Operator's Manual ELT} aM aR DOCUMENTO ILEGIVEL, ORIGINAL] ENCONTRA-SE NA TI/JUNBC.age marvin. DER 08-435, ZAP GTS CFESHORS COMPANY THIS BOOK APPLIES TO NATIONAL ORDER WO 8465-102 NATIONAL SUPPLY SPECIFICATION X16-S148, S/N 344 8 345 Be puja x0 O28 FOREWORD This manval has been compiled to assist in the operation and maintenance of the OS-435 pedestal crane. A great deal of effort was put into the development of this machine to assure ease of operation ond maintenance. There are, however, certain precautions that should be token to assure safe operation and long trouble free service. We, therefore, urge the operator to become fomiliar with this manual before operating the crane. NOTE: This manual applies only to cranes with serial no,’s ebove Serial No. 230. eel NATIONAL OILWELL P.O. BOX 4638 HOUSTON, TEXAS 77210-4638 As used herein, any references to Nai al shall be deemed to mean ational Oilwell. Copies of this monuol hove been furnished with soch unit of time of shipment on @ Ne Chorge" basis. A charge will be ossessed on oll requests for additional ar replacement copies.(CRANE NOMENCLATURE ‘ateave EXTENSION — sess — é y TREREEAE a, Sorr'ataexs ‘00m orsy unes —, jor 2 wacrneny courasenueny suns wean tr 0048TABLE OF CONTENTS Intraduction. Safe Operating Practices Inspection Operating Insiructions Lubrication Filters and Conditioners Electrical Schematic for Caterpillar Engine Cranes Electrical Schematic for Detroit Diese! Engine Cranes Hydraulic Motor Compartment Engine Compartment Rear Cab Wat! Triple Pume Drive Hydrostatic Orive Hydeoulic Control Circuit AirControl System Operation of the Primary Functions Brokes ‘Swing Bearing Maintenance Requirements Structural Maintenance ‘Over-Center Cluich Boom Angle Limiter Line Trovel Limiter Reeving and Wire Rope Specifications Boom Hoist Block Supports Wire Rope Maintenance and Inspection Reading Schematics Trouble Shooting - Control Pressure Circuit Trouble Shooting - Pump Drive Housing Trouble Shooting Aic Valve Repair, Maintenance and Operation Hydrosiatic Drive Trouble Shooting, Pump and Motor Replacement Pump and Motor Repoir Emergency Load Lowering Crane Start-Up Procedure after Storage or Shipping Appendix 107NATIONAL — HYDRAULIC PEDESTALCRANE S43. Tom US INTRODUCTION The O§-495 crane incorporates all the standard crane functions and utilizes o lattice type, wire line supported boem and high gantry permitting the reaching out with heavy loads and the use of long booms, Here, however, is where the similarities end. The 05-435 is a pneumatically controlled hydraulic unit Each hoi drom is powered by its own hydraulic motor powered by a variable displacement pump. This motor drives through a two stage planetary gear reduction that is completely enclosed within the drum. The fluid flow 10 and from each motor is controlled so that the speed of any function (hoist, lower, swing) depends only on the engine speed and how far the control handle is moved from the neutral position. This provides the vllimote in smooth conirel and ease of operation. The swing is @ completely independent hydraulic circuit t viiizes a voriable displacement pump driving a fined displacement motor. This motor drives the swing pinion through o totally enclosed three stage geor reduction, This modern hydraulic epproach greatly simplifies maintenance. Rather thon one large complex piece of machinery, the hydtaulic unit utilizes relatively small, completely independent modvles. The modules can be easily removed for repair or replacement The 0§-495 has only one friction clutch to adjust; this is the throw-out clutch between the prime mover and hydraulic pumps. All heavy braking is done hydraulically. The friction brakes are used only to hold the tood While the control handles are in neutral, This provides for long brake life and rare need for brake odjusiment The brakes and boom hoist lock pawl are spring set and pressure releosed, All hoist brokes release Gulomatically when the control handles are maved out of the neutral position. All the hoist brakes ond boom hoist lock pow! se! automatically when the heist control handles ore returned te the neutral position A hydraulic drive provides for a more compoct design. It alsa permits a more complete isolation of the ‘operator's cab for more efficient sound and temperoture control. The main frame is of welded steel construction utilizing high beam design gives maximum rigidity with minimum weight rrength steels in critical locations. Its deep m= Rev. Dec. 1978 | Page 1 onal Supp CompanyNATIONAL —= HYDRAULIC PEDESTALCRANE = OS--435 ‘SAFE OPERATING PRACTICES 1. Know the weight of the load you ore lifting 2, Do not exceed the crane’s load chart 3. Check the weight of unfamiliar loads if within 10% of the load chart capacity 4, Attach the load properly to the hook with slings or chains and balance the lood. 5. Do not wrap the heist rope around the lood. 6. Before hoi ing, check the wire rope for kinking or twisting. 7. Bring the hook over loads in such @ manner as to prevent swing. 8, If there is a slack rope condition, it should be determined that the rope is properly seated on the drum ond in the sheaves. 9. Move loads smoothly, without sudden acceleration or deceleration 10. Do not allow personnel to ride the load or hook 11. Avoid carrying loads over people 12, Test the brakes each time @ load approaching the rated loed 1s handled. 13, Do not leave the crane unattended while a load is suspended 14, The operator should respond to signals only from the oppointed signal man, but should obey a stop signal at any time no moter who gives it 15. Never allow fewer than three full wraps of wire rope on any drum, 16. Do not refuel crane with engine running, 17. A carbon dioxide, dry chemical, or equivalent fire extinguisher must be kept in the operator's cab or vicinity of the crane. INSPECTION ‘A sample inspection check lis! has been provided in order to acquaint an operator with the proper inspection of NATIONAL pedestal cranes. The inspection procedure hos been divided into three general groups based upon intervals at which inspection should be performed. The three inspection intervals ore: daily, weekly, ‘and monthly. These intervals are recommended for normal operation, but may be adjusted to the customer's ‘operating conditions. IFadjusiments or repairs are found to be necessary from an inspection, the inspector should promptly notify the proper personnel to assure problem