
7. Warm Up − Run the engine at low throttle with no 3. Remove the ignition keys from both cabs and lock
load while the engine is warming up. Observe the the doors if the crane is to be left unattended.
engine oil pressure gauge for proper indications. If
there is no engine oil pressure after 10−15 sec- Engine Shutdown Procedure From
onds of running time, shutdown the engine imme- The Upper Operator’s Cab
diately and repair the problem to avoid major en-
1. Lower any load to the ground and secure it prop-
gine damage. Refer to engine manufacturer’s
erly.
manual for proper oil pressure operating range.
2. Engage the travel swing lock.
8. When the engine has thoroughly warmed up, after
3. Throttle the engine back to idle.
all pressures and temperatures are within operat-
4. Turn the ignition switch to the
Off" position.
ing ranges, and all daily checks have been made,
the crane is ready for operation. Note: If the ignition switch is in the
On" posi-
tion in the carrier cab, it must also be turned to
Engine Shutdown Procedure From the
Off" position before the engine will shut-
The Carrier Cab down.
1. Throttle the engine back to idle. Engage the park
brake and shift the transmission to neutral. 5. Remove the ignition keys from both cabs and lock
2. Turn the ignition switch to the
Lock" position. the doors if the crane is to be left unattended.

Note: If the ignition switch is in the
On" posi-

tion in the upper operator’s cab, it must be
moved to the
Off" position before the engine
will shutdown.

1−106
 Operator’s Manual

2
Power Source 1
3

4
Frame Ground

Make connections in numerical order.

Disconnect in reverse order.

Figure 1−102
Battery Cable Connections

Jump Starting The Crane

The crane has four (4) 12V batteries. The batteries are
located on the left side of the crane next to the fuel tank.

WARNING
To avoid serious personal injury and/or
equipment damage, follow these procedures
in the order they are given.
Wear protective clothing and shield your face Wrong
and eyes when working around batteries.
Batteries contain sulfuric acid which burns
skin, eyes, and clothing. Figure 1−103
Do not jump start a damaged battery. Be sure Do not use an open flame near the battery.
vent caps are tight and level. If another
vehicle is used, be sure booster vehicle and 5. Connect the other end of the second cable to a
crane are not touching. good metallic surface on the carrier frame.
The gases around the battery can explode if 6. If another vehicle is used to jump start the crane,
exposed to open flames or sparks. An start the booster vehicle. Run the booster vehicle’s
explosion could result in serious personal engine at a moderate speed.
injury and/or equipment damage. 7. Turn on the key switch to allow discharged batter-
ies to charge for a few minutes prior to attempting
Battery posts, terminals, and related accesso- to start the disabled crane.
ries contain lead and lead compounds. Wash 8. Start the disabled crane. After the crane is started,
hands after handling. remove jumper cables in reverse order.
9. Let the crane’s engine run for a few minutes to
1. Check all battery terminals and remove any corro- charge the discharged batteries.
sion before attaching jumper cables. 10. Check the battery gauge in the operator’s cab.
2. Connect one end of the first jumper cable to the The gauge reading should be increasing toward
12V positive (+) terminal of the discharged battery. 14 volts.
3. Connect the other end of the first cable to the 12V
positive (+) terminal of the 12V power source or Note: If the batteries are severely discharged,
booster battery. voltage may increase slowly.
4. Connect one end of the second jumper cable to the
negative (−) terminal of the 12V power source or
booster battery.

Section 1 Operating Instructions 1−107

Operator’s Manual
And Foot Operated Controls" found earlier in this Sec-
tion for proper operating procedure.

Electric Engine Block Preheater

An electric engine block preheater is available for this
crane. It is provided to make engine start-up easier in
extremely cold weather by keeping the entire engine
warm. The unit is designed for all night operation but if
weather conditions are not severe, it can be used for 30
minutes before engine start-up, with good results.
The electric engine block preheater uses electrical
power to heat the coolant and circulate it through the
engine. The electric engine block preheater power
cord is located on the right side of the engine. Refer to
Figure 1−104.

1 To Start The Electric Engine Block

1. Preheater Cord Preheater
1. Park crane in suitable area for storage, engage the
Figure 1−104
park brake, shift the transmission to neutral, and
Electric Engine Block Preheater
shutdown the engine.
2. Plug preheater cord into 110V to 120V electrical
source.
Cold Weather Aids
These options are offered to aid in engine start up and
operator comfort in extremely cold weather conditions. WARNING
Each system operates independently of the other Areas adjacent to the preheater must be clean
which allows use of more than one of them at the same and free of oil and debris to avoid possible fire
time. The following is a brief description of each sys- hazard.
tem and operating instructions.

Hydraulic Pump Disconnect Note: Unplug the engine block preheater before
starting the engine.
The pump disconnect is used to disengage the main
hydraulic pump when not in use. Disconnecting the
main pump greatly reduces cranking resistance. The To Stop The Electric Engine Block Heater
pump should be disconnected for cold weather start- 1. Unplug preheater cord from electrical source.
ing. Refer to
Steering Column, Pump Disconnect,

1−108
 Operator’s Manual

1
5

2
4

1. Ether Fuel Cylinder 3. Metering Orifice 5. Ether Injector Relay (EIR)

2. Cylinder Clamp 4. Valve

Figure 1−105
Ether Start System

Ether Start System

The ether start system is a fully-automatic engine start-
ing fluid system designed to spray a controlled amount
of ether into the air intake system during and immedi-
ately after cranking. The engine control module (ECM)
determines when the system should function. The
ECM sends a signal to the ether injection relay (EIR)
which activates the valve assembly to inject ether.
Whenever the engine does not start within a normal pe-
riod of cranking the ether fuel cylinder may be empty.
Check the low cylinder indicator located on the EIR and
replace the cylinder as required. The ether fuel cylinder
is located just inside the engine access door on the left
side of the crane. Refer to Figure 1−105.

Figure 1−106
Ether Injector Relay

Section 1 Operating Instructions 1−109

Operator’s Manual
Note: The EIR requires a constant power supply in 5. Install the protective cap to protect the top of the
order to preserve the memory of the amount of valve from dirt after removal.
ether used. There is an internal backup circuit that 6. Find the new gasket from the inside of the thread
allows the EIR to retain its memory for 72 hours protective white cap on the new fuel cylinder.
without a battery connection. If the battery is dis- 7. Install the new gasket into the valve.
connected for longer than 72 hours, the EIR will re-
set. The ether fuel cylinder should be replaced to Note: Replace gasket inside valve each time a
synchronize the counter with the amount of ether cylinder is replaced. Read the entire cylinder la-
left in the cylinder. bel for additional information on cylinder and
valve gasket installation.

8. Coat the new cylinder’s threads with clean engine

WARNING oil.
9. Install the cylinder by turning the cylinder clock-
When maintaining or troubleshooting ether
wise until the cylinder dirt and moisture seal o-ring
start system, always make sure the area is
contacts the valve.
well ventilated and away from heat, open
10. Tighten an additional 1−1/2 turns. Do not
flames, or sparks. Wear goggles to avoid eye
overtighten.
injury. When opening ether fuel line or
disconnecting atomizer, make sure it is
pointed away from you. The ethyl ether fuel CAUTION
used in this system is extremely flammable,
toxic, harmful, and can be fatal. Do not overtighten the cylinder.
Over-tightening may damage the valve or the
cylinder.
Changing The Ether Fuel Cylinder
1. Park crane on a firm level surface, engage the park 11. Tighten the cylinder clamp.
brake, shift the transmission to neutral, and shut- 12. Reset the low cylinder indicator by passing a mag-
down the engine. net over the reset area 3 or 4 times. The lamp
2. Clean all dirt from the neck of the fuel cylinder and should flash indicating a reset. Refer to
top of the valve. Refer to Figure 1−105. Figure 1−106.
3. Loosen the cylinder clamp.
Note: The magnet must be capable of lifting a
4. Turn the fuel cylinder counterclockwise to remove
minimum of two pounds.
the cylinder from the valve. Remove the old gasket
from the valve and properly discard.

1−110
 Operator’s Manual

TRAVEL TRAVEL
HOIST LOWER USE MAIN HOIST (One track) (Both tracks)

USE WHIP LINE RAISE BOOM LOWER BOOM SWING STOP

RAISE THE BOOM AND LOWER THE BOOM AND EXTEND BOOM RETRACT BOOM
MOVE SLOWLY LOWER THE LOAD RAISE THE LOAD (Telescoping booms) (Telescoping booms)

EXTEND BOOM RETRACT BOOM

TRAVEL DOG EVERYTHING EMERGENCY STOP (Telescoping booms) (Telescoping booms)

Extracted from the American National Standard, Crawler, Locomotive and Truck Cranes, ANSI B30.5b−1985, with the
permission of the Publisher the American Society of Mechanical Engineers, 345 E. 47th Street, New York, New York 10017.

Figure 1−107
Standard Hand Signals For Controlling Crane Operations

Hand Signals Crane Operation

Hand Signals are important for communications be- Cranes are used primarily for making heavy lifts. In or-
tween the designated signalman and the operator. A der to do this properly, certain procedures must be fol-
hand signal chart is shown Figure 1−107. A copy is lowed. The following is a suggested procedure for
also located on the right hand side of the carrier, on the making typical lifts:
hydraulic reservoir. 1. Determine weight to be lifted. Be sure to add the
These signals should be used at all times unless voice weight of the hook block, slings, rigging, fly, etc.
instructions with a radio or telephone are being used. Determine height to which the load must be lifted.
One person should be designated as a signalman and 2. Consult the proper capacity, working areas and
their signals obeyed by the operator. Obey a stop sig- working range chart located in the Crane Rating
nal from anyone. Manual. Find the shortest boom length and load
radius that will accomplish the job.

Section 1 Operating Instructions 1−111

Operator’s Manual
3. Do not swing upper while on tires, use outriggers. 9. Lift the load to the desired height. Boom to the de-
Position crane so a minimum swing is necessary. sired angle. Be careful when booming down or
4. The crane must be supported by a firm, solid level swinging the load, as these increase the load ra-
surface before starting to lift. All capacities in the dius and result in a decrease in capacity. Make
Crane Rating Manual are based on the crane being sure the load being lifted remains within the lifting
level in all directions. If the crane is not level, out capacity of the crane at the boom length and ra-
swing or side swing of the load will greatly reduce dius being used.
lifting capacities and could cause crane damage or 10. Control the load at all times. Use hand lines to
an accident. If the ground is soft, use mats. guide the load. Do not guide loads into place with
5. If outriggers are used, the following points must be your hands. Swing slowly and smoothly. Avoid
observed: jerks when starting or stopping swings.
a. The outrigger beams must all be equally ex-
tended (all fully extended, intermediately ex- During Operation
tended, or fully retracted) to lift the loads
The operator must remain alert to possible malfunc-
shown in the Crane Rating Manual. Serious re-
tioning of the crane while operating. If the crane does
ductions in lifting capacity will result if all
malfunction, lower the load and shutdown the crane
beams are not in the same position and this
until the problem is found and corrected. During op-
could lead to serious crane damage or an acci-
eration, the operator must:
dent. 1. Remain alert to any noise or loss of power, or bad
b. The bumper outrigger must be properly set. response to control of the crane. Watch the engine
c. Outrigger pontoons must be on solid, smooth oil pressure and water temperature gauges for
footing, flush with the ground (no hills, or val- proper operating ranges.
leys under pontoons), otherwise pontoons 2. Watch the hydraulic system oil temperature
may be damaged or destroyed. If there is any gauge. If the temperature exceeds maximum tem-
doubt, use mats. perature, shutdown the crane until the problem is
d. All capacities listed for the crane on outriggers corrected. Refer to
Hi Performance Hydraulic Oil"
are based on the outrigger jacks being used to chart in Section 2 of this Operator’s Manual for the
raise the crane so that all tires are clear of the maximum temperature for each viscosity of hy-
ground and the crane level. A bubble level is draulic oil.
provided in the upper operator’s cab and at 3. Listen for any unusual noises in the hydraulic sys-
each outrigger ground control station to assist tem, power train, or the speed reducers. If any,
the operator in leveling the crane. correct problem.
6. When making lifts on tires, all tires must be inflated 4. Watch for oil leaks or any loss of control. If any de-
to pressures as listed in the Crane Rating Manual. velop, correct before continuing operation.
Do not make lifts which exceed Crane Rating 5. Make sure all controls work freely and easily, with
Manual specifications. no sticking or binding. Lubricate or adjust as nec-
7. Raise the boom and swing over the load. Extend essary.
the boom to the desired length. Make sure power 6. If working on outriggers, periodically check the
boom sections are properly extended. outriggers to make sure the crane is level and sta-
8. Lower the hook block and fasten it onto the load. ble. If working without outriggers, make sure the
The following points must be observed: tires are inflated to the proper pressure and the
a. The boom peak must be directly above the boom is positioned directly over the rear of the car-
load. Booms are made to lift, and should never rier with the travel swing lock engaged. Refer to
be used to drag a load sideways. Crane Rating Manual for proper tire pressure.
b. Always use chains, wire ropes or slings of am- 7. Heed all warning and caution labels. Observe
ple size and make periodic checks of their con- good safety practices at all times.
dition.
c. Always use sufficient parts of line. Consult wire
rope capacity chart located in the Crane Rat-
ing Manual for the number of parts of line
needed for a given lift.
d. When lifting loads, care should be taken to pre-
vent sudden loading or unloading of the winch
rope. Ease into the load. Lift load a few inches
off the ground and hold to check the winch
brakes.

1−112
 Operator’s Manual
Pick And Carry Operation
Travel during pick and carry operations is restricted to
WARNING
speeds of 1.0 mph (1.6km/h) or less on a firm, level sur- Do not travel above the maximum speeds
face. Lifts are to be made off the main boom only, with listed. Crane damage, property damage,
the crane prepared as follows: and/or personal injury may result.

Job Site Travel

WARNING Job site travel is limited to speeds less than 5.0 mph
Do not travel above the maximum speeds (8.0km/h) on a firm, smooth and level surface. The
listed. Crane damage, property damage, crane may be traveled on the job site with no load per
and/or personal injury may result. the following procedure:
1. Inflate the tires to pressure listed in the Tire Inflation
1. Inflate the tires to the pressure listed in the Crane Label for 5.0 mph (8.0km/h) maximum speed. Re-
Rating Manual for 1.0 mph (1.6km/h) maximum fer to Section 3 of this Operator’s Manual for tire
speed. Refer to Section 3 of this Operator’s Manu- inflation procedure.
al for tire inflation procedure. 2. If the crane is equipped with the axle lift system, en-
2. If the crane is equipped with the axle lift system, en- sure that the air ride suspension switch in the carri-
sure that the air ride suspension switch in the carri- er cab is in the
UP" position.
er cab is in the
UP" position. 3. Level the crane on fully extended outriggers.
3. Level the crane on fully extended outriggers with 4. Position the upper and attachments in one of the
the tires clear of the ground. following arrangements:
4. Position the upper over the rear and engage the a. The upper over the front or rear. The boom
travel swing lock. Release the 360° swing lock, if
sections fully retracted and the fly stored.
equipped.
b. The upper over the rear. The boom sections
fully retracted. The fly base erected and the fly
CAUTION tip stored or the fly base and tip erected.
Do not leave swing park brake or 360° swing Note: The fly must be in the 2° offset posi-
lock knob in the engaged position during pick tion.
and carry operations. Failure to release these
devices during this operation may result in c. The upper over the front. Boom fully retracted.
damage to the swing speed reducer. 9,000 lb counterweight or more located on up-
per. Fly base erected with fly tip stored, or fly
5. Properly store the fly. base and tip erected.
6. Retract all outrigger jacks just clear of the ground 5. Boom down fully. Engage the travel swing lock.
but leave the outrigger beams fully extended. Release the 360° swing lock, if equipped.
7. Attach as many hand lines as necessary to prevent
the load from swinging during travel.
8. Carefully attach the load to the winch rope and lift it
CAUTION
only as high as necessary. Do not leave the swing park brake or the 360°
9. Carefully travel at no more than 1.0 mph (1.6km/h). swing lock engaged when traveling the crane.
Take extra care due to the increased overall width Failure to release these devices during this
caused by the extended outrigger beams. The out- operation may result in damage to the swing
riggers or pontoons must not be allowed to hit any speed reducer.
obstructions. Maintain a safe distance from all per-
sonnel and obstructions. Travel only on a firm, 6. Retract all outrigger jacks just clear of the ground
level surface. but leave the beams fully extended.
10. Once the desired destination is reached, shift the 7. Carefully travel at no more than 5.0 mph (8.0km/h).
transmission to neutral and apply the park brake. Take extra care due to the increased overall width
caused by the extended outriggers. The outrig-
Traveling The Crane gers or pontoons must not be allowed to hit any ob-
structions. Maintain a safe distance from all ob-
Truck cranes are designed for highway and job site structions, structures and power lines.
travel. Certain conditions must be met for safe travel.
Refer to the following outlined procedures before trav-
eling the crane.

Section 1 Operating Instructions 1−113

Operator’s Manual
Highway Travel Counterweight Removal
Highway travel is considered to be any travel of the
Access to certain job sites may require the crane to
crane over 5.0 mph (8.0km/h). The following condi-
travel on roads with strict vehicle load limitations. In or-
tions and precautions must be met for any highway
der to meet such limitations the crane is designed so
travel.
the counterweights can be lowered on and pinned to
Note: If road weight or axle load limitations are a the carrier deck to balance axle loadings or removed
factor, the crane may be equipped with a counter- and transported separately. Removing the counter-
weight removal system or boom dolly/trailer kit. weights can reduce the weight of the crane by as much
Use these systems as necessary to meet road as 16,000 lb (7
258kg). Refer to the Crane Rating
weight or axle load limitations. Refer to the Gross Manual for the exact weight of the counterweight.
Axle Weight Rating (GAWR) plate for axle load lim-
its. To Remove The Counterweights
1. Park the crane on a firm level surface, engage the
1. If equipped, the fly must be secured in the stored park brake, and shift the transmission to neutral.
position on boom. 2. Properly level the crane on outriggers with the tires
2. Inflate the tires to pressure listed on the Gross Axle clear of the ground.
Weight Rating (GAWR) plate for speeds over 5.0 3. Fully retract all boom sections. If equipped, prop-
mph (8.0km/h). Refer to Section 3 of this Opera- erly store the fly on the boom.
tor’s Manual for tire inflation procedure. 4. Swing the upper over the rear of the carrier. En-
3. If the crane is equipped with the axle lift system, en- gage the travel swing lock and boom up to 30°.
sure the air ride suspension switch in the carrier 5. Remove the lock pins which secure the counter-
cab to the
UP" position. weights to the upper frame. Refer to
4. The boom must be fully retracted, over the front of Figure 1−108.
the crane and in the boom rest, unless a boom dol-
ly/trailer is being used, with the travel swing lock Note: Counterweights have to be raised (cylin-
engaged. Release the 360° swing lock, if ders retracted) to relieve pressure on the lock
equipped. pins to ease removal.
6. Pull the counterweight cylinder control lever to low-
CAUTION er (extend cylinders) the counterweights to the
storage lugs on the carrier deck.
Do not leave the swing park brake or the 360°
swing lock engaged when traveling the crane.
Failure to release this device during this
operation may result in damage to the swing
WARNING
To avoid personal injury, do not stand under
speed reducer.
counterweights during lowering or raising of
the counterweights.
5. Secure hook block to prevent excessive swinging.
6. All outriggers must be fully retracted (jacks and 7. Remove the lock pin which secures the counter-
beams) with all outrigger position pins in the re- weights to the counterweight removal cylinder.
tracted position and all main outrigger pontoons
removed from jacks and stored properly. Note: If all counterweights are not to be re-
7. All upper control levers must be in the neutral posi- moved, remove only the two counterweight
tion. The upper ignition key must be turned off, key connecting pins above the counterweights to
removed and all doors and windows locked. be removed.
8. Do not allow anyone to ride in the upper operator’s
cab during any highway travel. 8. Pull the counterweight cylinder control lever to re-
9. Disengage the main hydraulic pump. tract (raise) the cylinders away from the counter-
10. Obey all
Rules of the Road" and travel carefully. weights.
9. Remove the cylinder travel lock brackets from the
stored position and install them in the travel posi-
tion.

1−114
 Operator’s Manual

INFORMATION WARNING
8 KEEP CLEAR
OF MOVING
COUNTERWEIGHT
TO PREVENT
SERIOUS BODILY
INJURY.

DO NOT have more

WARNING
than (2) two
KEEP CLEAR
counterweights on OF MOVING
deck when lowering COUNTERWEIGHT
boom into rest. TO PREVENT
7 SERIOUS BODILY
INJURY.

9 10
6

11

10
VIEW A−A VIEW A−A
Counterweights Pinned to Upper Counterweights Lowered to Carrier Deck
A 1 2

A 3 4 INFORMATION
1. Lock Pins With Keepers − Counterweights to Upper Frame COUNTERWEIGHT CONTROL
2. Counterweight Removal Cylinder Control Lever (Shown Opposite) NEUTRAL
3. Counterweights Installed PULL TO PUSH TO
4. Connecting Pin With Keepers − Counterweight to Counterweight LOWER RAISE
5. Carrier Deck Storage Lugs
6. Lock Pin With Keepers − Counterweight to Counterweight Removal Cylinder
7. Cylinder Travel Lock Bracket in the Traveling Position − Counterweights Removed
8. Cylinder Travel Lock Bracket in the Stored Position − Counterweights Installed
9. Auxiliary Counterweight
10. Lifting Ring
11. Connecting Bolt

Figure 1−108
Counterweight Removal System

Section 1 Operating Instructions 1−115

Operator’s Manual
10. Install the connecting pins to secure the counter-
weights to the counterweight storage lugs on the
carrier deck. WARNING
11. If required, remove the counterweights from the To avoid personal injury, do not stand under
carrier deck. The boom may be used to lift the counterweights during lowering or raising of
counterweights onto a transport vehicle. Refer to the counterweights.
the Crane Rating Manual for lifting loads with no
counterweight. 10. Continue to lift the counterweights until the lugs on
the top counterweight align with the lugs on the up-
Note: If the crane is equipped with the auxiliary per frame.
counterweights, remove the connecting bolts 11. Install the lock pins and keepers which secure the
and remove each one using the swivel lifting counterweights to the upper frame.
rings. Refer to Figure 1−108. 12. Lower counterweights (extend cylinders) slightly to
transfer the weight of the counterweights from the
cylinders to the upper frame.
To Install The Counterweights
1. Park the crane on a firm level surface, engage the
park brake, and shift the transmission to neutral.
Traveling With Boom
2. Properly level the crane on outriggers with all tires Dolly/Trailer
clear of the ground.
3. If required, install the counterweights onto the car- A boom dolly/trailer can be used to reduce the weight
rier deck. The boom may be used to lift the coun- on each of the carrier axles by supporting a portion of
terweights onto carrier deck. Refer to the Crane the weight of the boom during highway travel, if high-
Rating Manual for lifting loads with no counter- way codes allow the use of this equipment. The fly may
weight. also be partially supported by the dolly/trailer if it is
properly stored on the boom. The crane must be
Note: If the crane is equipped with the auxiliary equipped with the boom dolly/trailer kit to provide the
counterweights, place each one on the top necessary hydraulic plumbing required to allow the
counterweight using the swivel lifting rings. boom to float freely on the dolly/trailer. The boom dolly/
Install the connecting bolts and torque to 200 ft trailer is for highway use only.
lb (271Nm), then install counterweights to the
upper. Refer to Figure 1−108.

4. Swing the upper over the rear of the carrier. En- WARNING
gage the travel swing lock and boom up to 30°. When initiating a turn with the boom
5. Remove the cylinder travel lock brackets from the dolly/trailer, the tip of the boom may swing
travel position and install them in the stored posi- outside the turning radius of the dolly/trailer
tion. Refer to Figure 1−108. axles. In some cases the tip of the boom will
6. Pull the counterweight cylinder control lever to ex- move into the line of traffic. The tip of the
tend (lower) the counterweight removal cylinders boom must be properly flagged before
to align connecting lugs on the top counterweight. roading the crane. Allow ample time to
7. Install the lock pins and keeper pins to secure the complete a turn before oncoming traffic
counterweights to the counterweight removal cyl- approaches.
inder.
8. Remove the connecting pins which secure the The dolly/trailer must be equipped with an air brake
counterweights to the storage lugs on the carrier system. Pressurized air for this system is supplied to
deck. the dolly/trailer through outlets on the rear of the carrier.
9. Push the counterweight cylinder control lever to re- Push in on the boom dolly/trailer air control valve knob,
tract (raise) the cylinders and lift the counter- on the carrier cab dash, to pressurize the outlets. Pull it
weights. out to shutoff the air supply to the dolly/trailer. Refer to
Figure 1−34. Electrical hook-ups for lights are also
available on the rear of the carrier.

1−116
 Operator’s Manual
1 2
A

4 A 1 3

6
1. Counterweight Storage Locations 3. Boom Dolly/Trailer 5. Electrical Cable
2. Boom 4. Control Air Line (Blue) 6. Supply Air Line (Red)

Figure 1−109
Typical Boom Dolly/Trailer

Boom Dolly/Trailer Installation

WARNING 1. Properly prepare the crane for highway travel. See

Traveling the Crane", found earlier in this Section
The counterweights must be removed from
of this Operator’s Manual for instructions.
the upper when traveling the crane with a
2. Using a signalman, back the crane to the dolly/trail-
boom dolly/trailer. Crane may tip over when
er.
initiating a turn when the counterweights are
3. Hook up the air lines and plug in the electrical
left installed on the upper. The
cable. Refer to Figure 1−109.
counterweights may be transported on the
4. Position the fully retracted boom at a 45° angle.
carrier deck or on the boom dolly/trailer. If
Swing the boom over the dolly/trailer as required.
the counterweights are transported on the
Lower the boom onto the dolly/trailer.
boom dolly/trailer, they must be equally
positioned on the sides of the dolly/trailer,
e.g. 4,000 lb (1 814kg) on one side and 4,000
lb (1 814kg) on the other side. Ensure that
WARNING
the counterweights are properly secured on When swinging over the side on tires maintain
the carrier deck and dolly/trailer. 45° boom angle. Crane may tip over
backwards causing personal injury and/or
crane damage.

5. Adequately secure the boom to the dolly/trailer.

6. Shutdown engine and disengage the main pump.

Section 1 Operating Instructions 1−117

Operator’s Manual

4 2

1
1. Swing Speed Reducer 3. Boom Hoist Cylinder
2. Boom Hoist Control Valve 4. Needle Valves − 2 Places

Figure 1−110
Boom Hoist Float Valves

7. Turn the needle valves at the boom hoist cylinder 9. Push in on the boom dolly/trailer air control valve,
and boom hoist control valve counterclockwise, as on the carrier dash, to supply air to the dolly/trailer.
far as possible, to open the valves and allow the Refer to Figure 1−34.
boom to float freely on the dolly/trailer. Refer to
Figure 1−110. Note: If the boom dolly/trailer air system is not
already pressurized, allow ample time for the
system to charge before attempting to move the
dolly/trailer.
WARNING
Check that the boom is properly supported by 10. Flag (lights if traveling at night) the end of the boom
the dolly/trailer before opening the needle before roading the crane. Obey all
Rules of the
valves.The boom could drop suddenly Road" and travel carefully.
causing damage or injury.
All needle valves must be fully open before
Boom Dolly/Trailer Removal
traveling the crane with a boom dolly/trailer. 1. Park the boom dolly/trailer where desired and ap-
Crane damage could result. ply the park brake. Shutdown the engine. Block
the wheels of the dolly/trailer.
8. Release the travel swing lock and the swing park 2. Turn the needle valves at the boom hoist cylinder
brake. Also release the 360° swing lock, if and boom hoist control valve clockwise, as far as
equipped. possible, to close the valves and allow normal
boom hoist operation. Refer to Figure 1−110.

CAUTION
Do not leave any swing lock device in the WARNING
engaged position when traveling the crane All needle valves must be fully closed before
with a boom dolly/trailer. Failure to release operating the crane. The boom could fall
these devices during this operation may result causing damage or injury.
in damage to the swing speed reducer.

1−118
 Operator’s Manual
3. Engage the main hydraulic pump and start the en- hoist line to account for the removal of any compo-
gine. Pull out on the boom dolly/trailer air control nent.
valve, on the carrier cab dash, to shutoff the air 5. The hook block and ball are not included in the to-
supply to the dolly/trailer. Refer to Figure 1−34. tal weight of the crane.
4. Disengage the boom from the dolly/trailer. 6. When lifting the entire crane, extend outriggers
5. Raise the fully retracted boom to a 45° boom beams to the intermediate position and install
angle. Swing the boom directly over the front of the slings around the beams. Protect slings from any
carrier and place it in the boom rest. Engage the sharps edges.
travel swing lock. 7. Do not reeve load lines through the fly when lifting
the entire crane or damage may result
8. Use only nylon straps to lift fly base or fly tip to pre-
WARNING vent damage to them. Protect the straps from
When swinging over the side on tires do not sharp edges.
exceed 45° boom angle. Crane may tip over 9. Do not allow the hoist lines to contact boom while
backwards causing personal injury and/or lifting crane. Damage to the boom may result.
crane damage.
6. Disconnect the electrical cable and air lines from
Towing The Crane
the rear of the carrier. Cap the outlets and the air Always use good judgment and reliable equipment
hoses using the storage hardware and brackets when towing the crane. Use extra caution when towing
provided. Refer to Figure 1−109. the crane on the highway and in traffic. When making
7. Carefully drive the crane away from the dolly/trailer. connections between the crane and towing vehicle, be
sure none of the connections will cause damage to
Lifting The Crane either vehicle. Pay particular attention to tie rods, brake
lines, steering cylinders and steering lines.
The entire crane can be lifted or the components may
Always exercise safety and follow all local codes when
be removed from the crane and lifted individually. Refer
towing the crane. Prepare the crane as follows before
to Figure 1−111 for the centers of gravity and weights
towing it.
for the entire crane and the individual components.
1. If equipped, store the fly on the boom.
The following conditions and precautions must be met
2. The boom must be fully retracted and over the front
before lifting the crane or removing any component.
of the crane with the travel swing lock engaged.
1. The crane must be parked on a firm level surface Release the 360° swing lock.
with the travel swing lock engaged, and boom in
the boom rest.
2. Use lifting equipment, shackles, slings, etc., of CAUTION
suitable size and strength. All lifting equipment Do not leave the 360° swing lock engaged
must be inspected before lifting the crane. The in- when towing the crane. Failure to release the
spection must be recorded and dated in accor- 360 degree swing lock during this operation
dance with current OSHA regulations. may result in damage to the swing speed
3. The weights and locations of all centers of gravity reducer.
include all possible options (heaviest crane) with
the fly base and fly tip stowed on the boom. Use 3. Secure the hook block to prevent excessive swing-
the centers of gravity as a starting point. Center ing.
hoist line on the center of gravity, lift a few inches 4. All outriggers must be fully retracted (jacks and
and adjust the hoist line to keep the crane/compo- beams) with all pontoons removed from jacks and
nents level at all times. stored properly.
4. Removal of any components from the crane will
shift the center of gravity of the entire crane. Adjust

Section 1 Operating Instructions 1−119

Operator’s Manual
FLY TIP 12’−2"
SHEAVE (3.7m) FLY TIP

FLY BASE 19’−6"

(5.9m)

BOOM (FULLY
FLY BASE SHEAVE
RETRACTED, 0° 18’−3"
BOOM ANGLE (5.6m)

BOOM FOOT PIN

7’−1"
2.5" (2.2 m)
(6.3cm) 5’−6"
(1.7m)
AUXILARY
ARM
UPPER
BOOM HOIST
CYLINDER BOOM
HOIST PIN
AUXILARY
ARM SHEAVE COUNTERWEIGHTS

CARRIER 7’−3" 12’−8"

(2.2 m) (3.9m)

TOTAL CRANE 4’−1"

(1.2 m)

TOW & TIE OF TOW & TIE

DOWN POINTS ROTATION DOWN POINTS
LIFT POINT LIFT POINT

DESCRIPTION WEIGHT
CARRIER 43,600 lb (19 777kg)
UPPER 13,800 lb (6 260kg)
BOOM HOIST CYLINDER 2,710 lb (1 229kg)
BOOM W/ FOOT PIN 19,100 lb (8 664kg)
COUNTERWEIGHTS 16,000 lb (7 258kg)
AUXILIARY ARM 110 lb (50kg)
FLY BASE 1,530 lb (694kg)
FLY TIP 710 lb (322kg)
TOTAL CRANE 97,560 lb (44 253kg)

Figure 1−111
Lifting The Crane

1−120
 Operator’s Manual
5. All control levers in the upper operator’s cab must
be in the neutral position.
6. The hydraulic pump must be disconnected. WARNING
7. Shift the transmission to neutral. Do not use the towing shackles as a means of
8. Remove the drive tube between the transmission lifting the crane. These shackles are not
and axle. intended to be used to lift the crane and may
break if subjected to the entire weight of the
crane. Severe personal injury or extensive
CAUTION equipment damage may result from this
Failure to disconnect the drive tube, or lift the practice.
driving wheels, before pushing or towing the
crane can cause serious transmission
damage. Prepare the crane as follows before transporting it:
1. If equipped, store the fly on boom.
2. The boom must be fully retracted and over the front
9. Unlock the steering column by turning the ignition
of the crane with the travel swing lock engaged.
switch to the
On" position. Turn on the hazard
Release the 360° swing lock.
flashers.
10. Release the park brake when the crane is attached
to the towing vehicle and ready to be towed. CAUTION
Do not leave the 360° swing lock engaged
Transporting The Crane when transporting the crane. Failure to
When transporting the crane, precautions should be release the 360° swing lock during this
taken in securing the crane to the trailer, barge, or other operation may result in damage to the swing
means of conveyance. The towing shackles are the mechanism.
recommended tie down points. If the crane is not
equipped with towing shackles, chains may be looped 3. Secure the hook block to prevent excessive swing-
around the outrigger boxes or the axle housings and ing.
used to secure the crane down. 4. All outriggers must be fully retracted (jacks and
beams) with all pontoons removed from jacks and
stored properly.
CAUTION 5. Engage the park brake and shift the transmission
If chains are wrapped around the axle to neutral.
housing, be certain the chains will not damage 6. All control levers in the upper operator’s cab must
the tie rods, brake lines, steering cylinders or be in the neutral position.
steering lines. 7. Lock all windows and doors. Remove the keys
from the crane.
8. Depending on the specific situations, further
If chains are wrapped around the outrigger box collar, preparations may be needed to protect the crane
be certain the chains will not damage the hydraulic from the environment or vandalism. See
Crane
lines and fittings. The chains should be wrapped Storage" for further suggestions.
around the outrigger box, not the outrigger beam.
Always exercise safety and follow all local codes when
loading, unloading or transporting the crane.

Section 1 Operating Instructions 1−121

Operator’s Manual
5. Inflate tires to pressures shown on the Gross
Crane Storage Weight Rating Plate. Check tire pressures periodi-
Anytime the crane is going to be left unattended, it cally during storage to make sure they do not go
should be prepared so that it will not be damaged by flat. Refer to Section 3 of this Operator’s Manual for
the elements, be an attraction to vandals, or a plaything correct procedure. If possible block the crane up
for children. so the tires are clear of the ground. Make sure the
blocking is placed so the crane cannot fall off it. If
Short Term Storage this is not possible, set the crane on planks so the
1. Do not leave the crane where it will be a traffic haz- tires will not sink in the ground. Block the tires to
ard. prevent the crane from rolling.
2. Lower all loads to the ground. 6. Fully retract all hydraulic cylinders if possible. If
3. The swing lock must be engaged. equipped, store the fly. Cover all cylinder rods, ma-
4. Fully retract the boom. Boom down to 0 degrees. chined and unpainted surfaces with a coat of
The fly may be erected if the crane is on outriggers. grease.
5. Tie off the hook block to the towing shackles. 7. Leave all control levers in neutral.
Winch lines should be snug. 8. Engage the park brake and shift the transmission
6. All control levers must be in the neutral position. to neutral.
7. Shift the transmission to neutral, engage the park 9. Prepare the engine as per the engine manufactur-
brake and shutdown the engine. Block the wheels ers manual. Make sure antifreeze protection is suf-
to prevent the crane from rolling if on tires. ficient to prevent the engine from freezing. If anti-
8. If the crane is on outriggers, the outriggers must be freeze protection is not adequate, completely drain
properly set and supported so the crane will re- the engine block.
main level. 10. Cover all open areas around the engine, cab, etc.
9. In cold weather, locate the crane where it will not to prevent entry of water. Cover the entire engine
freeze to the ground. area with a tarp if possible.
10. Lock all windows and doors. Remove the keys 11. If in a location where vandalism may occur, lock the
from the crane. cab doors. Cover all cab glass with plywood or
boards to prevent glass breakage. Provide a
Long Term Storage means of locking the engine access doors, fuel
tank and hydraulic reservoir.
1. Store the crane inside a building if possible.
12. Drain all moisture from the air reservoirs to prevent
2. Thoroughly clean the crane.
rust and deterioration.
3. Touch up any spots where paint has chipped. This
13. Store the crane so it does not provide a plaything
will prevent rusting.
for children. Such a unit can be an
attractive nui-
4. Lubricate the entire crane as per the Lubrication
sance" for children to play on. If they fall off it or get
Chart. Make sure all gear cases are full of oil.
entangled, serious injury may result.
14. While in storage, the crane should be
exercised"
every 60 days to ensure the working condition of
the crane. Uncover all closed-up areas and re-
move any tarp/cover from the engine. Start the en-
gine and operate all switches, control cables and
hydraulic functions several times to circulate lubri-
cants and to keep all mechanisms and linkages
operative.

