Crane Inspection PDF

LETOURNEAU, INC.
QUALIFIED CRANE INSPECTOR

TRAINING MANUAL
GENERAL TABLE OF CONTENTS
PREVENTIVE MAINTENANCE SCHEDULES AND CRANE

INSPECTION
1
NOTE
· Module 1: Pre-Use or Daily Inspections and Service
The contents of this Crane Inspector’s · Module 2: Monthly Inspections and Service
Training Manual include all publications or · Module 3: Quarterly Inspections and Service
excerpts from publications referenced in · Module 4: Annual Inspections and Service
the Preventive Maintenance Schedules.
However, it is recommended that the
inspector read, understand and follow all
PUBLICATION OSM-5 “WIRE ROPE USE, HANDLING AND 2
MAINTENANCE”
instructions contained within the crane’s
OPERATING AND SERVICE and REPAIR
AND OVERHAUL MANUALS prior to PUBLICATION OSM-6 “BRAKES” 3
performing any inspections or service
procedures to these cranes.
EXCERPTS FROM PUBLICATION OSM-4 4
· Lubricating Oil Analysis
· Power Loss Lowering System Inspection and Test
Procedures
PUBLICATION ROM-1 “STRUCTURAL COMPONENTS” 5

· PCM 120 SS
· PCM 350 SS
PUBLICATION LET-1 “FIELD WELDING PROCEDURES” 6
EXCERPTS FROM PUBLICATION ROM-6 7

· Automatic Overload Protection System Test and
Calibration Procedures
EXCERPTS FROM PUBLICATION OSM-2 “SAFETY” 8

· Identification and Safety Label Group
· Load Charts – PCM 120/350 SS
· Wire Rope Reeving Diagrams
COPYRIGHT 2002
7-OSL, Crane TOC (MSWord)
Training Manual
1
06-26-02 LeTourneau, Inc. Return to Main Page
PRE-USE OR DAILY WALK AROUND INSPECTIONS AND SERVICES
TO BE PERFORMED BY QUALIFIED OPERATOR
Needs
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1. Check hourmeter (located in Machinery House) for proper operation. Record
reading in space provided. Hourmeter reading:___________________
2. Check overall condition of crane and support structure. Look for damage.
3. Check safety and instructional signs. Replace any that are illegible, deteriorated
or missing.
4. Visually check column, boom and swing components for cracked welds and
broken or missing bolts.
5. SLOWLY operate all powered components to their travel limits to check for propĆ
er limit switch operation.
6. Check wire rope for attachment, damage, deterioration and proper lubrication.
7. Check all controls for proper operation.
8. Check load moment indicator for proper operation.
9. Check personnel warning horn for proper operation.
10. Check all lighting for proper operation. (Include helicopter warning light if appliĆ
cable).
11. Check all brakes for proper stopping action.
12. Check hydraulic lines to brakes for damage and leaks (where applicable).
13. Check hydraulic brake unit high pressure filters service indicator (located in MaĆ
chinery House). Service when required.
14. Check hydraulic brake power unit (located in Machinery House) breather filter
service indicator. Service when required.
15. Check all drive motors for proper operation.
16. Check swing gearbox and drivers for overheating and leaks.
17. Check hook and block for proper attachment and condition of safety latch.
18. Check all sheave pins and retainers.
19. Check Machinery House ventilation system.
20. Check fire extinguisher for proper charge, seal, and certification interval.
21. Check the swing gear lubricant for shavings.
22. Check for proper CW and CCW rotation and REPORT any unusual noises and
vibrations.
23. Check load rating chart at operator's controls. It must be correct and visible.
24. Check hoist driver for visible oil leaks.
25. Visibly check loose gear to be used, such as slings, sling hooks and shackles.
26. Lubricate components and correct deficiencies as required based on these inĆ
spections.
COPYRIGHT 2002
LeTourneau, Inc. 1
9ĆOSMĆ4.2.1b(M1), Gorilla
06/24/02
MONTHLY
TO BE PERFORMED BY QUALIFIED OPERATOR OR QUALIFIED INSPECTOR
Needs
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or missing.
cable).
vibrations.
26. Further check all control mechanisms for proper adjustment, excessive wear of
components, and contamination by foreign matter.
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06/24/02
PREVENTIVE MAINTENANCE REQUIREMENTS AND RECOMMENDATIONS PUBLICATION OSMĆ4
Needs
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27. Check boom hoist limit and anti-two block devices for proper operation. Care
should be exercised to prevent damage to crane components.
28. Check all electrically operated functions for proper operation.
29. Correct deficiencies as required based on these inspections.
MONTHLY INSPECTION AND LUBRICATION REQUIREMENTS
NOTE: Numbers in parentheses refer to lubrication points indicated on Figure 1.

STOW BOOM FOR SAFE ACCESS TO LUBE POINTS.
1. Thoroughly inspect wire rope per the instructions in Publication OSM 5, located
in the Operating and Service Manual.
2. Lubricate main hook sheaves. (1)
3. Lubricate main hook swivel bearing. (1)
4. Lubricate auxiliary hook bearings (optional). (2)
5. Lubricate auxiliary sheaves (optional). (3)
6. Lubricate boom sheaves (optional). (4)
7. Lubricate floating block and equalizer sheave. (5)
8. Lubricate boom selfĆaligning bushing (until new grease appears). (6)
9. Lubricate swing roller bearings. (7)
10. Lubricate swing gear and gearbox pinion. (8)
11. Lubricate gantry sheave. (9)
12. Lubricate swing bearing (PCM 350SS). (10)
13. Lubricate spherical and thrust bearing (PCM 120SS). (10)
COPYRIGHT 2002
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LeTourneau, Inc.
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PUBLICATION OSMĆ4 PREVENTIVE MAINTENANCE REQUIREMENTS AND RECOMMENDATIONS
3 4
6
4
8 7
1
2
10
PCM 350SS
10
4
3
8
7
PCM 120SS
CAUTION: PROPERLY STOW BOOM BEFORE LUBRICATING CRANE.

tag: lube points
FIGURE 1. LUBRICATING POINTS PCM 350 AND PCM 120

1ĆCGĆNGOĆ1600, P10Ć31 TAĆ8997ĆCG
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NOTES
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LeTourneau, Inc.
06/24/02
QUARTERLY
TO BE PERFORMED BY QUALIFIED INSPECTOR
Needs
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NOTE: The quarterly inspections includes an inspection of electric motors, servicĆ

ing drivers and swing gearbox and hydraulic brake system, structural inspection,
and operational tests of the crane. These inspections should only be conducted by
qualified and experienced inspectors.
or missing.
cable).
vibrations.
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LeTourneau, Inc. 1
06/24/02
Needs
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QUARTERLY INSPECTION AND LUBRICATION REQUIREMENTS

1. Thoroughly inspect and lubricate wire rope per the instructions in Publication
OSM 5, located in the Operating and Service Manual.
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LeTourneau, Inc.
06/24/02
3 4
6
4
8 7
1
2
10
PCM 350SS
10
4
3
8
7
PCM 120SS

tag: lube points

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LeTourneau, Inc. 3
06/24/02
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DRIVERS
MAIN HOOK, BOOM, AUXILIARY HOOK (OPTIONAL):
Take samples for lubricating oil analysis and refill. Service if iron content is 100
1. ppm or greater. Refer to LUBRICATING OIL ANALYSIS, Publication OSMĆ4, for
additional information.
CRANE SWING COMPONENTS
SWING GEARBOX:
Take sample for lubricating oil analysis and refill. Service if iron content is
1. 100 ppm or greater. Refer to LUBRICATING OIL ANALYSIS, Publication OSMĆ4,
for additional information.
HYDRAULIC BRAKE SYSTEM
Take oil sample for analysis. Flush system and refill if water or solid particle conĆ
1.
tamination is 60 ppm or greater.
WIRE ROPE
WIRE ROPE - INSPECTION AND LUBRICATION REQUIREMENTS:
Thoroughly inspect and lubricate wire rope per the instructions in Publication
1.
2. Inspect sheaves for wear, cracks, rope path alignment and bearing condition.
CABLE DRUM DEAD END INSPECTION:
Check torque on wire rope dead end setscrews (140Ć150 lbs. lubricated with
1.
30W motor oil).
OPERATIONAL INDICATORS
1. Check boom angle/radius indicators over full range for accuracy.
DC MOTOR BRAKES
SWING, BOOM, MAIN HOOK AND AUXILIARY HOOK (OPTIONAL):
Check the condition of all motor brakes. Refer to Publication OSMĆ6 in the OPĆ
1.
ERATING AND SERVICE MANUAL.
Check all motor brakes for proper operation. Refer to Publication OSMĆ6 in the
2.
OPERATING AND SERVICE MANUAL.
Check swing motor brake for proper adjustment. Refer to Publication OSMĆ6 in
3.
the OPERATING AND SERVICE MANUAL.
4. Check for damage or leakage in hydraulic brake systems.
5. Check speed sensors mounting, tightness and condition of leads.

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06/24/02
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POWER LOSS LOWERING SYSTEM
Inspect and test the power loss lowering system. Refer to POWER LOSS LOWĆ
1. ERING SYSTEM, located in Publication OSMĆ4 in the OPERATING AND SERĆ
VICE MANUAL.
QUARTERLY ELECTRICAL P.M.

Needs
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! CAUTION
Be sure all electrical power is turned off and locked out before touching any
electrical connection or terminal. Due to the potential for injury, only
qualified experienced persons should enter the Machinery House.
ELECTRICAL CONTROLS GROUP:
Check hook Controller condition. Insure card cover is secure and harness conĆ
1.
nections are tight.
Check Boom Controller condition. Insure card cover is secure and harness conĆ
2.
nections are tight.
Check Swing Controller condition. Insure card cover is secure and harness
3.
connections are tight.
Check all converter panels for tight connections and condition of components.
4.
Remove any accumulated dust.
5. Check circuit breakers.
6. Blow out the cabinet with clean, dry compressed air.
Check backĆup batteries for clean, tight terminal connections (located on top of
7.
machinery house).
COPYRIGHT 2002
LeTourneau, Inc. 5
06/24/02
QUARTERLY DC MOTOR BRUSH INSPECTION

VERNIER GAUGE
POSITION BRUSH IN GAUGE SAME WAY

BRUSH
FOR ALL MEASUREMENTS.
NOT ALL LEADS SHOWN
HIGH POINT ON BRUSH
1ĆCGĆ1088, P01Ć112 TA8010CG
ANY SPECIAL
MOTOR BRUSH # DIM. REPLACED? CONDITIONS
1.
2.
1. SWING
SĆ1A MOTOR
3.
4.
1.
2. MAIN HOOK 2.
N 9 MOTOR
NĆ9
3.
4.
1.
2.
2. BOOM
NĆ9 MOTOR
3.
4.
1.
2.
4. AUXILIARY HOOK
NĆ9 MOTOR
3.
4.
NOTES!ă 1. QUANTITY OF BRUSH TRACKS PER MOTOR COMMUTATOR VARIES WITH THE MOTOR TYPE AND SIZE.
2. ASSUME BRUSH #1 AS ALWAYS THE BRUSH CLOSEST TO THE RISERS.
3. SEE CHAPTER 4.0 OF TAKING CARE OF YOUR DC MOTOR" LOCATED IN SECTION 2, DC MOTORS, OF THE REPAIR
AND OVERHAUL MANUAL FOR CONDITIONS TO LOOK FOR.
COPYRIGHT 2002
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LeTourneau, Inc.
06/24/02
1 2 3 4 5
A B C D
SIMPLIFIED AND EXAGGERATED ILLUSTRATION OF ARMATURE AND COMMUTATOR

1ĆCGĆ1083, P01Ć112 TA8009CG
MOTOR TRACK # TIR MAX. BARĆTOĆBAR SURFACE CONDITION - SEE NOTE
1.
2.
1. SWING
SĆ1A MOTOR
3.
4.
1.
2.
2
2. MAIN HOOK
NĆ9 MOTOR
3.
4.
1.
2.
3
3. BOOM
NĆ9 MOTOR
3.
4.
1.
2.
4. AUXILIARY
HOOK
NĆ9 MOTOR 3.
4.
3. IN THE SURFACE CONDITIONS" COLUMN INDICATE OBSERVED CONDITION OF COMMUTATOR SURFACE CONĆ
CERNING THE FOLLOWING: (a) CONDITION OF FILM, (b) SIGNS OF ARCING, (c) GROOVING, (d) OTHER CHARACTERĆ
ISTICS. REFER TO TAKING CARE OF YOUR DC MOTOR" FOR AN INTERPRETATION OF THE OBSERVATIONS.
COPYRIGHT 2002
LeTourneau, Inc. 7
06/24/02
QUARTERLY STRUCTURAL INSPECTIONS
Needs
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! CAUTION
Dye penetrant and magnetic particle tests shall be conducted on any welds
suspected of being cracked. Structural repairs MUST be made in
accordance with the guidelines in STRUCTURAL REPAIRS, Publication
ROMĆ1, in the REPAIR AND OVERHAUL MANUAL and LeTourneau, Inc.,
Publication LeTĆ1, FIELD WELDING PROCEDURES, located in the back of
Section 1 of the REPAIR AND OVERHAUL MANUAL. Before ANY structural
repairs are made to the crane, the certifying authority shall be notified and
his surveyor present when the repairs are performed. Any inspections and
tests required by the certifying authority after structural repairs are made
shall be completed and a new certificate issued BEFORE the crane is
returned to service.
AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS):
Test the AOPS, Refer to AOPS TEST AND CALIBRATION PROCEDURE, loĆ
1.
cated in Publication ROMĆ6 in the REPAIR AND OVERHAUL MANUAL.
COLUMN GROUP - BASE:
1. Closely inspect welds holding bolt plate to column.
2. Closely inspect circumferential and vertical welds of column structure.
3. Closely inspect welds at all gusset plates.
4. Closely inspect welds on ladder assembly and holding ladder to column.
5. Closely inspect for missing, loose or broken bolts.
COLUMN GROUP - UPPER:
3. Closely inspect welds on platform assembly and holding platform to column.
6. Closely inspect all bearings, wear bands and king pin condition.
BOOM:
1. Closely inspect main boom hinge pins and attachment point welds.
2. Closely inspect splice joints in top chords for cracks.
3. Closely inspect welds at bridle cable ears and plates.
4. Closely inspect for excessive wear at pins and ears.