correction, The crane operator of the next shift should also be rotified of the defect if the problem has not been corrected prior to the shift change. Inspection records should be signed and dated by the inspector, and kep! available for future reference as recommended by the American Petroleum Institute. Page? Rev. Dec. 1978 Nona Supply CompanyNATIONAL — HYDRAULIC PEDESTAL CRANE INSPECTION CHECK LIST — DAILY CRANE SERIAL NUMBER. OATE INSPECTED. OS-435 NO. OF CRANE OPERATING HOURS. INSPECTED By CONDITION “Correction DAILY PROCEDURE | Requires COMMENTS: 1. CHECK FOR AND ELIMINATE SPILLAGE OF FLAMMABLE MATERIALS SUCH AS FUEL & OIL. 2. Service engine, checking water and oll levels, ‘and air cleaner “Chack engine fuel tank level Check hydraulic OW tank Tevel [Lubricate boom foot bushings. ‘Check operation of horn: Start engine and allow to warm up at idle speed. Gheck engine gages. ._Cheok clutch operation Engage clutch and allow nydauive oll to warm up al idle speed. 10. Observe charge pressures to see If they are in prover operating range, 160/300 psi (11/20.7 bar). 7 Observe control prassure to see if iis in the proper aperating range, 700/750 psi (4.9/5.7 bar). 12, Observe the tuple pump drive Tube oil gage to see] if it te In the proper operating range, 20/40 pst (1.4/2.8 bar) at 1800 RPM, 73. Check swing, boom, and holst conirol handles for adjustment and for proper centering when released, Ta. Ghesk air regulator 10 see Wiis in the proper operating range, 95/100 pst (6.6/6.9 ba 75, Drain moisture from air 1eceNers 76. Check ail “brake-off” indicators 7. Operate emergency brake sel to assure its operation, 18, Visually inepect all running wire rope and check all drums f0¢ proper spooling. 78. Check for leakage or deterioration of components In nyoraulic and pneumatic systems. 720, Observe condition of pump suction fine filter at engine speed of 1800 RPM. Di Check boom pins and gantry (eg pins For missing or dislocated cotter pins. 2. Check conaition at high pressure by depressing red button on down at fall speed. If button pops out, replace element, when a checkmark has been placed under the "correction requis column for a certain procedure, corrective work yaa a Sformed. Aiter correction of the defect, the dale and Initiale of the person making the correction are 10 be placed in the o.k. column of the procedure in question. National Supply Company Rev, Des. 1978 Page 3NATIONAL (CRANE SERIAL NUMBER. HYDRAULIC PEDESTAL CRANE OS-435 INSPECTION CHECK LIST — WEEKLY AND MONTHLY DATE INSPECTED. NO. OF CRANE OPERATING HOURS INSPECTED BY. WEEKLY PROCEDURE O.K. Required ‘CONDITION rFeSTON COMMENTS: 1 Lubricate crane per instructions in operator's 2. Check ai lvls 0” all shall assemblies, ewing gear housing, triste pump drive 3 Check boom saver system for proper operation, “Chock boom angie limiter system Tor proper ‘agjuetment (adjustment must be 80 {0 pronibit boom angles greater than 80°.) 'E. Check boom hoist lock paw! for correct engage- ment and disengagement Wh ratchet wheel teath {6 Chack brakes for adjustment and excessive wear Cf ining, loose oF missing components ana contamination by lubricants, 7. Ghack electrical apparatus such as lights and switches for malfunction or sighs of deterioration. Ghack air line lubricator oll levels . Chack clutch adjustment ‘CONDTHON Correction OK. Regulred COMMENTS: 1. Thoroughly inspect all wite cope and pendant ines, for deterioration such ag: roduction of rope dia, broken and worn outside wires corroded and ‘cracked end connections and severe kinking. ‘crushing and unstranding at wires 2._Check hooks for cracks and det 3, Inspect boom for deformed, cracked, corroded or russing members “4. Inspect gantry for deformed, cracked, corroded or nigsing members. 5. Inapect main frame for deVormed, cracked, or corroded members, ‘6. Ghack for loose bolts on hydraulic pumps and motors, swing bearing, gantry, swing gear reducer, and shafl assemblies 7 Inspect sheaves for cracks, exacsive wea and that they operate reel) . Inspect all load, angle and weight indicating systems over their full range for significant 8, Chack for worn, crake rope rollers, and swing bearing ‘boom pins, ‘gear teeth distorted, or dislocated TO. Ghack wisle pump drive chain for excossive stretch, and chain sprockels for wear ‘When a checkmark nas been placed under ine “correction required” column for a certain procedure, corrective work ‘must be pertormed. After correction of the detect, the date and initials of the persone making the correction are to be placed in the 0.k. column of the procedure in question. Page « Rev. Dee, 1978NowRene 10, nN 12. 13, 1 15, 16. 17. 18 20. 21 NATIONAL HYDRAULIC PEDESTAL CRANE OPERATOR'S CAB $-435 ao USA - rsaoso Figure | Engine Tachometer 22. Control Air Pressure Regulotor Boom Hoist Pressure Goge 23. Whip Hoist “Brake Off” Indicator Swing Pressure Gage 24. Main Hoist “Broke Off” Indicator ‘Main Hoist Pressure Goge 25. Boom Hoist “Brake-Off” Indicator Engine Water Temperature Gage 26. Swing Hoist "Brake-Off” Indicator Engine Oil Pressure Gage 27. Emergency Brake Set Valve Triple Pump Drive Low tube 28. Swing Broke Control Valve Pressure Indicator 29. Emergency Load Release Valve Low Hydraulic Tank Fluid 30. MainWhip Hoist Selector Control Valve Level Indicator 31. Engine Start Valve ‘Air Supply Low Pressure Indicator 32. Engine Kill Valve. Control Air Pressure Gage 33. Low Boom Limit Override Valve Control Pressure Goge 34. Horn Valve ‘Swing Charge Pressure Goge 35. Clutch Control Valve Boom Charge Pressure Gage 136. Cob Heater Power Switch ‘MoinWhip Charge Pressure Gage 37, Cob Heater Thermostat Switch Boom Hoist Control Pedal 38, Boom, Beacon, Frame, and Cab Light Switches Foot Brake Pedal 39. Electrical Circuit Breaker Cabinet Foot Throtile Pedot 40. Electrical Component Box Swing Control Handle 41. Main ond Whip Hoist (Hook) High Speed Boom Hoist Control Handle Selector Valve ‘MainWhip Hoist Control Handle 42, Main and Whip Hols! High Speed Indicator Hand Throttle Control 43, Transformer BP san i: Rev. July 1982 | Page SNATIONAL — HYDRAULIC PEDESTALCRANE —OS-435 muse NOTES Page &NATIONAL HYDRAULIC PEDESTAL CRANE OS.435 OPERATING INSTRUCTIONS. her, the crane is ransporting loads, the engine speed should be of leott 1500 RPM. Maximum engine Speed is 1800 RPM. Minimum engine idle speed is 1000 RPM. Figure 1 shows a view of the operator's cab and controls. These controls have been grouped for ease of operation