1−122
 Operator’s Manual
Table Of Contents
General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1

Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−3

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−4

Hi Performance Hydraulic Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−11

Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−12

Transmission Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−12
Transmission Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−12
Axle Differential Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−13
Axle Differentials Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−13
Axle Differentials Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−13
Wheel Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−14
Rear Axle Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−14
Front Axle Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−14
Front Axle Wheel End Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−14
Front Axle Wheel End Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−15
Fuel Filter/Separator/Warmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−16
Water Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−17
Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−17
Carrier Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−18
Air Dryer Desiccant Cartridge Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−18
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−19
Cooling System Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−19
Cooling System Coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−20
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−23
Water Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−23
Hydraulic Reservoir Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−23
Adding Oil To The Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−23
Hydraulic Reservoir Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−24
Hydraulic Reservoir Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−25
Hydraulic Pump Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−26
Pump Drive Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−26
Pump Drive Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−26

Section 2 − Lubrication And Preventive Maintenance i

Operator’s Manual
Engine Air System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−27

Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−27

Changing The Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−27
Cleaning The Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−28
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−28
Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−28
Inspecting The Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−28
Drive Tube And U-Joint Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−29
Lubrication Procedure For Drive Tubes/U-Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−29
Swing Speed Reducer Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−30
Swing Speed Reducer Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−30
Swing Speed Reducer Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−30
Winch Drum Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−31
Winch Drum Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−31
Winch Drum Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−31
Boom Lubrication And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−32

Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−34

Application Of Wire Rope Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−34
Fly Inspection & Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−34

Hook Block, Ball, And Swivel Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−35

Turntable Bearing Capscrew Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−36

Crane Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−36

Display Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−36
Paint Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−37
Regular Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−37
Polishing And Waxing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−37
Cab Dash Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−37

ii Section 2 − Lubrication And Preventive Maintenance

 Operator’s Manual
The following procedures are important for proper lu-
General Lubrication brication of the crane:
Information 1. Clean the grease gun nozzle and grease fitting be-
fore lubricating. This will help keep dirt and grit
The crane should be regularly and systematically lubri- from entering the bushing or bearing.
cated in accordance with the Lubrication Chart shown 2. Keep all grease and oil cans and containers clean.
on the following pages. Refer to Figure 2−1 and Always replace the lid on containers when finished
Figure 2−2. Another copy of the chart is located on the to prevent entry of foreign materials. Wipe off oil
the carrier. The time intervals shown on the Lubrication can covers before using.
Chart are intended as a guide only. Under unusual 3. Drain oil cases when hot to drain off accumulated
working conditions, such as working in dry, dusty con- sludge.
ditions, in water or mud, or around a corrosive atmos- 4. Watch for signs of incorrect lubrication such as fail-
phere, more frequent lubrication could be necessary. ure of clean grease to purge the old grease.
In these cases, the oiler must use his best judgment 5. Bleed off hydraulic pressure before opening or re-
and work out his own lubrication schedule. moving a line or fitting.
In addition to the points on the Lubrication Chart, all 6. Replace all guards before starting crane.
movable linkages and control cables should be peri- 7. Use a clean funnel equipped with a strainer for
odically lubricated to resist wear. pouring lubricants.
8. Clean the area around check and fill plugs before
There are some very practical reasons for lubricating removing them to prevent entry of foreign particles.
and lubricant changes. Lubricants serve more than
one purpose. They not only lubricate, but they trans- Note: See specific instructions later in this sec-
port chemically reactive additives, wash away minute tion for lubrication check and change proce-
wear particles, serve as a corrosion inhibitor, and act as dures on all gear compartments.
a heat transfer medium. Draining and refilling any gear
unit with a fresh supply of oil also assists in eliminating
wear particles not trapped by magnetic plugs.

WARNING
Shutdown engine before fueling or lubricating
crane. To avoid a fire hazard, do not smoke or
handle fuel around an open flame. To avoid
crane damage and to prevent serious injury,
do not lubricate gears or any assemblies
while they are in motion.

Keep grease, oil, containers, and guns clean. Wipe all fittings before lubrication. Raise
the crane on outriggers or block the wheels and shutdown the engine before working
on the crane. Replace all guards or panels before operating the crane.

Section 2 − Lubrication And Preventative Maintenance 2−1

Operator’s Manual

23 18 44 16 51 43 21 19 50 15

49 48 24 25 26 28 27 40 41 13 52

11 20 2 6 12 32

31 30 29 4

47 42 43 34 17 47 45

8 14 37 8 39 9 36 35 7 33 5 3 22 38 10 1 46

Figure 2−1
Lubrication Diagram

2−2 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

CAPACITY KEY
Lube Lube 1. SYMBOLS:
Code Code
Above Below * Check fluid level and fill as required.
Location Gallons Liters −10°F −10°F 0 Inspect, lubricate, adjust, repair, or replace as required.
Engine Oil 9.50 36.00 Key 2 Key 2 + Change oil (and filter if applicable).
Engine Coolant 13.75 52.00 Key 2 Key 2 # Change filter only.
Transmission 3.50 13.25 PP PP X Clean fins if needed.
Front-Rear Axle Differential 4.80 18.20 E LL $ Drain water.
Rear-Rear Axle Differential 4.60 17.40 E LL N/A Not applicable.
Fuel Tank 95.00 359.60 Key 2 Key 2 A,B,C,D, etc. are lubrication codes. Refer to the Lubrication Code Identification on this
Hydraulic System 276.00 1044.80 Key 3 Key 3 chart. Link-Belt recommends the lubrication codes on this chart, however if
Hydraulic Reservoir 165.00 624.60 Key 3 Key 3 an equivalent is to be used refer to the Operator’s Manual for detailed specifi-
Hydraulic Pump Drive 2.10 7.95 E TT
cations to ensure a correct equivalent is used.
Swing Speed Reducer 2.00 7.60 E LL
Winch Drum (Each) 4.50 17.00 HH QQ 2. Refer to engine manufacturer’s manual for proper maintenance, lubrication, fuel or
coolant grade, and additional information.
3. Refer to the Operator’s Manual for additional information.
4. Lubricate the turntable bearing through the grease fittings on the front of the upper
frame. Use a low pressure handgun and pump grease until clean grease comes
out. Rotate the upper a few degrees and pump grease until clean grease comes
out again. Repeat throughout the 360 cycle.

LUBRICATION CODE IDENTIFICATION

Lube
Code Recommended Type
A Bearing Grease NLGI Grade No. 2 LUBRICATION
C SAE 10W/30 Detergent Engine Oil Lube Lube
E 80W/90 Extreme Pressure Gear Lubricant Lube Code Code
H Open Gear Grease (Summer Grade) Reference Number Interval Above Below
V Molybdenum Disulfide Compound Lubricant Location Number Of Points (Hours) −10°F −10°F
HH Gear Lubricant Steering Column U-joint 23 1 250 A KK
KK Arctic Bearing Grease NLGI Grade No.1 Miter Gear Boxes (Each Box) 24 1 250 A KK
LL SAE 75W/140 Extreme Pressure Gear Oil Steering Drive Shafts/U-joints 25 6 250 A KK
MM 5W/30 Multi-Purpose Synthetic Fluid Master Steering Gear 26 1 250 A KK
PP Synthetic Transmission Oil CD SAE 50 Steering Idler Guide 27 2 250 A KK
QQ Synthetic Gear Oil Steering Drag Links 28 8 250 A KK
TT Synthetic Gear Oil − Grade 220 Tie Rod Ends (Front) 29 4 250 A KK
WW Type C3 Transmission And Torque Convertor Fluid King Pins (Each Wheel) 30 2 250 A KK
Front Wheel Bearings (Each Wheel) 31 1 Key 3 E LL
Brake Slack Adjusters 32 2 250 A KK
(Each Wheel)
MAINTENANCE Clutch Housing Shaft 33 2 250 A KK
Lube Lube Clutch Release Bearing 34 1 250 A KK
Service Code Code Transmission To Axle U-joints 35 3 250 A KK
Reference Interval Above Below Drive Tube Slip Joint 36 1 250 A KK
Location Number (Hours) Operation Key −10°F −10°F Inter-Axle Axle Drive Tube/U-joints 37 3 250 A KK
Radiator 1 10 X 1,2 Key 2 Key 2 Pump Drive Tube/U-joints 38 3 50 A KK
Surge Tank 2 10 * 1,2,3 Key 2 Key2 Turntable Bearing 39 2,Key 4 50 A KK
Engine 3 10 * 1,2 Key 2 Key 2 Turntable Gear Teeth 40 All 50 H H
Engine Fuel Filter 4 Key 3 0,$ 1,2,3 Key 2 Key 2 Travel Swing Lock 41 1 250 A KK
Engine Oil Filters 5 Key 2 0,+ 1,2,3 Key 2 Key 2 Rotating Joint 42 1 250 A KK
Engine Air Cleaner 6 10 0 1,3 N/A N/A Boom Hoist Cylinder Pins 43 3 10 A KK
Transmission 7 Key 3 *,+ 1,3 PP PP Boom Sliding Surfaces 44 All Key 3 V,H V,H
Rear Axle Differentials 8 Key 3 *,+ 1,3 E LL Boom Head Machinery 45 All 50 A KK
Hydraulic Reservoir 9 10 *,$ 1,3 Key 3 Key 3 Auxiliary Lifting Sheave 46 1 50 A KK
250 # 1,3 Key 3 Key 3 Fly Head Sheaves (Base & Tip) 47 3 50 A KK
1000 + 1,3 Key 3 Key 3 Hook Block & Sheaves 48 All 50 A KK
Hydraulic Pump Drive 10 50 * 1,3 E TT Hook Ball 49 1 50 A KK
2000 + 1,3 E TT Boom Foot Pin 50 2 10 A KK
Batteries 11 50 *,0 1 N/A N/A Boom Extend Sheaves 51 2 50 A KK
Air Reservoirs (3) 12 10 $ 1 N/A N/A Boom Retract Sheaves 52 2 50 A KK
Tires 13 10 0 1,3 N/A N/A
Swing Speed Reducer 14 50 * 1,3 E LL
1000 + 1,3 E LL
Winch Drum(s) 15 50 * 1,3 HH QQ
1000 + 1,3 HH QQ
Boom 16 10 0 1,3 V,H V,H
Fly 17 10 0 1,3 N/A N/A
Wire Rope 18 10 0 1,3 C C
Boom Extend & Retract 19 50 0 1,3 N/A N/A
Wire Rope Anchors
Air Dryer 20 10 0 1,3 N/A N/A
2000 # 1,3 N/A N/A
Hydraulic Cab Heater 21 10 * 1,3 WW MM
(If Equipped) 500 # 1,3 WW MM
1000 + 1,3 WW MM
Corrsosion Filter 22 Key 2 # 1,2 Key 2 Key 2

Figure 2−2
Lubrication Chart

Section 2 − Lubrication And Preventative Maintenance 2−3

Operator’s Manual

Lubrication Specifications
The following specifications are approved for use in Link-Belt cranes. The specifications are identified by a code letter.
When a code letter appears on the lubrication or maintenance chart, it is referring to one of the lubricants as de-
scribed on the following pages. These lubricants are listed by specifications and by one brand name. Most reputable
oil companies can provide a lubricant to match a particular specification. It may then be used in the crane no matter
what the brand name. When using other brand names, the user assumes all responsibility for product and patent
liability. It is recommended that types and brands of oil not be intermixed because of possible incompatibility.

Type A Type C
Bearing Grease SAE 10W/30 Detergent Engine Oil
NLGI Grade No. 2 A heavy duty refined petroleum product made with
This grease shall be a homogeneous combination high quality solvent refined neutral stocks combined
of refined mineral oil and lithium soap. This grease with a balanced detergent, dispersive additive com-
shall not contain any fillers which adversely affect bination to provide a margin of safety in oxidation sta-
the lubricating qualities of the product. It may have bility, anti-wear and extreme pressure, bearing corro-
additives that give a high degree of protection sion protection, and high and low temperature de-
against corrosion of metals and oxidation of the posit control. With high viscosity indices, low pour
grease. Also contains lead soap and extreme pres- points and excellent foam resistance.
sure additives.
Meets requirements of specification
The mineral oil shall meet the following specifica- MIL−L−46152, and exceeds the requirements of
tions: MIL−L−2104B. Meets API service classifications
Viscosity at 100F (38_C) SUS . . . . . . . . 1086 SE, SD, SC, SB, CC, CB and CA.
Viscosity at 210F (99_C) SUS . . . . . . . . . 82.5
Viscosity at Index (Minimum) . . . . . . . . . . . 65 Physical Properties:
Timken Test Lever Load (Minimum) . . . . 40 lb SAE Viscosity Number . . . . . . . . . . . . . . 10W−30
Pour Point (F) Maximum . . . . . . . . . . . . . 15 Gravity,  API . . . . . . . . . . . . . . . . . . . . . . . . . . 29.0
(_C) Maximum . . . . . . . . . −9.44 Flash Point (Minimum) COC . . . . . . . . . . . . . 425
Viscosity at 100F (38_C) SUS . . . . . . . . . . . 425
The grease shall have the following physical and Viscosity at 210F (99_C) SUS . . . . . . . . . . . 331
chemical properties: Viscosity Index (Minimum) . . . . . . . . . . . . . . . 167
Penetration, Worked at 77F (25_C) Ash (%) Sulfur . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
(60 Strokes) Units . . . . . . . . . . . . . . . . 280 Pour Point (F) . . . . . . . . . . . . . . . . . . . . . . . −40
Penetration, Unworked at 77F (25_C) (_C) . . . . . . . . . . . . . . . . . . . . . . . −40
(60 Strokes) Units . . . . . . . . . . . . . . . . 295
Mobil Delvac or Equivalent.
Penetration Change After 10,000
Strokes (%) Maximum . . . . . . . . . . . . . . 15
Dropping Point (F) . . . . . . . . . . . . . . . . . . 365
(_C) . . . . . . . . . . . . . . . . . . 185
Lithium Soap (%) . . . . . . . . . . . . . . . . . . . . . . 6.0
Lead Soap (%) . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Recommended Maximum Temperature
(F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
(_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Recommended Minimum Temperature
(F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . −20
(_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . −28.8
Water (%) Maximum . . . . . . . . . . . . . . . . . . 0.10

Texaco Marfak − All Purpose or Equivalent.

2−4 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

Type E Type H
80W/90 Extreme Pressure Gear Lubricant Open Gear Grease
An extreme pressure gear lubricant containing anti- For open gear applications. Satisfactory down to
foam protection, oxidation stability, anti-rust, and −40F (−40_C) on dry gears. Good adhesiveness
anti-corrosion qualities. Contains sulfur and phos- on open gears at 73F (22.7_C) and good retention.
phorus additive materials but no zinc in compliance The grease with use will become tacky and will resist
with Eaton, General Motors and International Har- leaking. Used on cast tooth gears and ring gear
vester truck driving axle requirements. teeth. Extremely resistant to water washing.

Must meet or exceed military specifications Physical Properties:

MIL−L−2104C, and are suitable for API service
designations GL3, GL4 and GL5, with a rating of 10
Mineral Oil Component:
as determined in the shock load test CRC−L−42.
Viscosity at 100F (38_C) SUS . . . . . . . . . . 4104
Physical Properties: Viscosity at 210F (99_C) SUS . . . . . . . . . . . 180
Load Wear Index . . . . . . . . . . . . . . . . . . . . . . . . 53
Gravity, API . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 Penetration, Worked at 77F (25_C)
Flash, COC (F) . . . . . . . . . . . . . . . . . . . . . 400 (60 Strokes) Units . . . . . . . . . . . . . . . . . . . . . . 270
(_C) . . . . . . . . . . . . . . . . . . . . . 204 Penetration, Unworked at 77F (25_C) . . . . 242
Pour Point (F) . . . . . . . . . . . . . . . . . . . . . −30 Dropping Point (F) Minimum . . . . . . . . . . . . 222
(_C) . . . . . . . . . . . . . . . . . . . . . −34 (_C) Minimum . . . . . . . . . . . . 105
Viscosity at 100F (38_C) SUS . . . . . . . . . 829 Soap Base − Calcium (%) . . . . . . . . . . . . . . . . 8.0
Viscosity at 210F (99_C) SUS . . . . . . . . . 79.9 With 22% graphite and 3% Molybdenum Disulfide
Viscosity Index . . . . . . . . . . . . . . . . . . . . . . . . 97 Water (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6
Sulfur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37 Recommended Maximum Temperature
Ash (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . None (F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
CU Corr 3 Hours 250F (121_C) . . . . . . . . 1 b (_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.4
Channel Point (F) Maximum . . . . . . . . . . . . 0 Consistency . . . . . . . . . . . . . . . . . Buttery Grease
(_C) Maximum . . . . . . . −17.7
Timken Test Lever Load (Minimum) . . . . 50 lb Texaco Texclad #2 or Equivalent.
Phosphorus (%) . . . . . . . . . . . . . . . . . . . . . . . 12

Texaco Code 2316 Multigear 80W/90 or Equiva-

lent.

Section 2 − Lubrication And Preventative Maintenance 2−5

Operator’s Manual

Type V Type HH
Molybdenum Disulfide Compound Lubricant Gear Lubricant
Recommended use for grease on cut tooth gears. This gear lubricant is suitable for use in a wide variety
of mobile equipment gear and brake applications.
A grease consistency mixture containing purified Has good oxidation and thermal stability, is non-cor-
molybdenum disulfide powder MS. Powder to rosive to most gear and bearing materials, is inhib-
meet or exceed specification MIL−L−7866 (AER) ited to provide good foam resistance and water sepa-
with max particle size of 40 microns. ration characteristics. Has moderate concentration
of EP additives.
Compound to have mineral oil base not to exceed
50% by volume containing not less than 40% MS. Must Meet performance requirements of AGMA
Specification 250.04 for extreme pressure lubricants.
Non-melting molybdenum disulfide compound. It
Is suitable for API service designations of GL2 and
is impervious to water and is not affected by most
GL3.
acids or alkalis. Helps prevent galling and seizing at
bearing pressures well over 100,000 pounds per
square inch. Has excellent lubricating qualities at Physical Properties:
sub-zero temperatures and elevated temperatures Gravity, API . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.7
up to 750F (398_C) under certain conditions. Has
Viscosity cSt @ 104F (40_C) . . . . . . . . . . . 144.0
a high film strength, low coefficient of friction and te-
Viscosity cSt @ 212F (100_C) . . . . . . . . . . . 14.7
nacious adherence to metal surfaces. Will prevent
Viscosity SUS @ 100F (38_C) . . . . . . . . . . 754.0
corrosion. Excellent lubrication on parts exposed to
Viscosity SUS @ 210F (99_C) . . . . . . . . . . . 78.0
water.
Viscosity Index . . . . . . . . . . . . . . . . . . . . . . . . . 101
Flash COC . . . . . . . . . . . . . . . . . 420F (215.5_C)
Physical Properties:
Pour Point . . . . . . . . . . . . . . . . . −20F (−28.8_C)
MS (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Sulfur, % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.66
Drop Point . . . . . . . . . . . . . . . . . . . . . . . . . . None Phosphorous, % . . . . . . . . . . . . . . . . . . . . . . . 0.03
Mineral Oil (%) . . . . . . . . . . . . . . . . . . . . . . . . 42 Timken Test Lever Load (Minimum) . . . . . . 60 lb
Viscosity, Base Oil @ 100F (38_C) . . . 2690 AGMA No. EP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . .NIL Appearance . . . . . . . . . . . . . . . . . . . . . . Dark Red
Water (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Texaco Code No. 2320, Meropa 150 or Equiva-
Alkali (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
lent.
Fillers (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Consistency . . . . . . . . . . . . . . . . . . . . . Medium
Jelling Agent . . . . . . . . . . . Pyrogenic Silicone

Bel-Ray Co. Molylube Anti-seize or Equivalent.

2−6 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

Type KK Type LL
Arctic Bearing Grease SAE 75W/140 Extreme Pressure Gear Oil
NLGI Grade No. 1 A synthetic, extreme pressure gear oil designed for
Low temperature, extreme pressure, all purpose cold weather operation in hypoid, spiral bevel and
grease made from a low pour point hydrocarbon lu- planetary gear axles. Must meet the requirements of
bricant, thickened with a modified bentonite clay. Military Specification MIL−L−2105C.
The grease is fortified with an extreme pressure ad-
ditive and a rust inhibitor to provide even better Physical Properties:
equipment protection.
A multi-purpose grease that can be pumped from Kinematic Viscosity @ 212F (100_C), cST
normal grease dispensing equipment at tempera- (ASTM D−443) . . . . . . . . . . . . . . . 24.0 to <41.0
tures down to a −65F (−54_C). Good for heavy Apparent Viscosity @ 75F (−40_C), ml
duty operation. (Brookfield) (ASTM 2983) . . . . . . . . 150,000 max.
Flash Point, COC (ASTM D−92)
Recommended for use in centralized lube systems,
(F) . . . . . . . . . . . . . 356 Min.
wheel bearings. chassis bearings, universal joints
(_C) . . . . . . . . . . . . 180 Min.
and all other applications requiring a grease of this
Channel Point (FTMS 791B Method 3456)
type. This grease offers full protection regardless of
(F) . . . . . . . . . . . . −49 Max.
the season. Pumpable at −65F (−54_C), even in a
hand grease gun. Excellent anti-wear and load carry- (_C) . . . . . . . . . . . −45 Max.
ing ability, stays in place better than lighter greases, Copper Corrosion,
waterproof to resist washout, good shear stability. 3 hrs. @ 250F (121_C) (ASTM D−130) . . 3 Max.
Assures good high temperature performances. Foaming Characteristics (ASTM D−892)
Compatibility of this grease with ordinary greases (Foaming readings taken immediately after 5
presents no problems below an operating tempera- minutes aeration)
ture of 200F (93.3C). Above this temperature, its @ 75F (24_C), ml . . . . . . . . . . . . . . . . 20 Max.
compatibility is like any other bentone thickened @ 200F (94_C), ml . . . . . . . . . . . . . . . 50 Max.
grease. Storage Stability, %
(FTMS 791B Method 3440) . . . . . . . . . 0.25 Max.
Physical Properties: Compatibility
Thickener . . . . . . . . . . . . . . . . . . . . . . . . . Bentone (FTMS 791B Method 3430) . . . . . . . . . . . . Note 1
Penetration worked @ 77F (25_C) (ASTM D217) The latest revision of all referenced specifications
60 stroke units . . . . . . . . . . . . . . . . . . . . . 340 and test methods shall be used.
10,000 units . . . . . . . . . . . . . . . . . . . . . . . 368
Roll Stability (ASTM D1831) Mobil Oil − Mobilube SHC or Equivalent.
Penetration Change . . . . . . . . . . . . . . . . . 28 Lubrizol − Anglamol 6055 or Equivalent.
Oil Separation, WT.% (ASTM D1742) . . . . . 12.6
Dropping Point (F) (ASTM D2265) . . . . . 500
(_C) . . . . . . . . . . . . . . . . . . 262
Viscosity @ -30F (-34_C) cSt (ASTM D446) 6750
Wheel Bearing Leakage Wt.% (D1263) . . . . 2.83
Water Washout Wt.% 77F (25_C) (D1264) . . 1.2
Rust Properties (ASTM D1743) . . . . . . . . . . . . . . 1
Falex Test (ASTM D2670)
Teeth Wear . . . . . . . . . . . . . . . . . . . . . . . . . 28
Seizure, PSI . . . . . . . . . . . . . . . . . . . . . . 3175
Four Ball, EP (ASTM D2596)
Wear, mm . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5
Weld, kg . . . . . . . . . . . . . . . . . . . . . . . . . . 240
LWI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
No Seizure, kg . . . . . . . . . . . . . . . . . . . . . . 80
Color . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Tan

Continental Oil Co. (CONOCO) DN600 Grease or

Equivalent.

Section 2 − Lubrication And Preventative Maintenance 2−7

Operator’s Manual

Type MM Type PP
5W/30 Multi-Purpose Synthetic Fluid (Winter Synthetic Transmission Fluid − CD SAE 50
Grade) A specially formulated synthetic lubricant designed
Multi-purpose synthetic fluid for use in cold climate for extended drain and severe service in heavy duty
as crankcase oil, hydraulic oil and torque convertor manual transmissions which require a straight min-
fluid. Exceeds the requirements of engine service eral oil (non EP) MIL−L−2104D or MIL−L−46152B
classifications SF−CC or SF−CD as defined by the engine lubricant.
API, SAE and ASTM. It meets the requirements of
MIL Spec MIL−L−46152C, MIL−L−46167, This lubricant is formulated from a synthetic base-
MIL−L46167A, Ford spec. M2C153−E and Gener- stock having a high viscosity index, low pour point,
al Motors spec GM 6048M and 6085M. This fluid is and sub-zero fluid flow. It also contains an anti-wear
approved for use in Allison automatic transmission additive as well as rust, oxidation and corrosion in-
in place of type C−3 fluid. hibitors.

CD SAE 50 synthetic lubricant provides:

Physical Properties:
 all-climate, year round performance
Gravity, API . . . . . . . . . . . . . . . . . . . . . . . . . 35.1  improved component protection
Flash Point (ASTM D−92)  easier cold weather shifting
(F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420  potential for fuel economy
(_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Physical Properties:
Viscosity. cPs (ASTM D−2602)
@ −13F (−25_C) . . . . . . . . . . . . . . . . 3100 SAE Grade (J306−B) . . . . . . . . . . . . . . . . . . . 50
Viscosity, cSt (ASTM D−445) Viscosity, cSt (ASTM D−445)
@ 104F (40_C) . . . . . . . . . . . . . . . . . . . 72.8 212F (100_C) . . . . . . . . . . . . . . . . . . . . . . . . 18.0
@ 212F (100_C) . . . . . . . . . . . . . . . . . . 11.7 104F (40_C) . . . . . . . . . . . . . . . . . . . . . . . . 138.2
Viscosity, SUS (ASTM D−2161) Viscosity, SUS (ASTM D−2161)
@ 100F (38_C) . . . . . . . . . . . . . . . . . . . 386 210F (99_C) . . . . . . . . . . . . . . . . . . . . . . . . . 92.2
@ 210F (99_C) . . . . . . . . . . . . . . . . . . . . 65 100F (38_C) . . . . . . . . . . . . . . . . . . . . . . . . . 685
Viscosity Index (ASTM D−2270) . . . . 156 Min Viscosity, cP (ASTM 2983)
Pour Point (ASTM D−97) 32F (0_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,250
(F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . −55 14F (−10_C) . . . . . . . . . . . . . . . . . . . . . . . . 3,850
(_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . −48 −4F (−20_C) . . . . . . . . . . . . . . . . . . . . . . 11,650
High Temperature, High (Tapered Bearing Sim- −15F (−26_C) . . . . . . . . . . . . . . . . . . . . . 24,250
ulator {TBS}) −22F (−30_C) . . . . . . . . . . . . . . . . . . . . . 45,250
Shear Rate Viscosity, cP . . . . . . . . . . . . . . . 3.3 −40F (−40_C) . . . . . . . . . . . . . . . . . . . 270,000
Borderline Pumping Temperature (ASTM D−3829) Viscosity Index (ASTM D−2270) . . . . . . . . . 154
(F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . −85 Pour Point F (_C) (ASTM D−97) . . <−40
(_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . −65 (−40)
Total Base Number (ASTM D−2896) . . . . . 8.8 Flash Point F(_C) (ASTM D−92) 455(235)
Total Acid Number (ASTM D−974) . . . . . . 3.0 Foam (ASTM D−892)
Sulfated Ash, Wt. % (ASTM D−874) . . . . 0.91 Sequence I . . . . . . . . . . . . . . . . . . . . . . . . . . Pass
Sequence II . . . . . . . . . . . . . . . . . . . . . . . . . Pass
Continental Oil Co. (CONOCO) High Perfor-
Sequence III . . . . . . . . . . . . . . . . . . . . . . . . . Pass
mance Synthetic Motor Oil or Equivalent.
Gravity, API . . . . . . . . . . . . . . . . . . . . . . . . . . 23.0
Density, lbs./gal . . . . . . . . . . . . . . . . . . . . . . . 7.63
Copper Strip Corrosion (ASTM D−130)
3 hrs. @ 212F (100_C) . . . . . . . . . . . . . . . Pass
3 hrs. @ 250F (121_C) . . . . . . . . . . . . . . . Pass

Eaton Corp. CD50/Eaton Roadranger CD−50 or

Equivalent.

2−8 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

Type QQ Type TT
Synthetic Gear Oil Synthetic Gear Oil
A specially formulated lubricant for applications A specially formulated lubricant for applications
where service conditions are severe because of where service conditions are severe because of high
high operating and bulk oil temperatures. Typical operating and bulk oil temperatures. The high vis-
applications are spur, helical, herringbone, bevel, cosity index allows the oil to flow at low temperatures
and planetary gears. This lubricant is derived from and maintain viscosity at high temperatures. Typical
synthetic based oils that are more resistant to ther- applications are spur, helical, herringbone, bevel,
mal and oxidation degradation. It can offer advan- planetary gears, and gear boxes with multiple disc
tages of extension of lubricant life and reduced risk brakes. This lubricant is derived from synthetic
of damage to machine elements. based oils that are more resistant to thermal and oxi-
dative degradation. It can offer advantages of exten-
Physical Properties: sion of lubricant life and reduced risk of damage to
machine elements.
AGMA Grade No. . . . . . . . . . . . . . . . . . . . 4 EP
Gravity, API . . . . . . . . . . . . . . . . . . . 25.4−34.4
Physical Properties:
ISO Viscosity Grade . . . . . . . . . . . . . . . . . . 150
Viscosity @ 100F (38_C), Cst . . . . . . . . 140.0 Gravity, API . . . . . . . . . . . . . . . . . . . . . 31.6−32.4
Viscosity @ 212F (100_C), Cst . . . . . . . . 14.0 ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . 220
Viscosity @ 100F (38_C), SUS . . . . . . . . 737 Viscosity, cSt (ASTM D−445)
Viscosity @ 210F (99_C), SUS . . . . 75−100 @ 104F (40_C) . . . . . . . . . . . . . . . . 217−228
Viscosity Index . . . . . . . . . . . . . . . . . . . 96−150 @ 212F (100_C) . . . . . . . . . . . . . . 25.2−28.8
Flash COC . . . . . . . . . . . . . . . . 460F (238_C) Viscosity Index (ASTM D−2270) . . . . 146−165
Pour Point . . . . . . . . . . . . . . . . −10F (−23_C) Pour Point (ASTM D−97)
Rust Test, Distilled Water . . . . . . . . . . . . . Pass (F) . . . . . . . . . . . . . . . . . . . . . . . . . . . −35−49
Copper Corrosion Test (_C) . . . . . . . . . . . . . . . . . . . . . . . . . . −37−45
24 hr. −30 hr. @ 212F (100_C) . . . . . . 1 b Flash Point, COC (ASTM D−92)
Timken Extreme Pressure Test (F) . . . . . . . . . . . . . . . . . . . . . . . . . . 482−510
Pass Value . . . . . . . . . . . . . . . . . . . . . . 60 lb (_C) . . . . . . . . . . . . . . . . . . . . . . . . . 250−266
FZG Test, Stages, Pass . . . . . . . . . . . . . . . . 12 Rust Test, Distilled Water (ASTM D−665) . Pass
Phosphorus, Wt. % . . . . . . . . . . . . . . .005−.03

Mobil SHC 629 or Equivalent. Mobil Oil Company − Mobilgear SHC 220 −
or Equivalent.

Section 2 − Lubrication And Preventative Maintenance 2−9

Operator’s Manual

Type WW
Type C3 Transmission And Torque Fluid
High viscosity index characteristics permit use over
a wide temperature range by providing low tem-
perature fluidity and at the same time retaining their
desired viscosity at high temperature conditions.
High temperature oxidation resistance, disper-
sancy, detergency, anti-corrosion, rust protection.
Has special friction characteristics and compatibil-
ity with the various automatic transmission compo-
nents such as elastomeric seals. Compatible with
synthetic and rubber seals as Buna N, polyacrylate
and silicone in transmissions minimizing the possi-
bility of leakage.

To meet all the requirements of Allison hydraulic

transmission fluid type C3 specifications.

Physical Properties:

Gravity, API . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5

Viscosity @ 100F (38_C), SUS . . . . . . . . . . 187.0
Viscosity @ 210F (99_C), SUS . . . . . . . . . . . 50.7
Viscosity O.F. (Brookfield) . . . . . . . . . . . . . . . . 1500
Viscosity Index . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Flash COC . . . . . . . . . . . . . . . . . . . . 370F (188_C)
Pour Point . . . . . . . . . . . . . . . . . . . −55F (−49_C)
Ash % (Sulfated) . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
Appearance . . . . . . . . . . . . . . . . . . . . . . . . Dark Pale
Color ASTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5

Texaco Code No. 1821 − C3 Torque Fluid or

Equivalent.

2−10 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

Hi Performance Hydraulic Oil Chart

Important
Use only pre-filtered hydraulic oil. Warranty is void if incorrect oil is used.
Incorrect oil may result in damage to hydraulic components. Hi Performance
Hydraulic Oil is available through your distributor in the following grades and
quantities.
Temperature Range Container Capacity
Link-Belt
Oil Grades Ambient Maximum Hydraulic
Gallons Liters Part Number
Temperature Use System Temperature

−45F to 80F 150F 5 18.9 830666001

Grade 22
−43_C to 27_C 65_C 55 208.2 830666002

10F to 100F 200F 5 18.9 830663001

Grade 46
−12_C to 38_C 93_C 55 208.2 830663002

Section 2 − Lubrication And Preventative Maintenance 2−11

Operator’s Manual

Correct;
Oil level at bottom of filler hole.
Incorrect;
Oil level below filler hole.
1. Check/Fill Plug 1 2
2. Drain Plug Note: Oil level close enough to the hole to be seen or touched is
3. Air Filter not sufficient. It must be level with the bottom of the hole.

Figure 2−3 Figure 2−4

Manual Transmission Lubrication Checking The Oil Level

Transmission Lubrication Transmission Oil Change

The best time to change transmission oil is just after the
The manual transmission is designed so that internal
parts operate in a bath of oil circulated by the motion of crane has been road driven. The oil will be warm and
any foreign particles will be suspended in the oil. This
gears and shafts. Some internal parts are equipped
with built in channels to ensure that the bearings and is especially desirable in cold weather situations.
1. Park the crane on a firm, level surface. Engage the
shafts are properly lubricated.
park brake, shift the transmission to neutral, and
On new or rebuilt transmissions, change transmission shutdown the engine.
oil after the initial 3,000 miles (4 800km). Change the 2. From the underside of the carrier, locate the
oil every 50,000 miles (80 450km) or annually check/fill plug on the left side of the transmission
thereafter. The oil level should be checked every housing. Refer to Figure 2−3. Locate the drain
10,000 miles (16 090km) or monthly, whichever occurs plug on the bottom of the transmission.
first. 3. Clean the transmission housing around the drain
and check/fill plugs. Remove the drain plug and
Transmission Oil Level Check check/fill plug. Allow the oil to drain into a suitable
1. Park the crane on a firm, level surface. Engage the container. The drain plug is magnetic and should
park brake, shift the transmission to neutral, and be inspected for large quantities of metal particles.
shutdown the engine. After the initial oil change, these are signs of dam-
2. From the underside of the carrier, locate the age or extreme wear in the transmission and in-
check/fill plug on the left side of the transmission spection of the entire unit may be necessary.
housing. Refer to Figure 2−3. 4. After the transmission has thoroughly drained, in-
3. Clean the transmission housing around the stall the drain plug and fill the transmission with
check/fill plug to prevent entry of foreign material light flushing oil or kerosene.
into the transmission. 5. Remove drain plug and drain flushing oil or kero-
4. Remove the check/fill plug. The oil must be level sene from transmission into a suitable container.
with the bottom of the hole. Refer to Figure 2−4. 6. Clean and install the drain plug. Add oil through
5. Add oil as required through the check/fill hole to the check/fill hole until it is level with the bottom of
bring the oil to the proper level. Install the check/fill the hole. Refer to Figure 2−4.
plug. Refer to the Lubrication Chart for the correct 7. Clean and install the check/fill plug. Properly dis-
grade of oil. pose of the used oil and flushing solution.
Note: Do not overfill. Overfilling the transmis-
sion will cause oil to be forced out of the case
through the main shaft opening.
Note: The transmission manufacturer recom-
mends that types and brands of oil not be inter-
mixed because of possible incompatibility.