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Needs
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5. Closely inspect welds in joints on bottom chords.
6. Closely inspect welds at all diagonal pipes.
7. Closely inspect condition and attachment of luffing ropes.
Closely inspect boom sections attachment points for loose, broken or missing
8.
bolts.
Closely inspect boom light assemblies for proper attachment, broken lenses,
9.
lose wiring and proper operation.
10. Closely inspect limit switches for proper mounting and adjustment.
Closely inspect catwalks and handrails for cracked welds and loose, broken or
11.
missing bolts.
JIB BOOM (OPTIONAL):
5. Closely inspect sheaves, pins and retainers.
SWING TABLE ROLLER ASSEMBLY:
1. Closely inspect welds at boom and gantry attachment points.
2. Closely inspect welds around the entire structure.
3. Closely inspect welds at Machinery House mounting points.
4. Closely inspect swing gearbox mounting.
5. Closely inspect all pins and retainers.
6. Closely inspect structure for loose, missing or broken bolts.
7. Closely inspect swing bearing and gear for loose, broken or missing bolts.
LOWER BEARING AND SOCKET ASSEMBLY:
1. Closely inspect for loose, missing or broken bolts or nuts.
2. Closely inspect all welds on assembly.
3. Closely inspect all bearings, bushings and oil seals.
SWING GEAR UNIT ASSEMBLY:
1. Closely inspect gearbox mounting.

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LeTourneau, Inc. 9
06/24/02
Needs
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2. Closely inspect gearbox pinion for cracks.
Closely inspect gearbox pinion adjustment. Should be .020" gap. Refer to the
3. REPAIR AND OVERHAUL MANUAL, Section 1, SWING GEAR UNIT, for informaĆ
tion on Swing Gearbox adjustment.
4. Closely inspect the gearbox lube level.
WINCH HOUSING ASSEMBLY:
1. Closely inspect the mounting structure welds.
2. Closely inspect for proper attachment of drivers and drive motors.
3. Closely inspect cable drum structures for cracks, wear and proper attachment.
GANTRY ASSEMBLY:
2. Closely inspect for wear at attachment points.
3. Closely inspect welds at attachment points.
4. Closely inspect welds at main pipes and support pipes.
5. Closely inspect boom stops.
GANTRY SHEAVE HOUSING ASSEMBLY:
1. Closely inspect pins, retainers and capscrews.
2. Closely inspect sheaves for wear.
3. Closely inspect housing assembly welds.
FLOATING SHEAVE HOUSING ASSEMBLY:
5. Closely inspect wire rope for proper attachment.
HOOK AND BLOCK ASSEMBLY:

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Needs
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5. Closely inspect hook assembly for bends, cracks and overall condition.
AUXILIARY HOIST ASSEMBLY:
COPYRIGHT 2002
LeTourneau, Inc. 11
06/24/02
ANNUAL
TO BE PERFORMED BY QUALIFIED INSPECTOR
Needs
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NOTE: The annual inspections includes an inspection of electric motors, servicing

drivers and swing gearbox and hydraulic brake system, structural inspection, and
operational tests of the crane. These inspections should only be conducted by
qualified and experienced inspectors.
or missing.
cable).
vibrations.
COPYRIGHT 2002
LeTourneau, Inc. 1
06/24/02
Needs
Okay Attention
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ANNUAL INSPECTION AND LUBRICATION REQUIREMENTS

1. Thoroughly inspect and lubricate wire rope per the instructions in Publication
COPYRIGHT 2002
2
LeTourneau, Inc.
06/24/02
3 4
6
4
8 7
1
2
10
PCM 350SS
10
4
3
8
7
PCM 120SS

tag: lube points

COPYRIGHT 2002
LeTourneau, Inc. 3
06/24/02
Needs
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DRIVERS - SERVICE REQUIREMENTS
MAIN HOOK, BOOM, AUXILIARY HOOK (OPTIONAL):
S Main Hook
1. Drain,, flush and refill drivers for: S Boom
S Auxiliary Hook
CRANE SWING COMPONENTS - SERVICE REQUIREMENTS
SWING GEARBOX:
1. Drain, flush and refill swing gearbox.
HYDRAULIC BRAKE SYSTEM - SERVICE REQUIREMENTS
1. Flush and refill hydraulic brake system.
WIRE ROPE - INSPECTION AND LUBRICATION REQUIREMENTS
Thoroughly inspect and lubricate wire rope per the instructions in Publication
1.
2. Inspect sheaves for wear, cracks, rope path alignment and bearing condition.
CABLE DRUM DEAD END INSPECTION
Check torque on wire rope dead end setscrews (140Ć150 lbs. lubricated with
1.
30W motor oil).
OPERATIONAL INDICATORS
1. Check boom angle/radius indicators over full range for accuracy.
DC MOTOR BRAKES
SWING, BOOM, MAIN HOOK AND AUXILIARY HOOK (OPTIONAL):
Check the condition of all motor brakes. Refer to Publication OSMĆ6 in the OPĆ
1.
ERATING AND SERVICE MANUAL.
Check all motor brakes for proper operation. Refer to Publication OSMĆ6 in the
2.
Check swing motor brake for proper adjustment. Refer to Publication OSMĆ6 in
3.
the OPERATING AND SERVICE MANUAL.
4. Check for damage or leakage in hydraulic brake systems.
5. Check speed sensors mounting, tightness and condition of leads.
COPYRIGHT 2002
4
LeTourneau, Inc.
06/24/02
ANNUAL ELECTRICAL P.M.

Needs
Okay Attention
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! CAUTION
Be sure all electrical power is turned off and locked out before touching any
electrical connection or terminal. Due to the potential for injury, only
qualified experienced persons should enter the Machinery House.
ELECTRICAL CONTROLS GROUP:
Check hook Controller condition. Insure card cover is secure and harness conĆ
1.
nections are tight.
Check Boom Controller condition. Insure card cover is secure and harness conĆ
2.
nections are tight.
Check Swing Controller condition. Insure card cover is secure and harness
3.
connections are tight.
Check all converter panels for tight connections and condition of components.
4.
Remove any accumulated dust.
5. Check circuit breakers.
6. Blow out the cabinet with clean, dry compressed air.
Check backĆup batteries for clean, tight terminal connections (located on top of
7.
machinery house).
CORROSION INHIBITORS:
1. Replace corrosion inhibitors inside controller panel.
COPYRIGHT 2002
LeTourneau, Inc. 5
06/24/02
ANNUAL DC MOTOR BRUSH INSPECTION

VERNIER GAUGE
POSITION BRUSH IN GAUGE SAME WAY

BRUSH
FOR ALL MEASUREMENTS.
NOT ALL LEADS SHOWN
HIGH POINT ON BRUSH
1ĆCGĆ1088, P01Ć112 TA8010CG
ANY SPECIAL
MOTOR BRUSH # DIM. REPLACED? CONDITIONS
1.
2.
1. SWING
SĆ1A MOTOR
3.
4.
1.
2. MAIN HOOK 2.
N 9 MOTOR
NĆ9
3.
4.
1.
2.
2. BOOM
NĆ9 MOTOR
3.
4.
1.
2.
4. AUXILIARY HOOK
NĆ9 MOTOR
3.
4.
3. SEE CHAPTER 4.0 OF TAKING CARE OF YOUR DC MOTOR" LOCATED IN SECTION 2, DC MOTORS, OF THE REPAIR
AND OVERHAUL MANUAL FOR CONDITIONS TO LOOK FOR.
COPYRIGHT 2002
6
LeTourneau, Inc.
06/24/02
1 2 3 4 5
A B C D
SIMPLIFIED AND EXAGGERATED ILLUSTRATION OF ARMATURE AND COMMUTATOR

1ĆCGĆ1083, P01Ć112 TA8009CG
MOTOR TRACK # TIR MAX. BARĆTOĆBAR SURFACE CONDITION - SEE NOTE
1.
2.
1. SWING
SĆ1A MOTOR
3.
4.
1.
2.
2
2. MAIN HOOK
NĆ9 MOTOR
3.
4.
1.
2.
3
3. BOOM
NĆ9 MOTOR
3.
4.
1.
2.
4. AUXILIARY
HOOK
NĆ9 MOTOR 3.
4.
3. IN THE SURFACE CONDITIONS" COLUMN INDICATE OBSERVED CONDITION OF COMMUTATOR SURFACE CONĆ
CERNING THE FOLLOWING: (a) CONDITION OF FILM, (b) SIGNS OF ARCING, (c) GROOVING, (d) OTHER CHARACTERĆ
ISTICS. REFER TO TAKING CARE OF YOUR DC MOTOR" FOR AN INTERPRETATION OF THE OBSERVATIONS.
COPYRIGHT 2002
LeTourneau, Inc. 7
06/24/02
ANNUAL STRUCTURAL INSPECTIONS

Needs
Okay Attention
n n
! CAUTION
Dye penetrant and magnetic particle tests shall be conducted on any welds
suspected of being cracked. Structural repairs MUST be made in
accordance with the guidelines in STRUCTURAL REPAIRS, Publication
ROMĆ1, in the REPAIR AND OVERHAUL MANUAL and LeTourneau, Inc.,
Publication LeTĆ1, FIELD WELDING PROCEDURES, located in the back of
Section 1 of the REPAIR AND OVERHAUL MANUAL. Before ANY structural
repairs are made to the crane, the certifying authority shall be notified and
his surveyor present when the repairs are performed. Any inspections and
tests required by the certifying authority after structural repairs are made
shall be completed and a new certificate issued BEFORE the crane is
returned to service.
COLUMN GROUP - BASE:
2. Closely inspect circumferential and vertical welds of column structure.
COLUMN GROUP - UPPER:
3. Closely inspect welds on platform assembly and holding platform to column.
6. Closely inspect all bearings, wear bands and king pin condition.
BOOM:
1. Closely inspect main boom hinge pins and attachment point welds.
3. Closely inspect welds at bridle cable ears and plates.
7. Closely inspect condition and attachment of luffing ropes.

COPYRIGHT 2002
8
LeTourneau, Inc.
06/24/02
Needs
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Closely inspect boom sections attachment points for loose, broken or missing
8.
bolts.
Closely inspect boom light assemblies for proper attachment, broken lenses,
9.
lose wiring and proper operation.
10. Closely inspect limit switches for proper mounting and adjustment.
Closely inspect catwalks and handrails for cracked welds and loose, broken or
11.
missing bolts.
JIB BOOM (OPTIONAL):
5. Closely inspect sheaves, pins and retainers.
SWING TABLE ROLLER ASSEMBLY:
1. Closely inspect welds at boom and gantry attachment points.
2. Closely inspect welds around the entire structure.
3. Closely inspect welds at Machinery House mounting points.
4. Closely inspect swing gearbox mounting.
6. Closely inspect structure for loose, missing or broken bolts.
7. Closely inspect swing bearing and gear for loose, broken or missing bolts.
LOWER BEARING AND SOCKET ASSEMBLY:
1. Closely inspect for loose, missing or broken bolts or nuts.
2. Closely inspect all welds on assembly.
3. Closely inspect all bearings, bushings and oil seals.
SWING GEAR UNIT ASSEMBLY:
1. Closely inspect gearbox mounting.
2. Closely inspect gearbox pinion for cracks.
Closely inspect gearbox pinion adjustment. Should be .020" gap. Refer to the
3. REPAIR AND OVERHAUL MANUAL, Section 1, SWING GEAR UNIT, for informaĆ
tion on Swing Gearbox adjustment.
COPYRIGHT 2002
LeTourneau, Inc. 9
06/24/02
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4. Closely inspect the gearbox lube level.
WINCH HOUSING ASSEMBLY:
1. Closely inspect the mounting structure welds.
2. Closely inspect for proper attachment of drivers and drive motors.
3. Closely inspect cable drum structures for cracks, wear and proper attachment.
GANTRY ASSEMBLY:
3. Closely inspect welds at attachment points.
4. Closely inspect welds at main pipes and support pipes.
5. Closely inspect boom stops.
GANTRY SHEAVE HOUSING ASSEMBLY:
FLOATING SHEAVE HOUSING ASSEMBLY:
5. Closely inspect wire rope for proper attachment.
HOOK AND BLOCK ASSEMBLY:
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10
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06/24/02
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AUXILIARY HOIST ASSEMBLY:
COPYRIGHT 2002
LeTourneau, Inc. 11
06/24/02
ANNUAL CRITICAL COMPONENT TESTING AND INSPECTION
Needs
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NOTE: Testing and inspection of critical crane components shall be conducted in acĆ
cordance with the requirements of the certifying authority under which the crane is
operating. Refer to API RP 2D 8/1999.
HYDRAULIC BRAKE SYSTEM:
Inspect and test the backĆup AC pump motor. Refer to Publication OSMĆ6 in the
1.
POWER LOSS LOWERING SYSTEM:
Inspect and test the power loss lowering system. Refer to POWER LOSS LOWĆ
1. ERING SYSTEM located in Publication OSMĆ4 in the OPERATING AND SERĆ
VICE MANUAL.
AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS):
Test the AOPS, Refer to AOPS TEST AND CALIBRATION PROCEDURE, located
1.
in Publication ROMĆ6 in the REPAIR AND OVERHAUL MANUAL.
LOAD AND SPEED TESTING:

The following weight will be needed during the test procedure. NOTE: SWL is Safe Working Load on the
hook in pounds, which is the crane rating minus hook and block weight per API 2C.
PCM 120SS PCM 350SS
RADIUS SWL RADIUS SWL
Main Hook - Boom Up 22 ft. 98,400 30 ft. 146,800
Aux Hook - Boom Up 30 ft. 20,000 35 ft. 20,000
Needs
Okay Attention
n n
The following inspection or tests must be performed before doing any load testing.
1. Verify that all controls are working properly.
2. Verify that regenerative braking systems are functioning properly.
3. Verify that all brake systems are functioning properly.
4. Verify that all limit switches are adjusted and functioning properly.
5. Inspect cable to verify proper reeving and that no rubbing or looseness of cable
is occurring.
6. Verify boom raise and lower electrical stop limits.
7. Replace brake system pressure filter.
COPYRIGHT 2002
12
LeTourneau, Inc.
06/24/02
Time
Test boom luffing and swing speeds with no load
load.
Start End
Record time required to raise boom from horizontal to maximum boom up posiĆ
1.
tion.
Record time required to lower boom from maximum up position to horizontal
2.
position.
LEFT
Test swing speed with no load through 180
180° and compare to
3
3.
specification. RIGHT
Verify that acceleration to full speed and regenerative braking to
4.
0 speed is smooth.
5. Verify that brake sets are smooth at the stopped position.
Evaluate hook speeds:
! CAUTION
Always use a minimum load of 2000 lbs. on the hook when running the hook at full speed to prevent
slack in cable spooling off of the drum.
Speed Motor Motor
Distance Time
FPM Volts Current
UP
Boom Up, Main Hook with
1
1.
2,000 lb. load DOWN
UP
Boom Up, Main Hook with
2
2.
75,000 lb. load DOWN
UP
Boom Up, Aux Hook with
3
3.
2,000 lb. load DOWN
UP
Boom Up, Aux Hook with
4
4.
10,000 lb. load DOWN
Needs
Okay Attention
n n
MAIN
Evaluate smoothness of acceleration, deceleration, and stopĆ
5
5.
ping.
AUX
Rated load testing:
With boom full up, lift rated load. During this test it is recomĆ MAIN
1
1. mended that the load not be raised over two feet from the deck
surface. AUX
MAIN
Evaluate electrical and disc braking systems to assure that they
2
2.
control and hold the load properly. Hold the load for five minutes.
AUX
COPYRIGHT 2002
LeTourneau, Inc. 13
06/24/02
PUBLICATION OSMĆ5
OPERATING AND SERVICE MANUAL
LeTOURNEAU, INC. PCM CRANE
WIRE ROPE USE, HANDLING & MAINTENANCE
TABLE OF CONTENTS TABLE OF CONTENTS

Page
LIST OF ILLUSTRATIONS (Con'd.)
SCOPE OF THIS PUBLICATION . . . . . . . . . . . . . . . 1
FIGURE Page
COMPONENTS OF WIRE ROPE . . . . . . . . . . . . . . . 2
8. WEDGE SOCKET ASSEMBLY
GENERAL PROCEDURES AND PRECAUTIONS . 2 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 15
TEST REPORTS AND WIRE ROPE 9. CORRECT INSTALLATION OF WEDGE
INSPECTION RECORDS . . . . . . . . . . . . . . . . . . . . . 3 SOCKET ASSEMBLY . . . . . . . . . . . . . . . . . . . 15
10. GO" - NOĆGO" METHOD OF DETERĆ
WIRE ROPE INSPECTION PROCEDURES . . . . . . . . 5 MINING CORRECT WIRE ROPE SIZE . . . . . 16
WIRE ROPE INSPECTION TOOLS . . . . . . . . . . . . . 5
11. TIGHTENING TORQUE VALUES . . . . . . . . . 16
WIRE ROPE REPLACEMENT CRITERIA 12. INCORRECT INSTALLATION METHODS
AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OF WEDGE SOCKET . . . . . . . . . . . . . . . . . . 16
WIRE ROPE REPLACEMENT CRITERIA . . . . . . . . 9 13. WIRE ROPE MAINTENANCE . . . . . . . . . . . . 17
REPLACEMENT ROPE SELECTION CRITERIA . . 10 14. WIRE ROPE SEIZING . . . . . . . . . . . . . . . . . . 20
WIRE ROPE REPLACEMENT PROCEDURES . . . . 10 15. METHOD OF CLEANING WIRE ROPE . . . . 22
16. METHOD OF LUBRICATING WIRE ROPE . 22
WIRE ROPE SLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
17. WIRE ROPE LUBRICATION . . . . . . . . . . . . . 24
SLING REPLACEMENT CRITERIA . . . . . . . . . . . . . 14
PROOF LOADING AND LABELING . . . . . . . . . . . . . 14
WIRE ROPE ATTACHMENT PROCEDURE . . . . . . . . 15

INSTALLATION SAFETY ADVISORIES . . . . . . . . . . 15
WEDGE SOCKET ASSEMBLY INSTALLATION . . . 15
OPERATIONAL SAFETY ADVISORIES . . . . . . . . . . 16
SCOPE OF THIS PUBLICATION
SHEAVES, ROLLERS AND DRUMS . . . . . . . . . . . . . . 17
SHEAVES, ROLLERS AND DRUM INSPECTION . 17 Publication OSMĆ5, WIRE ROPE USE, HANDLING, AND
SEIZING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . 19
MAINTENANCE, is to assist maintenance personnel
and operators with the basics of inspection, mainteĆ
LUBRICATING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . 21 nance and replacement of the wire rope on the crane.
THE IMPORTANCE OF REGULAR WIRE
ROPE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 21
As wire rope is a load bearing member of the crane, it is
ESSENTIAL to properly maintain it to ensure safe
CHOOSING THE PROPER LUBRICANT . . . . . . . . 21
operation.
WIRE ROPE LUBRICATING PROCEDURES . . . . . 21
PCMĆ350SS ELECTRIC DECK CRANE NOTE

WIRE ROPE SPECIFICATIONS . . . . . . . . . . . . . . . . . 25
In several places in this publication, the terms

LIST OF ILLUSTRATIONS
qualified" or competent" person are used
FIGURE Page
with regards to inspection, repair and
1. THE THREE BASIC COMPONENTS certification of the crane and its components.
OF WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . 2
2. ROPE MEASUREMENT . . . . . . . . . . . . . . . . . 5
A qualified" or competent" person is defined
3. WIRE ROPE INSPECTION PROCEDURES . 7
as follows: A person who, by possession of a
4. ROPE LAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
professional degree, certificate of professionĆ
5. WIRE ROPE TRANSFER PROCESS . . . . . . 10
al standing or who by extensive knowledge,
6. RATED CAPACITY SINGLEĆLEG
training, and experience, has successfully
WIRE ROPE SLINGS . . . . . . . . . . . . . . . . . . . 13 demonstrated the ability to solve or resolve
7. RATED CAPACITY - BRIDLE SLINGS . . . . 13 problems relating to the subject matter and
work.
COPYRIGHT 2002
LeTourneau, Inc. 1
1ĆOSMĆ5.1, 350SS
5/8/00
WIRE ROPE USE, HANDLING & MAINTENANCE PUBLICATION OSMĆ5
NOTE D Inspect regularly, following the PREVENTIVE MAINĆ

TENANCE SCHEDULES in the back of Publication
Mandatory rules of this publication per OSMĆ4.
ANSI/ASME are characterized by the word D Never overload.
SHALL." If a provision is of an advisory
D Minimize shock loading as overstressing of the rope
nature, it is indicated by the word SHOULD"
will occur.
and is recommended to be considered, the
advisability of which depends on the facts in NOTE
each situation.
In order to ensure that there is no slack in the
rope at the start of loading, start the load
COMPONENTS OF WIRE ROPE carefully and apply the power smoothly and
Wire rope, also referred to as rope, consists of three steadily.
basic components, the core, the individual wires that D Do not operate the machine if the ropes are frozen.
form the strands and the multiĆwire strands that are
helically laid around the core. Refer to Figure 1 for an ! CAUTION
illustration of the components of wire rope.
Take special precautions under the following
conditions:
1. the exact load is unknown,
CORE (1) 2.ąthere is a possibility of shock loading,

WIRE (2) 3.ąthe conditions are abnormal or severe,
4.ąthere is a hazard to personnel.
CENTER WIRE (3)
D Protect rope from sharp corners or edges with padĆ
ding.
STRAND
D Avoid dragging the rope from under loads or over
obstacles.
D Avoid dropping the rope from heights.
WIRE ROPE
D Avoid rolling loads with ropes.
D Store all unused rope in a clean, dry place.
tag: 3 basic comp D Never use wire rope which has been cut, badly
FIGURE 1. THE THREE BASIC COMPONENTS kinked or crushed.
OF WIRE ROPE
1ĆCGĆ1227, P08Ć15 TA8021CG D Prevent loops in slack lines from being pulled tight
and kinking.
NOTE
GENERAL PROCEDURES AND PRECAUĆ Once a kink has been made in a wire rope the
TIONS damage is permanent. A weak spot will always
Wire ropes, like the machines and hoists on which they remain no matter how well the kink seems to
are used, require careful use, handling and mainteĆ have been straightened out. If a loop forms, do
nance for satisfactory performance, long life and not pull it out; unfold it.
adequate safety. D Avoid reverse bends.
The following general precautions and procedures D Repair or replace faulty guides and rollers.
should be observed to meet these requirements: D Ensure the sheaves are aligned properly.
D Replace sheaves having deeply worn or scored
! CAUTION grooves, cracked or broken rims, and worn or damĆ
ALWAYS wear gloves when handling wire rope aged bearings.
to prevent hand injury. D Repair faulty clutches.
D If wire rope is replaced ensure that the correct replaĆ D Check for abnormal line whip and vibration.
cement rope is used. Refer to the PARTS CATALOG D Ensure that the rope is installed properly on the
for the correct rope for your machine. drums.
COPYRIGHT 2002
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LeTourneau, Inc.
1ĆOSMĆ5.1, 350SS
5/8/00
PUBLICATION OSMĆ5 WIRE ROPE USE, HANDLING & MAINTENANCE
D Never wind more than the proper amount of rope on apply a lubricant coating to the outside layer
a drum. of rope on the reel.
D Never allow the rope to crossĆwind. 3. On a crane that is out of service for long period
of time, apply a lubricant to the outside layer of
D Ensure that the rope ends are properly seized.
the rope on the drum. Apply additional
D Ensure that the ropes do not bind in sheaves. lubricant to the accessible exposed rope in
the hoist system.
NOTE
4. Care should be taken during shipping and
New wire rope requires a runĆin period before handling of the reel and rope to prevent
operating at full load and full speed. damage to the rope. The loose end of the rope
on the reel should be secured properly to the
D Use thimbles in eye fittings at all times.
reel.
a. LUBRICATION INSTRUCTIONS:
TEST REPORTS AND WIRE ROPE INĆ
Lubricate regularly according to the PREVENTIVE
MAINTENANCE SCHEDULES in the back of Publication SPECTION RECORDS
OSCĆ4 and the instructions in LUBRICATING WIRE Written, dated and signed operational test and inspecĆ
ROPE, this publication, page 21. Modify these recomĆ tion reports should be kept and readily available for a
mendations for extreme conditions. Also, refer to wire period of two years.
rope manufacturer's recommendations.
NOTE
b. STORAGE PROCEDURES:
Wire rope removed from service should be
Wire rope placed in storage whether mounted on a
identified and marked as unfit for use on
machine or not should be properly maintained. The
cranes, slings or other load carrying devices.
following procedures should be performed to prevent
rope damage and deterioration: NOTE
1. Stored ropes should be covered in a well
UNDER NO CIRCUMSTANCES shall any
ventilated area and away from excessive heat.
machine be reĆrated in excess of the original
2. Where covered storage is not available, the load ratings unless rating changes are
rope and reel should be covered with waterĆ approved by LeTourneau, Inc. and a new load
proof material. For long periods of storage chart is available.
COPYRIGHT 2002
LeTourneau, Inc. 3
1ĆOSMĆ5.1, 350SS
5/8/00
NOTES
COPYRIGHT 2002
4
LeTourneau, Inc.
1ĆOSMĆ5.1, 350SS
5/8/00
WIRE ROPE INSPECTION PROCEDURES