and to offer the operator a desirable field of vision Swing Tre utd lever (18) onthe left hand console operates the crane swing tystom. To swing the upper works to ihe right, the lever (handle) is moved forward, away from the aperaior To swing left he lever is anscey baward the operoter. Ata given engine RPM the swing speed depends on how far ihe contral lever ie moved from its neutral position. A valve (28) in the console is used 10 se! or fo release the swing brake, An indore (26) turns amber to inform the operator when the broke is released 800M HOIST Te eg ost shaft assembly isthe rear winch onthe crane and is contralled bythe inside lever (19) on the {eit ond console, This lever &s moved forward, away from the operator, to lower the boom ond eek ‘inform the operator when the brake and lock paw! are released The boom hois! can also be operated with the left foo} using the rocker pedal (15) on she floor, Thie methed °F eperoting leaves the operator's lef hand free 10 operate the swing controls while toomeg ‘he boom is equipped with an automatic stop for the high and low elevotions. This stop should be checked Pere he ago! Proper operation, When the stop is activated the conlol lever will only move the boom axar from the stop. MAIN AND WHIP UNE HOISTS TESS inches ore conrolied by the lever (20) on tho ight hand console. A two position voles (35) ieee NOTE: The his! selector control valve (20) MUST NOT be shifted while hosting or lowering @ load. Only when the contrat hondlle (18) is in neutral should an operator switch from one winch io orowa [nie Precaution must be observed by the operator lo prevent possible pressure surges or lowe a load control from damaging the hydroulie motors. MAIN AND WHIP LINE HOIST SPEED SELECTOR AND INDICATOR Bate ne main and whip line hoists ere equipped with hWwo-speed motors for low speed high torque, or high see, ‘am forgue operation. The “hook speed selector valve (dl) 8 used for both the mann and whig age ‘motors. The valve is pulled for high speed and pushed for low speed FB wt con [roca]NATIONAL = HYDRAULIC PEDESTAL CRANE —-OS-435 CoM USK The main and whip hoist high speed indicator (42), in the right hand control panel, will be omber whenever the main and whip hoist motors are in the high speed, low torque position (hoist speed selector valve (41) is in the “up” position) CAUTION: 00 NOT change speeds while hoisting or lowering a load. If the hoist pressure exceeds 3500 Psi, the main/ whip control handle should be returned 1o neutral and the speed selector valve pushed for “low” speed. EMERGENCY BRAKE SET The emergency brake set valve (25) is located on the left hand console. To set all hoist brakes and boom hoist lock powl, push this valve, To reset for normal operation, pull the volve up. EMERGENCY LOAD RELEASE The emergency load release valve (29) is located on the right hand console. To release @ lead, push this valve. To reset for normal operation, pull this valve up. CAUTION; This valve should ONLY be used in emergency situations to release o load. Indiscriminate use of th's valve may cause damage fo the main or whip hoist hydraulic motors, ENGINE GAGES The engine gages are located on the left hand console panel. These are the oil pressure gage (6), engine ‘water temperature gage (5) and the engine tochometer (1), These gages should be checked periodically for correct readings as specified in the engine manual. The minimum engine speed reading on the tachometer should be 1000 RPM and the maximum should be 1800 RPM. If gage shows an incorrect reading, immediately shutdown the engine and determine the cause to prevent possible engine or hydraulic system damage. HYDRAULIC FLUID TANK LEVEL A safe hydraulic tank level is demonstrated by the indicator (8), on the right hand console panel, displaying “green”. The indicator should be checked periodically during operation. If the hydroulic tank level indicator turns “red” during operation, the quantity of hydraulic fluid hos reduced to 0 critical level, The reduction of fluid quoniity is caused by leakage. The leak shauld be located and repaired promptly. DO NOT operate the crane when the indicator 's red The hydraulic fluid musi alwoys be kept CLEAN ond at the proper level to assure reliable operation of the crane’s hydraulic system. If the presence of water or emulsification in the fluid is noticed, or ifthe fluid color turns dork brown, the fluid should be changed as soon as possible The capacity of the hydraulic tank is 60 gallons (227 litres). FUEL TANK LEVEL The fuel tank level is checked with sight glasses instolled in the wall of the tank. The capacity of the fuel tank ¥s 130 gollons (492 liters) KILL VALVE The kill valve (32), locoted on the right-hand engine panel, shuts off all the cab controls and kills the engine, Prior to starting the engine this valve must be pulled up. To kill the engine, this valve is pushed down, Pages Rev. Dee. 1978 onal Supply CompanyNATIONAL HYDRAULIC PEDESTAL CRANE OS-435 mo musa START VALVE The stor valve (31) is located on the right hand engine ponel. To stor the engine firs pull he kil valve (32) 3B, Pull up on the engine start valve to permit compressed oi to poss to the engine's our starter Release he inattuchong, "mediately after the engine stars. Refer to the engine monvol for adsiionel storing instructions, ENGINE THROTTLE CONTROLS increase engine speed. CLUTCH OPERATION opproximately two seconds. HYDRAULIC SYSTEM GAGES Tren mscre, 2098s located on the right hand control pone! indicate the pressures of the cranes hydraulic circuits. The “MAIN” gage (4) indict {BOOM™ gage (2) indicates the pressure required for operating the boom hotey The “Swine goge (3) iraicates the pressure required ta swing the crane. The "MAIN", “BOOM” and "SWING goged sro [yaieler opproximately zero pressure with the control handles in the neutral position. Uneor core, Speroting concitions the pressure registered by the above gages should not exceed 2500 psi (241-4 bor) reyes, charge Pressure gages, located in the right hand rear panel, indicate the pressures required to insure tafe operation of the hydraulic systems. The "BOOM charge pressure gage {13} indices Ihe crecsure, Generated by the boom pump charge pump. The “MAIN” charge pressure gage (14) indiceles ine Traicares Ree erated, By the main/whip pump charge pump. The “SWING” charge pressure gage {19) sana ihe, ressure generated by the swing pump chorge pump. These goges shovid