2−12 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual
1 2 3

4 2 4
1. Front-Rear Axle 3. Rear-Rear axle
2. Check/Fill Plugs 4. Drain Plugs

Figure 2−5
Rear Axle Differentials

5. Add oil, as required, until it begins to flow from the

Axle Differential Lubrication check/fill hole. Refer to Lubrication Chart for cor-
For troublefree operation, over a period of years, the rect grade of oil.
differentials must be properly lubricated. Check the oil
Note: The axle manufacturer recommends that
level in each rear axle differential every 1,000 miles (1
types and brands of oil not be intermixed be-
600km). The oil in a new or rebuilt axle should be
cause of possible incompatibility.
changed after the first 1,000 miles (1 600km) but no
later than the first 3,000 miles (4 800km). Change the Note: When checking oil levels of the axle dif-
oil every 30,000 miles (48 000km) or semiannually ferentials, also check and clean axle housing
thereafter, whichever occurs first. breathers, located on the top of the axle hous-
ings.
Axle Differentials Oil Level Check
6. Clean and install the check/fill plug.
1. Park the crane on a firm, level surface, engage the
park brake, shift the transmission to neutral, and
shutdown the engine.
Axle Differentials Oil Change
2. From the underside of the carrier, locate the The best time to change oil in the differentials is imme-
check/fill plug of the differential. Refer to diately after the crane has been driven. At this time, the
Figure 2−5. lubricant will be warm and easily drained. This proce-
dure is especially desirable in cold weather conditions.
1. Park the crane on a firm, level surface, engage the
CAUTION park brake, shift the transmission to neutral, and
Do not tamper with the pinion drive gear shutdown the engine.
backlash adjusting screw located on the 2. From the underside of the carrier, locate the drain
opposite side of the axle from the check/fill plug in the bottom of the differential. Refer to
plug. Tampering with this screw may result in Figure 2−5.
differential damage. 3. Clean the area around the drain plug, before re-
moving it.
3. Clean the area around the check/fill plug. 4. Remove the drain plug and allow the oil to drain
4. Remove the check/fill plug and check the oil level. into a suitable container. The drain plug is mag-
Oil must be level with the bottom of the check/fill netic and should be inspected for large quantities
hole. Refer to Figure 2−4. of metal particles. After the initial oil change, this is
a sign of damage or extreme wear within the unit,
and a complete internal inspection may be neces-
sary. Clean the drain plug and install it after the oil
has thoroughly drained.

Section 2 − Lubrication And Preventative Maintenance 2−13

Operator’s Manual
Wheel Bearing Lubrication
2
3 Rear Axle Wheel Bearings
4
1 Under normal operating conditions, the rear axle wheel
bearings are protected by oil carried into the wheel
ends by the motion of axle shafts and gearing. Oil be-
5 comes trapped in the cavities of the wheel end and re-
mains there, ensuring that oil is instantly available
when the crane is in motion.
In short, as long as the rear axle differentials are operat-
ing with the proper oil levels and using the correct
grade oil, the rear wheel bearings are automatically lu-
bricated.

Front Axle Wheel Bearings

The wheel bearings of the front axles are oil lubricated.
A transparent hub cap us used, on each of the front ax-
1. Fill Plug 4. Full Line le wheel ends, to simplify filling and checking the oil
2. Transparent Hub Cap 5. Correct Oil Level level. Check the oil level, in each front wheel end, every
3. Add Line 1,000 miles (1 600km). Change the oil every 30,000
miles (48 000km) or semiannually, whichever occurs
Figure 2−6
first.
Front Axle Wheel End
5. Locate and remove the check/fill plug. Refer to Front Axle Wheel End Oil Level Check
Figure 2−5. 1. Park the crane on a firm, level surface, engage the
park brake, shift the transmission to neutral, and
shutdown the engine.
CAUTION 2. View the oil level in each axle wheel end, through
Do not tamper with the pinion drive gear the transparent hub cap. Refer to Figure 2−6.
backlash adjusting screw located on the 3. Check to see that the oil level is above the
ADD"
opposite side of the axle from the check/fill line on the hub cap.
plug. Tampering with this screw may result in 4. If the oil level is on or below the
ADD" line, thor-
differential damage. oughly clean the exterior surface of the hub cap
and remove the fill plug. Add oil as required to
6. Fill the differential with oil until it is level with the bot- bring the oil level to the
FULL" line. Refer to the Lu-
tom of the check/fill hole. Refer to Figure 2−4. Re- brication Chart for the correct grade of oil. Do not
fer to the Lubrication Chart for correct quantity and overfill.
grade of oil. 5. Clean and install the fill plug.

Note: The axle manufacturer recommends that

types and brands of oil not be intermixed be-
cause of possible incompatibility.
Note: When changing the oil of the axle differ-
entials, also check and clean the axle housing
breathers located on the top of the axle hous-
ing.

7. Clean and install check/fill plug. Properly dispose

of the used oil.

2−14 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual
2 1 1 2 3 4 5

4
5

6 7 8 9 10 11 12 7 6
1. Rim Assembly 5. Hub Cap 9. Outer Bearing 1. Hub 5. Deflector Ring
2. Brake Shoe 6. Cotter Pin 10. Spindle 2. Inner Bearing Cap 6. Spindle Shoulder
3. Hub 7. Adjusting Nut 11. Inner Bearing 3. Inner Bearing Cone 7. Spindle
4. Capscrew 8. Thrust Washer 12. Oil Seal 4. Oil Seal

Figure 2−7 Figure 2−8

Front Wheel Assembly Oil Seal Installation

Front Axle Wheel End Oil Change 7. Remove the oil seal and bearings from the hub.
1. Park the crane on a firm, level surface, engage the Use care not to damage the oil seal, if it is to be
park brake, and shift the transmission to neutral. reused.
Level the crane on outriggers and shutdown the 8. If the oil seal is to be replaced, remove the deflector
engine. ring from the spindle and discard. Refer to
2. Carefully remove the tire and rim assembly from Figure 2−8.
the wheel. Refer to Section 3 of this Operator’s 9. Thoroughly clean all components with kerosene.
Manual for the correct procedure. Be sure to remove all foreign material from bear-
3. Place a suitable container under the wheel assem- ings and interior cavity of the hub. Remove any old
bly to catch the oil which will be drained from the gasket material from the spindle.
hub. Remove the capscrews securing the hub cap 10. Thoroughly inspect all parts for damage, wear, and
to the hub. Refer to Figure 2−7. corrosion. Replace any defective parts as re-
4. Break the seal between the hub cap and hub, and quired. When replacing a bearing cone, install a
remove the hub cap. new bearing cup also. Remove any burrs on the
5. After the oil has thoroughly drained from the hub, spindle with an emery cloth. It is recommended
remove the cotter pin, adjusting nut, and thrust that the oil seal be replaced, however, the old oil
washer from the spindle. seal may be reused if it is properly inspected for
6. Adequately support the wheel assembly with an damage or wear before installation.
appropriate lifting device. Slowly remove the
wheel assembly, using care not to damage the
bearings, hub, or spindle.

Section 2 − Lubrication And Preventative Maintenance 2−15

Operator’s Manual
11. Install the oil seal on the spindle as follows: 19. Install the fill plug in the hub cap.
20. Install tire and rim assembly. Refer to Section 3 of
To Install A New Oil Seal this Operator’s Manual for the correct procedure.
a. Apply a light coat of Permatex No. 2, or equiva- 21. Repeat procedure for each front axle wheel end.
lent, to the O.D. of the spindle shoulder. Refer Properly dispose of the used oil.
to Figure 2−8.
b. Place the oil seal and deflector ring assembly
on the spindle so the words
OIL BEARING
Fuel Filter/Separator/Warmer
SIDE" can be read. A slight step in the I.D. of The function of the fuel filter/separator/warmer is to re-
the deflector ring, will allow it to be placed by move water and contaminants from the fuel before they
hand, approximately .12 inch (3mm) onto the enter the engine fuel system. Providing clean, dry fuel
shoulder of the spindle. is important for troublefree operation and long life of the
fuel system. Change the fuel filter element when the
Note: Do Not Install The Oil Seal Into The Bore fuel level has risen to the top of the filter element. The
Of The Hub. filter is located on the left side of the crane, next to the
fuel tank and behind the ladder. Refer to Figure 2−9.
c. Using the proper size seal installation tool, in-
stall the oil seal and deflector ring assembly on
the shoulder of the spindle, so it is square and
flush with the face of the shoulder. WARNING
Do not service the fuel filter/separator/warmer
To Reuse The Same Oil Seal until the fuel has cooled. When the temperature
a. Inspect the old oil seal and deflector ring to be of diesel fuel is elevated, as occurs when the
sure they are clean and suitable for reuse. Re- fuel is circulated through an operating engine, it
fer to Figure 2−8. may pose the following hazards which should
b. Lightly lubricate the oil seal and place it on the be guarded against.
deflector ring so the words
OIL BEARING
SIDE" can be read. Heated liquid fuel may cause scalding if
c. Rotate the oil seal back and forth to ensure it is allowed to come in contact with the skin.
properly seated on the deflector ring. Heated diesel fuel can form combustible vapor
12. Dip the inner bearing in oil and place it on the spin- mixtures in the area around the fuel source.
dle. Use care not to get oil on the brake linings.
The following precautions should be taken to
Refer to the Lubrication Chart for the correct grade
minimize the possibility of injuries from heated
of oil to use.
diesel fuel:
13. Carefully place the wheel assembly on the spindle
and slide it back until it just contacts the oil seal. Do 1. Whenever possible, the engine and fuel
Not Push The Wheel Onto The Seal By Hand. The should be given an opportunity to cool
wheel will be pushed onto the seal when the ad- down to ambient temperature before
justing nut is tightened. performing service operations that could
14. Dip the outer bearing in oil and place it on the spin- result in the spillage of fuel from the engine
dle. Install the thrust washer and adjusting nut. or vehicle fuel system. When this is not
15. Tighten the adjusting nut to 50 ft lb (68 Nm) while possible, protective clothing (face shield,
rotating the wheel back and forth. insulated gloves, apron, etc.) should be
16. Back off the adjusting nut 1/16 to 1/4 turn, to allow worn when performing these operations.
the wheel to turn freely and install the cotter pin. 2. Keep open flames, sparks, or other
17. Install the hub cap, using a new gasket and tighten potential ignition sources away and do not
the capscrews evenly. smoke during refueling and service
18. Remove the fill plug in the hub cap. Fill the hub with operations which could result in the escape
oil until the oil level reaches the
FULL" line on the of liquid or vaporized diesel fuel.
transparent cover. Refer to the Lubrication Chart 3. Fuel system service operations should be
for the correct quantity and grade of oil. Do not performed in a well ventilated area.
overfill. Refer to Figure 2−6.

Note: Allow sufficient time for the oil to seep

through the bearings and reach its actual level
before reading the oil level indicated on the
transparent cover.

2−16 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual
Water Drain
1. Park crane on a firm, level surface, engage park 1
brake, shift transmission to neutral, and shutdown 2
the engine.
2. Place a suitable container under the drain valve. 3
Turn the valve until draining occurs.
3. Continue draining until clear fuel is visible.
4. Turn the valve to close the drain valve. 4
5. Properly dispose of fuel.

Filter Change
5
1. Park crane on a firm, level surface and in a well ven-
tilated area. Engage park brake, shift transmission
to neutral, and shutdown the engine. 6
2. Allow the fuel in the system to cool to ambient tem-
perature before servicing the filter/separator/ 7
warmer. 14
3. Place a suitable container under the drain valve. 8
Turn the valve until draining occurs. Continue
draining until unit is empty.
9
4. Turn the valve to close the drain valve.
5. Properly dispose of fuel. 10
6. Remove the cover from the fuel processor by turn- 11 13
ing the collar counterclockwise. Be careful not to
lose the o-ring at the base of the cover. Remove the 12
filter element from the unit by pulling upward and
twisting slightly. Be sure the sealing grommet is re- 1. Collar 8. Check Valve Housing
moved from the center stud. 2. Vent Cap 9. Heater
7. Fill the fuel processor with clean diesel fuel through 3. Vent Cap Seal 10. Bottom Plate
4. Cover 11. Drain Valve
the elongated hole at the top. Do not fill through
5. Spring 12. 2-Way Harness
the center stud opening. This is the fuel outlet to 6. Filter Element 13. Collar
the fuel pump. 7. O-ring 14. Check Valve Assembly
8. With the filter sealing grommet inserted into the
base of the filter element, install the element on the Figure 2−9
processor center stud. After checking to make Fuel Filter/Separator/Warmer
sure the o-ring at the base of the cover is in place,
install the cover and collar. Tighten the collar by 11. After the air is purged, and with the engine running,
hand until secure. loosen the vent cap. When the fuel level falls to the
top of the collar, tighten the vent cap quickly.
Note: To avoid cover or collar damage, do not
12. Shutdown the engine, and hand tighten the collar
use tools to tighten the collar.
again.
9. Remove the vent cap from the top of the cover by
Note: To avoid cover or collar damage, do not
turning the vent cap counterclockwise. Fill the cov-
use tools to tighten the cover.
er full of clean fuel. Make sure the o-ring is installed
on the vent cap. Reinstall the vent cap and tighten 13. Restart the engine and check for leaks.
by hand only.
10. Start the engine. When the lubrication system Note: The cover will not fill completely during
reaches its normal operating pressure, increase engine operation. It will gradually fill over time
engine speed to high idle for 2 to 3 minutes. as the filter becomes clogged. The filter ele-
ment does not need to be changed until the fuel
level has risen to the top of the filter element.

Section 2 − Lubrication And Preventative Maintenance 2−17

Operator’s Manual
2. In areas where more than a 30 degree range of
temperature occurs in one day, small amounts of
water can accumulate in the system due to con-
densation.
3. Air usage is high. Check the entire system for
2 leaks. Check for leakage at the air dryer’s exhaust

ÂÂÂÂ
port purge valve and the delivery port check valve.
1 Refer to Figure 2−10. Check the operation of the

ÂÂÂÂ
ÂÂÂÂ
safety valve by pulling the exposed stem while the
compressor is loaded (compressing air). There

ÂÂÂÂ
must be an exhaust of air while the stem is held and
the valve should reseat when the stem is released.

Air Dryer Desiccant Cartridge

Change
The air dryer consists of a desiccant cartridge which
must be changed every 2,000 hours or annually, which-
ever occurs first. Refer to Figure 2−10.
4 1. Park the crane on a firm, level surface, shift the
transmission to neutral, and engage the park
brake.
3
2. Engage the travel swing lock and shutdown the en-
gine.

WARNING
Air lines may contain high pressure. Opening
lines and fittings before relieving air pressure
1. Desiccant Cartridge
may result in serious injury. Shutdown the
2. Cover 5 engine and drain the air system reservoirs
3. Check Valve before opening any line or fitting.
4. Purge Valve
5. Safety Valve
3. Open the drain valves on the air system reservoirs
Figure 2−10 to relieve the air system pressure.
Air Dryer 4. When pressure is fully relieved, close the drain
valves on the air system reservoirs.
5. Label for assembly purposes and disconnect the
Carrier Air System air lines. Cap the air lines to prevent contamina-
tion.
The air system is equipped with an air dryer which re- 6. Disconnect the electrical connector.
moves water, oil, and dirt from the system. The air dryer 7. Remove the capscrews from the mounting bracket
provides clean, dry air to the air system components. and remove the unit from crane.
To ensure the air dryer is functioning properly every 500 8. Remove the cover from the base.
hours or 3 months, whichever occurs first, open the air 9. Remove the desiccant cartridge from the base and
reservoir drain valves and check for moisture in the sys- properly discard the o-rings and used cartridge.
tem. If moisture is present, the desiccant cartridge may 10. Install the new cartridge and o-rings.
require replacement; however, the following conditions 11. Remove and replace the safety valve and the ex-
can also cause water accumulation and should be con- haust cover.
sidered before replacing the desiccant cartridge: 12. Install unit on crane.
1. An outside air source has been used to charge the
system. This air did not pass through the air dryer.

2−18 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual
2
1

FULL − COLD

Figure 2−11
Fan Caution Label

Engine Cooling System

The coolant in the engine cooling system must be
maintained at the proper level and proper concentra- 1. Fill Cap 3. Sight Gauge
tion levels to adequately keep the engine operating at 2. Coolant Level Label
safe temperatures. Figure 2−12
Anti-freeze must be used in all climates for both freez- Engine Coolant Surge Tank
ing and boiling protection. It broadens the operating
temperature range by lowering the coolant freezing Cooling System Level Check
point and by raising its boiling point. It is recom- Check the coolant level in surge tank every 10 hours of
mended that a 50% anti-freeze concentration level operation. Check the glycol (antifreeze) concentration
(40%−60% range) of ethylene glycol or propylene gly- and the freezing point protection with a refractometer
col be used in most climates. Never use more than every 2,000 hours or six months whichever comes first.
68% anti-freeze under any condition. Anti-freeze Do not use the
floating ball" type of density testers or
protection decreases above 68%. Use soft water in the hydrometers as they are not accurate enough for use
coolant mixture. Contaminants in hard water neutral- with heavy-duty diesel cooling systems.
ize the corrosion inhibitor components. Water must not 1. Park the crane on a firm, level surface, shift the
exceed 300 ppm hardness or contain more than 100 transmission to neutral, apply the park brake, and
ppm of either chloride or sulfate. Use low silicate anti- shutdown the engine.
freeze that meets ASTM4985 test (GM6038M spec) cri- 2. Check that the coolant level in the surge tank is at
teria. Refer to engine manufacturers manual for addi- least up to the
Full−Cold" level on the side of the
tional information on coolant selection. tank. Refer to Figure 2−12.

WARNING WARNING
Avoid prolonged and repeated skin contact
with antifreeze. Such prolonged, repeated Engine cooling system is pressurized. Do not
contact can cause skin disorders or other remove vent cap from a hot engine. Heated
bodily injury. Keep out of reach of children. coolant spray or steam can cause personal
injury. Wait until the engine has cooled before
Coolant is toxic. Keep away from children and slowly removing vent cap.
pets. If not reused, dispose of in accordance
with local environmental regulations. 3. If coolant must be added, allow the engine to cool
until the the coolant temperature is below 122°F
(50°C).
CAUTION
Overconcentration of antifreeze or use of
high-silicate antifreeze can cause damage to
the engine.

Section 2 − Lubrication And Preventative Maintenance 2−19

Operator’s Manual

1. Radiator Assy
2. Drain Valve

Figure 2−13
Engine Cooling System

5. Replace fill cap. Start the engine and let it run until
CAUTION it reaches normal operating temperature. Shut-
Do not add cold coolant to a hot engine. down the engine and repeat Step 2.
Engine castings can be damaged. Allow the
engine to cool until the coolant temperature is Cooling System Coolant Change
below 122°F (50°C) before adding coolant. Drain, flush, and fill the engine cooling system every
Never use a sealing additive to stop leaks in 6,000 hours of operation, or two years whichever oc-
the cooling system. This can result in cooling curs first. Use a pre-mixed solution of soft water and
system plugging and inadequate coolant ethylene glycol or propylene glycol-based antifreeze to
flow, causing the engine to overheat. protect the engine.

If additional coolant must be added, soft

water and ethylene glycol or propylene CAUTION
glycol-based antifreeze must be pre-mixed Protect the environment: Handling and
before being added to the system. Since the disposing of used anti-freeze is subject to
ability of antifreeze to remove heat from the federal, state, and local regulations. Use
engine is not as good as water, pouring authorized waste disposal facilities, including
antifreeze into the system first could civic amenity sites and garages providing
contribute to an overheated condition before authorized facilities for the receipt of used
the liquids are completely mixed. anti-freeze. If in doubt, contact your local
authorities or the EPA for guidance as to
4. Slowly remove the fill cap. Add coolant, as re- proper handling of used anti-freeze.
quired, to completely fill the tank.

2−20 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual
1. Park the crane on a firm, level surface, shift the 7. Fill the system with clean soft water and a good
transmission to neutral, apply the park brake, and cooling system cleaning compound, such as Nal-
shutdown the engine. prep® to flush the system. If the engine is warm, fill
2. Allow the engine to cool until the coolant tempera- slowly to prevent the rapid cooling and distortion of
ture is below 122°F (50°C). the metal castings.
8. Leaving the fill cap removed, start the engine and
let it run for approximately 15 minutes to circulate
WARNING the solution thoroughly.
9. Shutdown the engine and allow to cool. Drain the
Engine coolant may be hot and could cause system as described in Step 3.
burns. Avoid prolonged and repeated skin 10. Fill the system with clean soft water. Be sure to vent
contact with antifreeze. Such prolonged, the system during filling.
repeated contact can cause skin disorders or 11. Repeat Steps 8 and 9.
other bodily injury. Keep out of reach of 12. Flush the system as many times as required until
children. the water is clean.
Coolant is toxic. Keep away from children and 13. Fill the system with the proper mixture of clean soft
pets. If not reused, dispose of in accordance water and ethylene glycol or propylene glycol. Re-
with local environmental regulations. fer to engine manufactures manual for the correct
coolant selection. Be sure to vent the system dur-
3. Drain the cooling system by opening the drain ing filling.
valve on the radiator and engine block. Allow the 14. Start the engine and let it run for approximately 5
coolant to drain into a suitable container. Properly minutes to purge trapped air from the system.
dispose of used anti-freeze. Refer to Figure 2−13. Check System for leaks.
4. Check for damaged hoses and hose clamps. 15. Install the fill cap on the surge tank.
Hoses must be firm to the feel. If they are soft and
spongy they must be replaced. Replace as re-
quired. Check the radiator for leaks, damage, and WARNING
build up of dirt. Clean and replace as required. Engine cooling system is pressurized. Do not
5. Close the drain valve on the radiator. remove vent cap from a hot engine. Heated
coolant spray or steam can cause personal
CAUTION injury. Wait until the engine has cooled before
slowly removing vent cap.
During filling, air must be vented from the
engine coolant passages. Wait 2 to 3 minutes 16. Check the coolant level to make sure that the cool-
to allow air to be vented. Air trapped in the ant level has risen to the
Full−Cold" level on the
system may cause damage to the engine. side of the tank. Refer to
Coolant System Level
Check" found earlier in this Section of this Opera-
6. Remove the fill cap from the surge tank. tor’s Manual.

Section 2 − Lubrication And Preventative Maintenance 2−21

Operator’s Manual

Turn ignition off, push

plunger on relief valve
to release air pressure
before opening sump
tank.

1 2 3 4 5

10 9 8 7

1. Filter Housing 4. Sight Gauge 7. Water Drain Plug 9. Access Panel

2. Contamination Indicator 5. Access Panel 8. Pressure Relief Buttons 10. Hydraulic Reservoir
3. Filter Housing Cover 6. Relief Valves

Figure 2−14
Hydraulic Reservoir

2−22 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual
Hydraulic Reservoir Hydraulic Reservoir Oil Level Check
1. With all hydraulic cylinders fully retracted and the
The hydraulic reservoir is used to supply and store hy- boom in the boom rest, park the crane on a firm lev-
draulic oil needed to operate all hydraulic functions of el surface. Engage the park brake, shift the trans-
the crane. The hydraulic reservoir, as shown in mission to neutral and shutdown the engine.
Figure 2−14, is equipped with a sight gauge for check- 2. With the hydraulic oil cold [approximately 62F
ing the oil level. (17_C)], check its level through the sight gauge lo-
A filter housing is mounted on the top of the tank. It has cated on the front of the hydraulic reservoir. The
a contamination indicator which signals when the filter proper level must be maintained at all times. Add
is being bypassed. Drain any water from the hydraulic hydraulic oil as necessary to bring the oil level be-
reservoir, check the oil level, and inspect the contami- tween the
HIGH" and
LOW" marks. Use only Hi
nation indicator daily. Operating the crane with the oil Performance Hydraulic Oil or an approved substi-
level below the full mark or with the filter element by- tute. Do Not Overfill.
passed can lead to hydraulic component failure. Refer
to the following procedures (Figure 2−14 & Adding Oil To The Hydraulic
Figure 2−15) when servicing the hydraulic reservoir. Reservoir
1. Park the crane on a firm, level surface. Engage the
Water Drain park brake, shift the transmission to neutral, and
Drain the water from the hydraulic reservoir daily before shutdown the engine.
start-up. Contaminated oil will damage the systems 2. Relieve any trapped hydraulic system pressure by
hydraulic components. pushing the button on the pressure relief valve.
1. Relieve any trapped hydraulic system pressure by
pushing the button on the pressure relief valve.
WARNING
All trapped hydraulic pressure must be
WARNING exhausted from the system before removing
All trapped hydraulic pressure must be any plug or cover. A sudden release of hot oil
exhausted from the system before removing could cause burns or other serious injury.
any plug or cover. A sudden release of hot oil
could cause burns or other serious injury. 3. Clean the top of the hydraulic reservoir, the filter
housing, and filter housing cover to prevent foreign
2. Loosen the water drain plug and allow the water to material from entering the hydraulic system.
drain into a suitable container. The water drain 4. Remove the filter housing cover.
plug is slotted and need not be completely re- 5. Add oil, as required, through the filter element.
moved to drain the water. Check the oil level.
3. When a clean flow of hydraulic oil begins to drain 6. Install filter housing cover.
from the water drain plug, tighten the plug.
4. Check the oil level in the hydraulic reservoir before
beginning operation of the crane. Add oil if neces-
sary. Properly dispose of the contaminated water.

Section 2 − Lubrication And Preventative Maintenance 2−23

Operator’s Manual
Hydraulic Reservoir Oil Change
The hydraulic reservoir oil should be changed every WARNING
1,000 hours of operation or seasonally, whichever oc- Do not remove the bottom access panel
curs first. Change the hydraulic reservoir oil at the end before the hydraulic reservoir has completely
of a working day when any foreign particles will be sus- drained. A large volume of hot oil may
pended in the warm oil. If this is not possible, cycle the suddenly be released resulting in personal
crane until the oil is warm and proceed as follows: injury and/or property damage. Drain the oil
1. With all hydraulic cylinders fully retracted, park the from the hydraulic reservoir before removing
crane on a firm, level surface. Engage the park the bottom access panel.
brake, shift the transmission to neutral, and shut-
down the engine. 5. Remove the bottom access panel, filter housing
2. Relieve any trapped hydraulic system pressure by cover, and the filter element. Properly dispose of
pushing the button on the pressure relief valve. the filter element.
6. Clean any old gasket material off the access pan-
els and hydraulic reservoir.
WARNING 7. Remove and clean the oil diffuser in the bottom of
All trapped hydraulic pressure must be the filter housing.
exhausted from the system before removing 8. Clean the interior of the hydraulic reservoir with
any plug or cover. A sudden release of hot oil clean diesel fuel or kerosene.
9. Allow the diesel fuel or kerosene to drain into a suit-
could cause burns or other serious injury.
able container until the hydraulic reservoir is thor-
oughly drained. Inspect the interior of the hydrau-
3. Thoroughly clean the exterior surface of the hy-
lic reservoir for foreign material and wipe clean.
draulic reservoir to prevent foreign materials from
10. Clean and install the water drain plug.
entering the system, once the access panels and
11. Clean the filter housing. Install oil diffuser in the
filter housing are opened.
bottom of filter housing. Install a new filter element.
4. Remove the top access panel and pump the hy-
12. Install the access panels, using new gaskets.
draulic oil into suitable containers. Refer to the Lu-
13. Using clean, uncontaminated oil, fill the reservoir
brication Chart to determine the volume of oil to be
through the filter element until it reaches the full
removed.
mark by the sight plugs.
Note: If a pump is not available to remove the oil 14. Install the filter housing cover.
from the reservoir, place a suitable container 15. Engage the main pump and start the engine. Allow
under the water drain plug. Open the plug and the engine to idle several minutes to ensure oil is
drain one container full at a time, until the oil has being cycled properly. Check for any leaks.
thoroughly drained from the reservoir. Do not 16. Check the oil level in the hydraulic reservoir for
remove bottom access panel to drain reservoir. proper level. Add oil if necessary. Properly dis-
pose of the used oil.

Note: In case of hydraulic system component

failure, a more thorough oil change procedure
is required. Consult your distributor for this
procedure.

2−24 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual
Hydraulic Reservoir Filter Change
1
Change hydraulic reservoir filter element after the initial
50 hours of operation and every 250 hours of operation 2
thereafter. Change the filter element immediately if the
contamination indicator needle is in the red area.
1. Park the crane on a firm, level surface. Engage
park brake, shift the transmission to neutral, and
ËËË
ËËË
shutdown the engine. 3

ËËË
2. Relieve any trapped hydraulic system pressure by
pushing the button on the pressure relief valve.

WARNING
All trapped hydraulic pressure must be
exhausted from the system before removing
any plug or cover. A sudden release of hot oil
could cause burns or other serious injury.

3. Clean the top of the hydraulic reservoir, the filter

housing, and filter housing cover to prevent foreign
material from entering the hydraulic system.
4. Remove the filter housing cover.
5. Remove the filter element and inspect it for con- 4
tamination. Any dirt or foreign particles on the filter
1. Filter Housing Cover
element may indicate excessive system contami- 2. Contamination Indicator
nation or imminent system component failure. 3. Element
Once the filter has been thoroughly inspected, dis- 4. Oil Diffuser
pose of it properly. Figure 2−15
6. Install new filter element and filter housing cover. Filter Assembly
7. Start engine and check the filter housing for leaks.
8. Check the hydraulic reservoir oil level. Add oil if
necessary.

Section 2 − Lubrication And Preventative Maintenance 2−25

Operator’s Manual
3. Note the oil level in the sight gauge. If oil is not vis-
1 ible, remove the breather/fill plug and add oil until it
is visible in the sight gauge. Do not overfill. Refer to
the Lubrication Chart for the correct grade of oil.

CAUTION
Do not overfill the pump drive. This will result
in overheating and possible malfunction of
the unit. Fill the pump drive only until oil is
visible in the sight gauge.

4. Thoroughly clean the breather/fill plug and install it

in the pump drive.

Pump Drive Oil Change

1. Park the crane on a firm, level surface. Engage the
park brake, shift the transmission to neutral, and
3 2 shutdown the engine.
2. Engage the main pump and start the engine. Allow
1. Breather/Fill Plug 3. Sight Gauge the engine to run long enough to agitate the oil,
2. Drain Plug within the pump drive, so dirt and metal particles
Figure 2−16 will be suspended in the oil.
Hydraulic Pump Drive 3. Shutdown the engine and thoroughly clean the ex-
terior surface of the pump drive to prevent foreign
material from entering the unit once the magnetic
Hydraulic Pump Drive drain plug and breather/fill plug are removed. Re-
fer to Figure 2−16.
Lubrication 4. Remove the magnetic drain plug and allow the oil
to drain into a suitable container.
The internal components of the pump drive are splash 5. Inspect magnetic drain plug for large quantities of
lubricated with each cycle of the unit. Maintaining the metal particles. This is a sign of excessive wear or
proper oil level within the pump drive is essential to en- damage within the pump drive and disassembly of
sure an efficient power transfer from the engine to the the unit may be required for a thorough inspection.
hydraulic pumps. Check the oil level within the pump 6. After the oil has thoroughly drained from the pump
drive after each 50 hours of operation. On new or re- drive, clean and install the magnetic drain plug.
built pump drives change the oil after the first 500 hours 7. Remove breather/fill plug and fill the pump drive
of operation and then every 2,000 hours of operation or with oil, until oil is visible in the sight gauge. Do not
bi-annually. However, it should be noted that the oil overfill. Refer to the Lubrication Chart for the cor-
should be changed whenever it shows traces of con- rect quantity and grade of oil.
tamination or effects of high temperature, evidenced
by discoloration or strong odor. Lubricate the control
cable every 1,000 hours to ease operation. CAUTION
Do not overfill the pump drive. This will result
Pump Drive Oil Level Check in overheating and possible malfunction of
1. Park the crane on a firm, level surface. Engage the the unit. Fill the pump drive only until oil is
park brake, shift the transmission to neutral, and visible in the sight gauge.
shutdown the engine.
2. Thoroughly clean the exterior surface of the pump 8. Thoroughly clean the breather/fill plug and install it
drive, around the breather/fill plug, to prevent for- in the pump drive. Properly dispose of the used oil.
eign material from entering the pump drive. Refer
to Figure 2−16.

2−26 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

4
1
2

1. Air Cleaner Cover 5

2. Dust Exhaust Valve
3. Filter Change (Red) Line
4. Service Indicator
5. Reset Button
Figure 2−17
Engine Air Cleaner

Engine Air System Inspection Changing The Air Cleaner Element

1. Park the crane on a firm level surface. Shift the
In addition to servicing the air cleaner, it is also recom- transmission to neutral, engage the park brake,
mended that the engine air system be inspected every and shutdown the engine.
250 hours or 6 months. Inspect the air system pipes, 2. Inspect the service indicator to see if the yellow in-
hoses, air compressor, and turbocharger systems, as dicator has reached the filter change (red) line. If
equipped. (Be sure to inspect all the pipes and hoses the yellow indicator has reached the filter change
associated with the air compressor, turbocharger, air (red) line, proceed with the following steps. If it has
cleaner, and air intake.) Check for any cracks, corro- not reached the red line, there is no reason to ser-
sion, loose clamps, wear points, leaks or punctures
vice the air cleaner. Over servicing the air cleaner
which can allow contaminants to enter the system and
will shorten the life of the element and unnecessari-
damage air system components and/or the engine. All
ly increase downtime.
hoses should be kept free of oil contaminants, both in-
3. Remove the cover from the air cleaner body.
ternally and externally. Disassemble and clean as re-
4. Remove element from the air cleaner body.
quired. Tighten or replace parts as necessary to en-
5. Remove the dust exhaust valve and inspect it for
sure that the air system does not leak.
damage or wear. Replace it if required.
6. Wipe the inside of the air cleaner body clean using
Engine Air Cleaner a damp cloth. Install the dust exhaust valve.
Variations in job site conditions prevent establishing a 7. Clean or replace the element as required.
set interval for air cleaner servicing. For this reason a 8. Slide the element into the air cleaner body.
vacuum operated service indicator is mounted on the 9. Install the cover to the air cleaner body.
air cleaner to assist in determining the condition of the 10. Reset the service indicator by pressing the button
air cleaner element. Refer to Figure 2−17. Anytime the on top of it.
yellow indicator reaches the red line, service the air
cleaner immediately. Clean or replace the air cleaner
element as often as required. Replace the air cleaner
element after the sixth cleaning or annually, whichever
occurs first. Service the engine air cleaner as follows:

Section 2 − Lubrication And Preventative Maintenance 2−27

Operator’s Manual

Figure 2−18
Cleaning The Primary Air Cleaner Element Figure 2−20
With Compressed Air Inspecting The Air Cleaner Element

Compressed Air
Hold an air hose nozzle at least 1 in (25mm) away from
the primary air cleaner element. Spray air through the
element in the direction opposite to normal air flow.
Move the nozzle up and down while rotating the ele-
ment. Use air pressure of less than 100 psi (690kPa) to
prevent damage to the filter paper within the element.
Thoroughly inspect the element after cleaning. Refer
to Figure 2−18.

Washing
Soak the primary air cleaner element for 15 minutes or
more, in a solution of water and Donaldson D−1400
detergent, or equivalent. Refer to Figure 2−19. Thor-
Figure 2−19 oughly rinse the element by spraying it with a hose in
Cleaning The Primary Air Cleaner Element By the direction opposite the air flow. Use water pressure
Soaking of less than 40 psi (276kPa) to prevent damage to the
filter paper within the element. Rinse until the water is
clear; air dry. Do not attempt to dry the element using
Cleaning The Air Cleaner Element compressed air or light bulbs. This may ruin the ele-
ment. Thoroughly inspect the element after cleaning.
The primary air cleaner element can be cleaned by
washing or using compressed air. Compressed air is
recommended when the element is to be reused im-
Inspecting The Air Cleaner Element
mediately. A washed element must dry before reuse, Place a bright light inside the air cleaner element and
however the washing method does a better job and rotate the element. Inspect the element from the out-
must be used when exhaust soot has lodged in the fine side looking for ruptures, tears, and holes. If any dam-
pores of the filter media. Use one of the following pro- age is discovered, replace the element. Refer to
cedures to clean the primary air cleaner element. Figure 2−20.

2−28 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

1. Slip Yoke Grease Fitting

2. U-joint Grease Fitting (Each End)
Figure 2−21
Drive Tube And U-joint Lubrication

2. Check the slip yoke for looseness or side play.

Drive Tube And U-Joint 3. Apply grease through the fitting at the slip yoke un-
Lubrication til all the old grease is purged from the slip yoke.
Refer to Figure 2−21 for illustration of grease fitting
Drive tubes and u-joints are used to transmit torque locations.
from one drive line component to another. They also 4. Check each u-joint for looseness.
help absorb shock loadings. Because they are so criti- 5. Apply grease through the fitting on each u-joint un-
cal to crane operation, thorough lubrication is neces- til all the old grease is purged. Purging should oc-
sary. cur at all four seals on each u-joint. Refer to
Figure 2−21 for grease fitting locations.
Lubrication Procedure For Drive 6. If grease does not purge from each seal, manipu-
late the u-joint until purging occurs.
Tubes/U-Joints 7. If the above is not successful, remove the u-joint
1. Park the crane on a firm, level surface. Engage the and inspect it. If the grease is rusty, gritty, or burnt,
park brake, shift the transmission to neutral, and replace the u-joint.
shutdown the engine. Follow Steps 2−7 on each
drive tube.