Wire Rope is a structural component of the crane NOTE
requiring periodic replacement. Possible loss of
strength can result from wear, abuse and other forms of Wire rope removed from service should be
deterioration. The wire rope must be carefully selected, identified and marked as unfit for use on
inspected and maintained. The qualified person who cranes, slings or other load carrying devices.
determines whether replacement is necessary should
b. DAILY VISUAL INSPECTION
be knowledgeable in the inspection and maintenance of
wire rope. Wire ropes on the machine shall be inspected daily or
prior to use if the machine is not used daily. This visual
No precise rules can be given for determination of the
inspection should include moving and standing ropes,
exact time for replacement of rope, since many variable
end fittings and pins. The daily visual inspections should
factors are involved. Continued use depends largely
be concerned with discovering gross damage, such as
upon good judgement by the qualified person in
listed below, which may be an immediate hazard:
evaluating the strength remaining in the rope after
allowance for deterioration disclosed by inspection. 1. Distortion of the rope such as crushing,
Continued rope operation depends upon this remaining unĆstranding, birdcaging, main strand disĆ
strength. placement, or core protrusion; loss of rope
diameter in a short rope length or unevenness
of outer strands provide evidence that rope
WIRE ROPE INSPECTION TOOLS
replacement should be considered. Refer to
Tools for the inspection of wire rope should include but Figure 2 for an illustration of the wire rope
are not limited to the following: measuring process.
D Awl 2. General corrosion
D Marlin spike 3. Number, distribution, and type of visible

broken (Refer to WIRE ROPE REPLACEMENT
D Steel tape CRITERIA AND PROCEDURES, this publicaĆ
tion page 9.)
D Sheave groove gauges
4. Core failure in rotation resistant ropes. ParticĆ
D Calipers
ular care shall be taken when inspecting
D Chalk rotation resistant ropes because of their
susceptibility to damage from handling and
D Wiping cloth misuse and potential for deterioration when
D Gloves used on equipment with limited design paĆ
rameters. Internal deterioration of rotation
a. INSPECTION PROCEDURES: resistant ropes may not be readily observable.
ACTUAL DIAMETER
A. B. CORRECT C. INCORRECT
tag: rope measuremt

FIGURE 2. ROPE MEASUREMENT
1ĆCGĆ1229, P08Ć15 TA8023CG
COPYRIGHT 2002
LeTourneau, Inc. 5
1ĆOSMĆ5.1, 350SS
5/8/00
NOTE machine. Care should be exercised in inspecting the

rope at these points. Refer to Figure 3. Inspection
Rotation resistant wire rope is rope consisting should include but not be limited to the following areas:
of an inner layer of strand laid in one direction
1. Equalizer sheaves or saddles, also referred to
covered by a layer of strand laid in the
as fixed guides, or other sheaves where wire
opposite direction. This has the effect of
rope travel is limited.
counteracting torque by reducing the tendenĆ
cy of the finished rope to rotate. 2. End connections including socket or end
attachments to running ropes, boom penĆ
c. Particular care should be taken when inspecting dants and other standing wire ropes. Refer to
section of rope subject to rapid deterioration such as Figure 2.
flange points, crossover points, and repetitive pickup
3. Sections of wire rope where the rope is
points on drums.
continually running over sheaves within the
d. PERIODIC INSPECTION various hoist systems. This inspection is of
A qualified person should inspect the wire rope at a particular importance where boom angle and
frequency based on such factors as: expected rope life load block changes are frequent and limited
as determined by experience on the particular installaĆ to short distances.
tion or similar installations, severity of environment, 4. At crossover and flange points of the wire rope
percentage or lifts at maximum rating, frequency rates on hoist drums.
of operation, and exposure to shock loads. Inspections
5. Special care should be taken in the inspection
need not be at equal calendar intervals and should be
of rotation resistant wire rope (see above).
more frequent as the rope approaches the end of its
useful life. However, this inspection shall be made at j. WIRE ROPES NOT IN REGULAR USE
least annually. A written, signed and dated inspection Wire ropes which have been idle for one month or more
report should be kept and readily available for two years should be inspected by a qualified person before being
or until the wire rope is retired. The periodic inspection placed into service. A written, signed and dated
shall cover the entire length of the rope. Any deterioraĆ inspection report should be kept and readily available
tion resulting in appreciable loss of original strength, for two years or until the wire rope is retired.
such as described below, shall be noted and determinaĆ
tion made as to whether further use of the rope would NOTE
constitute a hazard: A long range inspection program should be
e. The points listed in the daily visual inspections established to include records on examination
above or ropes removed from service to establish a
relationship between visual observation and
f. Reduction of rope diameter below nominal diameĆ
actual condition of the internal structure.
ter due to loss of core support, internal or external
corrosion, or wear of outside wires k. INSPECT FOR LOCALIZED WEAR
g. Severely corroded or broken wires at end connecĆ Premature wear at one spot is common and can be
tions prevented if the cause is detected. Uneven wear can
be minimized by moving the rope at regular intervals so
h. Care shall be taken when inspecting rope sections that different stretches of it are at the critical wear points.
subject to rapid deterioration, such as the following: Changing layer and crossover points is merely a matter
1. Sections in contact with saddles, equalizer of cutting a few feet of rope from the drum end and
sheaves, or other sheaves where rope travel is refastening it. The cut should be long enough to move
limited; the change of layer at least one full coil from its former
position and to move the crossover points oneĆquarter
2. Sections of the rope at or near terminal ends
turn around the drum. Move the static section on an
where corroded or broken wires may proĆ
trude; equalizer sheave three sheave diameter lengths away
by cutting off the section on the drum end of the rope. To
3. Sections subject to reverse bends; distribute wear due to vibration, cut off a section next to
4. Sections of rope which are normally hidden the dead end and refasten the rope.
during routine visual examination, such a
parts passing over sheaves.
l. INSPECT FOR SLACK IN THE ROPE
i. ROPE INSPECTION AT CONTACT POINTS Even with the utmost care during installation, it is
Heavy wear and /or broken wires occur in wire rope quite common to find that the dead turns on the drum
sections in contact with certain components of the become somewhat slack in operation. This slackness
COPYRIGHT 2002
6
LeTourneau, Inc.
1ĆOSMĆ5.1, 350SS
5/8/00
THE WIRES BREAK IN

THE VALLEY WHERE
STRAND TO STRAND
CONTACT OCCURS
VALLEY BREAKS
CHECK FOR INTERNAL DAMAGE AFTER DISCOVERING
BROKEN WIRES BETWEEN STRANDS.
BROKEN WIRES IN THE INDEPENDENT WIRE ROPE CORE

ARE NOT DISCERNIBLE FROM
EXTERIOR EXAMINATION OF THE ROPE.
tag: wir rop inspect
FIGURE 3. WIRE ROPE INSPECTION PROCEDURES

1ĆCGĆ1231, P08Ć15 TA8002CG
COPYRIGHT 2002
LeTourneau, Inc. 7
1ĆOSMĆ5.1, 350SS
5/8/00
arises from a certain amount of stretch which occurs in a NOTE

new rope under tension and periodically throughout the
life of the rope from release of the load. When this Localized abrasion and fatigue can be dealt
slackness is noted, these turns should be rewound to with, without the necessity of discarding the
tighten them. If left uncorrected, a wedging action, whole rope, by installing a longer rope than
causing abrasion from the second layer, will occur and necessary, initially, and cutting one end or the
broken wires in the dead turns will appear. other to expose a new section of rope to the
place where the deterioration occurs.
NOTES
COPYRIGHT 2002
8
LeTourneau, Inc.
1ĆOSMĆ5.1, 350SS
5/8/00
WIRE ROPE REPLACEMENT CRITERIA AND PROCEDURES

Wire rope is an expendable item and is routinely The various rope conditions noted upon inspection
replaced in accordance with criteria set out in American should be used to determine continued use or retireĆ
Petroleum Institute API RP 2D Recommended Practices ment of the rope in question. The following replacement
for Maintenance and Operation of Offshore Cranes. It criteria examples are a list of wire rope applications for a
also has a variable load life characteristics which crane.
significantly differ from the more or less permanent When inspection indicates suspected loss of original
components of the crane. Because of this and the many strength, the qualified person shall make a determinaĆ
other inherent properties peculiar to wire rope, it was tion relative to further use of the wire rope. Conditions
decided to set singular design factors taking into such as the following shall be reasons for questioning
consideration each type rope and rope service. The continued use of the rope or for increasing the
design factors have been increased and based on frequency of inspection:
experience, are sufficiently large to account for minor
strength effects such as specified sheave sizes, tackle b. In running ropes, 12 randomly distributed broken
dynamics and nominal versus minimum rope strength. wires in 1 lay, or 4 broken wires in 1 strand in 1 lay.
c. In rotation resistant wire ropes, 4 randomly
WIRE ROPE REPLACEMENT CRITERIA distributed broken wires in one lay or 2 broken wires in 1
strand in 1 lay.
The following general instructions should be used in the
inspection process for determination of the replaceĆ d. One (1) outer wire broken at the contact point with
ment interval of wire rope on the machine. the core of the rope indicated by an externally protrudĆ
ing wire or loop of loose wires.
NOTE e. Wear of oneĆthird the original diameter of outside
individual wires.
Wire rope removed from service should be
identified and marked as unfit for use on f. Kinking, crushing, birdcaging, or any other damĆ
cranes, slings or other load carrying devices. age resulting in distortion of the rope structure.
g. Evidence of heat damage from any cause.
a. BROKEN WIRE REPLACEMENT CRITERIA
h. Reductions from nominal wear diameter greater
Broken wire replacement criteria were developed by than those shown below:
testing with hardened steel sheaves. When broken
wires begin to appear, additional broken wires can be
Maximum Allowable ReducĆ
anticipated in a short period. Once broken wires are Rope Diameter
tion from Nominal Diameter
observed, inspections should be made at more freĆ
quent intervals. Up to 5/16" (8 mm) 1/64" (.04 mm)
Over 5/16" to 1/2" (13 mm) 1/32" (0.8 mm)

NOTE
Over 1/2" to 3/4" (19 mm) 3/63" (1.2 mm)
The term ROPE LAY or LAY LENGTH will be
Over 3/4" to 1Ć1/8" (29 mm) 1/16" (1.6 mm)
used in later paragraphs of this publication. A
ROPE LAY or LAY LENGTH is the distance Over 1Ć1/8" to 1Ć1/2" (38 mm) 3/32" (2.4 mm)
measured parallel to the axis of the rope in
which a strand makes one complete helical Refer to Figure 2 for an illustration of the wire rope
revolution about the core. Refer to Figure 4 for measuring process.
an illustration of a ROPE LAY. i. Attention shall be given to end connections. Upon
development of more than 2 broken wires adjacent to a
socketed end connection, the rope shall be reĆsocketed
or replaced. ReĆsocketing shall not be attempted if the
resulting rope length will be insufficient for proper
operation.
NOTE
ONE ROPE LAY These replacement criteria were developed on
steel sheaves. When sheaves of other
FIGURE 4. ROPE LAY
1ĆCGĆ1228, P08Ć15 TA8001CG
materials are used, the manufacturer of the
sheave should be consulted.
COPYRIGHT 2002
LeTourneau, Inc. 9
1ĆOSMĆ5.1, 350SS
5/8/00
NOTE WIRE ROPE REPLACEMENT PROCEĆ

DURES
Inspection records should be maintained to
determine the time interval for retirement of These general instructions should be followed in the
the wire rope. Records should be readily replacement of the wire rope on the machine to prevent
available until the specific wire rope is retired. damage:
All observed rope deterioration as listed
above should be recorded on these inspection a. Unreeling or uncoiling of wire rope should be done
records. as recommended by the rope manufacturer. Care
should be taken to avoid kinking or introduction of twist
REPLACEMENT ROPE SELECTION into the rope. Use additional care when unreeling or
uncoiling rotationĆresistant rope.
CRITERIA
Replacement wire rope should be selected by using the b. To avoid introduction of twist into the rope while
following criteria: reeving, remove the rope from the same side of the reel
as it will operate on the drum, top to top or bottom to
NOTE bottom. When transferring wire rope from a storage reel
to a drum, the rope should travel from the top of the reel
Wire rope on the machine MUST be replaced to the top of the drum; or from the bottom of the drum.
with same diameter, length, construction and This will avoid a reverse bend in the rope as it is being
grade rope as the machine was originally installed. Installing a rope so that a reverse bend is put
equipped. The replacement rope MUST not be into it causes the rope to become twisty," difficult to
different unless approved by LeTourneau, Inc. handle and spool smoothly on the drum. This is
and all furnished load rating charts MUST be especially true of large diameter wire ropes. A braking
reviewed and changed as required. ReplaceĆ action should be applied to the reel at all times (use a
ment wire rope shall be certified to original block of timber against the reel flange) in order to get a
specifications and the certificate kept on file in good smooth wrap on the drum. Refer to Figure 5 for an
the Control Book. illustration of the transferring process.
WRONG WRONG
(THIS REVERSES THE NATURAL CURVE IN THE WIRE.)
REEL REEL
DRUM DRUM
BRAKE BRAKE
Never reel from top to bottom or from bottom to top.
RIGHT RIGHT
(THIS RETAINS THE NATURAL CURVE IN THE WIRE.)
REEL REEL
DRUM DRUM
BRAKE
BRAKE
Always reel from top to top or from bottom to bottom.