ssoicies irying berween 160 and 300 psi (11/20.7 bar). The pressure generally will increcce win Should the chorge pressure not fall within these limits, a problem may exis sith fronsmission. Ens ccontel pressure” gage (11) indicates the discharge pressure ofthe contol pressure pump. For proper broke eperation, he control pressure mus! be from 700 10 750 psi (48.3 t9 81.7 bor), AIR PRESSURE REGULATOR AND GAGE + [heir pressure regulator (22) and goge (10) are located inthe right hand rear panel. The regulator should Pe ediusied to maintain an cir pressure between 95 and 100 psi (6.6 ond 59 ker) Pw Rev. July 1980 | Page 9NATIONAL — HYDRAULIC PEDESTAL CRANE OS-435 Lo musa BRAKE PEDAL A foo! brake pedal (16) is provided in the cab for setting the main and whip hoist brakes. This brake pedal is primerily used for “running in”” new brake linings. It may also be used for drying wet brake linings or removing rust from the brake drum by depressing the pedal while hoisting on empty hook. The broke pedal also provides the operotor with control of o load when the emergency lead release function is actuated LOW BOOM LIMIT OVERRIDE The low boom limit override valve (33) is located in the right-hand engine control panel. This valve allows the ope ator 1o lower the boom below the limit established by the low boom angle limiter system, This valve must be pulled up end held to lower the boom. The air horn will sound as long os this valve is held up. NOTE: This volve is provided to permit the boom ‘o be placed in a rest. Caution should alwoys be exercised when using this valve and the maximum negative boom angle of five degrees (52) should never be exceeded. This system is only to be used when no load is suspended from the. hook or block HORN VALE The horn valve (34) 1s locoted on the right hond console control panel. This valve is pushed to sound the cir horn, TRIPLE PUMP DRIVE HOUSING LUBRICATION PRESSURE AND WARNING INDICATOR Located ot the rear of the pump drive housing is © gage (Fig. 13) for indicating the pressure of the oil used to lubricote the wiple pump drive's gears and beorings. With the clutch engaged, the lube (lubrication) oil worm and the engine set at 1800 RPM, this gage should indicate o pressure of 20 to 60 psi (1.4 to 4.1 bor] The “triple pump drive low lube pressure indicotor”” (7) loceted in the right hand conirol panel should display “green” when the engine is running and the clutch is engaged. The indicator directly senses the drive lubrication pressure. A foilure in the drive lubrication system and subsequent joss of lubrication pressure will cause ine indicator to disploy “red”. Should the indicatar display “red” during erane operction, the crane should be shut down os quickly as possible ond the drive lubrication system malfunction corrected, See poge 77 for the necessary trouble shooting procedures, TRIPLE PUMP DRIVE LUBE OIL RELIEF VALVE To protect the lubrication system for the triple pump drive, o relief valve is mounted on the discharge side of the pump. The valve is factory set to open of 100 psi (6.9 bar), No field adjustment should be required. AIR SUPPLY LOW PRESSURE INDICATOR Under normal operating conditions, the air supply low pressure indicator {9) in the right hond control panel will be green, Should the cir pressure to the controls drop from the normal 95/100 psi (5.5/6.9 bar) range to 75 psi (5.2 bar) the indicator will turn red. At this point crone operation should be terminated os quickly as possible until proper air pressure is restored fo the crane, If gir pressure to the controls drops to 50 psi (3.4 bbar) operction of the main and whip hoist will stop automatically ELECTRICAL COMPONENT BOX This enclosure (40) contains o rectifier to produce o direct curcent from the 24 volt alternating current and a fuse for the 24 volt D.C. circuit. Nationt Supply Comoany Page 10 Rev, uly 1982 raNATIONAL HYDRAULIC PEDESTAL CRANE —- OS..435 TRANSFORMER The transformer (43) reduces the crone electric supply (240 oF |20 volts) o 24 volis for use with the defroster fon, CIRCUIT BREAKER CABINET AND LIGHT SWITCHES The circuit breakers in the electrical circuit breaker cobine! (39) are provided 10 protect the crone electrical sysiems trom sustained overloads and ore clearly marked as to their function. The toggle switches (38) ore for the crane boom lights, engine compontment lights, and cab light. CAB HEATER The operator's cab heater, iocated on the rear cob wall is 0 thermostatically controlled electrical resistance heater. The thermostat (37) and power switch (26) are on the side of the heorer HYDRAULIC TANK HEATER Installed in the hydroulic tank is an’electrical immersion heater for maintaining the hydraulic fluid oto suitable temperature to protect the crane’s hydraulic system from the harmful effects of cold weather start-ups. Temperature control is provided by means of an adjustable knob located on the outside face of the heater's steel housing. the knob should be positioned with the pointer to provide o temperature setting of 759 to 00°F (249 to 38°C) NOTE: In order to prevent overheating and possible oxidation of the hydraulic fluid, the A.C. voltage supplied to the tank heater is one-half of the nameplate volioge stomped on the heater omeplate. Therefore, a heater stomped 240 V.A.C. must be wired with 120 V.A.C, and 0 heoter stomped 480 V.A.C. must be wired with 240 V.A.C. ENGINE BLOCK HEATER The diesel engines ore equipped with on electrical jocket woter heater 10 protect the engine from harmful effects of cold weather and facilitate cold weather starting. This heater is turned on by @ circuit breoker in the operator's cab and controlled by a thermostat in the heater. The thermostat should be set at 90%F (32°C) The heater circuit breaker can be left in the “on” position at all times without hormful effects DAILY CRANE START-UP Daily crane starting should be performed in the following sequence: (1) Inspect the crane in accordance with the maintenance schedule, (2) Position the hand throttle in the low idle position, (2) Pull the kill vale, (4) Push the clutch valve and hold for two seconds, (5) Pull the start valve, releasing immediately after ine engine starts, (6) Check the engine gages, {7) Allow the engine to worm up of low idle, (8) Pull the elurch valve and hold for five seconds to properly engage the clutch, (9) Check all the hydraulic system gages for correct readings, (10) Allow the crane to warm up before