Section 2 − Lubrication And Preventative Maintenance 2−29

Operator’s Manual
Swing Speed Reducer
Lubrication
Check the oil level in the swing speed reducer after ev-
ery 50 hours of operation. The oil in a new or rebuilt
swing speed reducer should be changed after the ini-
tial 200 hours of operation. Thereafter, change the oil
with each 1,000 hours of operation or seasonally,
whichever occurs first.

Swing Speed Reducer Oil Level Check

1. Park the crane on a firm, level surface. Shift the
1 transmission to neutral, and engage the park
brake.
2. Engage the travel swing lock and shutdown the en-
gine. Refer to Figure 2−22.
3. Clean the speed reducer around the check/fill plug
to prevent contamination from entering the sys-
tem. Remove the check/plug.
4. Oil should be within 0.25 in (6mm) of the bottom of
the hole. Add oil as required to bring the oil to the
proper level. Refer to the Lubrication Chart for the
correct grade of oil.
5. Clean and install the check/fill plug.

Swing Speed Reducer Oil Change

1. Park crane on a firm, level surface, shift the trans-
mission to neutral, and engage the park brake.
2. Level the crane on fully extended outriggers and
swing the upper for several minutes, to agitate and
warm the oil within the swing speed reducer.
3. Engage the travel swing lock, fully lower the boom,
and shutdown the engine.
4. Thoroughly clean the exterior surface of the swing
speed reducer around the check/fill and drain
plugs to prevent contamination from entering the
unit. Refer to Figure 2−22.
5. Remove the check/fill and drain plugs and allow
the oil to drain into a suitable container. The drain
plug is magnetic and should be inspected for large
quantities of metal particles. After the initial oil
change, this is a sign of damage or extreme wear
within the unit, and a complete internal inspection
may be necessary.
6. After the oil has thoroughly drained, clean and
2
install the drain plug.
7. Fill the unit with oil through the check/fill hole, until
1. Check/Fill Plug the oil is within 0.25 in (6mm) of the bottom of the
2. Drain Plug hole. For the correct grade and quantity of oil, refer
Figure 2−22 to the Lubrication Chart.
Swing Speed Reducer 8. Clean and install the check/fill plug. Properly dis-
pose of the used oil.

2−30 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

2
1

4 3

1. Fill Plug
2. Vent Plug
3. Sight Gauge
4. Drain Plug
Figure 2−23
Winch Drum Lubrication

Winch Drum Lubrication Winch Drum Oil Change

1. Park the crane of a firm, level surface, shift the
For maximum operating efficiency and service life of transmission to neutral, and engage the park
the winch drum, check oil level after every 50 hours of brake.
operation. The oil, in a new or rebuilt winch drum, 2. Cycle the winch for several minutes, without a load
should be changed after the initial 100 hours of opera- to agitate and warm the oil within the winch drum.
tion. Thereafter, change oil with each 1,000 hours of 3. Engage the travel swing lock and shutdown the en-
operation or seasonally, whichever occurs first. It is gine. Thoroughly clean the exterior surface of the
also recommended that every 2,000 hours of opera- winch around the vent, fill and drain plugs to pre-
tion, the winch should be disassembled and thor- vent contamination from entering the unit. Refer to
oughly inspected for damaged or worn parts. Replace Figure 2−23.
damaged or worn parts as required. 4. Remove the vent, fill and drain plugs and allow the
oil to drain into a suitable container.
Winch Drum Oil Level Check 5. After the oil has thoroughly drained, clean and
1. Park the crane on a firm, level surface, shift the install the vent and drain plug.
transmission to neutral, engage the park brake, 6. Fill the unit with oil through the fill hole, until oil is
and shutdown the engine. visible within the sight gauge. For the correct
2. Observe the oil level within the sight gauge. Oil grade and quantity of oil, refer the Lubrication
should be visible within the sight gauge. Refer to Chart.
Figure 2−23. 7. Clean and install the fill plug. Properly dispose of
3. If necessary, add oil until it reaches the proper lev- the used oil.
el. Refer to the Lubrication Chart for the correct
grade of oil.

Section 2 − Lubrication And Preventative Maintenance 2−31

Operator’s Manual
Right
Wrong

Figure 2−24
Shutdown the engine, ensure that the operator has vacated the upper operator’s cab, and insert
blocking through the diamond shaped hole closest to the base section of the boom before putting
hands or tools inside a boom section.

Boom Lubrication And

Inspection
Boom lubrication is important to extend wear shoe life
and to aid in smooth performance of the boom. Lubri-
cation involves covering all boom sliding surfaces with
a film of grease. This is accomplished by applying
grease directly to boom surfaces and the wear shoes
that slide on the boom and telescope cylinder surfaces.
Refer to Figure 2−26 for wear shoe locations.
Inspect the boom daily for adequate lubrication and
grease it as necessary. Visually inspect all boom sec-
tions daily for damaged or cracked members or welds.
If any dents, bends, cracked welds, etc. are found, do
not use the crane. Contact your nearest distributor for
Figure 2−25 repair procedures. Also check for damaged or leaking
Do not climb on boom or attachments. hoses, fittings, valves, cylinders etc. Repair as neces-
sary. At 250 hour intervals, check all boom wear shoes
for proper adjustment. See
Boom Wear Shoe Adjust-
ment" in Section 3 of this Operator’s Manual for further
WARNING details.
To avoid personal injury, do not climb, stand,
Grease boom extend and retract sheaves at 50 hour in-
or walk on the boom or fly. Use a ladder or
tervals. It is also recommended that every 4,000 hours
similar device to reach necessary areas.
of operation the boom should be disassembled and
Shutdown the engine, ensure that the the extend and retract wire ropes inspected, lubri-
operator has vacated the upper operator’s cated, and/or replaced as required. See
Wire Rope
cab, and insert blocking through the diamond Lubrication" found later in this Section and
Wire Rope
shaped hole closest to the base section of the Inspection And Replacement Recommendations" in
boom before putting hands or tools inside a Section 5 of this Operator’s Manual.
boom section. Movement of the boom could
cause serious injury.
Do not use a crane that has a damaged boom.
The structural integrity of the boom is lost and
could collapse with any load. Use the crane
only after the boom has passed a thorough in-
spection. Contact your distributor for the
proper inspection procedures.

2−32 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

2 3 4
A F 1

E D C B
7 6 5
B 10 C 12 D
9 11
8

14 E 15 G F G

13
17 17

17

15 16
1. Side Wear Shoe − Top (6 Places) 10. Side Wear Shoe − Base (2 Places)
2. Extend Wire Rope (3 Places) 11. Bottom Wear Shoe − Inner Mid (2 Places)
3. Extend Wire Rope Anchors (3 Places) 12. Side Wear Shoe − Inner Mid (2 Places)
4. Top Wear Shoe − (6 Places) 13. Bottom Wear Shoe − Outer Mid (2 Places)
5. Wear Block − Inner Mid (2 Places) 14. Side Wear Shoe − Outer Mid (2 Places)
6. Wear Block − Outer Mid (2 Places) 15. Telescope Cylinder Slider Bracket Wear Shoes
7. Retract Wire Rope 16. Retract Wire Rope Anchor
8. Side Wear Shoe − Bottom (6 Places) 17. Telescope Cylinder Wear Shoes
9. Bottom Wear Shoe − Base (2 Places)

Figure 2−26
Boom Lubrication And Inspection

Section 2 − Lubrication And Preventative Maintenance 2−33

Operator’s Manual
Wire Rope Lubrication 1. Continuous Bath
Run the rope through a container filled with lubri-
Wire rope is like a machine. Each time a wire rope cant. A sheave mounted in the center of the con-
bends over a sheave or straightens from a slack posi-
tainer will hold the rope submerged as it passes
tion many wires move against each other. Lubrication
through the container. Use swabbing to remove
is necessary to help prevent wear caused by this move-
excess lubricant as the rope leaves the container.
ment. Lubrication also helps prevent deterioration of
wire rope due to rust and corrosion. 2. Dripping
Place a container above a sheave so a spigot can
WARNING be opened to drip oil on the wire rope as it passes
through the sheave groove.
Rusty wire rope is dangerous since there is no
way to determine its remaining strength. 3. Swabbing And Painting
Two fast methods are swabbing the lubricant on
Most wire ropes are lubricated during manufacture, but with rags or painting it on with a brush.
the lubricant does not last the life of the rope. The lubri-
cant is squeezed out of the rope as it runs over sheaves 4. Spraying
under tension, or washed off by rain.
Light lubricants may be applied with a spray gun.
For the above reasons, wire rope MUST BE periodically Aerosol cans of lubricant are also available.
lubricated. Crude or used oils and grease should not
be used as lubricants because they may be grit or acid
laden. Either of these conditions can cause damage to
Fly Inspection & Lubrication
the rope. Inspect all parts of the fly daily. Lubricate head machin-
No set rule can be given for lubrication frequency. This ery as required. Pay particular attention to the chords
will depend on the type of conditions under which the and lattice. If any dents, bends, cracked welds, etc. are
rope is used. found, do not use the fly. Contact your nearest distribu-
tor for repair procedures.
A rope used in wet conditions would need to be lubri-
cated more often than one used in dry conditions, to
prevent rust and corrosion.
Lubricants used for wire rope lubrication should have
WARNING
the following properties: Do not use a fly which has been damaged.
1. They must have enough adhesive strength to stay The structural integrity of the fly is lost and the
on the rope. attachment could collapse with any load. Use
2. They must be able to penetrate between the wires the fly only after it has passed a thorough
and strands. inspection.
3. They must have high film strength.
4. They must resist oxidation.
5. They must remain soft and pliable.

Application Of Wire Rope Lubricant

Wire ropes that have been in service should be cleaned
before re-lubricating them. Use a wire brush and com-
pressed air to clean the rope. All possible foreign mate-
rial and old lubricant should be removed from the rope
before re-lubricating it. Use one of the following meth-
ods to apply the lubricant.

2−34 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual
Hook Balls: Check pin, nut, and washer to ensure
Hook Block, Ball, And Swivel ball halves are held securely together. Check lo-
Inspection And Maintenance cating pin for excessive wear. Inspect swivel parts
1. All nuts, set screws, pins, bolts, and retainers as specified previously. Check that hook latch is
should be checked for tightness every 14 to 30 operative.
days, depending on the operating conditions and 3. If a swivel is constantly overloaded, it will cause
the product involved. damage to the unit. The first sign of damage is
2. Inspect the components carefully at least once a often bearing brinelling (dimpling of the bearing
month. races). This condition is determined by spinning
the swivel by hand. If the motion is rough, or has a
Swivels: Check for excessive gap between the ro- ratchet-like effect, the bearing has been damaged
tating parts. Check threaded parts that are in- and should be replaced.
stalled together to see that they are secure and 4. The distance between the swivel barrel and shank
tight. Check all set screws to see that they are tight or rotating members are pre-set with a factory
and staked. clearance of 0.020−0.050 in (0.5−1.2mm). If this
Hook Blocks: Check all pins and bolts for tight- distance increases more than 0.060 in (1.5mm)
ness, spreading of side plates, weld cracks, over the above distance, it is a good indication of
sheave wear, bearing wear, spreading of hook, set bearing fatigue and the unit should be removed
screws that are tight and staked. Check that hook from service.
latch is operative.

Under Intermittent Under Continuous

Item
Operating Conditions Operating Conditions
Swivels, Swivel Overhaul Balls, Swivel Balls 14 days 24 hours
Blocks with Bronze Bushed Sheaves 14 days 8 hours
Blocks with Roller Bearing Sheaves 14 days 24 hours
Chart A − Hook Block, Ball, & Swivel Lubrication Frequency

Item Frequency What to Check For Appropriate Action

End play or gap of more than .06 inch
Remove from service immediately.
(1.5mm) along the axis.
14 days under continuous operation
Swivels Defective bearing. Remove from ser-
30 days under intermittent operation Rough turning.
vice immediately.
Elongated eye holes, bent clevis pins. Indicates overload. Remove for repairs.
Indicates severe bearing wear. Remove
Misalignment, as evidenced by wobble from service.
14 days under continuous operation or uneven groove flange wear. Check for wear in bronze spacers
Sheaves where used.
30 days under intermittent operation
Striations or corrugations in sheave
Result of rope wear. If serious, replace.
groove.
Missing, off center, bent, broken spring,
Hook Latch When Used Replace immediately.
missing, or defective.
An indication of overload. If serious, re-
place.
Permanent deformation or stretching. Any suspicion of fractures calls for an
immediate investigation and, if neces-
sary, replacement of part.
Hooks Daily or When Used
Hooks should be tested at least once a
year by magnafluxing, x-ray, or other
Crack or other defects. qualified method. Intermittent tests can
be conducted by a less accurate oil
stain method.
Chart B − Hook Block, Ball & Swivel Inspection Frequency

Section 2 − Lubrication And Preventative Maintenance 2−35

Operator’s Manual
7. Inspect the pressure transducers at the boom
hoist cylinders and the connecting hoses for oil
leaks.
8. Test that the function limiters activate properly by
two-blocking the crane. (Do this by manually lifting
the ATB weight.)
9. Check for erratic readings on the boom angle, the
boom length, and the operating radius displays.
Check the boom angle, boom length, and the op-
erating radius for accuracy every 30 days.
10. If a known test weight is available, check that the
displayed weight agrees with the test load. The
displayed load includes the hook block and any lift-
ing equipment such as slings, pins, shackles, etc.
11. If crane capacities are rated for specific areas e.g.
Figure 2−27 side, front, rear, check the system by swinging the
Display Cleaning boom into the permitted areas and checking that
the rated capacity reading agrees with the crane
capacities as listed in the Crane Rating Manual.
Turntable Bearing
Capscrew Torque
Proper tightening of turntable bearing capscrews is WARNING
very important. If the bearing has been replaced or the Any unusual or erratic system operation must
crane undecked for any reason, capscrews should be be investigated and corrected immediately. If
replaced. Reuse of capscrews is not recommended. any problem is found with any of the above
inspection steps, the problem must be
corrected/repaired as soon as possible. If
CAUTION necessary to continue crane operations, refer
Loctite® pipe sealant is used on the turntable to
System Inoperative Or Malfunctioning" in
bearing capscrews. The Loctite® pipe sealant Section 1 of this Operator’s Manual.
seals the threads to prevent rust and
corrosion.
Display Cleaning
Capscrews should be inspected and/or torqued after The Rated Capacity Limiter display is not field service-
the first 250 hours of operation. Inspect and/or torque able and should not be disassembled by anyone other
capscrews every 500 hours of operation thereafter. than an authorized service repair facility. However, the
Torque capscrews to 2,120−2,335 ft-lb screen can be sufficiently cleaned without unit disas-
(292.6−322.2kgm). sembly.
Compressed air used for cleaning electronic equip-
Crane Monitoring System ment can be obtained at any major electronic or office
supply store. Do not use compressed air from an air
Maintenance of the Microguard Rated Capacity Limiter compressor. Kensington Dust Blaster has been used
System consists of the following daily inspection prior with good results.
to the first operation:
After removing the display from the crane console, lo-
1. Check that the system is operating normally as de-
cate the rectangular ventilation hole on the side of the
scribed in Section 1 of this Operator’s Manual.
display. This is the area of access for cleaning the dis-
2. Check the electrical cables connecting the various
play.
parts of the system.
3. Check insulation on the boom reeling drum cable. Insert the nozzle of the compressed air just to the edge
4. Check boom reeling drum cable for proper tension. of the LCD display at the air gap, and angled toward the
5. Check all anti-two block switches for freedom of display screen cover. Activate the air container and
movement. slide from end to end of the display. Only a few seconds
6. Check that the anti-two block weights are installed of application should be required to sufficiently clean
and working properly with the anti-two block the display unit. If the unit cannot be adequately
switches. cleaned using this process, it must be returned to a fac-
tory authorized repair facility.

2−36 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual

burn" the paint, strip off protective coating, dimin-
Paint Maintenance ish the gloss and accelerate the contamination
Knowledgeable equipment owners realize the value of process.
periodic preventative maintenance and responsible 3. Periodic waxing will enhance the luster and protect
care. A regular surface care program should be fol- the paint surface.
lowed to protect the equipment’s paint finish and main- If environmental damage to the paint finish is detected
tain a like-new appearance. There is no one correct/ul- (loss of some of its luster due to lack of or inability to
timate procedure since the uniqueness of every maintain as recommended) the paint finish can be re-
crane’s operating environment and owner/operator stored to near-new appearance by following a simple
maintenance habits differ. However, it is important to polishing and waxing procedure.
remove surface contaminants before they have time to
bond or etch into the paint finish.
Polishing And Waxing Procedure
The crane has non-skid materials located in certain 1. Clean surface thoroughly by hand washing or
areas to assist operators and service personnel with power washing with a mild detergent. Rinse thor-
safe access/egress to/from the crane. Do not paint or oughly with water before buffing.
wax non skid materials. Paint or wax will cause the non- 2. Apply a polishing compound, such as Meguiar’s
skid materials to become slick, reducing their effective- M8432, or equivalent, to a surface area approxi-
ness for safey while walking on the crane. If any non- mately two feet by two feet at a time. Make sure the
skid materials becomes ineffective due to wear, age, or cleaner is applied liberally to entire area and work
destroyed in any way, it must be replaced. on only that area with the buffing wheel.
3. Buff surface with an electric or air buffer at 1,000
rpm using a 3M Superbuff polishing pad, or equiv-
WARNING alent, with light to medium pressure until a uniform
Do not apply paint or wax over non-skid materi- high gloss is obtained. Hand wipe with a clean
als. Keep all non-skid materials clean and free cloth.
of all contaminants. All walking surfaces on the 4. After surface has been buffed, apply a quality auto-
crane should be cleaned to eliminate any con- motive wax such a Meguiar’s M−26 Hi−Tech Yel-
taminants. Paint, wax, or other contaminants low Wax, or equivalent, and hand buff until the
will reduce the effectiveness of the materials. cloth moves freely. The original luster of coating
Ineffective materials can create unsafe access/ should be restored.
egress to/from the crane leading to serious per-
sonal injury. Mask off and/or cover non-skid
materials prior to painting or waxing areas
Cab Dash Cleaning
around any non-skid material(s). Contact your Care should be taken when cleaning the cab dash, es-
distributor for information regarding the re- pecially the new polycarbonate dashes. If the incorrect
placement or repair of any non-skid material(s). cleaning agent is used, the finish of the material could
be destroyed. It is recommended by the dash
Regular Preventative Maintenance manufacturer that only the following materials be used
1. Regular washing is the best way to remove surface for cleaning:
contaminants. 1. Soap and water
2. Always use mild cleaners and soaps, and rinse 2. Denatured alcohol
thoroughly after washing. Do not use harsh deter- 3. Joy and Palmolive dishwashing liquids
gents, such as household laundry detergents, or 4. Windex with Ammonia D
cleaners that contain phosphates, as they will 5. Formula 409, Fantastik, Mr. Clean

Section 2 − Lubrication And Preventative Maintenance 2−37

Operator’s Manual

2−38 Section 2 − Lubrication And Preventative Maintenance

 Operator’s Manual
Table Of Contents
Tires And Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

Tire And Rim Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1

Tire And Rim Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2

Dual Rear Tire And Rim Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−2
Dual Rear Tire And Rim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−3
Front Tire And Rim Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−5
Front Tire And Rim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−6
Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−7

Carrier Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9

Caging Dual Air Brake Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−9
Releasing A Caged Dual Air Brake Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−10
Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−11
Carrier Clutch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12
Clutch Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12
Clutch Pedal Free Travel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−13
Outrigger Beam Bearing Pad Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−15

Swing Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−16

Travel Swing Lock Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−17

360° Swing Lock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−18

360° Swing Lock Inspection And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−18
Bubble Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−19

Crane Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−19

Hydraulic System Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−20

Preparing The Crane For Checking Relief Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−20
Relief Valve Pressure Checking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−20
Boom Wear Shoe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−29

Boom Extend And Retract Wire Rope Inspection And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−31
Extend/Retract Wire Rope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−31
Extend/Retract Wire Rope Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−31

Section 3 − Periodic Adjustments i

Operator’s Manual

ii Section 3 − Periodic Adjustments

 Operator’s Manual

Right

Wrong

Figure 3−1
Tire Inflation Warning

Tires And Tire Inflation

Check the tire inflation pressures daily when the tires
DANGER
are cold. The tire inflation pressures for normal high- Servicing the tire and rim assemblies can be
way travel are listed on the Gross Axle Weight Rating extremely dangerous. For your protection,
plate. The tire inflation pressures for pick and carry op- read and understand all safety instructions
erations are listed in the Crane Rating Manual. before removing or installing a tire and rim
assembly.
Note: The crane should not be road driven with the
tires inflated to pick and carry pressures. Travel on
tires inflated to pick and carry pressures is limited
to 1.0 mph (1.6km/h) maximum.
Tire And Rim Safety
Instructions
Dual wheels and tires must be installed so the valve 1. Always remove the valve cores, and exhaust all air
stem of the inner tire is 180 opposite the valve stem of pressure from the tire, prior to removing any rim or
the outer tire. All tires of the same weight and size are wheel components, (Both tires on a dual tire and
interchangeable. Inspect the wheel rims, clamps, rim assembly). Rim components are under ex-
nuts, studs, etc., on a weekly basis. If any damage is treme pressure and could fly off. The lug nuts and
apparent, repair or replace before operating the crane. rim clamps may be the only thing holding the rim
A rim cage should be used when deflating or inflating assembly together.
tires to protect against a lock ring flying off and injuring 2. Use a rim cage and stand clear when deflating and
someone. Refer to Figure 3−1. inflating tires. A damaged or improperly assem-
bled rim assembly may burst. The operator should
stand well away from the potentially explosive
DANGER force. Refer to Figure 3−1.
3. After deflating the tire, check the valve stem by run-
Use a rim cage when inflating tire. Lock ring or ning a piece of wire through the stem, to ensure it is
side flange may explode if damaged or not clogged and the tire is completely deflated. Ice
improperly assembled. Always use a rim may form as the air leaves the tire, or foreign mate-
cage and stand clear of the tire while inflating rial may clog the stem.
it.

Section 3 − Periodic Adjustments 3−1

Operator’s Manual
11. Once it is determined that the tire and rim are prop-
erly assembled, inflate the tire to fully seat the tire
bead. Then, on tube type tires, completely deflate
Wrong the tire to prevent localized over stretching of the
tube. Reinflate the tire to the recommended oper-
ating pressure.
12. Never use excessive force or hammering to install
a tire and rim assembly on the spoke wheel. Deter-
mine the reason for the improper fit. Look for dam-
aged and distorted parts or components which are
improperly assembled. Repair the problem.
13. Do not run the crane on one tire of a dual assembly.
The excessive overload can cause damage to the
tire and rim assembly.
14. Always check rims and wheels for damage during
normal tire inspection. Early detection of potential
component failure may prevent serious injury.
15. Do not attempt to rework, weld, heat, or braze any
damaged rim components. Heating may weaken
the part and result in complete failure of the com-
Figure 3−2 ponent and possible injury.
Rim clamps may fly off, use caution.

4. Do not inflate a tire that has been run flat or ex-

Tire And Rim Removal And
tremely under inflated. Demount the tire and in-
spect it, the tube, tube flap, rim components, and
Installation
wheel assembly for damage. These components Carefully read and understand the safety instructions
may have been damaged or dislocated during the given earlier in this Section of this Operator’s Manual.
time the tire was under inflated. Then, choose one of the following procedures for tire
5. Exercise caution when removing the lug nuts and and rim removal.
rim clamps. The rim clamps could fly off suddenly
and cause injury. Loosen the lug nuts and unseat Dual Rear Tire And Rim Removal
the rim clamps before completely removing the lug 1. Properly park the crane and engage the park
nuts. Refer to Figure 3−2. brake. Level the crane on outriggers and shut-
6. When assembling the tire and rim assembly, use down the engine.
only parts of the same type, manufacturer, and cor- 2. Position a rim cage in front of the tire and rim as-
rect size. Mismatched parts may appear to fit but sembly, before deflating the tire.
when the tire is inflated they may fly apart with ex-
plosive force.
7. Always double check to be sure rim components
are properly installed before inflating the tire. Im-
DANGER
properly assembled parts could fly off during infla- Exhaust all air pressure from both tires before
tion. removing any wheel or rim component. Use a
8. Clean and inspect all parts prior to assembly. Do rim cage and stand clear when deflating the
not use bent, worn, damaged, or rusted parts. tires. Rim components are under extreme
9. When inflating a tire, use an air hose with a clip-on pressure and may fly off. Failure to exhaust
chuck and in-line pressure gauge. Be sure the air air pressure, or use a rim cage, could result in
hose is long enough, to permit the person inflating a fatal accident.
the tire, to stand clear of the rim cage. Refer to
Figure 3−1. 3. Remove the core from the valve stem (9) on the in-
10. Inflate the tire to 10 psi (68kPa), and check the rim ner rim (3) and outer rim (10). Allow all air pressure
components for proper fit, before completely inflat- to exhaust from both tires. Refer to Figure 3−3.
ing. If the assembly is not correct, completely de-
flate the tire and correct the problem. Do not ham-
mer on an inflated tire and rim assembly. Properly
matched and assembled rim components will seat
without tapping.

3−2 Section 3 − Periodic Adjustments

 Operator’s Manual

8 10 1 2 3 4 10 8 9 3 4

7
7
6

5 5

Spoke Wheel Disc Wheel

Note: * Valve Stem Position May Vary

1. Rim Spacer 4. Brake Drum 7. Lug Nut 9. Valve Stem*
2. Flange 5. Wheel 8. Stud 10. Outer Rim
3. Inner Rim 6. Rim Clamp

Figure 3−3
Dual Tire And Rim Assembly

4. Check each valve stem (9), by running a piece of Dual Rear Tire And Rim Installation
wire through the stems, to make sure they are not
plugged and the tires are completely deflated. Re- The correct installation, and tightening of the lug nuts,
move the rim cage. on a tire and rim assembly, on the spoke wheel, is one
5. Adequately support the outer rim (10) and tire as- of the most important operations in wheel mainte-
sembly with an appropriate lifting device. nance. When tire, rim, or wheel problems occur, incor-
6. Loosen the lug nuts (11) until the outer surface of rect installation and tightening procedures are usually
each lug nut is flush with the end of the studs (8). found to be the cause of the problem. The following
Do not completely remove the lug nuts. procedures must be carefully followed to ensure safe
and dependable service.
1. Check the tires to ensure that they are deflated. In-
spect all parts for damage and proper assembly.
WARNING Refer to Figure 3−3.
Exercise caution when removing wheel lug
nuts. The rim clamps may fly off suddenly and
cause personal injury.
DANGER
7. Using a rubber mallet, stand to the side and strike All air pressure must be exhausted from the
the rim clamp (6) sharply to unseat them. tires before installing them. An inflated tire
8. Check each rim clamp (6) to be sure it is unseated. may cause improperly assembled rim
Repeat Step 7 if necessary. Remove the lug nuts components to fly off. Failure to deflate the
(7) and rim clamps from the studs (8). tires could result in a fatal accident.
9. Remove the outer rim (10), rim spacer (1), and in-
ner rim (3) from the wheel (5).

Section 3 − Periodic Adjustments 3−3

Operator’s Manual

1
3
5 Spoke Wheel Disc Wheel 2

1. Tire
2. Stationary Object
3. Axle

Figure 3−5
Tire And Rim Alignment

6 Spoke Wheel Always rotate the lug nut to be tightened to the top
Figure 3−4 spoke position to ensure even tightening of the rim
Lug Nut Torquing Sequence clamps (6) and proper alignment of inner and outer
rims (3,10). Tighten the lug nuts in this manner un-
til all lug nuts are torqued to 175−225 ft lb
2. Using a wire brush, thoroughly clean the mounting
(237−305Nm) for spoke wheels and 450−500 ft lb
surfaces of the inner and outer rims (3, 10), wheel
(5), rim spacer (1), and rim clamps (6). Surfaces (610−678Nm) for disc wheels.
should be free of rust, dirt, and excess paint. Note: Check to see that rim clamps on the
3. Using an appropriate lifting device, slide the inner spoke wheels do not bottom out until at least
rim (3) over the wheel (5) and push it into position 140−180 ft lb (190−244Nm ) torque is applied.
against the mounting surface. Be sure that the
The edges of the rim spacer (1) should consis-
valve stem (9) points outward and is centered be-
tently meet the edges of the rims.
tween two spokes.
4. Carefully inspect the rim spacer (1) for concentric- 11. Check the alignment of the inner and outer rims by
ity. If it is distorted, bent, or damaged, replace it. placing an object on the floor beside the outer tire
5. Slide the rim spacer (1) on the wheel (5) and posi- and rotating the wheel. Note any variation in the
tion it against the inner rim (3). No misalignment is distance between the tire and the object. Refer to
permissible. Figure 3−5. If the variation in distance exceeds
6. Slide the outer rim (10) on the wheel (5). Be sure 0.25 in (6.3mm), the rims are misaligned.
the valve stem (9) points inward and is centered 12. To correct misalignment, loosen the lug nut where
between the two spokes opposite the valve stem of the greatest distance occurs and tighten the lug
the inner rim (3). nut opposite.
7. Push the assembly into position, so the inner rim 13. Repeat Steps 11 and 12 until the proper alignment
(3) fits snugly against the mounting surfaces of the is obtained. Check the lug nuts to be sure each is
wheel (5) at each spoke, and the rim spacer (1) fits torqued to the specified amount.
snugly and uniformly against the inner rim and
outer rim (10).
8. Install the rim clamps (6) and lug nuts (7) on each CAUTION
stud (8). Tighten the lug nuts until the face of each Improper torque can cause damage to
is flush with the studs. components, rim slippage, or alignment
9. Rotate the wheel (5) one half turn to allow the parts problems. Tighten the lug nuts to the
to seat naturally. specified torque only.
10. Tighten the lug nuts (7), one turn at a time, following
the criss-cross sequence shown in Figure 3−4.

3−4 Section 3 − Periodic Adjustments

 Operator’s Manual
1 7 6 1 6

4 2

3
5 5

Spoke Wheel Disc Wheel

Note: * Valve Stem Position May Vary

1. Tire And Rim 5. Wheel
2. Lug Nut 6. Brake Drum
3. Stud 7. Valve Stem*
4. Rim Clamp

Figure 3−6
Front Tire And Rim Assembly

14. Properly position a rim cage in front of the tire and 19. Inflate the tires to the pressure listed in the
Tire In-
rim assembly. Figure 3−1. flation" chart located in the Crane Rating Manual.
20. Start the engine, fully retract the outrigger jacks
and beams, and drive the crane approximately 1
DANGER mile (1.6km). Tighten the lug nuts again using the
proper torquing sequence (Figure 3−4) and rec-
Use a rim cage and stand clear when inflating ommended torque.
the tires. Rim components are under extreme
pressure and may fly off. Failure to use a rim Note: Lug nut torque values should be checked
cage could result in a fatal accident. every 10 hours, for the first 50 hours of opera-
tion, after any tire and rim assembly is installed.
15. Install the cores in the valve stems (9). Using an air Tighten any lug nuts, as required, to the recom-
hose equipped with a clip-on chuck and in-line mended torque value. Check the lug nut torque
pressure gauge, inflate the tires to 10 psi (68kPa). every 50 hours of operation thereafter.
Inspect all parts to see that they are properly
seated. Figure 3−3.
Front Tire And Rim Removal
Note: The air system of the crane is equipped 1. Properly park the crane on a firm, level surface,
with quick disconnect fittings, which may be shift the transmission to neutral, and engage the
used to supply air pressure to inflate tires. The park brake.
fittings are located on either side of the carrier 2. Loosen each of the lug nuts (2) one half turn. Refer
just behind the front axles. to Figure 3−6.
3. Level the crane on outriggers and shutdown the
16. If parts are not properly seated, completely deflate
engine.
the tires and correct the problem.
4. Adequately support the tire and rim assembly (1)
17. If parts are properly seated, inflate the tire until the
with an appropriate lifting device.
tire bead is fully seated.
18. Completely deflate the tire to prevent any localized
over stretching of the tube.

Section 3 − Periodic Adjustments 3−5

Operator’s Manual
5. Loosen the lug nuts (2) until the outer surface of Note: Check to see that rim clamps on the
each lug nut is flush with the end of the studs (3). spoke wheels do not bottom out until at least
Do not completely remove the lug nuts. 140−180 ft lb (190−244Nm ) torque is applied.
The edges of the rim spacer (1) should consis-
tently meet the edges of the rims.
WARNING 6. Check the alignment of the tire and rim assembly
Exercise caution when removing wheel lug by placing an object on the floor beside the tire,
nuts. The rim clamps may fly off suddenly and and rotating the wheel. Note any variation in the
cause personal injury. distance between the tire and the object. Refer to
Figure 3−7. If the variation in distance exceeds
6. Using a rubber mallet, stand to the side and strike 0.19 in (4.8mm), the tire and rim assembly is
the rim clamps (4) sharply to unseat them. misaligned.
7. Check each rim clamp (4) to be sure it is unseated. 7. To correct misalignment, loosen the lug nut where
Repeat Step 6 if necessary. Remove the lug nuts the greatest distance occurs, and tighten the lug
(2) and rim clamps from the studs (3). nut opposite.
8. Carefully remove the tire and rim assembly (1) from 8. Repeat Steps 6 and 7 until the proper alignment is
the wheel (5). obtained. Check the lug nuts to be sure each is
torqued to the specified amount.
Front Tire And Rim Installation
The correct installation and tightening of the tire and
rim assembly, on a spoke wheel, is one of the most im-
CAUTION
portant operations in wheel maintenance. When tire, Improper torque can cause damage to
rim, or wheel problems occur, incorrect installation and components, rim slippage, or alignment
tightening procedures are usually found to be the problems. Tighten the lug nuts to the
cause of the problem. The following procedures must specified torque only.
be carefully followed to ensure safe and dependable
service. 9. Check the tire and rim assembly to be sure the tire
1. Using a wire brush, thoroughly clean the mounting is properly inflated. Correct tire pressures are
surfaces of the wheel (5), tire and rim assembly (1), listed in the Crane Rating Manual, located in the
and rim clamps (4). Surfaces should be free of upper operator’s cab.
rust, dirt, and excess paint. Refer to Figure 3−6.
Note: The air system of the crane is equipped
2. Slide the tire and rim assembly (1) over the wheel
with quick disconnect fittings, which may be
(5), and push it into position against the tapered
used to supply air pressure to inflate tires. The
mounting surfaces of the wheel. Be sure the valve
stem (7) is centered between two spokes. fittings are located on either side of the carrier
3. Install the rim clamps (4) and lug nuts (2) on each just behind the front axles.
stud (3). Tighten the lug nuts until the face of each 10. Start the engine, fully retract the outrigger jacks and
is flush with the studs. beams, and drive the crane approximately 1 mile
4. Rotate the wheel (5) one half turn to allow the parts (1.6km). Tighten the lug nuts again using the proper
to seat naturally. torquing sequence (Figure 3−4) and recommended
5. Tighten the lug nuts (2), one turn at a time, follow- torque value (Step 5).
ing the criss-cross sequence shown in
Figure 3−4. Always rotate the lug nut to be tight- Note: Lug nut torque values should be checked
ened to the top spoke position. This will ensure every 10 hours, for the first 50 hours of opera-
even tightening of the rim clamps (4) and proper tion, after any tire and rim assembly is installed.
alignment of the tire and rim assembly (1). Tighten Tighten any lug nuts, as required, to the recom-
the lug nuts in this manner until all lug nuts are mended torque value. Check the lug nut torque
torqued to 175−225 ft lb (237−305Nm) for spoke every 50 hours of operation thereafter.
wheels and 450−500 ft lb (610−678Nm) for disc
wheels.