tag: wir rop transf
FIGURE 5. WIRE ROPE TRANSFER PROCESS
1ĆCGĆ1232, P08Ć15, 1/28/98 TA8000CG
COPYRIGHT 2002
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LeTourneau, Inc.
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c. For crane applications, care must be taken to bending the rope about small pipe or crane compoĆ
assure that the boom hoist system is reeved for the nents which might induce kinks or curling.
specific crane configuration in use.
i. Wire rope clips should be installed in accordance
d. When reeving through the sheave system avoid with wire rope or clip manufacturer's recommendations.
kinks or looping which could damage the rope. The saddle portion of the clip shall be applied to the live
e. Cut off all welded ends of the rope before installing rope segment and the UĆbolt to the dead or shortened
in a wedge socket or wedge in the drum. end segment. The wire rope clip nuts should be
tightened after initial use of the wire rope and periodicalĆ
f. New rope, when first installed, should be broken in
by slowly lifting and lowering a light load several cycles ly checked. This instruction does not apply to the use of
through the entire hoist mode. wire rope clips with wedge sockets.
g. Before cutting a rope, seize the rope at either side NOTE

of the cut location to prevent unĆlaying of the strands.
Seizing of the wire rope should be performed by or The wire rope is retained to the cable drum
supervised by a qualified person. Refer to SEIZING dead end with 3/4 UNC setscrews. These
WIRE ROPE, page 19, this publication. setscrews tighten to 140Ć150 lbs. torque with
h. Care should be taken during installation to avoid the threads lubricated with 30W motor oil.
contaminating, scraping or nicking the wire rope. Avoid Torque should be checked every six months.
NOTES
COPYRIGHT 2002
LeTourneau, Inc. 11
1ĆOSMĆ5.1, 350SS
5/8/00
NOTES
COPYRIGHT 2002
12
LeTourneau, Inc.
1ĆOSMĆ5.1, 350SS
5/8/00
WIRE ROPE SLINGS

This instruction applies to singleĆpart wire rope slings.
RATED CAPACITY FOR SINGLEĆLEG
Consult sling manufacturer's recommendations for
SLING IN U.S. TONS (2,000 Lb.)
multiĆpart rope slings.
ROPE DIAM.
(INCH) MS(1) HT(2) S(3)
! CAUTION
1/2 2.2 2.0 2.3
Wire rope slings should not be field fabricated 5/8 3.4 3.0 3.6
except where necessary under special cirĆ
cumstances. If circumstances require field 3/4 4.9 4.2 5.1
fabrication, proper equipment should be
7/8 6.6 5.5 6.9
available and qualified persons should
perform this function using accepted standard 1 8.5 7.2 9.0
practices. Zinc or resin poured sockets should
be fabricated in accordance with API RP 9B. 1Ć1/8 10.0 9.0 11.0
1Ć1/4 13.0 11.0 14.0

a. SINGLEĆLEG WIRE ROPE SLINGS
1Ć3/8 15.0 13.0 17.0
The data in Figure 6 shall be used to determine the rated
1Ć1/2 18.0 16.0 20.0
capacity of the various size singleĆleg wire rope slings of
improved plow steel (IPS), independent wire rope core 1Ć3/4 25.0 21.0 27.0
(IWRC) constructed with the terminals as noted.
Increase these values by 15 percent if extra plow steel 2 32.0 28.0 34.0
(EIPS) independent wire rope core (IWRC) rope is used
MS(1) Mechanical sleeve attachment
in the sling fabrication. Consult the wire rope manufacĆ HT(2) Hand tucked splice attachment
turer for ratings of wire rope slings of construction and MS(1) Zinc or resin poured
grades other than those listed in this section.
FIGURE 6. RATED CAPACITY SINGLEĆLEG
WIRE ROPE SLINGS
! CAUTION
No singleĆleg hitch should be used on slings ANGLE A COSINE OF ANGLE A

with a load that cannot be controlled. Always 15° 0.966
rig the sling and load so as not to allow the A A 30° 0.866
load or lifting device to rotate and unĆlay the 45° 0.707
sling rope. Rotation or twisting of the load can 60° 0.500
cause excessive stress on the attachment
connection and reduce the slings capacity or Example: TwoĆlegged bridle of 1 inch IPS, IWRC wire rope
pull out. with zinc poured socket attachments, at 45°.
Rated Capacity = 9.0 tons x 2 x 0.707
b. CHOKER SLINGS Cosine of Angle A
Number of Legs
Slings used in choker configurations have a rated Capacity from FigĆ
capacity of 70 percent or S(3) if the choke angle is 120° ure 6
or greater. Rated Capacity = 12.73 tons
tag: bridle slings
c. BRIDLE SLINGS FIGURE 7. RATED CAPACITY - BRIDLE SLINGS
For bridle slings and basket hitches where both legs are
not vertical use the following computation of the sling
d. SLING INSPECTION:
arrangement rated capacity. Rated Capacity equals
Single leg capacity (refer to Figure 7) times the number All loose slings should be visually inspected daily and a
of legs times the cosine of angle A. detailed periodic inspection should be performed on a
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regular basis with the frequency of inspection based on c. Kinking, crushing, birdcaging or any other damĆ
the following: age resulting in distortion of the rope strand and core
configuration.
Slings should not be made using wire rope clips.
d. Evidence of heat damage or exposure.
1. Frequency of sling use
e. Cracked, deformed or worn end attachments.
2. Severity of service conditions
f. Hooks that have been opened more than 15
3. Nature or type of lifts being made percent of their normal throat opening or twist more than
10 degrees from the plane of the unbent hook.
4. Experience based on service life of slings
used in similar applications g. Severe corrosion of the rope or end attachments.
NOTE PROOF LOADING AND LABELING

Slings of all rope grades and construction terminated by
Inspections should be made by qualified
mechanical, hand tucked or poured attachments shall
persons only. Deterioration which could
be proof loaded by the sling manufacturer when
contribute to loss of the original strength shall
specified by the purchaser.
be noted and the sling retired if such loss is
considered excessive. The proof load for singleĆleg slings with mechanical or
poured attachments shall be twice the vertical rated
capacity. Slings with handĆtucked splice attachments
SLING REPLACEMENT CRITERIA
shall be proof loaded to the vertical rated capacity.
Reasons for replacing the wire rope sling include but are The proof load for multipleĆleg bridle slings shall be
not limited to the conditions below. If there is any applied to each of the individual legs.
question relative to the integrity of the sling, it should be
retired. Slings of all types, grade and construction should be
labeled showing sling manufacturer and the vertical
a. In singleĆpart slings, ten (10) randomly distributed rated capacity when specified by the purchaser.
broken wires in one lay length or five (5) broken wires in
Slings of other than wire rope construction should be
one strand in one lay length.
used, inspected and tested in accordance with the sling
b. Severe localized abrasion or scraping. manufacturer's recommendations.
NOTES
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WIRE ROPE ATTACHMENT PROCEDURE

The PCM Electric Deck Cranes use a Wedge Socket D Repair minor cracks or gouges to socket or pin
Assembly with a cable clamp for attachment of the wire by lightly grinding until surfaces are smooth. Do
rope to components other than the cable drums. It is not reduce original dimension more than 10%.
CRITICALLY IMPORTANT that the Wedge socket
D Inspect permanent assemblies annually, or
Assembly be correctly installed. Incorrect installation
more often in severe operating conditions.
can result in bodily injury and/or damage to equipment.
D Use only with standard 6 to 8 strand wire rope of
INSTALLATION SAFETY ADVISORIES designated size. For intermediate size rope,
use next larger size socket. For example, when
using 9/16" diameter wire rope, use a 5/8" size
Wedge Socket Assembly. Welding of the tail on
standard wire rope is not recommended. The
D Loads may slip or fall if the wedge socket is tail length of the dead end should be a minimum
not properly installed. of 6 rope diameters but not less than 6". Refer to
Figure 9.
D A falling load can seriously injure or result in
the loss of life.
D Read and understand these instructions
before installing the wedge socket. TAIL
LENGTH*
D Do not side load the wedge socket.
D Apply first load to fully seat the wedge and
wire rope in the socket. This load should be
of equal or greater weight than loads
RIGHT
expected in use.
CORRECT INSTALLATION OF WEDGE SOCKET ASSEMBLY

WEDGE SOCKET ASSEMBLY INSTALLAĆ
TION *TAIL LENGTH
Standard 6 to 8 strand wire rope Rotation Resistant Wire Rope
Components of the Wedge Socket Assembly are shown
A minimum of 6 rope diameters, A minimum of 20 rope diameters,
in Figure 8. but not less than 6" but not less than 6"
PIN
FIGURE 9. CORRECT INSTALLATION
COTTER KEY OF WEDGE SOCKET ASSEMBLY
SOCKET
1ĆCGĆ1959, P10Ć73 TAĆ9259ĆCG
CABLE CLAMP D To use rotation resistant wire rope (special wire

rope constructions with 8 or more outer
strands), ensure that the dead end is welded,
brazed or seized before inserting the wire rope
into the wedge socket to prevent core slippage
WEDGE or loss of rope lay. The tail length of the dead
end should be a minimum of 20 rope diameters
FIGURE 8. WEDGE SOCKET but not less than 6". Refer to Figure 9.
ASSEMBLY COMPONENTS
NOTE
The wedge has GO" and NOĆGO" features to
The general guidelines listed below should be followed determine correct wire rope size cast into the
in the installation and maintenance of the Wedge Socket wedge. Refer to Figure 10.
Assembly:
The proper size wire rope is determined when
D Always inspect socket, wedge and pin before the following criteria are met:
installing.
1. The wire rope shall pass through the GO"
D Do not use any part showing cracks. hole in the wedge.
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WRONG WRONG WRONG TAIL

ROPE WEDGE CLIPPED TO
BACKWARD BACKWARD LIVE LINE
FIGURE 10. GO" - NOĆGO" METHOD OF

DETERMINING CORRECT WIRE ROPE SIZE FIGURE 12. INCORRECT INSTALLATION
1ĆCGĆ1960ĆP10Ć73 TAĆ9258ĆCG
METHODS OF WEDGE SOCKET
2. The wire rope shall NOT pass through the

NOĆGO" hole in the wedge. D Do not attach dead end to live end or install
wedge backwards. Refer to Figure 12.
D Use a hammer to seat wedge and rope as deep
Rope Size 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1Ć1/8 1Ć1/4
into socket as possible before applying first
Clip Size 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1Ć1/8 1Ć1/4
load.
*Torque Ft./Lbs. 45 65 65 95 95 130 225 225 225 360
*The tightening torque values shown are based upon the threads
being clean, dry and free of lubrication. OPERATIONAL SAFETY ADVISORIES
D Apply first load to fully seat the wedge and wire
FIGURE 11. TIGHTENING TORQUE VALUES rope in the socket. This load should be of equal
or greater weight that loads expected in use.
D Properly match socket, wedge and clip to wire D During use, do not strike the dead end section
rope size. Refer to Figure 11. with any other elements of the rigging (two
blocking).
D Align live end of rope with center line of pin.
Refer to Figure 9. NOTE
D Secure dead end section of rope. Refer to FigĆ
Efficiency rating of the wedge socket terminaĆ
ure 9.
tion is based upon the catalog breaking
D Tighten nuts on clip to recommended torque. strength of wire rope. The efficiency of a
Refer to Figure 11. properly assembled wedge socket is 80%.
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SHEAVES, ROLLERS AND DRUMS

During regular inspections and when ropes are f. Drum flange should be checked for cracks, chips
changed on a crane a number or areas effecting or other deterioration.
performance and rope life should be checked and g. Rope end attachment checked for compatibility of
corrected. This inspection or check should include but rope size.
not be limited to the following:
h. Rope spooling on drum checked for correct
spacing and cross over and winding.
SHEAVES, ROLLERS AND DRUM INSPECĆ i. Grooved drums checked for condition, size and
TION alignment of grooves.
a. Sheaves should be checked with a groove gauge j. Smooth drums checked for surface conditions to
for wear and checked for corrugation, the rope imprint in ensure that there are no cracks or corrugation from the
the groove surface. Refer to Figure 13 for and rope.
illustration of the sheave inspection process. MAINTENANCE OF SHEAVES, ROLLERS AND
DRUMS
b. Sheaves should be checked for broken or chipped
flanges. Proper maintenance of the equipment over which the
ropes operate has an important bearing on rope life.
c. Sheaves should be checked for cracks in the hub. Worn grooves, poor alignment of sheaves and worn
parts resulting in shock loads and excessive vibration
d. Sheaves should be checked for freedom of will have a deteriorating effect.
rotation without drag.
Sheaves and grooved rollers should be checked
e. Sheaves and shafts should be checked for bearing periodically for wear in the grooves, which may
or shaft wear. cause pinching and abrasion of the ropes. If the
CHECK FLANGES FOR WEAR,