lifting loads, (11) Check the operation of all the crane controls before lifting loads. Rev. July 1982 SGP sero soy conorNATIONAL — HYDRAULIC PEDESTAL CRANE OS.435 Umomuse COUD WEATHER STARTING NOTE Cranes Equipped with Ether Aid Kit ; If the ombient air temperature is in the range of +35°F (28C) "0 -20°F (-299C), on ether starting aidshould be used to ostist in storting the engine. DAILY CRANE SHUTDOWN, Dolly crane shuidown should be performed in the following sequence: (1) Position the boom in o rest, (2) Reduce the engine speed to low idle, (3) Push the clutch valve and hold for two seconds, (4) Push the lull valve down and wait for the engine to stop, (5) Close all cab windows and doors, CRANE LOAD RATINGS AND LOAD CHARTS The load ratings of the crane change with load radius, boom length and number of lines in moin hoist reeving, All of the Factors must be considered together. The load chart plote in the operater’s cob a a fobulotion of the ratings af the crore. Each plate is matched to 0 boom length. When the weight of o load Gnd the radius af the load are known, the load rating versus load radius table should be consulted to contin, the load does not exceed the roting of the crane ot thot radius. Ifthe load is within the rating of the crane, the reeving chart should be consulted to determine the minimum number of lines of reeving needed to li the loads, Loods lifted by the moin and whip hoists should not exceed load ratings given on the lead chort plate in the operator's cab, CAUTION: The operation of the crane during periods of high wind velocity is potentially dangerous. High winds increase the stress on certain struciural members. A combination of operster aclion, heavy load ond high winds could cause structural damage. Suspended loods may be tossed obou! and collide with the crane or other structures. Always exercise extreme care when the crane is operated in high winds. Page 12 Rev. July 1980 aa uf ARF anon supa companyNATIONAL —= HYDRAULIC PEDESTALCRANE —_OS-4. uTeg USA LUBRICATION HYDRAULIC FLU! CAUTION: When adding or changing the hydraulic fluid it t very important that every precaution be taken to prevent any contamination of the hydraulic fluid. Do not mix different types of hydraulic fluids. The following fluids ore recommended: First Choice — Automatic Transmission Fluid, Type F Second Choice — Automatic Transmission Fluid, “Dextron”” Third Choice — Hydraulic Oil, Premium Grade with Aati-Wear Additive, 48-55 SSU at 2100F (6.8-8.9 cSt at 100°C), Minimum Viscosity Index 170 Tank Capacity — 60 US. Gallons (227 Litres} Filters — Change Every 200 Hours or 2 Months SHAFT ASSEMBLIES AND SWING GEAR REDUCER* Use Industrial Mild EP Geor Oil AMBIENT TEMPERATURE AGMA MILD-EP LUBRICANT NUMBER 140F to 1409F AGMA Mild EP #5 SSU 918-1122 ot 100°F -209F 10 400F AGMA Mild EP #2 SSU 284-347 ot 1000F 4.49C to 60°C AGMA Mild EP #5 Figure 28 Lr ecces MAIN/WHIP HOIST CONTROL VALVE (C-4) This is a pressure regulating valve, This valve is linked directly to the main/whip hoist control handle. As the hoist control handle is moved, so is the lever on the side of the valve. The further the control handle is moved out of the neviral position (in either the hoist or lower direction) the greater will be the discharge Pressure of this valve. This control valve is located beneath the right-hand console in the operator's cab. BOOM HOIST CONTROL VALVE (C-2) Located beneath the left-hand console are hwo more pressure regulating valves. The lower valve is the boom hoist control volve, This valve is linked directly te the boom hoist conirel handle and boom hoist pedal. As the control handle or foo! pedal is moved, so is the lever on the side of the valve. The further the control handle or pedal is moved out of the neutral position (in either the hoist or lower direction) the greoter will bbe the discharge pressure of this valve, SWING CONTROL VALVE (C-1) The upper pressure reguloting valve beneath the left-hand control panel is the swing control valve, This valve is linked directly to the swing control handle. As the control handle is moved, so is the lever on the side. of the valve. The further the control handle is moved out of the neutral position (in either the swing left or swing right directions) the greater will be the discharge pressure of this valve. MAIN/WHIP HOIST PUMP ACTUATING CYLINDER (DC-3) Mounted to the moin/whip pump displacement control valve (see Pump Control) is a positioning cylinder (pump actuating cylinder). This cylinder is designed to extend or retract in direct proportion fo the pressure in the cylinder. The greater the pressure on either the piston or rod end of the cylinder the greater will be the extension oF retraction of the rod. This cylinder piston rod is connected to the displacement control valve lever ond functions to operate the displacement control valve Page 46 Rev. Dee. 1978 pb nator ‘CompanyNATIONAL — HYDRAULIC PEDESTALCRANE —OS.-43 UNO MUSA 800M HOIST PUMP ACUTATING CYLINDER (DC-2) ‘Mounted to the boom pump displacement control valve (see Pump Control} is @ positioning cylinder (pump actuating cylinder). This cylinder is designed to extend or retract in direct proportion to the pressure in the cylinder. The greater the pressure on either the piston or cod end of the cylinder the greater will be the extension or retraction of the rod. This cylinder piston rod is connected to the displacement control valve and functions to operate the displacement contro} valve. SWING PUMP ACTUATING CYLINDER (DC-1} Mounted to the swing pump displacement control valve (see Pump Control) i @ positioning cylinder (pump actuating cylinder). This cylinder is designed to extend or retract in direct proportion to the pressure tn the cylinder. The greater the pressure on either the pison or rod end of the cylinder the grecter will be the extension or retraction of the rod. This cylinder piston rod is connected to the displacement control valve lever and functions to operate the displacement conirol valve, HOIST BRAKE AND BOOM HOIST LOCK PAWL RELEASING VALVE (P-10, P17 ond P-13) Each of the theee hoist brakes, main, whip and boom, are spring set and hydraulically eleased. When a control handle in the operator's cab is moved out of neutral, an air pressure signal is sen’ by P-19 or P-20 10 the hoist brake releasing valve for the appropriate hoist. These valves ore piston operated ond require ‘approximately 35 psi (2.4 bor) pressure to the piston