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 Operator’s Manual

A B
1 1

3 2
2
2
C
A
1. Tire 3
2. Stationary Object 4
3. Axle
1. Tire 3. Carrier Frame
Figure 3−7 2. Scribed Lines 4. Tie Rod
Tire And Rim Alignment
Figure 3−8
Front Wheel Alignment
Front Wheel Alignment
6. Shutdown the engine. Make sure distance
A" has
The wheel alignment should be checked seasonally. not changed after engine was shutdown.
The best way to determine proper alignment is by eval- 7. Measure the distances from the scribed line of one
uating tire wear. If the tires are wearing correctly, the tire to the scribed line of the other, at the front and
alignment should be correct. If the tires are not wearing rear of the tire,
B" and
C". Refer to Figure 3−8.
correctly, the following procedure can be used to give
an approximately correct alignment. Professional laser Note: Measurement must be made with the
type alignment equipment should be used to achieve weight of the crane on the axle.
the best accuracy. If assistance is needed in finding
8. Proper toe-in requires the distance at the rear
C"
service facilities capable of doing this alignment,
be 0.06−0.25 in (1.5−6.4mm) greater than at the
please consult the factory.
front
B".
1. Park crane on a firm, level surface, shift the trans-
9. If adjustment is required, loosen the clamps on
mission to neutral, and engage the park brake.
each end of the tie rod and adjust the length of the
2. Raise the crane on outriggers to get the tires off the
tie rod to obtain the proper
B" and
C" dimen-
ground. Release the park brake.
sions. Tighten the clamps.
3. Scribe a line on the approximate center of each tire
10. Roll the crane forward at least 50 ft (15m) and re-
by bringing a pointed, stationary object into con-
peat Steps 2−8 to check the adjustment.
tact with the tread while rotating the wheel. Refer to
11. Repeat Steps 2−10 for the second axle. The toe-in
Figure 3−8. The line must begin and end at the
is now properly adjusted on both axles.
same point on the tread.
12. With the distances at
A" equal on the first axle,
4. Apply park brake and retract outriggers to allow
check the the distances at
A" on the second axle.
the entire weight of the crane to rest on the tires.
If the distances at
A" are equal proceed with Step
5. Turn the wheels to align the left wheel parallel with
13. If the distances at
A" are not equal proceed
the carrier frame. This can be done by equalizing
with the following:
the distances at
A". Refer to Figure 3−8.
a. Loosen the clamps on each end of the right
drag link on the second axle. Refer to
Figure 3−9.
DANGER b. Adjust the length of the drag link to equalize
Use extreme caution when operating the the distances at
A". Tighten the clamps.
steering with someone under the carrier. The 13. Turn the wheels full left and full right and check all
hydraulic force behind the steering clearances of the wheels, linkages, and other
components is capable of severely injuring crane components.
anyone caught in the steering linkage or 14. Adjust the axle stop bolts on the steering knuckle
trapped behind a tire. Post a signalman to as required to prevent any interference between
watch carefully to ensure the safety of the the wheels, linkages, and other crane compo-
person under the carrier. nents.

Section 3 − Periodic Adjustments 3−7

Operator’s Manual

1 2 3 4

8 7

6 5

1. Left Relief Plunger − Max Left Turn Angle 5. Right Rear Drag Link
2. Front Steering Gear 6. Right Front Drag Link
3. Right Relief Plunger − Max Right Turn Angle 7. Steering Drive Shaft
4. Rear Steering Gear 8. Miter Box

Figure 3−9
Steering Linkage

15. With the entire weight of the crane on the tires, turn relief just before the wheels contact the axle
the wheels full left and full right and check that the stop bolts. Refer to Figure 3−9.
steering gears go over relief just before the wheels
contact the axle stop bolts. Note: Turn relief plunger in to reduce maxi-
mum turn angle, turn out to increase angle.
Note: The steering gear will make a hissing
sound when it is going over relief. b. Turn the wheels full left. On the right side of the
crane adjust the left relief plunger on the front
16. If steering gears go over relief just before the steer gear until the steering gears go over relief
wheels contact the axle stop bolts, go to Step 17. If just before the wheels contact the axle stop
the steering gears do not go over relief just before bolts.
the wheels contact the axle stop bolts, proceed 17. Check that the steering wheel is centered when the
with the following: wheels are positioned straight. If the steering
wheel is centered when the wheels are positioned
straight, go to Step 18. If the steering wheel is not
WARNING centered when the wheels are positioned straight,
proceed with the following:
Do not loosen the relief plungers beyond
a. Position the wheels so they are straight ahead.
flush with the end cap. The relief plunger
b. Disconnect the steering drive shaft from the
could eject from the end cap causing a
miter box and center the steering wheel.
sudden release of hot oil which could cause
burns or other serious injury. c. Reassemble the steering drive shaft and
torque the drive shaft capscrew.
a. Turn the wheels full right. On the right side of 18. Test all steering functions before placing the crane
the crane adjust the right relief plunger on the in service.
front steer gear until the steering gears go over

3−8 Section 3 − Periodic Adjustments

 Operator’s Manual
Carrier Brakes

WARNING
Removal of the bands holding dual air brake 1
chambers together before caging the power 2
spring will result in the chamber and its
internal parts being rapidly and forcefully
ejected. This may result in severe personal
injury. Always cage the power spring before
attempting any brake or air chamber repair. If
any doubt exists as to whether a potential
safety hazard exists, contact your nearest 3
distributor before repairs are attempted.

1. Dust Plug
Caging Dual Air Brake Chamber 2. Side Pocket
3. Caging Bolt
A dual air brake chamber is a brake system component
that uses two internal air chambers to control the func- Figure 3−10
tions of the service and park brakes. This particular Air Brake Chamber
crane only uses dual air brake chambers on the rear
brakes. 5. Insert the caging bolt into the end of the air brake
The chamber closest to the push rod controls the serv- chamber as far as possible. Refer to Figure 3−11.
ice brake. The other chamber controls application of 6. Rotate the caging bolt 1/4 turn to lock it in place.
the park brake. The park brake chamber contains a Install the lockwasher and nut on the caging bolt.
large high force (power) spring that will cause the unit 7. Note the position of the push rod and clevis as the
to literally
explode" if it is not caged prior to disassem- caging bolt nut is tightened . It should be retracting
bly. Caging compresses and restrains the power into the brake chamber as the nut is tightened. Re-
spring. Use the following procedure to cage the power fer to Figure 3−12.
spring. 8. Continue to tighten the caging bolt nut until the
1. Park the crane on a firm, level surface. Engage the power spring is fully caged. Do not over tighten,
park brake and shift the transmission to neutral. 50 ft lb (67Nm) maximum.
2. Level the crane on fully extended outriggers, re-
Note: If the cranes air system is inoperative and
lease the park brake and shutdown the engine.
the park brake is engaged, tightening the cag-
Note: If leveling the crane on outriggers is not ing bolt nut will be more difficult than if the park
practical, the wheels may be blocked so that the brake is released.
park brake can be released.
9. The power spring has now been caged Continue
3. Remove the dust plug from the end of the air brake with any necessary repair. Repeat the above pro-
chamber. Refer to Figure 3−10. cedure for each brake serviced.
4. Locate and remove the caging bolt assembly
which is stored in the side pocket of the air brake
chamber.

Section 3 − Periodic Adjustments 3−9

Operator’s Manual

1
1

3
1. Power Spring
2. Push Rod 2
1. Power Spring 3. Clevis
Figure 3−11 Figure 3−12
Air Brake Chamber − Power Spring Free Air Brake Chamber − Power Spring Caged

Releasing A Caged Dual Air Brake 3. Slowly loosen the caging bolt to release the power
spring by turning it counterclockwise.
Chamber
Note: If the cranes air system is inoperative and
The park brake chamber contains a large high force
the park brake is engaged, tightening the cag-
(power) spring that will cause the unit to literally
ex-
ing bolt will be more difficult than if the park
plode" if it is not caged prior to disassembly. Caging
compresses and restrains the power spring. After in- brake is released.
stalling the air brake chamber on the crane, the power 4. Note the position of the push rod and clevis while
spring must then be released in order for the park loosening the caging bolt. It should begin to ex-
brake feature of the brake chamber to function. Use tend out of brake chamber as the nut is loosened.
the following procedure to release the caged power 5. When the power spring is fully released the caging
spring once the unit is installed on the crane. bolt and stop washer can be removed from the
1. Park the crane on a firm, level surface. Engage the chamber.
park brake and shift the transmission to neutral. 6. Store the caging bolt in the side pocket of the air
2. Level the crane on fully extended outriggers, re- brake chamber and install the washer and locknut.
lease the park brake, and shutdown the engine. Refer to Figure 3−10.
Note: If leveling the crane on outriggers is not 7. Install the dust plug on the end of the air brake
chamber. Refer to Figure 3−10.
practical, the wheels may be blocked so that the
park brake can be released.

3−10 Section 3 − Periodic Adjustments

 Operator’s Manual
Typical Front Axle Typical Rear Axle
Brake Chamber Brake Chamber

5 6

2
3
4

3
7
5
2
6
1. Slack Adjuster Arm 3. Push Rod 5. Retracted Length 7. Rear Air Brake Chamber
2. Grease Fitting 4. Front Air Brake Chamber 6. Applied Length

Figure 3−13
Front And Rear Brake Chambers

Brake Inspection 4. Make an 80−90 psi (552−620kPa) brake applica-

tion. Measure the pushrod length again.
The front and rear brakes are equipped with automatic
slack adjusters to compensate for brake lining wear. Note: To obtain an 80−90 psi (552−620kPa)
They should be checked periodically to ensure that brake application, start the engine and build
they are operating properly. Refer to Figure 3−13. system pressure to 100 psi (689kPa). Shut-
1. Park the crane on a firm, level surface. Shift the down the engine. Make and hold a full brake ap-
transmission to neutral and engage the park plication. This will give 80−90 psi
brake. (552−620kPa) in the air chamber.
2. Level the crane on fully extended outriggers with all
tires clear of the ground. Shutdown the engine. 5. Subtract the retracted length from the applied
3. Measure the pushrod length (distance from the length. The difference is the
applied stroke".
face of air chamber to the centerline of the pushrod 6. The applied stroke should be 2 in (5cm) or less.
clevis pin) when fully retracted. Refer to 7. If the automatic slack adjuster does not maintain
Figure 3−13. specified applied stroke, further service is re-
quired.

Section 3 − Periodic Adjustments 3−11

Operator’s Manual

0.125 in A
(3.175mm)
16
15
12
14
11

10 13

8.15 in
(20.7cm) A
3

1 4

1.5 in
2 (38mm)

8
5 11 in 7
(28cm) 9
6
1. Jam Nut 5. Clutch Cable 8. Inspection Plate 11. Release Yoke Shaft 14. Adjusting Arm
2. Rod End 6. Jam Nut 9. Transmission 12. Spring 15. Adjusting Bolt
3. Stop Block 7. Rod End 10. Clutch Lever 13. Clutch Switch 16. Jam Nut
4. Clutch Pedal

Figure 3−14
Clutch Linkage

Carrier Clutch Adjustment Clutch Linkage Adjustment

1. With clutch pedal (4) all the way out and clutch ca-
Clutches must be adjusted periodically to compensate ble (5) fully retracted in the cab, check the 8.15 in
for disc wear. The clutch must be kept in proper adjust- (20.7cm) dimension. Adjust, if necessary, by back-
ment by frequently inspecting the clutch pedal free ing the jam nut (1) off the rod end (2). Thread rod
travel. end in or out to obtain the specified dimension.
Check the free travel by pushing the pedal down by Tighten jam nut against rod end. Refer to
hand. Free travel should be 1.5 in (38mm). Make sure Figure 3−14.
the free travel is a result of actual release bearing clear- 2. At the clutch end, pull clutch cable (5) all the way
ance, and not worn linkage. Before adjusting clutch out and check the 11 in (28cm) dimension. Adjust,
pedal free travel, check and/or adjust the clutch link- if necessary, by backing the jam nut (6) off the rod
age and clutch brake. If necessary, adjust pedal free end (7). Thread rod end in or out to obtain the
travel. Refer to Figure 3−14 and Figure 3−15. specified dimension. Tighten jam nut against rod
end.
3. Attach the spring (12) to the clutch lever (10).

3−12 Section 3 − Periodic Adjustments

 Operator’s Manual
1 2 3 4 5

0.125" 0.5"
(3.175mm) (12.7mm)
1. Release Bearing Coupler 5. Clutch Brake
2. Release Bearing Locknut 6. Release Bearing Pad
3. Adjuster Ring 7. Release Bearing
4. Release Yoke 1. Spanner Wrench On Release Bearing Coupler
2. Spanner Wrench On Release Bearing Locknut

Figure 3−15 Figure 3−16

Carrier Clutch Adjustment Spanner Wrench Location

4. Turn adjusting arm (14) clockwise until contact is 9. Loosen clutch switch mounting screws and adjust
made inside the clutch housing. Turn adjusting the switch toward clutch lever until switch is acti-
bolt (15) to obtain the 0.125 in (3.175mm) dimen- vated. Tighten mounting screws.
sion. 10. Install stop block (3) firmly against clutch pedal
5. Check that the clutch brake engages by pushing arm.
the clutch pedal to the floor. Increased resistance 11. Install inspection plate (8) to transmission (9).
of the clutch pedal must occur approximately 1 in
(25.4mm) above the floor. Adjust, if necessary, by Clutch Pedal Free Travel Adjustment
backing the jam nut (1) off the rod end (2). Thread 1. Park crane on a firm, level surface. Shift the trans-
rod end in or out to obtain the specified dimension. mission to neutral and engage the park brake.
Tighten jam nut against rod end. 2. Level the crane on fully extended outriggers with all
6. Remove inspection plate (8) from transmission (9). tires clear of the ground.
7. Visually check release bearing (7) travel and free 3. Locate and remove the inspection plate (8) from
travel between release yoke (4) and release bear- the bottom of the transmission (9). Refer to
ing pad (6). Refer to Figure 3−15. Release bear- Figure 3−14.
ing travel should be 0.50 in (12.7mm) minimum. 4. Measure the distance between the release bearing
Free travel should be 0.125 in (3.1mm). (7) and the clutch brake (5). Refer to Figure 3−15.
8. Visually check clutch pedal (4) free travel. Refer to This distance should be 0.5 in (12.7mm). If this dis-
Figure 3−14. There must be 1.50 in (3.8cm) of tance measures 0.5 in (12.7mm), proceed to Step
pedal free travel at the top of the stroke. Adjust if 5. If distance is not correct, proceed with to the fol-
necessary. See
Clutch Pedal Free Travel Adjust- lowing:
ment" outlined later in this Operator’s Manual. a. Using 2 spanner wrenches, loosen the release
bearing locknut (2). Thread locknut back to-
Note: If there is no pedal free travel the clutch
ward transmission a small distance to ensure
will slip or burn out. This adjustment is made in-
that it will not interfere with the adjustment pro-
ternally in the clutch not in the linkage.
cess.

Section 3 − Periodic Adjustments 3−13

Operator’s Manual
b. Using the adjuster ring (3), rotate the re- 5. Measure the distance between the release yoke(4)
lease bearing threaded sleeve into or out of and the release bearing pad (6). Refer to
the release bearing coupler (1) to obtain the Figure 3−15. This distance should be 0.125 in
0.5 in (12.7mm) distance. If the threaded (3.175mm). If this distance is correct proceed to
sleeve is difficult to turn, it may be due to lack of Step 6. If this distance is not correct proceed with
clearance between the release yoke (4) and the following:
the release bearing pad (6). This will cause a. Locate the adjusting arm (14) on the end of the
tension on the threads of the release bearing release yolk shaft (11). Refer to Figure 3−14.
sleeve. In this case, disconnect the external Loosen the jam nut (16) and thread the adjust-
linkage. ing bolt (15) in or out to obtain the 0.125 in
(3.175mm) distance.
Note: When measuring the release bearing
travel distance, use slight pressure to hold Note: Turn the adjusting bolt in to decrease,
the release bearing rearward. This will re- out to increase the distance.
move end play in the bearing assembly.
b. Tighten jam nut (16) against the adjusting arm
c. Thread the release bearing locknut (2) forward (14).
by hand, toward the release bearing coupler 6. Verify clutch adjustment by checking the pedal free
(1), as far as it will go. travel. Also verify that the clutch brake engages
d. Using two spanner wrenches, place one on approximately 1 in (25.4mm) above the cab floor.
the notches of the release bearing coupler (1)
and the other on the release bearing locknut
(2). Use the first wrench to prevent the coupler
from rotating while using the second wrench to
tighten the locknut against the coupler as a
jam nut. Final tightening can be done by plac-
ing the two wrenches in notches that will result
in the two wrench handles diverging slightly
from one another. Refer to Figure 3−16. Then
both handles can be grasped with one hand
and squeezed snugly together.

3−14 Section 3 − Periodic Adjustments

 Operator’s Manual

9 8 4 5 10

3
2
1

1. Outer Outrigger Beam

2. Outrigger Box
3. Inner Outrigger Beam
4. Rear Inner Outrigger Beam Bearing Pad
5. Rear Outer Outrigger Beam Bearing Pad
6. Inner Outrigger Beam Bearing Pad
7. Outer Beam Bearing Pad
8. Bearing Pad Lock Plate
9. Capscrew And Washer
10. Shim 9 8 7 6 10
Figure 3−17
Outrigger Beam Bearing Pads

outer beam. Refer to Figure 3−17. Do this on all

Outrigger Beam Bearing four outrigger beams.
Pad Adjustment 3. Extend the outrigger jacks until the beams contact
the shims. Do not raise the crane off the ground.
Bearing pads are provided on the outrigger beams as a 4. Remove all outrigger box covers. Remove bear-
means of keeping the outrigger beams working ing pad lock plates. Shim, as required, to main-
smoothly. They must be adjusted periodically to pre- tain 0.15 in (3.8mm) clearance. Replace bearing
vent excessive deflection of the beams. Refer to pad lock plates. Use Loctite® 242 on threads of
Figure 3−17. capscrews.
1. Park crane on a firm, level surface. Extend the out- Note: If clearance can not be obtained due to
rigger beams approximately 4 in (10.1cm). bearing pad wear, replace the bearing pads as
2. Place the 0.15 in (3.8mm) shim on top of the inner required.
outrigger beam and between the beam and outrig- 5. Fully retract the outrigger jacks and check the
ger box. Place another 0.15 in (3.8mm) shim on 0.15 in (3.8mm) clearances.
top of the outer beam between inner beam and the 6. Remove shims from the top of the beams.

Section 3 − Periodic Adjustments 3−15

Operator’s Manual
Swing Brake Bleeding
Bleed the swing brake whenever a hydraulic line is re-
moved from the swing unit to remove any air that may
have been trapped in the circuit. Use the following pro-
cedure to bleed the swing brake.
1. Park the crane on a firm, level surface. Shift the
transmission to neutral and engage the park
brake.
2. Engage travel swing lock and shutdown the en-
gine.
3. Position a suitable container under the bleeder
plugs.
4. Loosen the park brake bleeder plug. Refer to
Figure 3−18. Turn the key switch to the
ON" posi-
tion but do not start the engine.
5. Operate the swing park brake control switch lo-
cated on the overhead control panel. Allow the
fluid to discharge into the container until no air is
1 present. Tighten the park brake bleeder plug.
6. Turn the key switch to the
OFF" position.
7. Loosen the service brake bleeder plug. Push the
swing brake pedal and allow the fluid to discharge
1. Park Brake Bleeder Plug − Top
Service Brake Bleeder Plug − Bottom into the container until no air is present. Tighten
the service brake bleeder plug.
Figure 3−18 8. Check the hydraulic oil level. Refer to
Hydraulic
Swing Unit − Standard Reservoir Oil Level Check" found in Section 2 of
this Operator’s Manual.
9. Test all swing brake functions before operating the
crane.
10. Properly dispose of used oil.

3−16 Section 3 − Periodic Adjustments

 Operator’s Manual
Travel Swing Lock Adjustment
The travel swing lock is a two position, positive lock of
the upper over the carrier to prevent swinging of the up-
per. The travel swing lock must be kept adjusted.
1. Park the crane on a firm, level surface. Shift trans- 1
mission to neutral and engage the park brake.
Level the crane on outriggers.
2. Check that the travel swing lock is engaged and
shutdown engine. Refer to Figure 3−19.

Note: The travel swing lock control cable

should only operate after the release button in 2
the center of the control knob is depressed. Re- 0.25 in
place the control cable if the release button 3 (6.35mm)
does not operate properly. Engaged
4 Clearance
3. Check the engagement of the swing lock pin in the 5
retainer ring on the carrier deck. The pin should ex-
tend in the retainer plate to within 0.25 in (6.35mm) 6
of the carrier deck.
4. Adjust the stroke of the swing lock as required by 1. Cable Adjusting Nuts 4. Pin Guide Tube
using the cable adjusting nuts. 2. Swing Lock Pin 5. Retainer Ring
3. Grease Fitting 6. Carrier Deck
5. Test the swing lock in each working position before
operating the crane. Figure 3−19
Travel Swing Lock Adjustment

Section 3 − Periodic Adjustments 3−17

Operator’s Manual

1 2

4 3
1. Control Cable 3. Swing Lock Pawl
2. Adjusting Nuts 4. Turntable Bearing Gear Teeth

Figure 3−20
360° Swing Lock Adjustment

2. Engage the travel and 360° swing locks. Shut-

360° Swing Lock System down the engine.
The 360 swing lock system, if equipped, functions to 3. Visually inspect the 360 swing lock pawl. The
prevent rotation of the upper over the carrier. The 360 pawl should be fully engaged with the linkage just
swing lock functions by engaging a pawl in the external over center. Refer to Figure 3−20.
turntable bearing gear teeth. The swing lock must be 4. If the pawl is not fully engaged and the linkage is
correctly adjusted in order to operate properly. Use the not just over center, use the cable adjusting nuts to
following procedures to properly inspect and adjust correctly position it.
the 360 swing lock. 5. Tighten the adjusting nuts and test the 360 swing
lock before operating the crane.
360° Swing Lock Inspection And
Adjustment
1. Park the crane on a firm, level surface, shift the
transmission to neutral, and engage the park bra-
ke. Level the crane on outriggers.

3−18 Section 3 − Periodic Adjustments

 Operator’s Manual
Bubble Level Adjustment
1 3 2
A bubble level, for leveling the crane on outriggers, is
mounted in the upper operator’s cab on the right side
wall, and at each of the remote outrigger stations on the
carrier. They should be checked periodically to ensure
proper adjustment.

5
°
1. Park the crane on a firm, level surface. Engage the
park brake and shift the transmission to neutral.

0°
2. Level the crane on fully extended outriggers. Posi- 3° 1° 1° 3°

0°
tion the upper over the rear of the carrier and en-
gage the travel swing lock. Fully retract the power

°
5
sections of the boom. Boom down to 0° angle.
3. Verify the crane is level by placing a carpenter’s
level on the turntable bearing. Check levelness
with the upper over the rear and over the side of the
crane. Adjust the outriggers as necessary. 1. Glass Vial
4. Rotate the adjustment nuts as required until the 2. Adjusting Nut
3. Spring
bubble is centered within the vial. Refer to
Figure 3−21. Figure 3−21
Note: Do not flatten out the springs under the Bubble Level Adjustment − Style 2
bubble level. Loosen rather that overtighten the
adjustment nuts to gain the necessary adjust-
ment.
Crane Monitoring System
A properly calibrated Rated Capacity Limiter is critical
for safe crane operation. The boom angle and length
are crucial factors in determining crane capacities. The
Rated Capacity Limiter must be checked for accuracy
on a daily basis and calibrated as needed.
The Rated Capacity Limiter should be calibrated by a
qualified technician only. Contact your local distributor
to arrange for a qualified technician to perform the cal-
ibration procedures.

Section 3 − Periodic Adjustments 3−19

Operator’s Manual
Hydraulic System Relief Relief Valve Pressure Checking
Instructions
Valve Adjustment
Refer To Figure 3−23 thru Figure 3−28 for relief valve
The following instructions pertain to checking and set- and quick disconnect fitting locations.
ting all relief valve pressures in the hydraulic system.
1. Use a gauge of known accuracy. Have the gauge
All cranes are tested and properly adjusted before leav-
calibrated if necessary. Use a snubber or gate
ing the factory and should not need checking when first
valve to reduce shock loading in the gauge.
put into operation. Each 250 hours of operation, the re-
2. Release the hydraulic system precharge pressure
lief valve pressure settings should be checked. A drop
and work the control, for the circuit being checked,
in relief valve pressure setting may be noticed the first
back and forth to relieve any trapped hydraulic
time checked. This is normal and is probably due to
pressure.
lessening of spring tension or stress relief in relief valve
parts. Note: For functions which are operated by a
If a new or rebuilt pump is installed, all relief valve pres- toggle switch, the ignition switch must be in the
sures must be backed off and reset, as outlined in this
ON" position but do not start the engine.
Section before putting the crane in operation. The pur-
pose of this is to avoid the possibility of damaging the
new pump from over pressurization, if relief valves are
set incorrectly. Do not operate the crane over relief WARNING
pressures for extended periods of time to avoid over- All trapped hydraulic pressure must be
heating of hydraulic oil. exhausted from the system before installing a
gauge in any quick disconnect. A sudden
CAUTION release of hot oil could cause burns or other
serious injury.
Relief valves are provided to protect the
hydraulic system. Do not increase relief valve 3. Install the pressure gauge on the quick disconnect
pressures above specifications or hydraulic fitting.
system damage may occur. 4. Refer to
Hydraulic Pressure Settings",
Figure 3−22, to determine the correct pressure
setting for the circuit being checked. Also, review
Preparing The Crane For Checking the procedure for checking that particular circuit
Relief Pressures outlined in the chart.
1. Park the crane on firm, level surface. Shift the 5. Start the engine.
transmission to neutral and engage the park 6. If applicable, fully engage the control for the circuit
brake. being checked and hold it in that position.
2. Level the crane on outriggers and operate the hy- 7. With the engine running at the speed specified in
draulic functions, as required, to bring the hydrau- the
Hydraulic Pressure Settings", Figure 3−22,
lic oil temperature to its normal operating range. check the gauge for the correct reading, adjust as
Refer to
Hi Performance Hydraulic Oil" chart lo- required.
cated in Section 2 of this Operator’s Manual for oil Note: Obtain each final pressure by bringing
operating temperature ranges.
the pressure up to the proper setting, not by
3. Engage the travel swing lock with the upper di-
backing down to it.
rectly over the front of the carrier.
4. Fully retract and lower the boom. Shutdown the 8. Allow the engine to return to idle before shutting it
engine. down.
9. Release the hydraulic system precharge pressure
Note: Checking relief valve pressures is simpli-
and work the control back and forth to relieve any
fied by using two persons, one in the upper op-
hydraulic pressure before removing pressure
erator’s cab to operate the controls and one to gauge from the quick disconnect fitting.
check and adjust the relief valves.

3−20 Section 3 − Periodic Adjustments

 Operator’s Manual

Hydraulic Pressure Settings

Relief Hydraulic Quick Disconnect & Relief Valve
Procedure For Setting The Relief Valve
Valve Circuit Adjustment Location Setting
Set upper pilot control relief valve (#6) to
1,750 psi (12 066kPa).
Set carrier pilot control relief valve (#3) to
Counter- 1,750 psi (12 066kPa).
weight Re-
Figure 3−23 1,700 psi Engage counterweight control and hold. Ad-
moval
A&B (11 721kPa) just with engine at idle.
1 (With Air Sus-
pension) Reset carrier pilot control relief valve (#3) to
1,900 psi (13 100kPa).
Set upper pilot control relief valve (#6) to
475±25 psi (3 275±172kPa).
Figure 3−23 1,000 psi Engage axle lift control and hold. Adjust with
Axle Lift
A&C (6 895kPa) engine at idle.
Outrigger Figure 3−23 3,000 psi Fully retract an outrigger beam and hold.
2
Inner Mid Tele D&E (20 685kPa) Engine at full throttle.
Pilot Con- Figure 3−24 1,900 psi
3 Adjust with engine at idle.
trol(Carrier) A&F (13 100kPa)
650 psi
Level crane on main outriggers.
Bumper Figure 3−24 −0 +50 psi
4 Fully extend bumper outrigger and hold.
Outrigger G&H (4 481kPa)
Engine at idle.
(+0 −344kPa)
Crane on tires, boom fully retracted, travel
Figure 3−25 2,000 psi swing lock engaged with boom over front.
5 Steering
I&J (13 790kPa) Retract bumper outrigger jack and hold.
Engine at idle.
Note:
1. Adjust all pressures to within ±50 psi (344kPa) except where noted.
Figure 3−22
Relief Valves Pressure And Adjusting Procedures

Section 3 − Periodic Adjustments 3−21

Operator’s Manual

Hydraulic Pressure Settings

Relief Hydraulic Quick Disconnect & Relief Valve
Procedure For Setting The Relief Valve
Valve Circuit Adjustment Location Setting
Pilot Control Figure 3−26 475±25 psi
6 Adjust with engine at idle.
(Upper) K&L (3 275±172kPa)
Engage travel swing lock.
Swing
Engine at idle.
Figure 3−27
Left Swing left and hold. Check pressure.
M&N
1,500 psi
(10 342kPa)
7 Right Figure 3−27 Swing right and hold. Check pressure.
M&O
Crane on fully extended outriggers, travel
Tip Telescope swing lock engaged with boom over rear.
Figure 3−27 3,000 psi
M&P (20 685kPa) Engine at full throttle.
Outer Mid Tele Fully retract tip telescope cylinder and
hold.
Crane on fully extended outriggers, travel
swing lock engaged, boom fully retracted
Figure 3−27 3,500 psi
8 Boom Hoist and over rear.
Q&R (22 408kPa)
Fully boom up and hold.
Engine at full throttle.
Travel swing lock engaged with boom over
rear.
Rear Winch Figure 3−28 Winch selector switch in position.
(Main) S&T Remove and plug line to winch brake.
Engage winch down and hold.
Engine at full throttle.
3,500 psi Travel swing lock engaged with boom over
9 rear.
(22 408kPa)
Winch selector switch in position.
Remove and plug line to winch brake.
Front Winch Figure 3−28
(Auxiliary) S&U Set rear winch relief to 3,800 psi (26 201
kPa).
Engage winch down and hold.
Engine at full throttle.
Reset rear winch relief to proper setting.
Note:
1. Adjust all pressures to within ±50 psi (344kPa) except where noted.
Figure 3−22
Relief Valves Pressure And Adjusting Procedures − Continued

3−22 Section 3 − Periodic Adjustments

 Operator’s Manual

1 2
Bottom View of Carrier
Front

1 B C

D
Figure 3−23
Relief Valves 1 And 2 − Carrier

Section 3 − Periodic Adjustments 3−23

Operator’s Manual

3 4
F H

Figure 3−24
Relief Valve 3 And 4 − Carrier

3−24 Section 3 − Periodic Adjustments

 Operator’s Manual

Front

Figure 3−25
Relief Valve 5 − Carrier

Section 3 − Periodic Adjustments 3−25

Operator’s Manual

6
Bottom View of Upper Operator’s Cab
Front

6
K

Figure 3−26
Relief Valve 6 − Upper

3−26 Section 3 − Periodic Adjustments

 Operator’s Manual

7
7 M
P
N
O

Figure 3−27
Relief Valves 7 And 8 − Upper

Section 3 − Periodic Adjustments 3−27

Operator’s Manual

9
T

Figure 3−28
Relief Valve 9 − Upper

3−28 Section 3 − Periodic Adjustments

 Operator’s Manual
Right
Wrong

Figure 3−29
Shutdown the engine, ensure that the operator has vacated the upper operator’s cab, and insert
blocking in the diamond shaped hole closest to the base section of the boom before putting hands or
tools inside a boom section.

3. Check the thickness of all the wear shoes. Refer to

Boom Wear Shoe Adjustment the charts below for the minimum allowable thick-
Boom wear shoes are provided as a means of keeping ness of each wear shoe. Replace the shoes in
the boom working smoothly. They must be adjusted pairs as required.
periodically to prevent excessive deflection of the 4. After adjusting the boom wear shoe clearances,
boom sections. Refer to Figure 3−30. boom up to a 60° angle and fully extend the boom.
1. Level the crane on fully extended outriggers with all Make sure that the boom is straight and the sec-
tires clear of the ground. Swing the upper over the tions are centered within each other. Thoroughly
front of the carrier and engage the travel swing lubricate all boom wear shoes and their sliding sur-
lock. Lower the boom and extend each boom sec- faces as outlined is Section 2 of this Operator’s
tion as required to gain access to each wear shoe. Manual.
2. Center each boom section within the next and ad-
just the top side wear shoes (item 1) to maintain a
Minimum Wear Shoe Thickness−
0.09 in (2.3mm) maximum clearance. Adjust the
Refer to Figure 3−30
bottom side wear shoes (items 9, 11, 13, & 15) to Item Wear Shoe in mm
maintain a 0.03 in (0.8mm) maximum clearance. 4 Top Wear Shoes 0.5 12.7
Bottom Rear Wear Shoe
0.5 12.7
Inner Mid − Nylon
WARNING 5
Bottom Rear Wear Shoe
To avoid personal injury, do not climb, stand, 2.62 66.5
Inner Mid − Metal
or walk on the boom. Use a ladder or similar
Bottom Rear Wear Block
device to reach necessary areas. 6 0.62 15.7
Outer Mid − Metal
To prevent movement of individual boom
10 Bottom Wear Shoe − Base 2.25 57.1
sections, shutdown the engine, ensure that
the operator has vacated the upper operator’s 12 & Bottom Wear Shoes
0.5 12.7
cab, and insert blocking in the diamond 14 Inner Mid, Outer Mid
shaped hole closest to the base section of the 16 Slider Bracket Wear Shoes 0.5 12.7
boom before putting hands or tools inside a 17 Cylinder Wear Shoes 0.38 9.7
boom section.

Section 3 − Periodic Adjustments 3−29

Operator’s Manual

2 3 4
A F 1

E D C B
8 6 5
B 11 C 13 D

10 12
9

E 16 G F G
15

14
17 17

17

16 7
1. Side Wear Shoe − Top (6 Places) 10. Bottom Wear Shoe − Base (2 Places)
2. Extend Wire Rope (3 Places) 11. Side Wear Shoe − Base (2 Places)
3. Extend Wire Rope Anchors (3 Places) 12. Bottom Wear Shoe − Inner Mid (2 Places)
4. Top Wear Shoe − (6 Places) 13. Side Wear Shoe − Inner Mid (2 Places)
5. Bottom Rear Wear Shoe − Inner Mid (2 Places) 14. Bottom Wear Shoe − Outer Mid (2 Places)
6. Bottom Rear Wear Block − Outer Mid (2 Places) 15. Side Wear Shoe − Outer Mid (2 Places)
7. Retract Wire Rope Anchor 16. Telescope Cylinder Slider Bracket Wear Shoes (2 Places)
8. Retract Wire Rope 17. Telescope Cylinder Wear Shoes (3 Places)
9. Side Wear Shoe − Bottom (6 Places)

Figure 3−30
Boom Wear Shoe Adjustment And Inspection

3−30 Section 3 − Periodic Adjustments

 Operator’s Manual

1 3 2

2
Boom Extend Wire Rope Anchors Boom Retract Wire Rope Anchor
1. Extend Rope Anchors 3. Retract Rope Anchor (Both Sides)
2. Jam Nut

Figure 3−31
Boom Extend And Retract Wire Rope Anchors

4. Inspect extend/retract wire rope for wear. Refer to

Boom Extend And Retract
Wire Rope Inspection And Replacement Recom-
Wire Rope Inspection And mendations" in Section 5 of this Operator’s Manu-
al.
Adjustment 5. Lubricate the extend/retract wire ropes. Refer to

Wire Rope Lubrication" in Section 2 of this Opera-
The boom extend and retract wire ropes must be in- tor’s Manual.
spected and the rope anchors torqued periodically to
compensate for stretching of the wire rope. Refer to Extend/Retract Wire Rope Adjustment
Figure 3−30 and Figure 3−31 for locations. 1. Level the crane of fully extended outriggers with all
tires clear of the ground. Swing the upper over the
front of the carrier and engage travel swing lock.
WARNING 2. Fully retract the boom sections. Boom down to 0
To avoid personal injury, do not climb, stand, angle.
or walk on the boom. Use a ladder or similar Note: If the tip section does not contact the out-
device to reach necessary areas. er mid section when fully retracted, loosen the
extend wire ropes and tighten the retract wire
rope until boom is fully retracted.
Extend/Retract Wire Rope Inspection
1. Level the crane on fully extended outriggers with all 3. Access the retract wire rope through the cutout on
tires clear of the ground. Swing the upper over the each side of the boom.
front of the carrier and engage travel swing lock. 4. Loosen the jam nut and torque retract wire rope an-
2. Using the boom telescope override switch, fully ex- chor to 18 ft lb (24Nm). Refer to Figure 3−31.
tend the outer mid and tip sections at 0° angle. Re- Tighten the jam nut.
tract the sections 0.5−1 ft (152−304mm) to re- 5. Remove access cover on the top rear of the boom.
move the load from the extend wire ropes and al- 6. Torque each of the three extend wire rope anchors
low them to sag. to 25 ft lb (34Nm). Repeat the torque until all an-
3. Visually inspect the ropes through the diamond chors are torqued to 25 ft lb (34Nm).
shaped cutouts of the outer mid boom section. If
one or more of the extend wire ropes sag to less Note: A 2 in (50mm)
crows foot" tool is pro-
than 4 in (101mm) from the bottom of the outer mid vided to aid in this adjustment.
section or if there is a difference of more than 1 in Note: Extend wire rope should measure 9 in
(25.4mm) between any of them, wire ropes must (228.6mm) from the bottom of the outer mid
be adjusted. Refer to
Extend And Retract Wire section when properly adjusted.
Rope Adjustment".