CHIPS AND CRACKS
ÎÎÎ A PROPER FITTING SHEAVE GROOVE

SHOULD SUPPORT THE ROPE OVER 135-
CHECK SHEAVE
ÎÎÎ 150 DEGREES OF ROPE CIRCUMFERENCE.
GROOVES FOR
WEAR.
ÎÎÎ
CHECK BEARINGS FOR
WOBBLE, LUBRICATION
& EASE OF ROTATION
ÎÎÎ
A SHEAVE BADLY CORRUGATED BY
THE ROPE'S "PRINT", A CONDITION ÎÎÎ
ÎÎÎ
WHICH COULD SERIOUSLY DAMAGE
THE WIRE ROPE.
IMPROPER
ÎÎÎ
ÎÎÎ
CHECK GROOVES
FOR PROPER SIZE
OBSERVE THE GROOVE SO THAT IT
MAY BE CLEARLY SEEN WHETHER
THE CONTOUR OF THE RADIUS GAUGE
MATCHES THE CONTOUR OF THE
BOTTOM OF THE RADIUS GAUGE.
tag: wire rope maint
FIGURE 13. WIRE ROPE MAINTENANCE
1ĆCGĆ701, P01Ć50 TAĆ7635CG
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groove bears the imprint of the rope, it should be rope and wear on the sheave flange. This should be
machined clean or replaced. The same should be done corrected immediately as a distorted groove will also
with drums showing similar effects. Sheaves with result.
oversized grooves do not properly support the rope and
must be replaced. A radius gauge should be used to Sheave and roller bearings should be checked for
check the alignment of the rope in the grooves ( Refer to free operation. Sticking will cause unnecessary wear.
Figure 13). Excessive wear in the sheave bearings can cause
Poor alignment of sheaves will result in wear on the rope fatigue from the vibration.
NOTES
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SEIZING WIRE ROPE

Seizing is as process in which wire ropes are bound and sufficient. But for those that are not preĆformed, a
secured prior to a cut being made. While there are minimum of two seizings is recommended (Method
numerous ways to cut wire rope, in every case certain B"). Seizings should be spaced six rope diameters
precautions must be observed. For one thing, proper apart.
seizings are always applied on both sides of the place
where the cut is to be made. In a wire rope, carelessly or SEIZING THE ROPE
inadequately seized ends may become distorted and Figure 14 lists seizing lengths and seizing wire diameĆ
flattened, and the strands may loosen. Subsequently, ters suggested for use with some commonly used wire
when the rope is put to work, there may be an uneven ropes.
distribution of loads to the strands, a condition that will
significantly shorten the life of the rope. METHOD A": Lay one end of the seizing wire in the
groove between two strands and wrap the other end
There are two widely accepted methods of applying
tightly in a close helix over a position of the groove, using
seizing (Refer to Figure 14 for Method A" and Method
a seizing iron (a round bar 1/2" to 5/8" diameter x 18"
B"). The seizing itself should be a soft, or annealed,
long) as shown in Figure 14. Seizing widths should not
wire or strand. The seizing wire diameter and the length
be less than the rope diameter.
of the seize will depend on the diameter of the wire rope.
But the length of the seizing should never be less than METHOD B": The procedure illustrated in Figure 14 is
the diameter of the rope being seized. For preĆformed the second of the two (A and B) accepted methods for
ropes, one seizing on each side of the cut is normally placing seizing on wire rope.
NOTES
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6
1
4 5
METHOD A" METHOD B"
SEIZING - SUGGESTED DIAMETERS AND LENGTHS

Rope Diameters Seizing Wire Diameters* Seizing Lengths
inches mm inches mm inches mm

1/8–5/16 3.5–8.0 .032 0.813 1/4 6.0
3/8–9/16 9.5–14.5 .048 1.21 1/2 13.0
5/8–15/16 16.0–24.0 .063 1.60 3/4 19.0
1–1-15/16 26.0–33.0 .080 2.03 1-1/4 32.0
1-3/8–1-11/16 35.0–43.0 .104 2.64 1-3/4 44.0
1-3/4–2-1/2 45.0–64.0 .124 3.15 2-1/2 64.0
2-9/16–3-1/2 65.0–89.0 .124 3.15 3-1/2 89.0
*The wire rope manufacturer should be consulted for seizing wire diameters of rope not included in this chart.
tag: wir rop seiz

FIGURE 14. WIRE ROPE SEIZING TAĆ6029
1ĆCGĆ1240, P08Ć15
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LUBRICATING WIRE ROPE

The lubrication new ropes receive during manufacture
is adequate for initial storage and early stages of the
! CAUTION
rope's working life, but a regular lubrication program is Used crankcase oil should NEVER be used to
essential to gain the maximum service life from the rope. lubricate a wire rope. It contains tiny metal
The following instructions provide guidelines for the chips which abrade the rope, it is acidic, and it
proper lubricating of the wire rope on the machine. has few of the characteristics that a good rope
lubricant should have.
THE IMPORTANCE OF REGULAR WIRE NOTE
ROPE LUBRICATION
Lubricants recommended by LeTourneau, Inc.
Lubricating a rope is as important as greasing any are listed in Publication OSMĆ4, PCM CRANE
other piece of machinery. If a planned program of LUBRICATION SPECIFICATIONS, this manuĆ
regular lubrication is not carried out, then the rope will al. Lubricate the wire rope at regular intervals
deteriorate as follows: in accordance with the PREVENTIVE MAINTEĆ
NANCE SCHEDULES in the back of publicaĆ
D Corrosion and pitting will occur, causing a loss of
tion OSMĆ4. For off shore cranes, a rust
steel area and, therefore, a loss in strength of the
preventive lubricant such as Mobil MobilarĆ
rope.
ma 798" or Texaco Crater X" or equivalent is
D The wires will become brittle from excessive corroĆ recommended.
sion and will break easily.
WIRE ROPE LUBRICATING PROCEDURES
D Since each wire in the rope moves relative to the
a. ROPE CLEANING TECHNIQUES
others during operation, they are subject to fricĆ
tional wear. Lack of lubrication will increase the wear The rope must be clean and dry before the lubricant
rate, causing a marked reduction in strength from is applied because effective lubrication occurs only
loss of steel area. when the dressing comes in contact with bare metal.
If this is not done, the lubricant will fall off, allowing
D Pits also cause internal nicking of the wires, which moisture to work into the rope to cause corrosion.
results in loss of strength. Excessive moisture gradually leaches out the internal
D Ropes not in regular service or those not considĆ lubricant.
ered as operating ropes are vulnerable to weatherĆ
! CAUTION
ing out of the lubrication. Moisture seeps in, and
both core and wires deteriorate. ALWAYS wear gloves when handling wire rope
to prevent hand injury.
CHOOSING THE PROPER LUBRICANT The old lubricant can be removed by stationary or
powerĆdriven wire brushes or by compressed air jets
Wire rope should be lubricated with a lubricant which (Figure 15). It is advisable to use a light penetrating
provides excellent protective covering properties proĆ cleaner to soften the builtĆup material before removing
ducing a nonĆtacky but firm and flexible coating. This it. The lubricant supplier should be contacted regarding
lubricant should also be water repellent, have excellent the proper cleaning oil to use.
resistance to very high and very low temperatures, good
lubricating properties and free of mineral acids. ! CAUTION
Good wire rope lubricants have the following characterĆ Do not use gasoline or kerosene to clean wire
istics: rope as too much of it will remove the internal
lubricant.
D Corrosion resistance.
b. LUBRICANT APPLICATION TECHNIQUES
D Water repellent.
In view of the small space existing between wires in the
D Penetrating ability. strand and strands in the rope, do not expect externally
applied lubricant to completely penetrate the rope.
D Chemically neutral.
The main object in external lubrication is to fill the gaps
D High pressure flow characteristics. between the strands and rope so that a complete seal is
provided. The lubrication should be carried out periodiĆ
D Adhesiveness and an affinity for steel.
cally to maintain this seal. The frequency required will
D Temperature stability. depend upon the particular installation.
COPYRIGHT 2002
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COMPRESSED AIR
WIRE BRUSHES
AIR BLAST DRYING
BATH OF PENETRATING CLEANER
tag: clean wire rope
FIGURE 15. METHOD OF CLEANING WIRE ROPE
TEMPORARY AIR BLAST

WINDING DRUM PREFERRED APPLICATION
METHOD SINCE
ROPE OPENS UP
OVER SHEAVE
ALLOWING OIL
TO PENETRATE. AIR OIL
OIL BATH
APPLICATION
BRUSH
APPLICATION
DIP AND SWAB

APPLICATION
OIL BATH APPLICATION
tag: lub wire rope USING SPLIT WOODEN OR METAL BOXES

ROPE PASSES THROUGH BURLAP OR SIMILAR WIPER AT OUTLET END OF BOX
1ĆCGĆ705, P01Ć51 FIGURE 16. METHOD OF LUBRICATING WIRE ROPE TA7654CG
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Application of the lubricant may be accomplished by blast may also be used provided that dry air is used as
several methods. These should be considered with due any moisture would promote corrosion.
regard to the viscosity of the compound in its state for Where long lengths of rope are involved, brushing or
application, length of rope involved and limitation of hand application is tedious. However, a thorough
facilities. examination can be carried on at the same time so that
two important jobs can be accomplished in one
Light oils may be applied by brushing or running the operation.
rope through an oil bath, by spraying, drip method and
mechanical force feed (Figure 16). General recommendations regarding the time interval
that should elapse between lubrications are found in the
For maximum penetration, the lubricant should be PREVENTIVE MAINTENANCE SCHEDULES located in
applied to the rope where it opens up" as it travels the back of Publication OSMĆ4, in the OPERATING AND
around a sheave or winds on a drum. It is also advisable SERVICE MANUAL. The rope should be properly
to apply the lubricant in a warm area. If the lubricant lubricated at all times, and thorough periodic inspecĆ
must be applied manually in an extremely cold area, tions will indicate when it must be done.
however, rope lubricants are available with pour points NOTE
as low as -50° F to -60° F.
If a wire rope is taken out of service for an
Medium weight lubricant or heavy lubricant applied hot appreciable length of time, it should be
can be brushed on, applied by hand or by running the cleaned, lubricated and stored in a dry place
rope through a funnel containing the lubricant. The air where it will be protected from the elements.
NOTES
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WIRE ROPE LUBRICATION

LUBRICATION OF WIRE ROPES IN SERVICE
(1) (2) (3) (4) (5)
Operating CondiĆ Ropes working in inĆ Ropes subject to Ropes working over As (3) but for friction Standing ropes not
tions dustrial or marine enĆ heavy wear. sheaves where (1) drive applications. subject to bending.
vironments. and (2) are not critical.
Predominant cause Corrosion. Abrasion. Fatigue. Fatigue-corrosion. Corrosion.

of rope deterioration
Typical applications Cranes and derricks Mine haulage, excaĆ Cranes and grabs, jib Lift suspension, comĆ Pendant ropes for
working on ships, on vator draglines, scrapĆ suspension ropes, pilĆ pensating and goverĆ cranes and excavaĆ
docksides, or in polĆ ers and slushers. ing, percussion and nor ropes, mine hoist tors. Guys for masts
luted atmospheres. drilling. ropes on friction windĆ and chimneys.
ers.
Dressing requireĆ Good penetration to Good antiĆwear propĆ Good penetration to NonĆslip property. Good corrosion
ments rope interior. Ability to erties. Good adhesion rope interior. Good luĆ Good penetration to protection. Resistance
displace moisture. InĆ to rope. Resistance to brication properties. rope interior. Ability to to wash off". ResistĆ
ternal and external removal by mechaniĆ Resistance to fling displace moisture. InĆ ance to surface crackĆ
corrosion protection. cal forces. off". ternal and external ing.
Resistance to wash corrosion protection.
off". Resistance to
emulsification.
Type of lubricant Usually a formulation Usually a very viscous Usually a good generĆ Usually a solventĆdisĆ Usually a relatively
containing solvent oil or soft grease conĆ al purpose lubricating persed temporary corĆ thick, bituminous
leaving a thick taining M0S2 or oil of about SAE 30 rosion preventative compound with solĆ
(0.1 mm) soft grease graphite. Tackiness viscosity. leaving a thin, semiĆ vent added to assist
film. additives can be of hard film. application.
advantage.
Application techĆ Manual or mechaniĆ Manual or mechaniĆ Mechanical. Normally by hand. Normally by hand.
nique. Refer to FigĆ cal. cal.
ure 16.
Frequency of apĆ Monthly. Weekly. 10/20 cycles per day. Monthly. Six months/2 years.
plications*
*The periods indicated are for the general case. The frequency of operation, the environmental conditions and the economics of service dressing will more
correctly dictate the period required.
Opening of rope sections during passage over sheave or drum.