for actuation, When the valves shift they direct control Pressure in the broke cylinders and release the brakes, The three valves are mounted to the crane main frame above the swing gear reducer. AIR PRESSURE REGULATOR (R-1) On the righthand rear contol panel in the operator's cab isan air pressure regulator. This regulator supplies Gr to all the controls and should be set to maintain a pressure of 95 to 100 psi (6.6 to 89 bar) on ihe it pressure gage in the operator's cab EMERGENCY LOAD RELEASE VALVES (V-5 & V-6) When depressed, these valves perform wo functions. First, valve V-5 will signal the brake releasing valve of the hoist in use, as directed by the hoist selector cortral valve (V-3) in the operator's cab. When the broke {eleasing valve is signalled it shifts and supplies conttol pressure to the broke cylinder, releasing the broke Second, valve V-6 shits the hoist selector valve operctor(P-11}, This action establishes on Unresrleted poh for the flow of oil through the hoist motor in use, thus permitting the motor to free-wheel and the loca to “free-fall”. Indescriminate use of the load release will cause damage to the hydraulic system, This volve is for emergency use only EMERGENCY BRAKE SET VALVE (V-1] This valve, when depressed, sets all hoist brakes ond the boom hoist lock pawl. The cir supply forall he hoist controls comes through the brake set valve, Therefore, when this valve is depressed no hoisting or lowering can be performed from the operator's cab, Swinging of the crane is possible while the emergency broke tor valve is depressed. The valve is pulled to resume normal operation, ‘SWING BRAKE VALVE (V-2) The swing broke valve controls the air supply to the swing control valve (C-1) and the swing brake releasing valve (P12). When this valve is depressed, no air is available to operate the swing controls When the vale is pulled up, oir 's supplied to the swing control vaive and the brake releasing valve, Air pressure te the brake releasing valve causes the spool! to shift and direct control pressure to the swing broke cylinder. Re. be. wre] Page? ae National Supply CompanyNATIONAL — HYDRAULIC PEDESTALCRANE —OS-435 LO musa HOIST SELECTOR CONTROL VALVES (V-3 and V-4) The hoist selector control valve (V-4) signals the hoist selector valve operator (P-16) and V-3 functions to determine which hoist brake {main or whip) will be released when the main/whip hoist control handle moved out of the neviral position MAIN/WHIP HOIST LOW CHARGE PRESSURE BRAKE SET VALVE (P-7) After passing through the emergency brake set valve, the control air supply for the main/whip hoist conicals must poss through the low charge pressure brake set valve, This valve monitors charge pressure from the main/whip pump. If the charge pressure drops to an unacceptable level [opproximately 125 psi (8.6 bat)], this valve closes off the air supply to the controls and permits the main or whip brake te set ond the main/whip pump to return to neural. If main/whip charge pressure is 125 psi (8.6 bar) or below, the cob controls will not operate the main or whip hoist or release the main or whip hoist broke BOOM HOIST LOW CHARGE PRESSURE BRAKE SET VALVE (P-8) After passing thraugh the emergency brake set valve, the control air supply for the boom hoist controls must oss through the low charge pressure brake set valve. This valve monitors charge pressure from the beow ump. If he charge pressure drops to an unecceprable level [approximately 125 psi (8.6 bar)), ths valve Navona Supply CompanyNATIONAL —= HYDRAULIC PEDESTALCRANE —OS-435 UK USA WHIP LINE HOISTING A LOAD LOWERING A LOAD AND POWERING DOWN With the ho'st selector control valve (Fig. 1, Item 30) pulled for “WHIP”, the whip hoist paeumatic system is made operable and the hoist selecior valve operator (P-16} receives on air pressure signol, shifts ond directs control pressure to shift the selector valve for operation of the whip hoist. Control handle (Fig. 1, Item 20) movement in either the hoist or lower direction sends air pressure to the whip hoist brake releasing valve {(P-10}, shifting the valve which directs control pressure into the whip hoist brake cylinder. Pressure to the broke cylinder releases the brake. The movemant of the coniral handle clso directs air pressure to the “BRAKE OFF” indicator (|-7) which turns amber to indicate the hoist brake has been signaled to release. When the control handle (Fig. 1, Item 20} is moved in the hoist direction the main/whip pump actuator (0C-3) receives air pressure on the piston end, The actuotor then pushes the pump displacement control valve lever and causes the pump to “cam. When the pump cams, high pressure (5000 psi max} fluid is pumped out of port “A” and through the tubing to the holding valve, through the hoist selector valve and then fo port “A” of the whip hoist motor. At port “A” the high pressure fluid shifts the shuttle valve in the motor valve manifold and then rotates the motor. The fluid leaves port "B” of the motor at charge pressure. Part of the fluid passes through the shuttle valve and charge pressure relief valve in the motor valve manifold and enters the motor case. Most of the fluid leaving the motor goes through the tubing to the tee in the hoist selector valve subplate, by-passes the in-line filter element and returns 10 port “8 of the main/whip pump. At pump pert "B", the fluid from the moter mixes with the Fluid from the charge pump fond then re-enters the main/whip pum. When the control handle (Fig. 1, ltem 20) is moved in the lower direction, with @ load on the hook, the main/whip pump cetvator {DC-3) receives air pressure on the rod end, The actuator then pulls the pump. displacement contral valve ‘ever and causes the pump to “cam”. Wnen the pump cams, fluid is discharged ‘out of the port “8 at charge pressure. As the fluid leaves the main/whip pump it mixes with the fluid fram, the charge pump. The fluid now posses through the tubing and is filtered by the in-line filter, The filiered fiyid now goes 1 the tee in the hoist selector valve subplate and then to port B" of the whip hoist motor, At por! "8" part of the fluid passes through the shurtle value and charge pressure relief valve in the motor valve manifold and enters the motor caso. Most of the fluid enters the motor and is pressurized from charge pressure fo high prssure (5000 psi max), {While lowering e load the motor is pressurizing the fluid. The load fon the hook cttempis