Section 3 − Periodic Adjustments 3−31

Operator’s Manual

3−32 Section 3 − Periodic Adjustments

 Operator’s Manual
Table Of Contents
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1

Auxiliary Lifting Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1

Installation Of The Auxiliary Lifting Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1
Removal Of The Auxiliary Lifting Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−2
Offset Lattice Fly Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3
Installation Of The Offset Lattice Fly Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−3
Removal Of The Offset Lattice Fly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−6
Changing The Fly Offset Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−7
Storage Of The Fly Base Section From The Erected Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−10
Storage Of The Fly Base And Tip Sections From The Erected Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−11
Erection Of The Fly Base Section From The Stored Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−13
Erection Of The Fly Base And Tip Section From The Stored Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−16

Section 4 − Attachments i
Operator’s Manual

ii Section 4 − Attachments
 Operator’s Manual

1 2 3 4 5
1. Boom Head Machinery 4. Inner Mid Section
2. Tip Section 5. Base Section
3. Outer Mid Section

Figure 4−1
Four Section Boom Nomenclature

3. Boom down and/or extend the boom, as required,

Boom to ease access to the head machinery.
The boom is a four section boom assembly. It consists 4. Adequately support the auxiliary lifting sheave with
of four basic parts: a base section, an inner mid sec- an appropriate lifting device. It weighs approxi-
tion, an outer mid section, and a tip section. Refer to mately 110 lb (50kg). Position the auxiliary lifting
Figure 4−1. The base section is connected to the up- sheave frame under the boom head cross shaft.
per revolving frame. It is raised and lowered by a boom Align the holes in the auxiliary lifting sheave frame
hoist cylinder. Refer to Section 1 of this Operator’s with the lugs in the main boom and install
Manual for boom operating instructions. capscrews, locknuts, and washers. Refer to
Figure 4−2.
Auxiliary Lifting Sheave 5. Remove the rope guard from the auxiliary lifting
sheave. Reeve the winch rope on the boom deflec-
The auxiliary lifting sheave connects to the boom head
tor sheave, then over the sheave on the auxiliary
machinery. Refer to Figure 4−2. It is used for reeving
lifting sheave. Install the rope guards.
winch rope for the second winch drum. Once installed,
the unit may be left in place without interfering with the
installation, erection, or storage of other boom attach- CAUTION
ments.
All rope guards must be in proper position
during operation.

WARNING 6. Disconnect plug assembly from jumper assembly

The auxiliary lifting sheave adds weight to the on the main boom head and connect it to the auxil-
boom which must be considered in lifting iary arm connector.
capacities. When making lifts from the main 7. Install the anti-two block weight to the auxiliary lift-
boom or fly, refer to the Crane Rating Manual ing sheave anti-two block switch.
for the appropriate deductions from lifting 8. Properly install lockout pin and flag in main boom
capacities. anti-two block switch.

Note: When lockout pin and flag are installed,

Installation Of The Auxiliary Lifting the anti-two block switch is inactive. The flag is
there as visual verification of an inactive switch.
Sheave
When both main boom and auxiliary sheave are
1. Park the crane on a firm, level surface. Shift the
reeved for operation, the lockout pin and flag
transmission to neutral and engage the park
must be removed and properly stored and an
brake.
anti-two block weight must be suspended from
2. Fully retract the boom and position the upper over
each anti-two block switch.
rear of the carrier. Engage the travel swing lock.
9. Properly set the Rated Capacity Limiter to the cur-
rent crane configuration. Refer to Section 1 of this
WARNING Operator’s Manual.
To avoid personal injury, do not climb, stand,
or walk on the boom. Use a ladder or similar
device as required to reach necessary areas.

Section 4 − Attachments 4−1

Operator’s Manual

12 A

2
10
3
4 11

5
LOCKOUT PIN INSTALLED
6
A
7 WARNING
MAIN BOOM ATB IS DISABLED
WHEN LOCK OUT PIN IS IN
HOLE. TO OPERATE MAIN BOOM
9 10 ATB, REMOVE PIN AND STORE
IN STORAGE HOLE BEHIND
SWITCH. FAILURE TO HAVE
FULLY OPERATIONAL ATB SYSTEM
COULD RESULT IN SERIOUS
INJURY OR DEATH.
8 LOCK OUT PIN HOLE

1. Jumper Assembly 6. Auxiliary Lifting Sheave Rope 9. Capscrew, Locknut, & Washer
2. Plug Assembly Guard 10. Main Boom Anti-Two Block Switch
3. Main Boom Head 7. Auxiliary Lifting Sheave Anti-Two 11. Lockout Pin & Flag (Installed)
4. Auxiliary Lifting Sheave Block Switch 12. Lockout Pin Storage Hole
5. Auxiliary Arm Connector 8. Anti-Two Block Weight

Figure 4−2
Auxiliary Lifting Sheave And Anti-Two Block Assembly

10. Check the Crane Rating Manual in the operator’s

cab for necessary deductions with the auxiliary lift-
ing sheave installed before continuing operations.
WARNING
To avoid personal injury, do not climb, stand,
or walk on the boom. Use a ladder or similar
WARNING device to reach necessary areas.
The auxiliary lifting sheave adds weight to the
4. Disconnect the plug assembly from the auxiliary
boom which must be considered in lifting
lifting sheave and connect it to the jumper assem-
capacities. When making lifts from the main
bly on the main boom head.
boom or fly, refer to the Crane Rating Manual
5. Remove, and properly store, the lockout pin and
for the appropriate deductions from lifting
flag from the main boom head anti-two block
capacities.
switch.
6. Remove the anti-two block weight from the auxilia-
ry lifting sheave and install it on the main boom anti-
Removal Of The Auxiliary Lifting two block switch.
Sheave 7. Remove the rope guard from the auxiliary lifting
1. Park the crane on a firm, level surface. Shift the sheave. Remove the winch rope and install the
transmission to neutral and engage park brake. rope guard for storage.
2. Fully retract the boom and position the upper over 8. Adequately support the auxiliary lifting sheave. It
the rear of the carrier. Engage travel swing lock. weighs approximately 110 lb (50kg). Remove the
3. Boom down and/or extend the boom, as required, capscrews, locknuts and washers. Remove the
to ease access to the head machinery. auxiliary lifting sheave. Refer to Figure 4−2.

4−2 Section 4 − Attachments

 Operator’s Manual
9. Properly store the auxiliary lifting sheave, the imately 1,600 lb (721kg) and the tip fly section
capscrews, locknuts, and washers and the winch 780 lb (353kg).
rope which was used on the auxiliary lifting sheave.
10. Properly set the Rated Capacity Limiter to the cur- Note: Fly base section may be installed by itself
rent crane configuration. Refer to Section 1 of this if desired.
Operator’s Manual.

Offset Lattice Fly Section WARNING

To avoid personal injury, do not climb, stand,
The crane may be equipped with either a one or two or walk on the boom or fly. Use a ladder or
piece offset lattice fly. The offset lattice fly section, as similar device to reach necessary areas.
seen in Figure 4−3, connects to the main boom head.
It can be mounted in one of three offset positions: 2, 6. Remove the winch rope from the main boom head
20, and 40. The fly sections extend the boom length machinery or the auxiliary lifting sheave, whichever
for greater heights. The fly sections extend the boom is to be used on the fly, and lay it aside to prevent
length for greater heights. The tip section of the fly ex- damage to it during installation of the fly.
tends its overall length from 34 ft (10m) to 61 ft (18.6m) 7. Lower the boom and extend it to the fly. Slowly
Once installed, the offset lattice fly sections can be raise or lower the boom to engage the fly lugs with
stored on the right side of the boom base section. the head machinery cross shafts.
8. Remove the four fly connecting pins from storage
Installation Of The Offset Lattice Fly rings at the rear of the fly base section. Refer to
Sections Figure 4−3. Install all four pins to connect the fly
1. Park the crane on a firm, level surface, shift the lugs to the head machinery cross shafts on the
transmission to neutral, and engage the park right side of the boom. (Install the pins with the
brake. head on top and keeper on the bottom). Install the
2. Level the crane on fully or intermediate extended pin keepers.
outriggers with all tires clear of the ground. 9. Remove the two fly connecting pins from the boom
3. Position the upper directly over the rear of the car- head machinery cross shaft on the left side of the
rier and engage the travel swing lock. boom head. Refer to Figure 4−3. Install the top
pin to connect the fly lug to the boom head machin-
ery cross shaft on the left side of the boom. If
WARNING equipped, turn the T-handle to push and align the
bottom left fly lug and the bottom boom head cross
Install the offset fly with the crane level on shaft. Install the bottom left fly connecting pin. (In-
fully or intermediate extended outriggers, all stall the pins with the head on top and keeper on
tires clear of the ground, the upper directly the bottom). Install the pin keepers.
over the rear of the carrier, and the travel
swing lock engaged.
Refer to the Crane Rating Manual for the WARNING
maximum boom length with which the fly can
All fly tip and base connecting pins must be
be raised/lowered to/from the ground.
properly installed before operating the crane
Failure to do so could result in the crane with the fly erected. Damage could occur to
tipping. the fly if all connecting pins are not properly
installed.
4. Check that the fly adaptor lug and offset connect-
ing pins are installed in the 2 offset position. Refer 10. Remove the rope guards from the fly base and
to Inset
B", Figure 4−3. boom head deflector sheaves. Reeve the winch
5. Pin the base and tip fly together on secure block- rope over the boom deflector sheave, then on the
ing approximately 5 ft (1.5m) at the base and 81 ft fly base deflector sheave.
(25m) from the boom foot of the crane. Refer to 11. Remove the rope guards from either the fly base or
Figure 4−4. The base fly section weighs approx- fly tip head sheaves, whichever is to be used.

Section 4 − Attachments 4−3

Operator’s Manual
Reeve the winch rope over the appropriate head 15. Properly set the Rated Capacity Limiter to the cur-
sheave and install the rope guards. rent crane configuration. Refer to Section 1 of this
Operator’s Manual.
16. Check the Crane Rating Manual, in the upper oper-
CAUTION ator’s cab, for deductions from the lifting capacities
All rope guards must be in proper position with the fly installed before continuing operations.
during operation.

12. Disconnect plug assembly from jumper assembly

on the main boom head and connect it to the offset
WARNING
lattice fly section connector. The fly adds weight to the boom which must
be considered in lifting capacities when the fly
13. Install the anti-two block weight on the offset lattice
is erected. When making lifts from the main
fly anti-two block switch.
boom or auxiliary lifting sheave with the fly
14. Install lockout pin and flag in anti-two block switch
erected, refer to the Crane Rating Manual for
on the main boom head.
the appropriate deductions from lifting
Note: When lockout pin and flag are installed, capacities. Use the offset lattice fly only when
the anti-two block switch is inactive. The flag is the crane is level on fully or intermediate
there as visual verification of an inactive switch. extended outriggers with all tires clear of the
ground.
When both main boom and fly are reeved for op-
eration, the lockout pin and flag must be re-
moved and properly stored and an anti-two
block weight must be suspended from each
anti-two block switch.

4−4 Section 4 − Attachments

 Operator’s Manual

14 15
18
17
16

15
13

21

20

19

12

11
3
10
4

8 6
9 7
1. Right Side Fly Base Connecting Pin (Pivot Pin) 12. Fly Base Section
2. Right Side Fly Base Connecting Pin 13. Fly Tip Section
3. Boom Head Machinery Cross Shaft 14. Fly Tip Rope Guards
4. Left Side Fly Base Connecting Pin (Fly Stored Position) 15. Fly Base Rope Guard
5. Fly Connecting Pin Storage Rings 16. Fly Tip Connecting Pin Storage Location
6. Boom Head 17. Right Side Fly Tip Connecting Pin
7. T-Handle 18. Right Side Fly Tip Connecting Pin (Pivot Pin)
8. Left Side Fly Base Connecting Pin (Fly Erected Position) 19. Fly Base Deflector Sheave
9. Offset Connecting Pins (2° Position Shown) 20. Fly Base Head Sheave
10. Fly Adaptor Lug 21. Left Side Fly Tip Connecting Pin
11. Offset Connecting Pin Storage Ring

Figure 4−3
Offset Lattice Fly Sections

Section 4 − Attachments 4−5

Operator’s Manual

1. Blocking 1 1
Figure 4−4
Installation And Removal Of The Fly

Removal Of The Offset Lattice Fly 8. Install all fly base and tip rope guards back in the
1. Park the crane on a firm, level surface. Shift trans- deflector and head sheaves. Install the boom head
mission to neutral and engage the park brake. and deflector sheave rope guards.
2. Level the crane on fully or intermediate extended 9. Extend the boom until the fly tip sheave rests on the
outriggers with all tires clear of the ground. ground.
3. Position the upper directly over the rear of the car- 10. Securely block up the fly sections to support it.
rier and engage the travel swing lock. Refer to Figure 4−4. Fly base section weighs
approximately 1,600 lb (721kg) and the fly tip
section 780 lb (353kg).
WARNING 11. Remove the six fly connecting pins and store four
of the pins and keepers in the storage rings at the
Remove the offset fly with the crane level on
fully or intermediate extended outriggers, all rear of the fly. Install the remaining two pins and
tires clear of the ground, the upper directly keepers in the storage holes on the left side of the
over the rear of the carrier, and the travel boom head machinery cross shafts to prevent the
swing lock engaged. shaft from rotating. Refer to Figure 4−3.
Refer to the Crane Rating Manual for the
maximum boom length with which the fly can Note: If only the fly tip section is to be removed,
be raised/lowered to/from the ground. remove the connecting pins from the fly tip lugs.
Failure to do so could result in the crane
tipping.
WARNING
4. If the fly is not in the erected position, erect it per Use extreme care when removing the tapered

Erection Of The Fly Base And Tip Sections From fly connecting pins. They could pop out
The Stored Position" found later in this Section of suddenly and cause personal injury.
this Operator’s Manual.
5. Check that the fly adaptor lug and offset connect- 12. Retract the boom away from the fly.
ing pins are installed in the 2° offset position. Refer 13. Properly reeve or secure the winch rope which was
to Inset
B", Figure 4−3. If necessary, change the used on the fly.
fly offset to the 2° position. Refer to
Changing The 14. Remove the anti-two block weight from the offset
Fly Offset Angle" found later in this Section for de- lattice fly and install it on the main boom head anti-
tailed instructions. two block switch.
6. Boom down fully. Disconnect the electrical cable 15. Remove the plug assembly from the offset lattice
for the anti-two block system and remove the anti- fly and connect it to the jumper assembly on the
two block weight. main boom head.
7. Remove all fly base and tip rope guards. Remove 16. Properly set the Rated Capacity Limiter to the cur-
boom head and deflector sheave rope guards and rent crane configuration. Refer to Section 1 of this
lay the winch rope aside. Operator’s Manual.
17. Properly store fly section to prevent damage to it.

WARNING
To avoid personal injury, do not climb, stand,
or walk on the boom or fly. Use a ladder or
similar device to reach necessary areas.

4−6 Section 4 − Attachments

 Operator’s Manual

2° Offset
1 2 1

Pin Location

20° Offset

Pin Location

7 5
40° Offset

Pin Location
4
3
6

1. Offset Connecting Pin (2° Position Shown) 5. Fly Connecting Pin Storage Ring
2. Fly Adaptor Lug 6. Fly Tip Head Sheave
3. Offset Lattice Fly Tip Section 7. Offset Connecting Pin Storage Location
4. Offset Lattice Fly Base Section

Figure 4−5
Changing The Fly Offset Angle

Changing The Fly Offset Angle

1. Park the crane on a firm, level surface. Shift the WARNING
transmission to neutral and engage the park
Change the fly offset angle with the crane
brake.
level on fully or intermediate extended
2. Level the crane on fully or intermediate extended
outriggers with all tires clear of the ground,
outriggers with all tires clear of the ground.
the upper directly over the rear of the carrier,
3. Position the upper directly over the rear of the car-
and the travel swing lock engaged.
rier and engage the travel swing lock.
Refer to the Crane Rating Manual for the
maximum boom length with which the fly can
be raised/lowered to/from the ground.
Failure to do so could result in the crane
tipping.

Section 4 − Attachments 4−7

Operator’s Manual
4. If the offset lattice fly section is not in the erected If the existing offset angle is 20° and a 40°
position, erect it per
Erection Of The Fly From The offset is desired:
Stored Position" found later in this Section of this a. Relocate the offset connecting pin from the
Operator’s Manual. 20° offset position to the 40° offset position.
5. Carefully extend and/or lower the boom until the fly b. Make sure to properly locate the offset con-
tip head sheave is resting on the ground. Use a necting pins on both sides of the fly and see
signalman to alert the operator when the sheave is that the keeper pins are securely installed.
resting on the ground. c. Slowly boom up to allow the fly section to ad-
just itself to the desired offset angle.
Note: If the crane is not equipped with the fly tip
section or the fly tip section is not erected, lower If the existing offset angle is 40° and a 2°
the fly base section until the fly base head offset is desired:
sheave is resting on the ground a. Carefully extend and/or lower the boom until
the 2° angle is reached.
b. Remove the offset connecting pin from the
CAUTION storage ring on the fly and install it through the
fly adaptor lug, in the front 2° offset hole.
Do not extend the boom or boom down to the c. Make sure to properly locate the offset con-
point of over stressing the offset lattice fly necting pins on both sides of the fly and see
section. Structural damage to the fly could that the keeper pins are securely installed.
occur if care is not taken. Use a signalman to d. Slowly boom up to allow the fly section to ad-
aid the operator in lowering the fly head just itself to the desired offset angle.
sheave to the ground.
If the existing offset angle is 40° and a 20°
6. Use one of the following procedures and the infor- offset is desired:
mation label, located on the offset lattice fly sec- a. Carefully extend and/or lower the boom until
tion, to determine the correct offset connecting pin the 20° angle is reached.
location for the desired offset angle of the fly. Refer b. Relocate the offset connecting pin from the
to Figure 4−5. 40° offset position to the 20° offset position.
c. Make sure to properly locate the offset con-
If the existing offset angle is 2°: necting pins on both sides of the fly and see
a. Remove one of the offset connecting pins from that the keeper pins are securely installed.
each side of the fly and place it in the storage d. Slowly boom up to allow the fly section to ad-
ring provided. just itself to the desired offset angle.
b. Locate the other offset connecting pin in the 7. Properly set the Rated Capacity Limiter to the cur-
correct location for the desired offset angle. rent crane configuration before continuing opera-
c. Make sure to properly locate the offset con- tions. Refer to Section 1 of this Operator’s Manual.
necting pins on both sides of the fly and see 8. Check the Crane Rating Manual, in the operator’s
that the keeper pins are securely installed. cab, for deductions from the lifting capacities with
d. Slowly boom up to allow the fly section to ad- the fly installed before continuing operations.
just itself to the desired offset angle.

If the existing offset angle is 20° and a 2°

offset is desired: WARNING
a. Carefully extend and/or lower the boom until The fly adds weight to the boom which must
the 2° angle is reached. be considered in lifting capacities, whether
b. Remove the offset connecting pin from the the fly is erected or stored on the boom. When
storage ring on the fly and install it through the making lifts from the main boom or auxiliary
fly adaptor lug, in one of the 2° offset holes. lifting sheave, refer to the Crane Rating
c. Relocate the other offset connecting pin from Manual for the appropriate deductions from
the 20° offset position to the 2° offset position. lifting capacities. Use the offset lattice fly only
d. Make sure to properly locate the offset con- when the crane is level on fully or intermediate
necting pins on both sides of the fly and see extended outriggers with all tires clear of the
that the keeper pins are securely installed. ground.
e. Slowly boom up to allow the fly section to ad-
just itself to the desired offset angle.

4−8 Section 4 − Attachments

 Operator’s Manual

Top View

Swinging The Fly Base And Tip Sections

Swinging The Fly Base Section

Figure 4−6
Swinging The Fly

Section 4 − Attachments 4−9

Operator’s Manual
Storage Of The Fly Base Section 9. Remove rope guards from fly base head sheave,
fly base deflector sheave, boom head sheave, and
From The Erected Position boom deflector sheave. Refer to Figure 4−3. Re-
1. Park crane on a firm, level surface. Shift the trans- move the winch rope and lay it aside. Install rope
mission to neutral and engage the park brake. guards back into all sheaves for storage.
2. Level the crane on fully or intermediate extended 10. Properly store winch rope which was used on fly.
outriggers with all tires clear of the ground. Attach a hand line to the tip of the fly base.
3. Position the upper directly over the rear of the car-
rier and engage the travel swing lock.
WARNING
WARNING Do not remove the fly connecting pivot pins on
Store the fly with the crane level on fully or the right side of the boom until the fly is pinned
intermediate extended outriggers with all tires to the storage bracket. The fly could fall.
clear of the ground, the upper directly over the Use extreme care when removing the tapered
rear of the carrier, and the travel swing lock fly connecting pins. They could pop out
engaged. suddenly causing personal injury.
Refer to the Crane Rating Manual for the
maximum boom length with which the fly can 11. Remove the two fly base connecting pins (8) on the
be raised/lowered to/from the ground. left side of the fly and store them in the storage
holes (4) on the boom head cross shafts (3) located
Failure to do so could result in the crane on the left side of the boom.
tipping. 12. Remove the two fly base connecting pins (2) on the
right side of the fly. Refer to Figure 4−3. Store the
4. Check that the offset connecting pins (1) are in-
two pins and keepers in the storage rings (5) on the
stalled in the 2° offset position. Refer to
rear picture frame of the fly base section (12).
Figure 4−5. If necessary, change the fly offset to
the 2° position. Refer to
Changing The Fly Offset
Angle" found earlier in this Section of this Opera-
tor’s Manual for detailed instructions. WARNING
Use a hand line to control fly swing. Fly could
swing around the boom rapidly. Keep all
CAUTION personnel clear of swing path to avoid injury.
Do not extend the boom beyond the
recommended 2−5 ft (0.61−1.5m) length. 13. Slowly swing the fly base section around to the
Extending the boom beyond the 2−5 ft right side of the boom while slowly booming up to
(0.61−1.5m) length may cause boom damage. 20. Refer to Figure 4−6.
14. Align the lug on the front storage bracket with the
5. Position the boom at a 0° angle and extend the mounting hole on the rear of the fly base. Refer to
boom 2− 5 ft (0.61−1.5m). Figure 4−8.
15. Slowly retract the boom to slide the storage lug on
the front of the fly base into the slot on the rear stor-
WARNING age bracket (10). At the same time, the lug on the
front storage bracket (15) should engage through
To avoid personal injury, do not climb, stand,
or walk on the boom or fly. Use a ladder or the hole on the rear of the fly base.
similar device to reach necessary areas. 16. Boom down to 0°. Pull down and rotate retaining
pin (16). Release retaining pin to engage the pin
6. Disconnect plug assembly from fly and connect it through the lug on the front storage bracket (15).
to the jumper assembly on the main boom head.
7. Remove lockout pin and flag from main boom head
anti-two block switch. Properly store lockout pin WARNING
and flag. Do not remove the fly connecting pivot pins on
8. Remove the anti-two block weight from the fly base the right side of the boom until the fly is pinned
section and install it on the main boom anti-two to the storage bracket. The fly could fall
block switch. causing crane damage and/or personal injury.

4−10 Section 4 − Attachments

 Operator’s Manual
17. Remove two fly base connecting pivot pins (1) from
the right side of the boom. Refer to Figure 4−3.
Store pins and keepers in storage rings (5) on the
WARNING
Store the fly with the crane level on fully or
rear picture frame of the fly base section (12).
intermediate extended outriggers with all tires
clear of the ground, the upper directly over the
CAUTION rear of the carrier, and the travel swing lock
engaged.
Before operating or traveling the crane be
sure the right side fly connecting pins are Refer to the Crane Rating Manual for the
properly stored in their storage rings, and the maximum boom length with which the fly can
left side connecting pins are stored in their be raised/lowered to/from the ground.
storage holes in the boom head cross shafts. Failure to do so could result in the crane
Damage could result to the fly and/or boom if tipping.
fly connecting pins are not properly stored.
4. Check that the offset connecting pins (1) are in-
18. Disconnect the plug assembly from the jumper as- stalled in the 2° offset position. Refer to
sembly on the fly base section and connect it to the Figure 4−5. If necessary change the fly offset to
main boom head. the 2° position. Refer to
Changing The Fly Offset
19. Install the anti-two block weight. Refer to Section 1 Angle" found earlier in this Section for detailed in-
of this Operator’s Manual. structions.
20. Properly install lockout pin and flag in main boom
head anti-two block switch.
CAUTION
Note: When lockout pin and flag is installed, the
Do not extend the boom beyond the
anti-two block switch is inactive. The flag is
recommended 2−5 ft (0.61−1.5m) length.
there as visual verification of an inactive switch.
Extending the boom beyond the 2−5 ft
21. Properly set the Rated Capacity Limiter to the cur- (0.61−1.5m) length may cause boom
rent crane configuration. Refer to Section 1 of this damage.
Operator’s Manual.
22. Check the Crane Rating Manual for lifting capaci- 5. Position the boom at a 0° angle and extend the
ties with the fly in the stored position before con- boom 2−5 ft (0.61−1.5m).
tinuing operations.

WARNING
WARNING To avoid personal injury, do not climb, stand,
or walk on the boom or fly. Use a ladder or
The fly adds weight to the boom which must
similar device to reach necessary areas.
be considered in lifting capacities, whether
the fly is erected or stored on the boom. When 6. Disconnect plug assembly from fly and connect it
making lifts from the main boom or auxiliary to the jumper assembly on the main boom head.
lifting sheave, refer to the Crane Rating 7. Remove lockout pin and flag from main boom head
Manual for the appropriate deductions from anti-two block switch. Properly store lockout pin
lifting capacities. and flag.
8. Remove the anti-two block weight from the fly base
section and install it on the main boom anti-two
Storage Of The Fly Base And Tip block switch.
Sections From The Erected Position 9. Remove rope guards from fly base head sheave,
1. Park crane on a firm, level surface. Shift the trans- fly base deflector sheave, the boom head sheave
mission to neutral and engage the park brake. and boom deflector sheave. Refer to Figure 4−3.
2. Level the crane on fully or intermediate extended Remove the winch rope and lay it aside. Install
outriggers with all tires clear of the ground. rope guards back into all sheaves for storage.
3. Position the upper directly over the rear of the car- 10. Properly store winch rope which was used on fly.
rier and engage the travel swing lock. Attach a hand line to the tip of the fly tip section.

Section 4 − Attachments 4−11

Operator’s Manual
15. Remove the two fly base connecting pins (8) on the
left side of the fly and store them in the storage
holes (4) on the boom head cross shafts (3) located
on the left side of the boom.

WARNING
Do not remove fly base connecting pivot pins
on the right side of the boom until the fly is
pinned to the storage bracket. Fly could fall
causing crane damage and/or personal injury.

16. Remove the two fly base connecting pins (2) on the
right side of the fly. Refer to Figure 4−3. Store the
two pins and keepers in the storage rings (5) on the
rear picture frame of the fly base section (12).

Figure 4−7
Fly Tip Storage Label WARNING
Use a hand line to control fly swing. Fly could
swing around the boom rapidly. Keep all
personnel clear of swing path to avoid injury.
WARNING 17. Attach a hand line to the tip of the fly base section.
Do not remove fly tip connecting pivot pins on Slowly swing the fly base section around to the
the right side of the fly until the fly is pinned to right side of the boom while slowly booming up to
the storage bracket. Fly tip could fall causing 20°. Refer to Figure 4−6.
crane damage and/or personal injury. 18. Align the lug on the front storage bracket with the
Use extreme care when removing the tapered mounting hole on the rear of the fly base. Refer to
fly connecting pins. They could pop out Figure 4−8.
suddenly causing personal injury. 19. Slowly retract the boom to slide the storage lug on
the front of the fly base into the slot on the rear stor-
11. Remove the two fly tip connecting pins (21) on the age bracket (10). Refer to Figure 4−8. At the
left side of the fly tip section (13). Refer to same time, the lug on the front storage bracket (15)
Figure 4−3. Store pins and keepers in the storage should engage through the hole on the rear of the
holes (16) on the rear of the fly tip section. fly base.
12. Remove the two fly tip connecting pins (17) on the 20. Boom down to 0°. Pull down and rotate retaining
right side of the fly tip section (13). Refer to pin (16). Release retaining pin to engage the pin
Figure 4−3. Store pins and keepers in the storage through the lug on the front storage bracket (15).
holes (16) on the rear of the fly tip section.

WARNING WARNING
Use a hand line to control fly swing. Fly tip Do not remove the fly base connecting pivot
could swing around fly base rapidly. Keep all pins on the right side of the boom until the fly
personnel clear of swing path to avoid injury. is pinned to the storage bracket. The fly could
fall causing crane damage and/or personal
13. Attach a hand line to the tip of the fly tip section. injury.
Slowly swing the fly tip section around to the right
side of the fly base section. Refer to Figure 4−6. 21. Remove two fly base connecting pivot pins (1) from
14. Align the storage bracket on the fly tip section with the right side of the boom. Refer to Figure 4−3.
the storage bracket on the fly base section. Refer Store pins and keepers in storage rings (5) on the
to Figure 4−8. Install the hitch pin (12) through the rear picture frame of the fly base section (12).
storage brackets and secure the hitch pin.

4−12 Section 4 − Attachments

 Operator’s Manual
Erection Of The Fly Base Section
CAUTION
From The Stored Position
Before operating or traveling the crane, be
1. Park crane on a firm, level surface. Shift the trans-
sure the right side fly connecting pins are
mission to neutral and engage the park brake.
properly stored in their storage rings, and the
2. Level the crane on fully or intermediate extended
left side connecting pins are stored in their
outriggers with all tires clear of the ground.
storage holes in the boom head cross shafts.
3. Position the upper directly over the rear of the car-
Damage could result to the fly and/or boom if
rier and engage the travel swing lock.
fly connecting pins are not properly stored.

22. Remove the two fly tip connecting pivot pins (3) on
the right side of the fly tip section. Refer to WARNING
Figure 4−8. Store one pin and keeper in the stor- Erect the fly with the crane on fully or
age hole (2) on the rear of the fly tip section and one intermediate extended outriggers with all tires
pin and keeper in the top fly tip connecting lug (1) clear of the ground, the upper directly over the
on the left side of the fly tip section. rear of the carrier, and the travel swing lock
engaged.
Refer to the Crane Rating Manual for the
WARNING maximum boom length with which the fly can
A connecting pin and keeper must be installed be raised/lowered to/from the ground.
in the top fly tip connecting lug on the left side
of the fly tip section when the fly tip is in the Failure to do so could result in crane tipping.
stored position. The fly tip could fall causing
crane damage and/or personal injury. 4. Check that the fly tip connecting pins are in the
stored position.
23. Disconnect the plug assembly from the jumper as- 5. Retract the boom to engage the fly lugs with the
sembly on the fly base section and connect it to the head machinery cross shafts on the right side of
main boom head. the boom. Fully lower the boom.
24. Install the anti-two block weight. Refer to Section 1 6. Remove two fly connecting pins from the storage
of this Operator’s Manual. rings on the rear fly picture frame on the fly base
25. Properly install lockout pin and flag in main boom section. Install them through the fly pivot lugs (18)
head anti-two block switch. on the right side of the boom. Refer to Figure 4−8.
(Install the pins with the head on top and the keep-
Note: When lockout pin and flag are installed, er on the bottom). Install the pin keepers.
the anti-two block switch is inactive. The flag is
there as visual verification of an inactive switch.
26. Properly set the Rated Capacity Limiter to the cur- WARNING
rent crane configuration. Refer to Section 1 of this
To avoid personal injury, do not climb, stand,
Operator’s Manual.
or walk on the boom or fly. Use a ladder or
27. Check the Crane Rating Manual for lifting capaci-
similar device to reach necessary areas.
ties with the fly in the stored position before con-
tinuing operations. 7. Remove the winch rope from the head machinery
or the auxiliary lifting sheave whichever is to be
used on the fly and lay it aside to prevent damage
WARNING to it during erection of the fly.
The fly adds weight to the boom which must be
considered in lifting capacities, whether the fly
is erected or stored on the boom. When making
lifts from the main boom or auxiliary lifting
WARNING
sheave, refer to the Crane Rating Manual for the Check that the fly base connecting pins are
appropriate deductions from lifting capacities. installed on the right side of the boom in the
Use the offset lattice fly only when the crane is pivot holes before disconnecting the fly from
level on fully or intermediate extended the storage brackets. The fly could fall.
outriggers with all tires clear of the ground.

Section 4 − Attachments 4−13

Operator’s Manual

1
6
2 4
3
7
5

8 9 A B C

10 A B C
11
19
20
12
15

13

18 23 24 21

16
14

9 17
22

VIEW A−A VIEW B−B VIEW C−C

1. Left Side Fly Tip Connecting 8. Fly Base Deflector Sheave 15. Front Fly Storage Bracket 20. Boom Deflector Sheave
Pin Storage Location 9. Offset Lattice Fly Base Section 16. Retaining Pin in Engaged 21. Left Side Fly Base Connecting
2. Fly Tip Connecting Pin Stor- 10. Rear Fly Storage Bracket Position Pin (Erected Position)
age Holes 11. Fly Base Connecting Pin Stor- 17. Retaining Pin in Disengaged 22. Boom Head Sheave
3. Fly Tip Pivot Hole age Location Position 23. Right Side Fly Base Connect-
4. Rear Fly Tip Storage Lug 12. Hitch Pin 18. Fly Base Pivot Pins ing Pin (Erected Position)
5. Offset Lattice Fly Tip Section 13. Fly Tip Rope Guards 19. Boom Deflector Sheave Rope 24. Fly Base Connecting Pin Stor-
6. Front Fly Tip Storage Lug 14. Fly Tip Head Sheave Guard age Location
7. Boom
Figure 4−8
Fly Erection And Storage

4−14 Section 4 − Attachments

 Operator’s Manual
8. Pull down the retaining pin (17) to disengage the
pin from the lug on the front storage bracket. Ro-
tate and release the retaining pin to lock it in the
disengaged position.

CAUTION
Do not extend the boom beyond the
recommended 2−5 ft (0.61−1.5m) length.
Extending the boom beyond the 2−5 ft
(0.61−1.5m) length may cause boom
damage.

9. Attach a hand line to the tip of the fly base and

boom up to 20°. Slowly extend the boom approxi-
mately 2− 5 ft (0.61−1.5m) to slide the fly off the
storage brackets.
10. Slowly lower the boom to 0° angle to swing the fly
base around the boom head until the fly lugs en-
gage with the cross shafts on the left side of the Figure 4−9
boom. Refer to Figure 4−6. Left Side Fly Base Connecting Pin Label

13. Remove the rope guard from the fly base head and
WARNING deflector sheaves. Refer to Figure 4−3. Reeve the
Use a hand line to control fly swing. The fly winch rope on the boom deflector sheave then
could swing around the boom rapidly. Keep over the fly deflector and head sheaves. Install all
all personnel clear of the swing path to avoid rope guards.
injury.

11. Remove the two connecting pins from the storage

CAUTION
rings (11) on the rear fly picture frame on the fly All rope guards must be in proper position
base section and install them in the cross shafts during operation.
(23) on the right side of the boom. (Install the pins
with the head on top and the keeper on the bot- 14. Disconnect the plug assembly from the jumper as-
tom). Install the pin keepers. sembly on the main boom head and connect it to
12. Remove the two fly connecting pins from the stor- the connector assembly on the fly.
age location (24) on the boom head machinery 15. Install the anti-two block weight on fly. Refer to
cross shaft on the left side of the boom. Refer to Section 1 of this Operator’s Manual.
Figure 4−8. Install one pin through the top fly lug 16. Properly install lockout pin and flag in anti-two
(21) on the left side of the boom. If equipped, turn block switch on main boom head.
the T-handle to push and align the bottom left fly lug Note: When lockout pin and flag are installed,
and the bottom boom head cross shaft. Install the the anti-two block switch is inactive. The flag is
bottom left fly connecting pin. (Install the pins with there as visual verification of an inactive switch.
the head on top and the keeper on the bottom). In-
stall the pin keepers. When both main boom and fly are reeved for op-
eration, the lockout pin and flag must be re-
moved and properly stored and an anti-two
block weight must be suspended from each
WARNING anti-two block switch.
All six fly base connecting pins must be
properly installed before operating the crane 17. Properly set the Rated Capacity Limiter to the cur-
with the fly base erected. Damage could rent crane configuration. Refer to Section 1 of this
occur to the fly base if all connecting pins are Operator’s Manual.
not properly installed.

Section 4 − Attachments 4−15

Operator’s Manual

WARNING
Erect the fly with the crane on fully or
intermediate extended outriggers with all tires
clear of the ground, the upper directly over the
rear of the carrier, and the travel swing lock
engaged.
Refer to the Crane Rating Manual for the
maximum boom length with which the fly can
be raised/lowered to/from the ground.

Failure to do so could result in crane tipping.