Arrows indicate the access points for lubricant.
1ĆCGĆ1241, P08Ć15
FIGURE 17. WIRE ROPE LUBRICATION
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PCMĆ350SS ELECTRIC DECK CRANE

WIRE ROPE SPECIFICATIONS
The crane is equipped with wire rope of the specificaĆ c. BRIDLE LINE ASSEMBLY
tions listed below. The wire rope on the crane shall be 1. 2Ć3/8 inch x 68 ft. wire rope (412Ć1305)
replaced with rope of the same specifications only. āĂĂĂĂĂ(123.5 ft. boom)
a. MAIN HOOK LINE ASSEMBLY 2Ć3/8 inch x 93 ft. wire rope (423Ć5450)
1. 1 inch wire rope x 2225 ft. (423Ć5088) āĂĂĂĂĂ(149.5 ft. boom)
2. Rotation resistant 2. 6 x 26 Warrington Seale Ć IWRC Ć EIPS
3. DYFORM 34LR GR2160 3. 274 tons breaking strength

4. 70.03 tons breaking strength NOTE
NOTE Must have written certification of 274 tons
breaking strength.
Must have written certification of 70.03 tons
breaking strength. d. AUXILIARY HOOK LINE ASSEMBLY
b. BOOM LINE ASSEMBLY 1. 1 inch wire rope x 550 ft. (P/N 422Ć9660)
1. 1 inch wire rope x 1075 ft. (P/N 422Ć9575) 2. Rotation resistant.
2. Constructex 3. DYFORM 18 HSLR
3. 62.5 tons breaking strength 4. 57.5 tons breaking strength
NOTE NOTE
Must have written certification of 62.5 tons Must have written certification of 57.5 tons
breaking strength. breaking strength.
NOTES
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BOOM POINT SHEAVE WHEELS
1" WIRE ROPE

2225' LONG
70.3 TONS B.S.
HOOK SHEAVE WHEELS
HOOK CABLE DRUM
PCM 350SS CRANE

MAIN HOOK CABLE REEVING SCHEMATIC
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GUIDE SHEAVE WHEEL
AUX. BOOM TIP

SHEAVE WHEEL
1" WIRE ROPE

550' LONG, 57.5 TONS B.S.
10 TON HOOK
AUX. HOOK CABLE DRUM
PCM 350SS CRANE

AUX. HOOK CABLE REEVING SCHEMATIC
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FLOATING SHEAVE WHEELS

4
1 10
12
3
GANTRY SHEAVE WHEELS 9

D.E.
11
1” WIRE ROPE (9 X 40 CONSTRUCTEX)

1075’ LONG, 62.5 TONS B.S.
CABLE DRUM
PCM-350SS CRANE
BOOM UP CABLE REEVING SCHEMATIC
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PCMĆ120SS ELECTRIC DECK CRANE

WIRE ROPE SPECIFICATIONS
The crane is equipped with wire rope of the specificaĆ c. BRIDLE PENDANTS
tions listed below. The wire rope on the crane shall be
replaced with rope of the same specifications only. 1. 1Ć3/4 inch x 50 ft. (P/N 422Ć9572)
a. MAIN HOOK LINE ASSEMBLY 2. 6 x 26 Warrington Seale - IWRC - EIPS

1. 1Ćinch swaged wire rope x 1375 ft. (423Ć5086) 3. 168 tons breaking strength
2. 70.03 tons breaking strength
NOTE
3. DYFORM 34LR GR2160
4. Rotation resistant Must have written certification of 168 tons
breaking strength.
NOTE
d. AUXILIARY HOOK LINE ASSEMBLY
Must have written certification of 70.03 tons
breaking strength. 1. 1 inch wire rope x 550 ft. (P/N 422Ć9660)
b. LUFFING 2. 57.5 tons breaking strength
1. 1 inch wire rope x 460 ft. (P/N 422Ć9571) 3. DYFORM 18 HSLR
2. 62.5 tons breaking strength
4. Rotation resistant.
3. CONSTRUCTEX
NOTE NOTE
Must have written certification of 62.5 tons Must have written certification of 57.5 tons
breaking strength. breaking strength.
NOTES
COPYRIGHT 2002
LeTourneau, Inc. 25
1ĆOSMĆ5.2, 120SS
5/8/00
1" WIRE ROPE

1375' LONG
70.3 TONS B.S.
HOOK SHEAVE WHEELS
HOOK CABLE DRUM
PCM 120SS CRANE

COPYRIGHT 2002
26
LeTourneau, Inc.
1ĆOSMĆ5.2, 120SS
5/8/00
6 FLOATING SHEAVE HOUSING
DEAD END
3
1” WIRE ROPE
1 460” LONG
62.5 TONS B.S.
GANTRY SHEAVE HOUSING
BOOM UP CABLE DRUM
1ĆNGOĆ1588, P10Ć30, 5/3/00 TAĆ8928ĆCG
COPYRIGHT 2002
LeTourneau, Inc. 27
1ĆOSMĆ5.2, 120SS
5/8/00
COPYRIGHT 2002
28
LeTourneau, Inc.
1ĆOSMĆ5.2, 120SS
5/8/00
PUBLICATION OSMĆ6
LeTOURNEAU, INC. ELECTRIC DECK CRANE
BRAKES

Page LIST OF ILLUSTRATIONS (Cont'd.)
SCOPE OF THIS PUBLICATION . . . . . . . . . . . . . . . . . 1 FIGURE Page
4 SWING MOTOR DISC BRAKE STACKING . 5
GENERAL WARNINGS AND CAUTIONS . . . . . . . . . . 1
5 480 VAC BACKĆUP PUMP INSTALLATION . 9
SWING MOTOR ELECTROĆMECHANICAL BRAKE 2
6 HYDRAULIC POWER UNIT . . . . . . . . . . . . . . 10
WORKING AIR GAP ADJUSTMENT
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 7 HYDRAULIC BRAKE ASSEMBLY . . . . . . . . . 13
8 BRAKE CALIPER GROUP . . . . . . . . . . . . . . . 14
BENCH (MAXIMUM) AIR GAP ADJUSTMENT
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9 MANUALLY RELEASING HYDRAULIC
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DISASSEMBLY OF SWING MOTOR 10 SERVICING BRAKE ACTUATOR . . . . . . . . . 19
ELECTROĆMECHANICAL BRAKE HEAD . . . . . . . . . 3
11 HYDRAULIC BRAKE SCHEMATIC,
BRAKE DISC REPLACEMENT . . . . . . . . . . . . . . . . . . . 3 PCM 120SS/350SS . . . . . . . . . . . . . . . . . . . . 21
12 BRAKE CONTROL DIAGRAM . . . . . . . . . . . . 22
ASSEMBLY OF THE SWING MOTOR
ELECTROĆMECHANICAL BRAKE HEAD . . . . . . . . . 3
HOIST BOOM AND AUXILIARY HOOK
ASSEMBLY DC MOTOR HYDRAULIC BRAKES . . . . 7
GENERAL WARNINGS AND CAUTIONS . . . . . . . . 7
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . 8 SCOPE OF THIS PUBLICATION
DC MOTOR HYDRAULIC BRAKE - SYSTEM
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Publication OSMĆ6, BRAKES, is to assist maintenance
INSPECT HYDRAULIC OIL RESERVOIR
personnel with the inspection, adjustment, replacement
EVERY 50 HOURS OR WEEKLY . . . . . . . . . . . . . . . 8 of discs, and repair or the electric swing motor brake
SYSTEM PRESSURE CHECKS . . . . . . . . . . . . . . . . 11 and the hydraulic brakes found on the main hook,
OPERATION AND INSPECTION OF DC MOTOR boom, and auxiliary hook DC motors. In routine
HYDRAULIC BRAKE CALIPER ASSEMBLIES . . . . 11 operation of the crane it is ESSENTIAL to pay close
DISC PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . 12 attention to the stopping action of all of these compoĆ
nents. Brakes are wear items whose service life is
MANUALLY RELEASING THE HYDRAULIC
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 affected by production, scheduling of the machine,
load, speed, and the operator's skill in stopping the
SERVICING THE HYDRAULIC BRAKE
ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 crane's movements properly to minimize wear.
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 GENERAL WARNINGS AND CAUTIONS
INSPECTIONS UPON DISASSEMBLY . . . . . . . . . . 17
The following general warnings and cautions apply to
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 both the swing motor electroĆmechanical brake and the
BRAKE SYSTEM LEAKAGE CHECK . . . . . . . . . . . . 18 hydraulic brakes or the hoists and boom:
FIGURE Page
1 SWING MOTOR ELECTROĆMECHANICAL
BRAKE SPECIFICATIONS . . . . . . . . . . . . . . . 3 When performing service or repair operations
2 MOTOR BRAKE ADJUSTMENT . . . . . . . . . . 3 on elevated structures of the crane, NEVER
3 BRAKE WIRING . . . . . . . . . . . . . . . . . . . . . . . 4 proceed beyond the safety of hand railed
platforms. Serious injury or loss of life from
falling is possible outside these areas.
COPYRIGHT 2002
LeTourneau, Inc. 1
1ĆOSMĆ6.2a, 120SS & 350SS, Gorilla
6/6/00
BRAKES PUBLICATION OSMĆ6
the maximum air gap. Maximum air gap for the brake is
0.125 inch (refer to Figure 1).
When the working air gap reaches the Reset gap (refer
The boom must be in the stowed position and to Figure 1), perform the following procedure:
the drum safety lock pin installed before a. Back off the three locking capscrews just enough
inspecting, servicing or repairing any part of to free the brake adjusting screws.
the crane's hydraulic brake system. Also,
place a DO NOT OPERATE sign on the b. Turn the adjusting screws to change the air gap.
controls and lock the operators control panel Turn clockwise to increase air gap; counterclockwise to
before performing maintenance or inspecting decrease air gap.
the hydraulic brake system. Serious injury or c. Check gap in at least three equally spaced
death is possible if the crane is started or locations around brake ring.
moved while maintenance or repairs are being d. When desired air gap of 0.080 inch is obtained,
conducted. tighten the three locking capscrews to lock the adjustĆ
ing screws and recheck air gap. Tightening the locking
! CAUTION capscrews may cause a slight change in brake
adjustment. Torque capscrew to value listed on torque
Swing movement WILL NOT stop immediately
tag affixed to brake head.
when the SWING joystick potentiometer is
returned to the neutral position. Swing speed, BENCH (MAXIMUM) AIR GAP ADJUSTMENT
load, brake adjustment and wind will effect the PROCEDURES
distance the boom will travel before regeneraĆ If the brake has been removed from the motor for any
tive braking will bring it to a full stop. The reason, the following procedure should be performed to
operator should be aware that there are adjust the Bench (maximum) air gap (refer to Figure 1):
variable factors involved and start and stop
swing movements with caution. a. When reassembling the brake, assemble the coil
ring and inner magnet ring and set the maximum air
CAUTION gap, refer to Figure 1 for the correct bench air gap.
!
b. This air gap is measured between the bottom of
DO NOT attempt to stop the crane's rotation by the maximum air gap adjusting nut and the outer
moving the BRAKE switch to the SET position, magnet plate with the brake head completely comĆ
except in an emergency. Doing so may pressed.
damage the swing gear and swing motor
c. Tighten the jamnut against the adjusting nut, once
pinion.
the correct air gap has been obtained.
d. Attach the coil and magnet assembly to the
SWING MOTOR ELECTROĆMECHANICAL endbell or continuous brake ring.
BRAKE
e. After attaching the coil and magnet assembly to
the endbell, the air gap can be adjusted with the three
WORKING AIR GAP ADJUSTMENT PROCEDURES adjusting screws. This will not affect maximum air gap
The electroĆmechanical swing motor brake is properly which is limited to the settings prescribed in Figure 1 by
adjusted when the working air gap between the two the three hex nut and jamnut combination.
magnet rings is 0.080 of an inch. The inner magnet ring NOTE
structure is secured to the outer magnet ring and coil
assembly by three studs, nuts and jamnuts. The setting If brake air gap is allowed to open to 0.150
of these three nut and jamnut combinations determines inch, the brake will start to slip.
COPYRIGHT 2002
2
LeTourneau, Inc.
6/6/00
PUBLICATION OSMĆ6 BRAKES
Working Air Gap .080" STATIONARY ROTATING

DISC DISC BRAKE
AIR GAP Maximum Air Gap 0.125" ENDBELL ADJUSTING
SETTINGS SCREW
Air Gap Gauge P/N 095Ć5056 LOCKING

CAPSCREW
Compressed to 65 lbs., P/N 078Ć2389
SPRINGS
(6 ea.) at 2.8125" MAXIMUM
AIR GAP
ADJUSTING NUT
600 VAC, Resistance between phases 8.92
COILS
ohms at 20°C, P/N 403Ć6237 (6 ea.)
Rotating P/N 401Ć5420 (3 ea.)