fo rotate the motor but the speed of the motor is limited by the amount of fluid passing through #t. The pump serves to regulate the amount of fluid passing through the motor.) The high pressure fluid at motor port “A” shifts the shuttle valve and then posses through the tubing ond heist selector valve to the holding valve. At the holding valve, the fluid must pass through the flow conirol valve before it continues, con through the tubing to the main/whip pump “A” port. Ai pump port “A, the fluid re-enters the cylinder block ond its pressure is dropped to charge pressure as it pastes through the pume. When the control hondle (Fig. 1, tem 20) is moved in the lower direction, with no load on the hook, the moin/whip pump actuator (OC-3} receives air pressure on the rod end. The acluator then pulls the pump displacement contro! valve lever and causes the pump to “eam”. When the pump cams, high pressure (1500 31 mox) fluid is pumped out of port “B of the pump ond passes through the tubing ta the in-line filter. After filtration, the fluid continues on through the tubing to port “B' of the whip hoist moter. The high pressure fluid then passes through the whip meter, causing it to rotate, and leaves the motor port “A” al charge pressure. The fluid now passes through the tubing, hoist, selector valve, ond holding valve re-entering the ump ot port “A”. During this operation the shuttle valve and charge pressure relief valve in the motor valve manifold do nor have fluid passing through them ond the only fluid entering the system from the charge. pump is fluid replacing interna! pump and moter leakage Returning the control handle (Fig. 1, tterm 20) to neural exhousts oir pressure to the piston of the whip hoist brake releasing valve (P-10) ond the valve returns, exhausting the pressure in the brake cylinder. With the release of the pressure in the whip hoist brake cylinder, the whip hoist brake sets. At the same time, the air pressure fo the pump ccciuating cylinder (DC-3) is exhausted ond the main/whip pump returns to the neutral, no flow of fluid, position. BOOM HOISTING, LOWERING AND POWERING DOWN With the control handle (Fig. 1, Item 19) in neutral, the boom heist brake is set and the lock paw! is engaged, Control handle movement, in either the hoist or (ewer direction, sends air pressure to the boom hoist brake releasing valve (P-13) shifting the valve which directs control pressure inta the boom hoist brake cylinder Pane 54 ev. Dee 178 ee RP ater sup companyNATIONAL — HYDRAULIC PEDESTALCRANE —-Q S435 “LTO im USA ‘and boom hoist lock pawl cylinder. Pressure to the broke cylinder releases the brake. Pressure to the lock Paw! cylinder releases the pawl, The movement of the control handle also directs air pressure to the “broke off” indicator (1-2) which turns amber to indicate the hoist brake hos been signaled to release, When the control handle is moved in the hoist direction, the boom pump octuoter (DC-2) receives air pressure on the piston end, The actuator then pushes the pump displacement control valve lever and causes, the pump to “cam”. When the pump cams, high pressure (6000 psi max) fluid is pumped out of port “A” ond through the tubing to the holding valve. From the holding valve the fluid goes through the tubing to port “A” of the boom hoist motor. At port “A” the high pressure fluid shifis the shuille valve in the motor valve manifold and then rota'es the motor. The fluid leaves port “B” of the moter at chorge pressure. Part of the fluid leaving the motar posses through the shuttle valve and charge pressure releif valve in the motor valve monifold and enters the motor case. Most of the fluid leaving the motor goes through the tubing, by-possing the in-line filter element, 1o por! “B' of the boom pump. At pump port "B” the fluid from the motor mixes with fluid from the charge pump ond re-enters the boom pump. When the control hondle (Fig. 1, Item 19) is moved in the lower direction, the boom pump actuator {DC-2) receives air pressure on the rod end. The actuator then pulls the pump displacement contral valve lever and causes the pump 19 “cam”. When the pump cams, fluid is discharged out of port “B” at charge pressure, As the fluid leaves the boom pump it mixes with fiuid from the charge pump. The fluid now passes through the tubing ond is filtered by the in-line filter. The filtered fluid now goes through the tubing to port "B" of the: ‘boom hoist moter. At port “8, part of the fluid posses through the shuttle valve and charge pressure relict valve in the motor valve manifold and enters the motor case. Most of the fluid enters the motor and is Pressurized from charge pressure to high pressure (6000 psi max). (While lowering the boom, the motor is Pressurizing the fluid. The weight of the boom and load attempt to rotate the motor, bu! the speed of the motor is limited by the amount of fluid passing through it. The pump serves to regulate the amount of fluid ossing through the motor.) The high pressure fluid at motor port “A” shifts the shuttle valve in the motor valve monifold and then pases through the tubing to the holding valve. At the holding valve, the fluid must pass through the flow control valve before it continues through the tubing to the boom pump “A” port, At Pump port“A”, the fluid re-enters the pump cylinder block and its pressure is dropped fo charge pressure os 1 passes through the pump. When the control handle (Fig. 1, tem 19) is moved in the lower direction, with the boom at high angles and 1no load on the hook, the boom pump actuator (DC-2) receives air pressure on the rod end, The actuator then pulls the pump displacement control valve lever and causes the pump to "cary. When the pump cams, high pressure (1500 psi mox) fluid is pumped out of port "B” of the pump and passes through the tubing to the incline filter. After filtration the fluid continues on through the tubing to por! ’B of the boom motor. The high pressure fluid then passes through the boom motor causing itto rotate and leaves port “A” of the rotor ft chorge pressure. The fluid now passes through the tubing tothe holding valve and on to re-enter the pump ot port “AY. During this operation the shuttle valve ond charge pressure relief valve in the motor valve manifold do not have fluid passing through them and the only fluid entering the system from the charge Pump is fluid replacing internal pump end motor leakage. Returning the control handle (Fig, 1, Item 