4. Fully lower the boom. Retract the boom to engage

the fly lugs with the head machinery cross shafts
on the right side of the boom.
5. Remove two fly connecting pins from the storage
rings (11) on the rear fly picture frame on the fly
base section. Install them through the fly base piv-
ot lugs (18) on the right side of the boom. Refer to
Figure 4−10 Figure 4−8. (Install the pins with the head on top
Right Side Fly Base Connecting Pin Label and the keeper on the bottom). Install the pin
keepers.
18. Check the Crane Rating Manual for lifting capaci- 6. Remove the connecting pin and keeper from the
ties with the fly installed before continuing opera- top fly tip connecting lug (1) on the left side of the fly
tions. tip section. Remove another fly tip connecting pin
from the storage hole (2) on the rear of the fly tip
section. Refer to Figure 4−8. Install them through
WARNING the fly tip pivot lugs (3). (Install the pins with the
The fly adds weight to the boom which must head on top and the keeper on the bottom). Install
be considered in lifting capacities, whether the pin keepers.
the fly is erected or stored on the boom. When
making lifts from the main boom or auxiliary
lifting sheave, refer to the Crane Rating WARNING
Manual for the appropriate deductions from To avoid personal injury, do not climb, stand,
lifting capacities. Use the offset lattice fly only or walk on the boom or fly. Use a ladder or
when the crane is level on fully or intermediate similar device to reach necessary areas.
extended outriggers with all tires clear of the
ground. 7. Remove the winch rope from the head machinery
or the auxiliary lifting sheave whichever is to be
used on the fly and lay it aside to prevent damage
Erection Of The Fly Base And Tip to it during erection of the fly.
Section From The Stored Position 8. Check that the hitch pin (12) is installed through
1. Park crane on a firm, level surface. Shift the trans- the lugs on the fly tip and base sections.
mission to neutral and engage the park brake.
2. Level the crane on fully or intermediate extended
outriggers with all tires clear of the ground.
3. Position the upper directly over the rear of the car-
rier and engage the travel swing lock.

4−16 Section 4 − Attachments

 Operator’s Manual
the head on top and the keeper on the bottom.) In-
stall the pin keepers.
WARNING
Check that the fly base and tip connecting
pins are installed in the pivot holes before
disconnecting the fly from the storage
WARNING
brackets. Also check that the hitch pin is All six fly base connecting pins must be
installed through the lugs on the fly tip and properly installed before operating the crane
base sections. The fly could fall causing with the fly base erected. Damage to the fly
crane damage and/or personal injury. base may occur if all connecting pins are not
properly installed.
9. Pull down the retaining pin (17) to disengage the
pin from the lug on the front storage bracket. Refer 14. Attach a hand line to the tip of the fly tip section.
to Figure 4−8. Rotate and release the retaining pin Remove the hitch pin (12) which connects the fly tip
to lock it in the disengaged position. section to the fly base section. Refer to
Figure 4−8. Store the hitch pin back in the lug on
the fly tip section once it is erected.
CAUTION 15. Swing the fly tip section around the fly base section
Do not extend the boom beyond the until the fly tip lugs engage with the fly base lugs on
recommended 2−5 ft (0.61−1.5m) length. the left side of the fly.
Extending the boom beyond the 2−5 ft 16. Remove the fly tip connecting pins from the stor-
(0.61−1.5m) length may cause boom age holes on the rear of the fly tip section. Install
damage. them through the fly tip connecting lugs on both
sides of the fly. (Install the pins with the head on top
10. Attach a hand line to the tip of the fly base and and the keeper on the bottom). Install the pin
boom up to 20°. Slowly extend the boom approxi- keepers.
mately 2− 5 ft (0.61−1.5m) to slide the fly base off
the storage brackets.
11. Slowly lower the boom to 0° angle to swing the fly WARNING
base around the boom head until the fly lugs en- All six fly tip connecting pins must be properly
gage with the cross shafts on the left side of the installed before operating the crane with the
boom. Refer to Figure 4−6. fly tip erected. Damage could occur to the fly
tip if all connecting pins are not properly
installed.
WARNING
Use a hand line to control fly swing. The fly 17. Remove the rope guards from the fly base head,
could swing around the boom rapidly. Keep deflector and fly tip head sheaves. Refer to
all personnel clear of the swing path to avoid Figure 4−3. Reeve the winch rope on the boom
injury. deflector sheave then over the fly deflector, head
and fly tip head sheaves. Install all rope guards.
12. Remove the two connecting pins from the storage
rings (11) on the rear fly picture frame on the fly
base section and install them in the cross shafts
CAUTION
(23) on the right side of the boom. (Install the pins All rope guards must be in proper position
with the head on top and the keeper on the bot- during operation.
tom). Install the pin keepers.
13. Remove the two fly connecting pins from the stor- 18. Disconnect the plug assembly from the jumper as-
age location (24) on the boom head machinery sembly on the main boom head and connect it to
cross shaft on the left side of the boom. Refer to the connector assembly on the fly.
Figure 4−8. Install one pin through the top fly lug 19. Install the anti-two block weight on fly. Refer to
(21) on the left side of the boom. If equipped, turn Section 1 of this Operator’s Manual.
the T-handle to push and align the bottom left fly lug 20. Properly install lockout pin and flag in anti-two
and the bottom boom head cross shaft. Install the block switch on main boom head.
bottom left fly connecting pin. (Install the pins with

Section 4 − Attachments 4−17

Operator’s Manual
Note: When lockout pin and flag are installed,
the anti-two block switch is inactive. The flag is
there as visual verification of an inactive switch.
WARNING
The fly adds weight to the boom which must
When both main boom and fly are reeved for op-
be considered in lifting capacities, whether
eration, the lockout pin and flag must be re-
the fly is erected or stored on the boom. When
moved and properly stored and an anti-two
making lifts from the main boom or auxiliary
block weight must be suspended from each
lifting sheave, refer to the Crane Rating
anti-two block switch.
Manual for the appropriate deductions from
21. Properly set the Rated Capacity Limiter to the cur- lifting capacities. Use the offset lattice fly only
rent crane configuration. Refer to Section 1 of this when the crane is level on fully or intermediate
Operator’s Manual. extended outriggers with all tires clear of the
22. Check the Crane Rating Manual for lifting capaci- ground.
ties with the fly installed before continuing opera-
tions.

4−18 Section 4 − Attachments

 Operator’s Manual
Table Of Contents
Crane Rating Manual And Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1

Wire Rope Capacity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1

Wire Rope Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1

Wire Rope Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1

Wire Rope Inspection And Replacement Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−3

Wire Rope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−4
Wire Rope Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−4
Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−4
Winch Roller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−5
Uncoiling Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−6
Anchoring Wire Rope To Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−6
Winding Rope On Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−7
Wire Rope Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−7
Socket And Wedge Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−7
Rope Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−8
Single Part Line Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−9

Rotation Resistant Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−9

Non-Swivel Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−9
Swivel Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−9
Rope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−9
Hook Ball Usage With Rotation Resistant Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−9
Wire Rope Sockets With Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−10

Wire Rope Clip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−10

Cutting Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−11

Crane Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−14

General Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−14
Boom, Attachments, and Upper Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−15
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−15
Upper Operator’s Cab and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−15
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−16
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−16
Load Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−16

Section 5 − General Information i

Operator’s Manual
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−17
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−17
Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
Steering and Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−18
Carrier Speeds and Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−19
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−19
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−19
Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−19
Lower Cab and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−19
Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−20
Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−21
Axle Loads with 2-Axle Boom Dolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−22

ii Section 5 − General Information

 Operator’s Manual
required to make the lift. Use at least that number of
Crane Rating Manual And parts of line to make the lift. When making a lift with
Serial Number more parts of line that is needed to make the lift, re-
member to add one (1) pound (0.45kg) for each one (1)
The Crane Rating Manual is located in the lower right foot (0.3m) of extra rope required to reeve the extra
interior of the upper operator’s cab. This manual has parts of line, to the actual load weight. The extra parts
the crane serial number on it. The serial number is also of line act as additional load weight.
stamped on the top of the bumper on the right side of
the carrier and on the right side of the upper frame just
above the boom hoist cylinder lug. The serial number
must be used with any correspondence with the fac-
WARNING
Do not exceed the capacities listed for wire
tory concerning parts or warranty. This manual also
rope capacity or crane capacity, whichever is
lists the maximum allowable lifting capacities for the
less, when making a lift. Serious personal
crane. The manual should be checked for the proper
injury or crane damage may result.
lifting capacities before making any lifts.
If the Crane Rating Manual becomes lost, dam-
aged, or unreadable, it must be replaced before op-
erating the crane. Information contained in the Crane
Wire Rope Specifications
Rating Manual is important and failure to follow the in- The specifications for the wire rope used on this crane
formation it contains could result in an accident. A re- are on the Wire Rope Capacity chart located in the
placement manual can be ordered through your dis- Crane Rating Manual. Refer to Figure 5−1 for a typical
tributor. example. Always refer to the Wire Rope Capacity Chart
in the Crane Rating Manual when ordering replace-
ment wire rope.
CAUTION
The Crane Rating Manual in the crane is the Wire Rope Diameter
only authorized listing of lifting capacities for
In standard practice, the nominal diameter of wire rope
the crane. It supercedes any other printed
is the minimum acceptable diameter. It is always made
literature which lists lifting capacities. It alone
larger, not smaller, than the nominal diameter accord-
is to be used for determining crane capacities.
ing to the allowable tolerances shown in the following
chart:

Wire Rope Capacity Chart Nominal Rope Diameter

Allowable
Limits
The Wire Rope Capacity chart gives the maximum lift-
ing capacities based on wire rope capacity. A typical Thru 1/8" (3.2mm) −0 +8%
example is shown in Figure 5−1. It is located in the Over 1/8" (3.2mm) thru 3/16" (4.8mm) −0 +7%
Crane Rating Manual. It lists the maximum load that
should be lifted with different sizes and types of wire Over 3/16" (4.8mm) thru 5/16" (8.0mm) −0 +6%
rope. The weights shown are based on wire rope ca- Over 5/16" (8.0mm) and larger −0 +5%
pacity alone. Exceeding these load weights may result
in rope damage or failure. Wear and stress tend to reduce the diameter. It should
be measured periodically and replaced if the size is be-
Before making a lift, compare the weight being lifted
low the nominal size of the wire rope being used as
(remember to add the weight of the hook block, slings
shown in the chart on page 5−4. It should always be
and riggings to the actual load weight) with the Wire
measured across the largest diameter that will fit inside
Rope Capacity Chart located in the Crane Rating
a true circle. Refer to Figure 5−2.
Manual. Check the chart for the number of parts of line

Section 5 − General Information 5−1

Operator’s Manual

Wire Rope Capacity

Maximum Lifting Capacities Based On Wire Rope Capacity
Parts 3/4" 3/4"
of Notes
Line Type RB Type ZB

1 12,920* 15,600 Capacities shown are in pounds and working loads

must not exceed the ratings on the capacity charts in
2 25,840 31,200
the Crane Rating Manual.
3 38,760 46,800
Study Operator’s Manual for wire rope inspection pro-
4 51,680 62,400 cedures and single part of line applications.
5 64,600 78,000
6 77,520 93,600
7 90,440 109,200
8 103,360 124,800
9 116,280 140,400
10 129,200 156,000
LBCE TYPE DESCRIPTION
19 Strand, Compacted Strand, Rotation Resistant −Extra Extra Improved Plow Steel − Pre-
RB formed Right Regular Lay
ZB 36 X 7 Non-Rotating − Extra Improved Plow Steel − Right Regular Lay

Note: The Wire Rope Capacity chart depicted above is shown as an example only. Use the official Wire
Rope Capacity chart located in the Crane Rating Manual. Use it to determine the correct parts of line
required for the given wire rope type and diameter.

Figure 5−1
Typical Wire Rope Capacity chart (Example Only)

Right
Wrong

Figure 5−2 CD00325

Measuring Wire Rope Diameter

5−2 Section 5 − General Information

 Operator’s Manual

Figure 5−3
Typical Wire Rope Inspection Report

According to ASME standards, all wire ropes in active

Wire Rope Inspection And service MUST BE visually inspected daily. A qualified,
Replacement trained person should be appointed to conduct the in-
spection. Also on a monthly basis, that person is re-
Recommendations quired to inspect all wire ropes and keep a dated, written
record noting any damage and recording when ropes
The three basic reasons for deterioration of wire rope are replaced.
are abrasion, corrosion, and damage caused by fa-
tigue bending, crushing, kinking, and forces or abuse These inspections should be done to determine the de-
acting against the rope during normal usage. gree of deterioration of the rope at any given section
(refer to the following on rope replacement). This will
When wire rope is replaced, use the type specified on determine the suitability of the rope for continued serv-
the Wire Rope Capacity Chart located in the Crane Rat- ice. A sample inspection report is shown in
ing Manual. Cranes are designed to use a specific type Figure 5−3. It can be reproduced and used if desired.
and size of rope. Using ropes other than those recom-
mended, may result in short life or even failure of the
rope.

Section 5 − General Information 5−3

Operator’s Manual
Wire Rope Inspection Wire Rope Replacement
Any of the following are reasons to question rope Any of the following are reasons for rope replacement:
safety: 1. In running ropes, six randomly distributed broken
1. More than one broken wire in any one strand wires in one rope lay or three broken wires in one
should be cause for caution. Breaks that occur on strand in one rope lay.
the worn crowns of the outside wires usually indi- For rotation resistant ropes, two randomly distrib-
cate normal deterioration. Breaks that occur in the uted broken wires in six rope diameters, or four
valleys between strands can indicate an abnormal randomly distributed broken wires in thirty rope di-
condition, possibly fatigue and breakage of other ameters.
wires that are not readily visible. One or more val- 2. In pendants or standing ropes, evidence of more
ley breaks should be cause for replacement. than two broken wires in one lay in sections be-
2. Wire breaks generally occur in those portions of yond end connections or more than one broken
wire rope which pass over sheaves, wind onto wire in one rope lay at end connection.
drums, or receive mechanical abuse. Breaks that 3. One outer wire broken at the contact point with the
occur near attached fittings are apt to result from core of the rope which has worked its way out of
fatiguing stresses concentrated in these localized the rope structure and protrudes or loops out from
sections. Breaks of the latter type should be cause the rope structure.
for replacement of the rope or renewal of the at- 4. Abrasion, scrubbing, or peening causing loss of
tachment to eliminate the locally fatigued area. more than 1/3 the original diameter of individual
When running ropes over sheaves, inspect the wires.
wire rope where it travels over the sheaves. In- 5. Evidence of rope deterioration from corrosion.
spect for a loss of diameter and then bend the rope 6. Kinking, crushing,
bird caging", or other damage
to inspect the internal wires for breaks and wear. resulting in distortion of the rope structure.
3. Heavy wear, or broken wires, may occur in sections 7. Evidence of any heat damage.
under equalizer sheaves or other sheaves where 8. Marked reduction in diameter indicates deteriora-
rope travel is limited, or in contact with saddles. tion of the core resulting in lack of proper support
Particular care should be taken to inspect rope at for the load carrying strands. Excessive rope
these points. If wire rope wear is detected at these stretch or elongation may also be an indication of
locations, these wear points can be shifted by re- internal deterioration. Reduction from nominal di-
moving the rope from the drum and cutting a 20 ft ameter or more than:
(6.1m) section off at the drum end. This may assist
in extending the wire rope life. Reduction of Nominal Rope Diameters
4. Rope stretch is generally greatest during initial 1/64" (.4mm) up to and including 5/16" (8mm)
stages of operation when the strands are becom- 1/32" (.79mm) over 5/16" (9.5mm) to 1/2" (13mm)
ing adjusted and seated. This is accompanied by 3/64" (1.2mm) over 1/2" (13 mm) to 3/4" (19mm)
some reduction in rope diameter.
1/16" (1.6mm) over 3/4" (19mm) to 1−1/8" (29mm)
5. Time for rope replacement is indicated by the ex-
3/32" (2.4mm) over 1−1/8" (29mm)
tent of abrasion, scrubbing, and peening on the
outside wires, broken wires, evidence of pitting or 9. Noticeable rusting or development of broken wires
severe corrosion, kink damage, or other mechani- in the area of connections.
cal abuse resulting in distortion of the rope struc-
ture. Wire Rope Installation
6. Sheaves, guards, guides, drums, flanges, and
When installing wire rope, the primary concern is get-
other surfaces contacted by wire rope during op-
ting the rope onto the drum without trapping any twist
eration should be examined at the time of inspec-
that may have been induced during handling. Use the
tions. Any condition harmful to the rope in use at
following procedure to install the rope on the crane.
the time should be corrected. The same equip-
ment and particularly sheave and drum grooves
should be inspected and placed in proper condi-
tion before a new rope is installed.

5−4 Section 5 − General Information

 Operator’s Manual

12

1 11

2 10
9

4 5 6 7 8
1. Drum Flange 4. Capscrew 7. Spring 10. Roller Stop
2. Setscrew 5. Torque Shaft 8. Lock Collar 11. Upper Frame
3. Capscrew 6. Shoulder Bolt 9. Setscrew 12. Roller

Figure 5−4
Winch Roller Alignment

Winch Roller Adjustment a Ensure capscrew (3) is tightened securely in

torque shaft (5).
Before installing wire rope on the drum, adjust the b Using a breaker bar or long handle wrench,
drum roller. Refer to Figure 5−4. If the roller is not hold tension on torsion spring (7) while
aligned to the drum, it may cause excessive wear on loosening the setscrews (9) on both ends of
the wire rope, winch roller, or impede spooling of the torque shaft (5).
rope on the drum. To adjust the roller, loosen the caps- c Allow torque shaft (5) to rotate counterclock-
crews (4) and adjust roller assembly as required to wise, as far as possible while maintaining con-
align the roller parallel to the drum. Roller should lay flat trol of the torque shaft (5), then securely tight-
across each full layer of rope on the drum and be cen- en setscrews (9).
tered between the drum flanges. Center the roller be- d Reposition breaker bar or wrench on
tween the drum flanges by loosening the setscrews (2) capscrew (3).
in the lock collars (8), centering the roller (12), and e Repeat Steps b−d until tension is fully relieved
tightening the setscrews. After roller is aligned and from torsion spring (7).
centered, preload the spring using the following proce- 2. Turn the capscrew (9), which will rotate the torque
dure. shaft (5), until the bolt (6) through the torque shaft
contacts the spring (7).

WARNING CAUTION
Do not attempt to service winch roller before Do not overtighten the spring. Damage to the
properly relieving torsion spring tension. If
wire rope may occur.
proper directions are not followed, the torsion
spring could rapidly and forcefully uncoil.
3. With the roller stop (10) resting against the drum
This may result in serious personal injury and
flange or with the roller resting evenly on the first
component damage. Always release tension
layer of rope on the drum, use 105 ft lb (124Nm) of
on torsion spring before attempting any winch
torque to rotate the spring not to exceed one revo-
roller repair.
lution (360°).
1. Properly release torsion spring (7) tension as 4. Tighten setscrews (9). The roller should roll freely
follows. This procedure is greatly simplified by when the drum rotates.
using two service technicians. One to hold the
breaker bar/wrench, the other to loosen and
tighten setscrews.

Section 5 − General Information 5−5

Operator’s Manual
3
Right
2

4
1. Winch Drum
2. Wire Rope
3. Wedge
Figure 5−5 4. Seizings for Type ZB Rope Only (Remove after installation)
Uncoiling Wire Rope
Figure 5−6
Anchoring Wire Rope To Drum
Uncoiling Wire Rope
1. To avoid twists, unreel the entire rope on the Anchoring Wire Rope To Drum
ground in line with the boom deflector sheave and
drum. Set the reel up horizontally so it can rotate as
the rope is reeled off. Refer to Figure 5−5. Reel the CAUTION
rope off slowly, so the reel won’t tend to
throw" the
The ends of type ZB rope must be fuse
rope off. If the new rope cannot be laid out on the
welded. Failure to do so may cause the core
ground, further steps are necessary:
to slip and/or the strands to loosen causing
a. Mount the reel on a shaft through flange holes
serious rope damage.
and on jack stands, making sure the reel is set
to be unreeled over the top. Do not allow the
reel to
free-wheel". Brake the reel by applying If crane is equipped with type ZB wire rope, attach two
pressure to a flange. Do not apply braking seizings (hose clamps are an effective and efficient al-
pressure to the rope on the reel or pass rope ternative if traditional seizings are not available) about
between blocks of wood or other material. 24 in (609.6mm) from the end with a 3 in (76.2mm)
2. Reeve the rope over the boom deflector sheave space between them. Refer to Figure 5−6. The seiz-
and anchor it to the drum. ings will prevent any looseness of the outer strands
from traveling up the rope during installation. Insert
Note: When replacing wire rope, the sheaves the free end of the rope into the small opening of the
and grooves in drums should be checked for anchor pocket. Loop the rope and push the free end
wear or damage and replaced if necessary. about 3/4 of the way back through the pocket. Install
Damaged, worn or undersized sheaves will the wedge, then pull the slack out of the rope. If
damage the rope. On older equipment, remem- using type ZB rope, remove the seizings after the rope
ber that new rope is usually larger in diameter is secured in the drum. Keep tension on the rope to
than the worn rope it replaces. The sheave prevent the rope from becoming slack and forming
grooves may be worn to the smaller diameter of loops or kinks and also to allow uniform winding on
the old rope. the drum. It is important that original rope lay is main-
Note: A new rope should be broken in by run- tained at all times.
ning it slowly through its working cycle for a
short period under a light load. Refer to
Rope
Break-In" found later in this Section of this Op-
erator’s Manual.

5−6 Section 5 − General Information

 Operator’s Manual
Winding Rope On Drum Right
Proper winding of the first layer of rope on a multiple Wrong
wrap drum is important. If the first layer is properly
wound, succeeding layers will be easier to control.
This is especially important on ungrooved drums.
When starting new wire rope on such drums, drive
each wrap of the first layer lightly with a wooden mallet
so each wrap barely contacts the preceding one. Keep
tension on the rope to prevent the rope from becoming
slack and forming loops or kinks and also to allow uni-
form winding on the drum. It is important that original
rope lay is maintained at all times.
It’s important to apply a tensioning load while spooling
the rope on the drum. (If not, the lower layers may be
loose enough that the upper layers become wedged
into the lower layers under load, which can seriously
damage the rope.) The tensioning load should range
from 1 to 2% of the rope’s nominal capacity.
Figure 5−7
Wire Rope Reeving Hook Block Reeving
Hook blocks should be reeved correctly so they hang
straight and do not cause excessive wear on the rope The fly section may be reeved with two parts of line for
and sheaves. Refer to Figure 5−7. better line control. Figure 5−14 and Figure 5−15
gives the proper reeving for various parts of line. The
reeving patterns illustrated must be used at all times.
WARNING To determine how many parts of line to use for a par-
To avoid personal injury, do not climb, stand, ticular lift, check the Wire Rope Capacity chart and the
or walk on the boom or fly. Use a ladder or Winch Performance chart located in the Crane Rating
similar device to reach necessary areas when Manual.
reeving the crane. Note: Rope guards must always be used during op-
Only if certain criteria are met may a swivel erations. They must be pinned in place to prevent
hook ball be used with rotation resistant rope. wire rope from jumping off the sheaves.
Refer to
Hook Ball Usage With Rotation
Resistant Rope" found in this Operator’s
Manual.
Socket And Wedge Connections

The crane can use multiple parts of line when reeving CAUTION
the main winch, depending on the lift being made and
Use the proper size wedge with a wire rope
the number of sheaves available. When reeving the
socket or lagging. The use of an off-size
main winch, odd parts of line dead end at the hook
wedge in a socket or lagging is dangerous as
block and even parts dead end at the boom head. The
it may not hold. Wedges and sockets shipped
auxiliary lifting sheave may be reeved with either one or
from the factory are stamped with size and
two parts of line.
type identification. A lagging or socket may
Note: Do not use a swivel at the dead end of a be stamped for two or more sizes of rope and
multi-part reeving a wedge for one or two. The size on the
lagging, socket and wedge must correspond
with the size of rope being used.

Section 5 − General Information 5−7

Operator’s Manual

Right
Wrong

1
4
2 5

6 Type RB Type ZB
3
Figure 5−10
1. Seizing (Type ZB Only) (Remove after installation)
Wire Rope Identification
2. Wire Rope Live End
3. Socket The dead end must also be seized and a minimum tail
4. Dead End Seizing length of 20 rope diameters (15 inches for 3/4 inch
5. 20 Rope Diameters Minimum Tail Length rope) is required. The clips will help prevent core slip-
6. Wedge
page and any looseness of the outer strands from trav-
Figure 5−8 eling up the rope during installation while still allowing
Socket And Wedge Connections the rope strands to be free to adjust. If using type ZB
rope, remove clips from the live end after rope is se-
curely installed into the socket.
Right
Wrong
Note: Refer to Figure 5−10 to identify which type of
rope is installed on the crane.

CAUTION
The ends of type ZB rope must be fuse welded
and the tail length of the dead end must be a
minimum of 20 rope diameters (15 inches for
3/4 inch rope). Failure to do the above may
cause the core to slip and/or the strands to
loosen causing serious rope damage.
Figure 5−9
Socket And Wedge Installation
When anchoring the socket to the boom head, make
sure the flat face is facing out as shown in Figure 5−9.
The correct and incorrect methods of attaching a sock- If socket is not installed correctly structural damage to
et and wedge to wire rope are shown in Figure 5−8. the boom head may occur.
The dead end of the wire rope must always be on the It is recommended that the wire rope socket and
sloped portion of the socket. The load line must be in a wedge connection be reestablished on an annual ba-
straight line pull with the eye of the socket. If the rope is sis. This can be accomplished by cutting the rope 6 in
installed wrong as shown in Figure 5−8, a permanent (0.15m) above the socket and wedge connection. See
set will develop at the point where the rope enters the
Cutting Wire Rope" found in this Section of this Opera-
socket. tor’s Manual. Install the socket and wedge connection
Before installing type ZB wire rope into a socket or as shown in Figure 5−8.
wedge attach two clips (hose clamps are an effective
and efficient alternative if traditional clips are not avail- Rope Break-In
able) approximately 3−4 ft (0.9−1.2 m) from the end After the rope has been installed and the ends secured
with a 3 in (76.2 mm) space between them. Refer to in the correct manner, the new rope must be run
Figure 5−8. through a break-in period. This allows the component
parts of the new rope to gradually adjust itself to actual
operating conditions.

5−8 Section 5 − General Information

 Operator’s Manual
1. Level the crane on fully extended outriggers with all Swivel Usage
tires clear of the ground. Swing the upper over the
rear of the carrier and engage the travel swing lock. A swivel hook ball can be used with rotation resistant
2. Fully raise and fully extend the boom. Attach a light rope if:
load at the hook and raise it a few inches off the 1. The wire rope is not shock loaded or overloaded.
ground. Allow to stand for several minutes. 2. Wire rope working strength is reduced to maintain
3. Run the rope through a cycle of operation at very original design factors.
slow speeds. During this trial operation, a very 3. The wire rope is inspected frequently as outlined
close watch should be kept on all working parts− below.
sheaves, drums, roller, etc. to make certain that the
rope runs freely, and without any possible obstruc- Rope Inspection
tions as it makes its way through the system. Marked reduction in diameter indicates deterioration of
the core resulting in lack of proper support for the load
Note: Run these loads with reeving that places
carrying strands. Excessive rope stretch or elongation
the loads on the block with all rope off the drum
may also be an indication of internal deterioration. Ma-
except the last three wraps. If this is not pos-
jor concerns and replacement recommendations in-
sible, alternate methods must be used to assure
clude:
proper tensioning of the rope on the drum.
1. Loss of rope diameter (in excess of those listed in
4. If no problems appear in running the rope, repeat the table in the
Wire Rope Replacement" section
procedure with an increased load. found earlier in this Operator’s Manual), abnormal
lengthening of rope lay, or protrusion of wires be-
Single Part Line Hoisting tween the outer strands.
2. 2 randomly distributed broken wires in 6 rope di-
Non-rotating, rotation-resistant, or spin-resistant wire ameters, or 4 randomly distributed broken wires in
ropes are recommended for single part of line applica- 30 rope diameters.
tions. This is of utmost importance for long fall hoist line
applications. Link-Belt type
P",
RB", and
ZB" are ex- Hook Ball Usage With Rotation
amples of ropes recommended for single part hoisting. Resistant Rope
See the Wire Rope Capacity Chart in the Crane Rating
Manual for the specific types of rotation resistant wire The rotation resistant characteristic is achieved by lay-
rope recommended for your crane. ing the outer strands around an independent wire rope
that is wound in the opposite direction. When the rope
The use of non-rotation resistant rope is not recom-
has tension on it, opposing rotational forces are
mended for long falls of single part of line hoisting since
created between the core and outer strands. If a swivel
the rope and load may spin. If the crane operator al-
hook ball is utilized with rotation resistant rope, the
lows either the load or the rope to rotate, the crane or
rope is allowed to twist. The outer strands unwind and
rope can be damaged. The anti-two block weight may
get longer while the inner core is forced to rotate in the
also become entangled with the wire rope and could
same direction and shortens in length. As a result of
damage the anti-two block system, wire rope, and/or
this treatment, the inner core sees a disproportionately
head machinery.
greater load, and core damage may occur due to
shock loading or overloading. A rotating load on an un-
Rotation Resistant Wire restrained, non-swivel hook ball without a tagline, af-
fects the internal loading of the rope in this manner.
Rope This practice, or any other which allows the rope to ro-
tate while in service, leads to unbalanced loading be-
Non-Swivel Usage tween the inner and outer layer of strands, which may
A non-swivel hook ball in conjunction with a tagline or result in core failure. Wire rope manufacturer’s testing
other device to control load spin should be used when has shown that rotation resistant rope utilized with a
the crane is equipped with rotation resistant wire rope. swivel hook ball has reduced the breaking strength by
This is to avoid unrestrained rotation of the wire rope. as much as 50% if excessive rotation occurs.

Section 5 − General Information 5−9

Operator’s Manual

The Double-Saddle-Clip Method The Loop Back Method

Figure 5−11
Wire Rope Socket With Clip

Wire Rope Sockets With Clips CAUTION

Some codes require the use of a wire rope clip in con- The ends of type ZB rope must be fuse welded
junction with a socket and wedge connection. and the tail length of the dead end must be a
Figure 5−11 illustrates some typical methods of clip minimum of 20 rope diameters (15 in for 3/4 in
installation with sockets. In some cases, particularly in rope). Failure to do the above may cause the
wrecking ball work, there is a chance that the wedge core to slip and/or the strands to loosen
can loosen, releasing the socket from the rope. This causing serious rope damage.
could be caused by the banging action and alternate
loading and unloading of the rope that occurs during
this type work. Wire Rope Clip Installation
The correct method of installing wire rope clips is
WARNING shown in Figure 5−13. The u-bolt must always be over
the short end of the wire rope and the base must al-
Regularly inspect the integrity of the wire rope
ways contact the long end.
at the point of exit at the dead end side. High
velocity spin of wire rope when loading and Clips should NOT be staggered, that is u-bolt of one
unloading can cause the rope to flip-flop, clip over short end and u-bolt of next clip over long end.
fatigue, and finally break off. This practice will not only distort the wire rope exces-
sively, but will prevent maximum capacity of this type
fastening. Placing all clips with the u-bolt over the long
The use of wire rope clips with a socket and wedge
end of the wire rope will damage strands and result in
connection can weaken the connection if done improp-
an unsafe condition.
erly. Do not attach the dead end of the rope to the live
side with the clip as this will seriously weaken the con- The distance between clips should be not less than six
nection. The clip may ultimately take the load and may times the wire rope diameter. In relation to size of wire
deform or break the rope. rope, the minimum number of clips recommended for
safe connections is given in Figure 5−12.
If using the loop back method, the loop formed must
not be allowed to enter the wedge, or the connection
will be weakened. The tail length of the dead end must CAUTION
be a minimum of 20 rope diameters (15 inches for 3/4
Apply the initial load and retighten nuts to the
inch rope).
recommended torque. Rope can stretch and
reduce in diameter when loads are applied.
Inspect periodically and retighten as
required.

5−10 Section 5 − General Information

 Operator’s Manual

Minimum No. Amount Of Rope

Clip Size Torque
Of Clips To Turn Back *
in mm Quantity in mm ft lb Nm
@ 3.2 2 3¼ 82.5 −−− −−−

@ 4.7 2 3¾ 95.2 −−− −−−
¼ 6.3 2 4¾ 120.6 15 20.0
@ 7.9 2 5¼ 133.3 30 40.7

@ 9.5 2 6½ 165.1 45 60.1
@ 11.1 2 7 177.8 65 86.8
½ 12.7 3 11½ 292.1 65 86.8
@ 14.3 3 12 304.8 95 126.9
@ 15.9 3 12 304.8 95 126.9
¾ 19.0 4 18 457.2 130 173.6

* If a greater number of clips are used than shown in this table, the amount of rope turnback should be increased proportionally.

Figure 5−12
Wire Rope Clip Application Recommendation

Cutting Wire Rope Right

CAUTION
The ends of type ZB rope must be fuse
welded. Failure to do so may cause the core
to slip and/or the strands to loosen causing
serious rope damage.

When wire rope is to be cut, seizings should be placed Wrong

on each side of the point where the rope is to be cut, to
keep the strands in place. On preformed rope such as
type RB, one seizing on each side of the cut is enough.
On non-preformed rope less than 7/8 in (23mm) diame-
ter such as type ZB, two seizings are recommended.
On non-preformed rope over 7/8 in (23mm) diameter,
three seizings are recommended. Original rope lay
must be maintained at all times.
Three basic methods of cutting wire rope are recom-
mended: Figure 5−13
1. Abrasive cutting tools. Wire Rope Clip Installation
2. Shearing tools. (Wire cutters on small rope, a wire
rope cutter and hammer for larger ropes.)
3. Oxy/acetylene fuel torch. This is the only sug-
gested method for cutting type ZB rope.

Section 5 − General Information 5−11

Operator’s Manual

1 Part 2 Parts 3 Parts 4 Parts

5 Parts 6 Parts 7 Parts 8 Parts

9 Parts 10 Parts

Auxiliary Sheave
2 Parts
11 Parts

Note: Some of the diagrams shown may not

CAUTION
apply to this particular crane. This reeving is only applicable for those rated
Do not use a swivel at the dead end of capacity lifts that require additional parts of line to
a multi-part reeving. maintain the required wire rope safety factor.

Figure 5−14
Wire Rope Reeving Diagrams

5−12 Section 5 − General Information

 Operator’s Manual

Auxiliary
Deflector Sheave
Sheaves

Head Sheaves

Hook Block
Rear Drum

Front Drum
Note: Reeving shown is typical. Either drum may be reeved over head sheaves or auxiliary sheave.

Figure 5−15
Wire Rope Reeving Diagrams

Section 5 − General Information 5−13

Operator’s Manual
Crane Specifications
The information in Figure 5−16 and the following instructions is general in nature and is used for reference
purposes only. Depending upon the vintage of the crane, some features may no longer be available. Standard
and optional features may vary from crane to crane. Consult the factory to verify the specific information if
required.