19) to neutral exhausts the air pressure to the piston of the boom hoist brake releasing valve (P-13] and the valve returns, exhausting the pressure in the broke and lock pow! ylinders, With the release of pressure in the cylinders the boom brake and lock pawl set. Al the some lime, the air pressure fo the pump actuating cylinder (DC-2} is exhausted and the boom pump returns 10 neutral, no flaw of fluid, position, SWING CIRCUIT OPERATION With the swing handle (Fig. 1, Item 18) in neviral, pulling the swing brake valve (Fig. 1, Hem 28) supplies air pressure to the swing brake releasing valve (P-12) pisten and aculates the swing control system. The broke releasing valve shifts and directs control pressure to the swing brake, releasing the brake With the swing brake released, control handle (Fig. |, Item 18) movement toward the operator (swing left) directs air pressure 10 the piston end of the pump acluator (DC-1). The actuator then pushes on the pump displacement control valve lever and causes the pump to “cam”. When the pump coms, high pressure (4500 Psi max) fluid is pumped out port A” of the pump, through a hose by possing the in-line filter element, to inal ae ap [National Supety CompanyNATIONAL HYDRAULIC PEDESTALCRANE —_—OS-.435 ber" of he swing motor At por “6” the hgh rate fd shite he shu valve inthe motor ele Ierifold he Fi hen poses hough he moter cousin tohon ana lamest otra charg eure Amott por “A pat of te ui posts ver he shut valve nd choge pensure eit ware te motor valve manic ond enters the motor cva Mast ofthe fii faosing he te rau foe sin buma"8"porhvovgh the hose A pump post” the fad rom ihe moter nines nth fd em he charge Pomp ond recon the sing pump With the swing broke releese, control handle (Fig. 1, hem 18) movement away from the operator (swing right) directs air pressure to the rod end of the pump actuator {DC-1}. The actuator then pulls on the pump. displocement control valve lever and causes the pump to ‘cam’. When the pump cams high pressure (4500 psi max) fluid is pumped out of port “B” of the pump, through the hose to port “A” of the swing valve manifold, The fluid then passes through the motor causing rotation and leaves the motor at charge pressure At motor port “8”, part of the fluid passes over the shutle valve and charge pressure relief valve in the motor valve manifold and enters the motor case. Most of the fluid leaving the motor passes through the in-line filter and returns to the swing pump “A” port through the hose, A port “A”, the fluid from the motor ‘mixes with fluid from the charge pump and re-enters the swing pump. To reset the swing brake, the swing brake valve (Fig. 1, Item 28) is pushed. This action exhousts the oir Pressure to the swing control valve (C-1} and the piston of the swing brake releasing valve (P-12). When ai pressure is removed from the brake releasing valve piston, the valve returns, exhousting the control pressure fo the brake cylinder, permitting the brake 10 set Page $6 Rev. Dec. 1978 ee fg atonal Supply CempenyNATIONAL ~— HYDRAULIC PEDESTALCRANE —-Q)S-435 BRAKES HOIST BRAKES The bakes on the three hoist drums are identical. These are on the right hand end of the hoist drums and ore protected by eosily removable rain shields. They are band type brakes on 0 29-1/2" diameter drum that is on integral part of the shaft assembly. Each of these brakes has a cylinder in the motor compartment that operates the brake through @ rocker arm ‘assembly. The red end of these cylinders contains springs to maintain the broke in the set position. The “springs of the brake cylinder are lubricated for protection against rust and wear. A reservoir is mounted to ‘each cylinder fo provide for lubricant displacement when the brake is released, The brakes ore released by ‘applying control pressure under the piston, This hydraulic prossure compresses the springs and raleases the brakes. Whenever a hoist control handle is returned to the neutral position, the brake sets automatically to hold the load and prevent creeping, When the control handle is moved out of neutral, in either the hoist or lower direction, the brake 1s fully released. During lood lowering, the load is controlled entirely through the hydraulic system. This gives sure, precise control that makes the spotting of heavy loads safe and easy HOIST BRAKE ADJUSTMENT (Fig. 3? {f the crane hos not been working regularly it should be worked for a short period 10 dry the linings and remove any rust that may be on the drum. This can be done eosily by hoisting the emply hook and boom (simultaneously) ¢ few times with the broke pedal depressed. The control pressure should be in the 700/750 psi (48.9/51.7 bar) range while adjusting the brokes. ‘The pressure ot the main and whip brake cylinder pressure tops, Fig. 27, should also be checked. If this reads less than the control pressure the foot operated brake valve needs adjusting (see “Broke Pedal” page 58). This should be done before proceeding with broke adjustment. The brake bonds are suspended from the main frame with coil springs (!wo springs are used on the boom broke}. These should be adjusted so thot they life the upper mos! brake block clear of the drum about | /32” (0.8 mm} when the brake is released There ore olso two threaded rads protruding from the main frame that restrain the broke band in the fore and oft direction when the brake is released. These should be set approximately 1/32” (0.8 mm) from the brake band when the brake is set When the adjustments have been made the brake con be adjusted with the brake adjusting nut. This requires Iwo men; one to release the brakes by operating the crane and the other to adjusi the brake. There are Iwo holes through the top of the main frame in line with the main and whip broke cylinders and one hole below the boom hoist wire rope drum. These holes give easy access ro the brake adjusting nuts. A 1.1/2" deep socket is required for the adjustment. A brake adjusting tool which incorporates © 1-1/2" deep socker is shipped with each crane. For proper hoist brake adjustment the brake cylinder rod avel should be 1/4” (6 mm). The brake should then be checked under load. If the load creeps down with the control handle in neutral, the brake band is, not holding. IF the brake is properly adjusted ond will not hold the load, check the brake lining and drum for ail oF the brake cylinder for broken springs. Rev, Dee. 1978 | Page 57 National Supply Company