General Dimensions
CL OF ROTATION
45’ 7"
(13.89m )
38’ 0"
(11.58m )
7’ 0" 4.50"
(2.13m) (114mm)

11’ 7"
(3.53m) 10’ 9"
(3.28m)
6’ 7.75"
(2.03m) 5’ 6.25"
(1.68m)

17° 15°

13.25"
(0.34m)
Ground 44.50"
5’ 1.50" Clearance
(1.56m) 5’ 1" (1.13m)
(1.55m)
11’ 0" 8’ 11"
(3.35m) (2.72m)

4’ 2" 10’ 1" 5’ 0"

(1.27m) (3.07m) (1.52m)
4.50" 26’ 9.50" 9’ 11.50" 3.50"
(114mm) (8.17m) (3.04m) (89mm)

Turning Radius English Metric

Wall to wall over carrier 46’ 3" 14.1m
Wall to wall over boom 47’ 1" 14.4m
Wall to wall over boom attachment 49’ 2" 15.0m
Curb to curb 41’ 10" 12.8m
Centerline of tire 41’ 1" 12.5m

Tail Swing English Metric

With counterweight 13’ 8" 4.2m
Without counterweight 13’ 1" 4.0m

4’ 7"
(1.40m)

12.25" 20.25"
(0.31m) (0.51m)

14" 8.25"
(0.36m) (0.21m) GROUND LEVEL
7’ 9" (2.36m) WITH CRANE
FULLY RETRACTED ON OUTRIGGERS

9’ 9" (2.97m)
FULLY RETRACTED

14’ 7" (4.45m)

INTERMEDIATE EXTENDED

16’ 7" (5.05m)

INTERMEDIATE EXTENDED

24’ 0" (7.32m)

FULLY EXTENDED

26’ 0" (7.92m)

FULLY EXTENDED Not To Scale

Figure 5−16
Overall Dimensions

5−14 Section 5 − General Information

 Operator’s Manual
Boom, Attachments, and Upper Structure
J Boom J Upper Operator’s Cab and Controls
Design − Four section, box type construction of high ten- Environmental Cab − Fully enclosed, one person cab of
sile steel consisting of one base section and three tele- galvaneal steel structure with acoustical insulation.
scoping sections. The vertical side plates have diamond Equipped with:
shaped steel impressions for superior strength to weight
Tinted and tempered glass windows
ration. The first telescoping section extends indepen-
Extra-large fixed front window with windshield wiper
dently by means of one double-acting, single stage hy- and washer
draulic cylinder with integrated holding valves. The sec-
Swing up roof window with windshield wiper
ond and third telescoping sections extend proportionally
Sliding left side door with large fixed window
by means of one double-acting, single stage cylinder with
Sliding rear and right side windows for ventilation
integrated holding valves and cables.
Six way adjustable, cushioned seat with seat belt and
storage compartment
Boom
Engine dependent warm-water heater with air ducts

38−115 ft (11.6−35.1m) four section full power boom for front windshield defroster and cab floor

Two mode boom extension: A-max mode provides
Defroster fan for the front window
superior capacities by extending the first telescoping
Bubble level
section to 63.6 ft (19.4m). Standard mode synchro-
Circulating fan
nizes all the telescoping sections proportionally to
Adjustable sun visor
115 ft (35.1m). Controlled from the operator’s cab.
Dome light

Mechanical boom angle indicator
Cup holder

Maximum tip height for A-max mode is 72 ft (21.9m)
Fire extinguisher
and standard mode is 122 ft (37.2m).
Left side viewing mirror
Boom Head
Pull−out cabwalk

Five 16.5 in (41.9cm) root diameter nylon sheaves to
Air Conditioning − Optional − Integral with cab heating
handle up to ten parts of line
system utilizing the same ventilation outlets

Easily removable wire rope guards

Rope dead end lugs on each side of the boom head Controls − Two dual axis hydraulic joystick controllers or

Boom head is designed for quick-reeve of the hook optional single axis hydraulic controllers for:
block
Swing

Boom hoist
Boom Elevation

One double acting hydraulic cylinder with integral
Main rear winch
holding valve
Auxiliary front winch − optional

Boom elevation: −3° to 78°
Drum rotation indication

Drum rotation indicator activation switch
Auxiliary Lifting Sheave − Optional
Winch high/low speed and disable switch(es)

Single 16.5 in (41.9m) root diameter nylon sheave

Third wrap selector switch − optional

Easily removable wire rope guards

Telescopic override switch

Does not affect erection of the fly or use of the main

Warning horn button
head sheaves

Swing park brake
Hook Blocks and Balls − Optional

40 ton (36.3mt) 4 sheave quick-reeve hook block with Right Front Console − Controls and indicators for:
safety latch
Engine ignition
Warning horn

60 ton (54.4mt) 4 sheave quick-reeve hook block with
Engine throttle lock
Heating controls
safety latch
Pump enable
Two position house lock

75 ton (68.0mt) 5 sheave quick-reeve hook block with
Function disable
Bubble level
safety latch
Console dimmer switch
12 volt power connection

8.5 ton (7.7mt) swivel and non-swivel hook balls with
Front windshield wiper
Air conditioning − optional
safety latch and washer
Boom floodlight − optional

Cab floodlights
Fly − Optional

36 ft 6 in (11.1m) one piece lattice fly, stowable, off-
settable to 2°, 20°, and 40°. Maximum tip height is
157 ft (47.9m).

36 ft 6 in−61 ft (11.1−18.6m) two piece bi-fold lattice
fly, stowable, offsettable to 2°, 20°, and 40°. Maxi-
mum tip height is 182 ft (55.5m).

Section 5 − General Information 5−15

Operator’s Manual
Outrigger Controls − Hand held control box with umbili- Internal RCL Light Bar − Optional − Visually informs the
cal cord gives the operator the freedom to look about operator when crane is approaching maximum load ca-
while setting the outriggers. pacity with a series of green, yellow, and red lights.
Foot Controls External RCL Light Bar − Optional − Visually informs

Boom telescope the ground crew when crane is approaching maximum

Swing brake load capacity with a series of green, yellow, and red lights.

Engine throttle
Cab Instrumentation − Ergonomically positioned, ana- J Swing
log instrumentation for crane operation including: Motor/Planetary − Bi-directional hydraulic swing motor

Check and stop engine indicators mounted to a planetary reducer for 360° continuous

Engine coolant temperature with warning indicator smooth swing at 1.7 rpm.

Hydraulic oil temperature with warning indicator Swing Park Brake − 360°, electric over hydraulic, (spring

Engine oil pressure with warning indicator applied/hydraulic released) multi-disc brake mounted on

Voltage indicator with warning indicator the speed reducer. Operated by a toggle switch from the

Fuel level operator’s cab.

Tachometer
Swing Brake − 360°, foot operated, hydraulic applied
Rated Capacity Limiter − Microguard graphic audio-
disc brake mounted to the speed reducer.
visual warning system built into the dash with anti-two
block and function limiter. Operating data available in- Swing Lock − Two-position house lock (boom over front
cludes: or rear) operated from the operator’s cab.

Crane configuration 360° Positive Swing Lock − Optional − Meets New York

Boom length and angle City requirement.

Boom head height

Allowed load and % of allowed load J Electrical

Boom angle
Swing Alarm − Audio warning device signals when the

Radius of load
upper is swinging.

Actual load

Presettable defined area alarms (includes): Lights

Maximum and minimum boom angles
Two working lights on front of the cab

Maximum tip height
One rotating amber beacon on top of the cab − op-

Maximum boom length tional

Swing left/right positions
One amber strobe beacon on top of the cab − op-
tional

J Load Hoist System

Load Hoist Performance
Main (Rear) and Auxiliary (Front) Winches − 3/4 in (19mm) Rope
Maximum Line Pull Normal Line Speed High Line Speed Layer Total
Layer lb kg ft/min m/min ft/min m/min ft m ft m
1 16,506 7 487.0 176 53.6 352 107.3 114 34.7 114 34.7
2 15,175 6 883.4 192 58.5 383 116.7 124 37.8 238 72.5
3 14,043 6 369.9 207 63.1 414 126.2 134 40.8 372 113.4
4 13,068 5 927.6 223 68.0 445 135.6 144 43.9 516 157.3
5 12,220 5 543.0 238 72.5 476 145.1 154 46.9 670 204.2

Maximum
Diameter
Wire Rope Application Type Permissible Load
in mm lb kg
Main (Rear) Standard 3/4 19 18x19 rotation resistant − right regular lay (Type RB) 12,920 5 860.5
Winch Optional 3/4 19 36x7 rotation resistant − right regular lay (Type ZB) 15,600 7 076.2
Auxiliary Standard 3/4 19 18x19 rotation resistant − right regular lay (Type RB) 12,920 5 860.5
(Front) Winch Optional 3/4 19 36x7 rotation resistant − right regular lay (Type ZB) 15,600 7 076.2

5−16 Section 5 − General Information

 Operator’s Manual
2M Main and Optional Auxiliary Winches Swing Brake Release − For transporting the boom over

Axial piston, fixed and half displacement (2-speed) the rear of the crane with a boom dolly. Holds the 360º
motors driven through planetary reduction unit for swing park brake in the released position allowing free
positive control under all load conditions. rotation of the upper structure.

Combined winch mode merges the hydraulic flow of
two pumps for high-speed operation for either the J Counterweight
main or auxiliary winch.
Standard − Total of 12,000 lb (5 445kg) of total counter-

Grooved lagging
weight consisting of three, hydraulically removable

Power up/down mode of operation
4,000 lb (1 815kg) counterweights with capacities for 0

Hoist drum cable follower
lb (0kg), 4,000 lb (1 815kg), 8,000 lb (3 630kg), and

Drum rotation indicator
12,000 lb (5 445kg) counterweight configurations. As-

Drum diameter: 16 in (40.6cm)
sembled and disassembled by hydraulic cylinders con-

Rope length:

Main: 630 ft (192.0m) trolled from the left side of the upper structure.

Auxiliary: 630 ft (192.0m) Optional − 4,000 lb (1 815kg) in addition to standard

Maximum rope storage: 834 ft (254.2m) counterweight for a total of 16,000 lb (7 260kg)

J Hydraulic System Counterweight Usage Combinations

Counterbalance Valves − All hoist motors, boom extend
cylinders, and boom hoist cylinders are equipped with 4
counterbalance valves to provide load lowering and to 1
prevent accidental load drop if hydraulic power is sud- 2
denly reduced. 3
Hydraulic Oil Cooler − Remote mounted cooler with hy-
draulically driven fan removes heat from the hydraulic oil. Standard Optional
Located behind the operator’s cab. Ctwt 0 lb 4,000 lb 8,000 lb 12,000 lb 16,000 lb
Boom Hoist Float Valves (Optional) − For transporting (0kg) (1 815kg) (3 630kg) (5 445kg) (7 260kg)
the boom over the rear of the crane with a boom dolly. Al- 1 X X X X
lows hydraulic oil within the boom hoist cylinder to flow
2 X X X
between piston side and case side.
3 X X
4 X

Section 5 − General Information 5−17

Operator’s Manual
Carrier Rear − Eight (dual) 12R22.5 tires on aluminum disc
wheels
J General
Spare tires and wheels − optional

8 ft 6 in (2.6m) wide
Tire inflation kit − optional

23 ft 9.2 in (7.24m) wheelbase (centerline of first axle
to fourth axle) J Brakes

Frame − Box-type, torsion resistant, welded Service − Full air brakes on all wheel ends. Dual circuit
construction made of high tensile steel. Equipped compressed air system with air dryer.
with front and rear towing and tie-down lugs, tow con-
nections, and access ladders. Parking/Emergency − Spring loaded type, acting on 3rd
and 4th axles automatically apply when air pressure
J Outriggers drops below 40 psi (275.8kPa) in both circuits.
Boxes − Two double box, front and rear welded to the car- J Electrical
rier frame
Battery − Four batteries provide 12-volt starting and op-
Beams and Jacks − Four dual stage beams with Con- eration
fined Area Lifting Capacities (CALC) provide selectable
outrigger extensions of full, intermediate, and retracted. Lights
Hydraulically controlled from the operator’s cab and on
Front lighting includes two main headlights, two high
both sides of carrier with integral check valves. A fifth front beam lights, two parking/directional indicators, and
bumper outrigger is hydraulically controlled from the op- three cab marker lights.

Side lighting includes three parking/directional indica-
erator’s cab and at the front bumper of carrier with integral
tors per side.
check valve.

Rear lighting includes two parking/directional indica-
Pontoons − Four lightweight, quick-release, 24 in tors, two parking/brake lights, two reverse lights,
(61.0cm) diameter, aluminum pontoons with a contact three marker lights, and a license plate light.
area of 452 in2 (2 916cm2) can be stored for road travel in
Other equipment includes hazard/warning system,
storage racks on the carrier. The fifth pontoon is a self- cab light, instrument panel light, and signal horn.
stowing 14.75 in (37.5cm) diameter steel pontoon with a
One amber strobe beacon on top of the cab − op-
contact area of 171 in2 (1 103cm2). tional
Main Jack Reaction − 97,400 lb (44 180.6kg) force and
Daytime running lights − optional
215.5 psi (1 485.8kPa) ground bearing pressure
J Engine
J Steering and Axles Specification Detroit Diesel Series 60

Sheppard full integral master gear/slave gear steering Numbers of cylinders 6
system provides hydraulic assisted steering with me- Cycle 4
chanical link between steering wheel and wheels Bore and Stroke: inch (mm) 5.12 x 6.30 (130x160)

Drive − 8 x 4 for on/off-highway travel Piston Displacement: in3 (L) 778 (12.7)

Axle 1 & 2 − Tandem steered, non-driven Max. Brake Horsepower: hp 378 (281.9) @ 1,800 rpm

Axle 3 & 4 − Tandem non-steered, driven with reduc- (kW) 375 (279.6) @ 2,100 rpm
tion: 6.17 to 1 Peak Torque: ft lb (J) 1,350 (1 831) @ 1,200 rpm

Inter-Axle Differential Lock − Traction adding device Alternator: volts − amps 12 − 130
that locks axle 3 with axle 4. Operated by a rocker Crankcase Capacity: qt (L) 32 (30.3)
switch from the carrier cab.
Cruise control

Three-stage engine compression brake
J Suspension
Thermostatically controlled, hydraulically driven radiator fan

120 V engine block heater
Front − Four 9-leaf springs with center equalizers
Ether injection system − optional
Rear − Raydan Air Link walking beam air suspension with
height adjustment. The rear of the carrier can be lowered J Transmission
with rocker switch in the carrier cab.

Axle Lift System − Improves rear tire ground clear- Manual − Eaton RTO−14909ALL has 11 forward gears
ance when the crane is up on outriggers. and 3 reverse gears.

J Tires and Wheels

Front − Four (single) 445/65R22.5 tires on aluminum disc
wheels

5−18 Section 5 − General Information

 Operator’s Manual
J Carrier Speeds and Gradeability
Gradeability
Eaton Speed (@ Peak Torque
Except Creep @ Idle)
Gear Ratio mph km/h % Grade
8th .73 58.4 94.0 2.1
7th 1.00 42.6 68.6 3.4
6th High Range 1.38 30.9 49.7 5.1
5th 1.95 21.9 35.2 7.6
Reverse 3.43 12.4 20.0 10.9
4th 2.77 15.4 24.8 11.2
3rd 3.79 11.2 18.0 15.6
2nd 5.23 8.2 13.2 21.8
Low Range
1st 7.41 5.8 9.3 31.1
Low 16.30 2.6 4.2 54.5
Reverse 13.01 3.3 5.3 43.4
LL2 11.85 3.6 5.8 50.2
LL1 26.08 1.6 2.6 54.0
Deep
Reverse 20.82 2.1 3.4 43.0
Reduction
LL1 @ 700 rpm 26.08 0.5 0.8 51.2
Reverse @ 700 rpm 20.82 0.7 1.1 40.7

J Fuel Tank J Pump Drive

One 100 gal (378.5L) capacity tank All functions are hydraulically powered allowing positive,
precise control with independent or simultaneous opera-
J Hydraulic System tion of all functions.
Main Pumps

Five fixed displacement gear pumps for the main out- J Lower Cab and Controls
riggers, main and auxiliary winches, swing, boom Environmental Ultra-Cab − Fully enclosed, one-person
hoist, and telescope with manual disconnect for use cab of composite structure with acoustical insulation.
when crane is in travel mode Equipped with:

One fixed displacement gear pump for steering and
Tinted and tempered glass windows
the fifth outrigger
Roll down left side window for ventilation

One variable displacement piston pump for the con-
Sliding rear and right side windows for ventilation
trols circuit
Windshield washer and wiper

One fixed displacement gear pump for engine cool-
Six way adjustable and air suspended driver’s seat
ing fan with seat belt

Combined pump capacity of 195 gpm (738.2Lpm)
Two adjustable rear-view mirrors
Hydraulic Reservoir − 169 gal (639.7L) capacity
Engine dependent warm-water heater with air ducts
equipped with sight level gauge. Diffusers built in for for windshield defroster and cab floor
deaeration.
Adjustable sun visor

Dome light
Filtration − One 10 micron, full flow, return line filter. All
12 volt connection
oil is filtered prior to return to reservoir. Accessible for easy
Fire extinguisher
filter replacement.

Section 5 − General Information 5−19

Operator’s Manual
Cab Instrumentation − Ergonomically positioned ana-
Park brake
log instrumentation for driving including:
Warning lamps

Speedometer with odometer, hourmeter, and trip
Engine ignition
odometer Foot Controls For:

Front and rear air pressure with warning indicator
Carrier service brakes

Engine coolant temperature with warning indicator
Engine throttle

Engine oil pressure with warning indicator
Transmission clutch

Voltage indictor with warning indicator

Fuel level J Additional Equipment

Tachometer
Standard:
Dash Mounted Controls and Indicators For:
Adjustable boom rest

Check and stop engine indicators
Aluminum full deck fenders with mud flaps

Windshield wipers and washers
Left and right bubble levels

Carrier lights and turn indicators
Air hose connection ports

Transmission controls
Clearance flags

Carrier/upper throttle control

Engine cooling fan override Optional:

Cruise controls
Pneumatic and electrical quick disconnect connec-

Engine compression brake controls tors mounted on the rear for trailer or boom dolly

Cab heater brakes and lights

Console dimmer switch
Left side aluminum storage box

Engine diagnostic switch
Rear mounted pintle hook

5−20 Section 5 − General Information

 Operator’s Manual
Axle Loads
Gross Vehicle
Front Axles Rear Axles
Base crane with full tank of fuel Weight (1)
and no counterweight lb kg lb kg lb kg
76,187 34 558 34,679 15 730 41,508 18 828
Driver in the carrier cab 200 91 252 114 −52 −24
Rear pintle hook 25 11 −11 −5 36 16
Pneumatic and electrical connectors for trailer or
7 3 −3 −1 10 5
boom dolly
Carrier aluminum storage box 57 26 16 7 41 19
Ether injection 13 6 12 5 1 0.5
Air conditioning − carrier cab 42 19 51 23 −9 −4
Auxiliary winch with 630 ft (192.0m) of 3/4 in (19mm)
855 388 −274 −124 1,129 512
type
RB" rope
Remove 630 ft (192.0m) of rope − main winch −702 −318 338 153 −1,040 −472
Remove 630 ft (192.0m) of rope − auxiliary winch −702 −318 254 115 −956 −434
Hydraulic heating − upper operator’s cab 100 45 1 0.5 99 45
Air conditioning − upper operator’s cab 120 54 −4 −2 124 56
360° mechanical swing lock 140 64 22 10 118 54
One slab of counterweight on upper 4,000 1 815 −2,094 −950 6,094 2 764
Two slabs of counterweight on upper 8,000 3 630 −4,187 −1 899 12,187 5 528
Three slabs of counterweight on upper 12,000 5 445 −6,281 −2 849 18,281 8 292
Three slabs and two cheek weights of counterweight
16,000 7 260 −8,374 −3 798 24,374 11 056
on upper
Floodlight to the front of the boom base section 10 5 17 8 −7 −3
Fly mounting brackets to boom base section for fly
160 73 148 67 12 5
options
36.5 ft (11.1m) offsettable lattice fly − stowed 1,542 699 1,338 607 204 93
36.5−61 ft (11.1−18.6m) offsettable lattice fly −
2,248 1 020 1,700 771 548 249
stowed
Auxiliary lifting sheave 125 57 231 105 −106 −48
40 ton (36.3mt) 4 sheave hook block at front bumper 720 327 1,163 528 −443 −201
60 ton (54.4mt) 4 sheave hook block at front bumper 1,109 503 1,791 812 −682 −309
70/75 ton (63.5/68.0mt 5 sheave hook block at front
1,400 635 2,261 1 026 −861 −391
bumper
8.5 ton (7.7mt) hook ball at front bumper 360 163 581 264 −221 −100

Front Axles Rear Axles

Counterweight Load Transfer
lb kg lb kg
Transfer one slab of counterweight to carrier deck 5,264 2 388 −5,264 −2 388
Transfer two slabs of counterweight to carrier deck 10,528 4 775 −10,528 −4 775
Transfer three slabs of counterweight to carrier deck 15,792 7 163 −15,792 −7 163

Axle Maximum Load @ 65 mph (105km/h)

Front 46,400 lb (21 047kg) − aluminum disc wheels with 445/65R22.5 tires
Rear 50,350 lb (22 838kg) − aluminum disc wheels with 12R22.5 tires

(1) Adjust gross vehicle weight and axle loading according to component weight.
Note: All weights are ±3%.

Section 5 − General Information 5−21

Operator’s Manual
Axle Loads with 2-Axle Boom Dolly
Gross Vehicle
Front Axles Rear Axles Dolly Axles
Base crane and 5,700 lb (2 585kg) boom dolly Weight (1)
with full tank of fuel and no counterweight lb kg lb kg lb kg lb kg
81,887 37 143 30,440 13 807 33,538 15 213 17,909 8 123
Driver in the carrier cab 200 91 252 114 −52 −24 0 0
Rear pintle hook 25 11 −11 −5 36 16 0 0
Pneumatic and electrical connectors for trailer or
7 3 −3 −1 10 5 0 0
boom dolly
Carrier aluminum storage box 57 26 16 7 41 19 0 0
Ether injection 13 6 12 5 1 0.5 0 0
Air conditioning − carrier cab 42 19 51 23 −9 −4 0 0
Auxiliary winch with 630 ft (192.0m) of 3/4 in (19mm)
855 388 588 267 267 121 0 0
type
RB" rope
Remove 630 ft (192.0m) of rope − main winch −702 −318 −527 −239 −175 −79 0 0
Remove 630 ft (192.0m) of rope − auxiliary winch −702 −318 −443 −201 −259 −117 0 0
Hydraulic heating − upper operator’s cab 100 45 25 11 75 34 0 0
Air conditioning − upper operator’s cab 120 54 36 16 84 38 0 0
360° mechanical swing lock 140 64 16 7 124 56 0 0
One slab of counterweight on carrier deck 4,000 1 815 3,171 1 438 829 376 0 0
Two slabs of counterweight on carrier deck 8,000 3 630 6,341 2 876 1,659 753 0 0
Three slabs of counterweight on carrier deck 12,000 5 445 9,512 4 315 2,488 1 129 0 0
Three slabs and two cheek weights of counterweight
16,000 7 260 12,682 5 752 3,318 1 505 0 0
on carrier deck
Floodlight to the front of the boom base section 10 5 −1 −0.5 −1 −0.5 11 5
Fly mounting brackets to boom base section for fly
160 73 29 13 29 13 103 47
options
36.5 ft (11.1m) offsettable lattice fly − stowed 1,542 699 225 102 227 103 1,090 494
36.5−61 ft (11.1−18.6m) offsettable lattice fly −
2,248 1 020 409 186 412 187 1,427 647
stowed
Auxiliary lifting sheave 125 57 −20 −9 −20 −9 165 75
40 ton (36.3mt) 4 sheave hook block at front bumper 720 327 −97 −44 −98 −44 915 415
60 ton (54.4mt) 4 sheave hook block at front bumper 1,109 503 −150 −68 −151 −68 1,410 640
70/75 ton (63.5/68.0mt 5 sheave hook block at front
1,400 635 −189 −86 −191 −87 1,780 807
bumper
8.5 ton (7.7mt) hook ball at front bumper 360 163 −58 −26 −58 −26 476 216

Front Axles Rear Axles Dolly Axles

Counterweight Load Transfer
lb kg lb kg lb kg
Transfer two slabs of counterweight to boom dolly −6,341 −2 876 −1,659 753 8,000 3 629

(1) Adjust gross vehicle weight and axle loading according to component weight.
Note: All weights are ±3%.

5−22 Section 5 − General Information

 Operator’s Manual
Table Of Contents
Fundamental Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6−1

Section 6 − Fundamental Terms i

Operator’s Manual

ii Section 6 − Fundamental Terms

 Operator’s Manual
Boom Section: The base, inner mid, outer mid and
Fundamental Terms manual segments which are used as the telescoping
Many terms are used which refer to crane function, as- extension.
sembly, operation and maintenance. The following list Bumper (5th) Outrigger: An outrigger located on the
gives a brief definition as to how the terms are used in front of the carrier that provides additional stability for
this Operator’s Manual and how they fit this particular
On Outrigger" capacities when deployed.
crane.
By-Pass: A secondary passage of fluid flow, in addi-
Accumulator: A container in which fluid is stored un- tion to the main flow path.
der pressure as a source of hydraulic energy.
Capacity Chart: The chart(s) in the Crane Rating
Aeration: The condition when air is present in the hy- Manual in the crane which gives rated lifting capacities
draulic fluid. This causes the fluid to appear milky and for the crane under different load conditions.
components to operate erratically because of the com-
pressibility of air trapped in the fluid. Carrier: The portion of the crane located below the
turntable bearing.
Annually: Once a year.
Carrier Cab: A housing which covers the driver’s sta-
Anti-Two Block System: A system of electromechani- tion on the carrier of a truck crane.
cal devices used to alert or prevent the crane operator
from two blocking the crane. See Two Block. Carrier Frame: The main structure of the carrier sec-
tion of the crane.
Attachment: The boom assembly, offset fly section(s),
or auxiliary lifting sheave. Cavitation: A condition where air is induced into a cav-
ity, line, or chamber normally filled with oil. This condi-
Audio/Visual Warning System: 1. Alarm device that tion can cause damage to pumps, cylinder walls, etc.
signals the operator of low engine oil pressure, high en-
gine coolant temperature, and high hydraulic oil and Check Valve: A valve which permits flow in one direc-
transmission oil temperature. 2. Device utilizing buzzer tion only.
and/or lights as a signal of approaching two block and/ Circuit: A complete or partial path over which current
or overload condition. See Rated Capacity Indicator. or fluid may flow.
Automatic Brake: Drum brake system that is applied Closed Center Circuit: The condition where the fluid
automatically any time the drum control lever is in neu- only flows through the main control valves when a con-
tral. trol valve spool is actuated. This can be done two dif-
ferent ways: (1) using a pressure compensated pump,
Auxiliary Lifting Sheave: A unit which connects to the
or (2) using a fixed displacement pump, unloading
boom head machinery and is used for reeving winch
valve, and an accumulator.
rope for a second (auxiliary) winch drum.
Collector Ring (Slip Ring): A device used to transmit
Backward Stability: Resistance to overturning of the
the electrical power from the carrier to the upper utiliz-
crane in rearward direction.
ing a rotating disk to allow rotation of the upper and
Base Section: The segment of the boom which at- maintain connectivity.
taches to the upper frame by the boom foot pin.
Compressibility: The change in volume of fluid when
Boom: The assembly of the base, inner mid, outer mid it is subjected to a unit change in pressure.
and tip sections used as the telescoping extension.
Counterbalance Valve (Holding Valve): A valve
Boom Angle: The angle above or below horizontal of which regulated fluid flow by maintaining resistance in
the longitudinal axis of the boom. one direction, but allows free flow in the other direction.
Boom Angle Indicator: An accessory which meas- Counterweight: Weight used to supplement the
ures the angle of the boom relative to horizontal. weight of the crane in providing stability for lifting loads.
Boom Foot: Base of boom where it attaches to the up- Cracking Pressure: The pressure at which a pressure
per revolving frame. actuated valve begins to open to allow flow.
Boom Hoist: The hydraulic method of raising and low- Crane Configuration: The relative position and ar-
ering the boom to different boom angles. rangement of the parts or elements of the crane e.g.
Boom Length: The straight line through the centerline amount of counterweight, attachment position, etc.
of the boom foot pin to the centerline of the boom head Crane Rated Capacity: The maximum weight allowed
sheave shaft, measured along the longitudinal axis of to be lifted with the crane setup in a particular crane
the boom. configuration.

Section 6 − Fundamental Terms 6−1

Operator’s Manual
Crane Rating Manual: A compilation of the necessary the anti-two block system or rated capacity indicator
information needed to plan a safe lift with the crane. It system which will disable the crane function of winch
includes instructions such as the allowable lifting ca- up, telescope out, and/or boom down (as applicable)
pacity charts, Working Range Diagrams, Working as two block or overload situations approach.
Areas chart, etc. Gradablity: The slope which a crane can climb ex-
Crane Set Up: The act or instance of preparing the pressed as a percentage. (45° equals 100% slope.)
crane for operation which entails the positioning of the Ground Pressure: Weight of crane divided by the area
crane and its elements. It concerns such details or of the surface directly supporting the crane.
items such as finding a suitable location to perform the
lift, setting the outrigger position, leveling, cribbing or Head Machinery: An arrangement of sheaves on the
blocking of the crane, etc. end of an attachment used to reeve wire rope.
Cylinder: A device which converts fluid power into me- High Idle: Governed engine speed at full throttle and
chanical force and motion. It usually consists of a no load.
moveable element such as a piston and piston rod, Hoist: Function of lifting and lowering loads.
which operates within a cylindrical bore.
Hoist Drum: See Winch Drum.
Delivery: The volume of fluid discharge by a pump in a
Hoist Rope: The wire rope used to reeve the winch
given time, usually expressed in gallons per minute
and the attachments for lifting loads.
(gpm) or liters per minute (L/min).
Holding Valve (Counterbalance Valve): A valve
Displacement: The quantity of fluid which can pass
which regulates fluid flow by maintaining resistance in
through a pump, motor, or cylinder in a single revolu-
one direction, but allows free flow in the other direction.
tion or stroke.
Hook Ball: Ball with hook attached used in lifting serv-
Double Acting Cylinder: A cylinder in which fluid
ice. It is used with one part of line only.
force can be applied in either direction.
Hook Block: Block with hook attached used in lifting
Drum Lagging: See Winch Drum.
service. It may have a single sheave for two or three
Drum Rotation Indicator: A device that is used to indi- part line, or multiple sheaves for four or more parts of
cate winch drum motion and can also be used to moni- line.
tor speed.
HTC: Hydraulic highway truck crane.
Filter: A device which functions to remove insoluble
Hydraulic Reservoir: The storage tank for hydraulic
contaminants from a fluid by a porous media.
fluid.
Flow Divider: A valve which divides a flow of oil into
Inner Mid Section: The segment of the boom which is
two streams.
attached to the base and outer mid sections.
Fly Base Section: Boom tip extension supported only
Instability: A
tipping condition" in which the mo-
at its base.
ments acting to overturn a crane exceed the moments
Force: Any cause which tends to produce or modify acting to resist overturning.
motion. In hydraulics, total force is expressed by the
Lifting Capacity: The rated load for any given load ra-
product of pressure (P) and the area of the surface (A)
dius and boom angle under specified operating condi-
on which the pressure acts. (Formula − F = P X A)
tions.
Frame: Structure on which either upper or carrier ma-
Line Pull: The rope pull generated off a rope drum or
chinery is attached.
lagging at a specified pitch diameter.
Friction: The property which tends to resist the relative
Line Speed: The rope velocity at a rope drum or lag-
motion of one surface in contact with another surface.
ging at a specified pitch diameter.
It always exerts a
Drag" in the direction opposite of the
motion, thus consumes power. Load Radius: The horizontal distance from the center-
line of rotation of the upper to the center of gravity of a
Full Flow: In a filter, the condition where all the fluid
suspended load.
must pass through the filter element.
Mat: Support, usually of timber or wire construction,
Full Load Speed: The speed at which an engine runs
for supporting the pontoons on soft surfaces where the
when it is delivering its full rated horsepower.
pontoon areas are not large enough to support the
Function Limiter (Function Lockout, Hydraulic Cut- load without settling.
outs, Hydraulic Kickouts): Devices incorporated into

6−2 Section 6 − Fundamental Terms

 Operator’s Manual
Motor (Hydraulic): A rotary motion device which Pressure: Force per unit of area usually expressed in
changes hydraulic energy into mechanical energy, a pounds per square inch (psi) or Kilopascals (kPa).
rotary actuator. Pressure Drop: The reduction in pressure between
Offset Fly: A fly section that is capable of being pinned two points in a line or passage due to the energy lost in
at different angles. maintaining flow.
Oil Cooler: A heat exchanger used to remove heat Pressure Reducing Valve: A valve which limits the
from the hydraulic or transmission fluid. maximum pressure at its outlet regardless of the inlet
Open Center Circuit: A circuit where the pump con- pressure.
tinuously circulates fluid through the control valves Pump Disconnect: Device which engages and dIsen-
when they are in a neutral position. gages the main hydraulic pump. Disengaging the
Operational Aid: An accessory that provides informa- pump aids in engine start-up by reducing cranking re-
tion to facilitate operation of a crane or that takes con- sistance.
trol of particular crane functions without action of the Pump (Hydraulic): A device which converts mechani-
operator when a limiting condition is sensed. cal force and motion into hydraulic fluid power.
Operator’s Cab (Upper Cab): A housing which cov- Radius Of Load: The horizontal distance from the cen-
ers the operator’s station. terline of rotation of the crane to the center of gravity of
Outer Mid Section: The segment of the boom which is the suspended load.
attached to the inner mid and tip sections. Rated Capacity Indicator (RCI): A device that auto-
Outrigger: An extendable supporting device used to matically monitors radius, load weight, and load rating
level the crane and increase stability. and warns the crane operator of an overload condition.
Outrigger Beam: The part of the outrigger which ex- Rated Capacity Limiter (RCL): A device that automat-
tends horizontally and acts as the support for the out- ically monitors radius, load weight, and load rating and
rigger jack. prevents movements of the crane that would result in
an overload condition.
Outrigger Jack: The hydraulic cylinder on the outrig-
ger beam which extends vertically to raise and lower Reeving: Passing of ropes over pulleys or sheaves.
the crane. Relief Valve: A pressure operated valve which by-
Pick And Carry: The crane operation of lifting a load passes pump delivery to the reservoir, limiting system
and traveling with it suspended. pressure to a predetermined maximum valve.
Pilot Pressure: Auxiliary pressure used to actuate or Reservoir: A container for storage of fluid in a fluid
control hydraulic components. power system.
Pinion: The small gear in a gear train which drives the Restriction: A reduced cross-sectional area in a line
other gears. which produces a pressure drop.
Pitch Diameter: Root diameter of drum, lagging, or Rigging Switch (System Override Switch): A switch
sheave, plus the diameter of the rope. which can be used to override any or all of the function
limiters (cutouts) which have been activated on the
Planetary: A set of gears used to either speed up or crane during crane rigging/set up.
slow down the input vs the output to gain speed or
power, whichever is applicable. Rope: Refers to wire rope unless otherwise specified.
See
Wire Rope".
Platform: A device (basket, work platform, bucket,
cage, etc.) designed and fabricated with its intended Rotating Joint: Component which transfers fluid be-
use being to position personnel. tween a stationary and a rotating member.
Pontoon: The support which attaches to the outrigger Schematic: A diagram or representation of a system
jack to increase the supporting area. showing everything in a simple way. No attempt is
made to show the various devices in their actual rela-
Poppet: A disc, ball, or cone shaped part of certain tive positions. A schematic points out the operation of
valves, which when closed against a seat prevents a circuit for troubleshooting purposes.
flow.
Seasonally: Four times per year.
Port: The open end of a passage. May be within or at
the surface of a hydraulic component housing or body. Semiannually: Twice per year.

Section 6 − Fundamental Terms 6−3

Operator’s Manual
Service Brake: A foot operated brake which regulates travel swing lock is mandatory when traveling or trans-
the amount of air or fluid delivered to the brake cham- porting the crane and during pick and carry operations.
ber, which determines the braking force. Turntable Bearing: A large bearing which attaches
Shall: The word shall is to be understood as mandato- the upper to the carrier allowing the upper to rotate on
ry. the carrier.
Should: The word should is to be understood as advi- Two Block: The condition when the crane’s hook
sory. block, ball, any other load attachment means, or the
Side Loading: A load applied at an angle to the vertical load itself, comes into contact with any of the attach-
plane of the boom. ment’s load sheaves or other physical entity on the at-
tachment.
Single Acting Cylinder: A cylinder in which fluid
power can only be used in one direction. Another force Two Block Warning System: A system of electrome-
must be used to return the cylinder. chanical devices used to warn the crane operator of im-
pending two block condition.
Spool: Term applied to almost any moving cylindrically
shaped part of a hydraulic component which moves to Unloading Valve: A valve which by-passes flow to
direct flow through the component. tank when a set pressure is maintained on its pilot port.

Strainer: A filtering device for the removal of coarse Upper: The portion of the crane located above the
solids from a fluid. turntable bearing.

Stroke: The length of travel of a piston or spool. Upper Revolving Frame: The main structure of the
upper section of the crane which serves as mounts for
Suction Line: The hydraulic line connecting the pump other components in the upper section.
inlet port to the hydraulic reservoir.
Valve: A device for controlling flow rate, flow direction,
Sump Tank: See Hydraulic Reservoir. or pressure of a fluid.
Surge: A very sudden rise in hydraulic pressure in a Viscosity: The resistance to flow. High viscosity indi-
circuit. cates a high resistance, low viscosity, a low resistance.
Swing: The rotation of the upper with the carrier re- Winch: Function of lifting and lowering loads.
maining stationary.
Winch Drum: A rotating cylindrical spool with side
Swing Brake: A brake which is used to resist the rota- flanges used to wrap the winch rope during the raising
tion of the upper during normal, stationary crane op- and lowering with the winch.
erations.
Winch Rope: The wire rope used to reeve the winch
Swing Motor: Hydraulic device which uses a plane- and the attachments for lifting loads.
tary to rotate the upper on the carrier.
Wire Rope: A flexible, multiwired member usually con-
Swing Park Brake: A self contained brake used for sisting of a core member around which a number of
holding the upper, in any position, during normal, sta- multiwired strands are helically wrapped.
tionary crane operations.
Wiring Diagram: A diagram that includes all the de-
Tailswing: The swing radius from the centerline of ro- vices in an electrical system and shows their functional
tation of the upper frame to the extreme rear edge of relationships to each other. Such a diagram gives the
the counterweight. necessary information for actual wiring or physically
Tip Section: The outer most live segment of a tele- tracing circuits when troubleshooting is necessary.
scopic boom. It is attached to an outer mid section and Working Weight: Weight of crane with full radiator, half
contains the head machinery of the attachment. full fuel tank, and attachments installed.
Torque: Turning or twisting force usually measured in 360° Swing Lock: A positive mechanical lock against
foot pounds (ft lb) or Newton meters (Nm). rotation of the upper over the carrier during normal, sta-
Travel Swing Lock (2 Position Swing Lock): A me- tionary crane operations.
chanical lock that engages with the upper directly over
either the front or the rear of the carrier only. Use of the

6−4 Section 6 − Fundamental Terms