BRAKE DISCS*
JAMNUT
Stationary P/N 403Ć9598 (4 ea.)
Inner P/N 078-8338

MAGNET RINGS
Outer P/N 081Ć4667 MAXIMUM
AIR GAP
BRAKE HEAD
P/N 403Ć6240
ASSEMBLY
*Refer to Figure 4 for brake disc stacking procedure.
FIGURE 1. SWING MOTOR ELECTROĆ

MECHANICAL BRAKE SPECIFICATIONS WORKING
AIR GAP
DISASSEMBLY OF SWING MOTOR ELECĆ BRAKE

SPRING
TROĆMECHANICAL BRAKE HEAD

OUTER
The motor brake head consists of two major compoĆ MAGNET
PLATE
INNER
nents: Inner Magnet Ring and Outer Magnet Ring and MAGNET
RING
Coil Assembly.
FIGURE 2. MOTOR BRAKE ADJUSTMENT
NOTE 1ĆCGĆ700, P06Ć02 TAĆ7661CG
If a safety or instructional sign is on a part that

is replaced, make sure a new sign is installed NOTE
on the replaced part.
Do not mix coils on the same outer magnet
a. Separate the inner magnet ring from the outer ring.
magnet ring and coil assembly by removing six (6) nuts
from the studs. Lift the outer magnet ring and coil f. Inspect inner magnet ring for physical damage.
assembly off the inner magnet ring. g. Inspect outer magnet ring and coil assembly for
physical damage, especially in the area of the brake
b. Remove the brake springs from the spring reĆ
adjusting screws. Replace any broken coil anchor bolts.
cesses of the inner magnet ring. Note the number of and
location of the springs on the inner magnet ring.
BRAKE DISC REPLACEMENT
c. Check for broken or weak brake springs. Check When installing brake discs, care should be made to
brake spring tension in accordance with Figure 1. assure that discs (both stationary and rotating) be flat.
d. If the three studs mounted in the inner magnet ring Warped discs should not be used. Air gaps should be
are worn, they should be replaced. set up and maintained in accordance with air gap
adjustment procedures as outlined in this publication.
NOTE The discs should be stacked as shown in Figure 4.
The stud threads in the inner magnet ring are ASSEMBLY OF THE SWING MOTOR
3/ " NPT.
8 ELECTROĆMECHANICAL BRAKE HEAD
e. Check for continuity of the coils in the inner magnet a. Place the inner magnet ring on a bench and torque
ring assembly with an ohmmeter. Replace any defective the three studs to 110-120 ft. lbs. The studs must not
coil. Refer to Figure 1 for the brake coil resistance. protrude above the flat surface of the inner magnet ring.
COPYRIGHT 2002
LeTourneau, Inc. 3
6/6/00
L1
L1
1 1
4 9
1 6
5
1
2 12
4
7 L2
11
4 2
10 5
3
11
6 8
12
5 8 3
9 3 L3 6 7
2 5 6 10
4
2 3
L2 L3
SWING BRAKE
FIGURE 3. BRAKE WIRING

If necessary, grind the end of the studs flush with the e. Position the outer magnet ring and coil assembly
surface of the inner magnet ring. into the inner magnet ring so that the studs do not line
up with the adjusting screws in the outer magnet ring
b. Install the brake springs in the spring recesses of
and coil assembly.
the inner magnet ring with the number of springs
required (by the PARTS CATALOG) to meet the specifiĆ f. With three (3) 1/2" UNF nuts, pull the outer magnet
cations for the particular motor on which the brake head ring and coil assembly down until the proper air gap is
assembly will be used. met (refer to WORKING AIR GAP ADJUSTMENT
PROCEDURES, page 2, to adjust the maximum air
c. If the coils have been removed from the outer
gap). Use the other three (3) 1/2" UNF nuts to lock this
magnet ring, they must be installed with the pigtail
adjustment.
facing inward. Refer to Figure 3 for the wiring diagram of
the coil connections. NOTE
d. Lock the coils in position with the coil anchors. There must not be interference or dragging of
the inner magnet ring with the coil boxes. If
! CAUTION necessary, loosen the anchors of the offendĆ
ing coil and readjust.
Tighten the capscrews just enough to prevent
coil movement. Safety lock the capscrews g. Install the brake adjusting screws in the outer
with 1/4" UNC nuts. magnet ring and coil assembly.
COPYRIGHT 2002
4
LeTourneau, Inc.
6/6/00
ROTATING DISCS
STATIONARY DISCS
FIGURE 4. SWING MOTOR DISC BRAKE STACKING

1ĆCGĆ1564, P10Ć32 TAĆ8980ĆS
NOTES
COPYRIGHT 2002
LeTourneau, Inc. 5
6/6/00
NOTES
COPYRIGHT 2002
6
LeTourneau, Inc.
6/6/00
HOIST, BOOM, AND AUXILIARY HOIST ASSEMBLY

DC MOTOR HYDRAULIC BRAKES
The Hoist, Boom, and Auxiliary Hoist Assembly DC
Motors are equipped with a dual caliper, spring applied,
! CAUTION
hydraulically released disc brake. Hydraulic power is Handling and disposal of used oils may be
provided by a hydraulic power unit. System operation subject to federal, state and local laws and
and maintenance procedures are provided below. regulations. Use authorized waste disposal
facilities; for example, local collection sites
and garages providing authorized facilities for
GENERAL WARNINGS AND CAUTIONS receipt of used oil. If in doubt, contact your
state and local environmental authorities or
the Environmental Protection Agency for
direction on proper handling and disposal of
used oil.
The boom must be in the stowed position ! CAUTION

before inspecting, servicing or repairing any To prevent injury, wear hard hat, protective
part of the crane's hydraulic brake system. glasses and other protective equipment as
Also, place a DO NOT OPERATE sign on the required by job conditions.
controls and lock the operators control panel
before performing maintenance or inspecting ! CAUTION
the hydraulic brake system. Serious injury or
To ensure future safety, if a safety or
death is possible if the crane is started or
instructional sign is on a part that is replaced,
moved while maintenance or repairs are being
make sure a new sign is installed on the
conducted.
replaced part. Replace immediately any safety
or instructional sign that is not legible. Refer to
the PARTS CATALOG to order replacement
signs.
SYSTEM DESCRIPTION
Hydraulic fluid under pressure can penetrate
the skin and cause serious personal injury, NOTE
blindness, or death. If any fluid is injected into
The hydraulic power unit owner's manual is
the skin it must be removed within a few hours
provided at the end of this publication. Refer to
by a doctor familiar with treating this type of
Figure 6 for an illustration of the hydraulic
injury.
power unit.
Fluid leaks under pressure may not be visible. a. Hydraulic System: The primary hydraulic power
When searching for leaks, NEVER use your source is a low pressure gear pump. A secondary
hand, use a piece of cardboard or wood. Wear 480 VAC pump (see Figure 5) is available as a backup to
work gloves and keep your hand well away the primary pump (see BACKUP AC PUMP MOTOR
from the possible source of leakage. Do not section in Publication OSMĆ4 of this manual). In the
tighten or loosen hydraulic lines without first event of crane power loss, a Power Loss Lowering
relieving the pressure. Wear safety goggles System (PLLS) exists to allow for the constant speed
for eye protection. lowering of a load from the operator's console (see PCM
Crane Power Loss Lowering System, located in Section
5, SOLID STATE CONVERSION SYSTEM, in the REPAIR
AND OVERHAUL manual). This system uses a 24 VDC
motorĆdriven pump mounted on the hydraulic power
unit and powered by four 12 VDC batteries. A manual
The hydraulic brake canisters are under release method also exists (see page 15 OF THIS
spring pressure. Do not attempt to disasĆ PUBLICATION) as a backup to the PLLS.
semble them without the special tools b. Primary Hydraulic Power Source: The primary
required. Refer to SERVICING THE HYĆ hydraulic power source is mounted on a 20Ćgallon
DRAULIC BRAKE ACTUATORS, page 17. reservoir with the pump inside the reservoir and the
COPYRIGHT 2002
LeTourneau, Inc. 7
6/6/00
primary motor protruding from the top. This motor is a bronze, suitable for use in the corrosive marine
IEEE 45 Class in a 3 HP size with 3Ćphase 480Ćvolt power environment. A thermocouple mounted in proximity to
required. The pump produces 5 gpm at the 130 psi the disc monitors temperature during the power loss
requirement. hoist lowering function.
c. Power Loss Lowering System Power Source: ! CAUTION
The PLLS hydraulic pump and 24 VDC motor are
mounted to the top of the reservoir. At full pressure, the Refer to the REPAIR AND OVERHAUL
24 VDC motor will consume 30 to 35 amps from a MANUAL, Section 5, SOLID STATE CONVERĆ
battery power pack. The pump produces 3 gpm at 130 SION SYSTEM, for information on the power
psi and has a maximum rating of 3000 psi. This system loss lowering card and thermocouple before
is only used for partially releasing the hoist brake and any adjustments, disassembly, or assembly of
allowing a load to slip through the brakes to the deck the thermocouple is attempted.
(POWER LOSS HOIST LOWERING Ċ see Section 5,
SOLID STATE CONVERSION SYSTEM, in the REPAIR SYSTEM OPERATION
AND OVERHAUL MANUAL). a. The hydraulic pump becomes operational when
d. Valving: The valving is solenoid operated by 24 the MASTER switch is turned to the ON position. System
VDC and is rated at 4000 psi. It is sized to handle up to pressure is regulated to 130 psi when the BRAKE switch
20 gpm. and is being utilized at 5 gpm except during is turned to the ENABLE position.
spring brake apply when the flow will approach 15 gpm. b. The brakes do not release until the appropriate
The solenoids for these valves are equipped with a joystick (hoist or boom) is moved off of the neutral
manual override feature which allows for manual position. The appropriate electronic controller enerĆ
operation if control voltage is lost or if a coil should fail. gizes relay CR2 (hoist) or CR3 (boom) which applies
The coil connector is also equipped with an LED to system pressure through solenoids to the appropriate
indicate it is being energized. springĆapplied brake canisters and releases the brakes.
Various external conditions, however, can prevent the
e. Reservoir: The reservoir is of steel construction
controller from releasing the brakes or automatically set
and is coated to withstand marine environment. It holds
the brakes once they have been released (low hydraulic
20 gallons of hydraulic fluid. The suction strainers for
fluid pressure, low hydraulic fluid level, high hydraulic
each pump are inside the reservoir and the pressure
fluid temperature, various limit switches, etc.).
filter is mounted on top of the reservoir. A visual level and
temperature gauge is used in conjunction with a low DC MOTOR HYDRAULIC BRAKE - SYSĆ
level switch and a temperature switch. A screw type fill
TEM MAINTENANCE
port is incorporated into the top of the reservoir and a
combination filterĆdesiccant breather is used to control Routine maintenance is required to keep the Hydraulic
atmospheric air ingestion quality. Brake System functioning properly. Refer to Figure 6 for
an illustration of the hydraulic power unit. Also, refer to
f. Hydraulic Fluid: Use only nonĆflammable hydrauĆ the hydraulic power unit owner's manual at the end of
lic fluid LeTourneau, Inc. P/N 423Ć5122. this publication.
g. Hose and Fittings: The hosing and fittings in the
NOTE
system are rated at 2000 psi minimum which yields an
extremely conservative safety factor at 130 psi working Refer to SERVICE UPON RECEIPT, located in
pressure. the elastomers are rated for usage from Ć50° F Publication OSMĆ1, in the OPERATING AND
to +300° F. SERVICE MANUAL for service and inspecĆ
tions required during startĆup and the initial 50
h. Brake Caliper Assembly (refer to Figures 7 and
and 100 hours of operation. It is essential that
8): The caliper CĆclamp and base mount is a steel
these services be performed to achieve
casting machined by LeTourneau, Inc. The pads are
proper operation and efficient service from the
metallic filled, organic material containing no asbestos.
hydraulic brake system.
The actuating cylinder is a device with the outer
chamber containing a high force spring that applies the
INSPECT HYDRAULIC OIL RESERVOIR
brake when pressure is removed. The cylinder end
closest to the attachment bolts allows a pressure to be EVERY 50 HOURS OR WEEKLY
applied to release or modulate the torque of the brake. Inspect the hydraulic oil reservoir weekly for proper level
Stored externally on the cylinder is a release bolt that and condition of the fluid. The hydraulic power unit is
screws into the spring end of the cylinder to allow equipped with an Electrical Fluid Level Indicator. This
release or modulation of the brake using common hand device provides a sight gauge for quickly checking the
tools (refer to Figure 9). The disc is made of aluminum fluid level. If the system is low, the leak should be
COPYRIGHT 2002
8
LeTourneau, Inc.
6/6/00
5
2
6 1
1 FITTING
2 FITTING
3 HOSE
4 FITTING
9 12 5 CHECK VALVE
6 BUSHING
7 PUMP MOTOR
8 FITTING
9 HOSE
10 11 13
10 FITTING
11 PIPE FITTING
12 POWER UNIT
13
13 NIPPLE
14 DRAIN VALVE
14
FIGURE 5. 480 VAC BACKĆUP PUMP INSTALLATION

COPYRIGHT 2002
LeTourneau, Inc. 9
6/6/00
10
BRAKES
1ĆCGĆ1601, P10Ć41
A A 4
18
3
11
10
4 4
B
3
2
2 1
9
8
19
1
SOL 1
4
8 C
B B B B B
5 5 4 3 2 1
13
B
LeTourneau, Inc.
tag: hyd power unit
A A A A A
20
6 17 16
12
5
2
15
7
21
COPYRIGHT 2002
14
24 25
3 4 18 4 2
11
10
22
11 23
AB 1 MOTOR 14 SHUTTLE VALVE 3
a b
19
SOL 2
2 CHECK VALVE 15 SUCTION STRAINER
a
AB
b
3 BREATHER 16 COUPLING
4 PRESSURE FILTER 17 RELIEF VALVE
SOL 3
1
SOL 4
5 MANIFOLD 18 PRESSURE GAUGE
AB
a b
SOL 6 AB
SOL 5
6 OIL FILTER 19 GEAR PUMP
7 RESERVOIR 20 ADAPTER
a b
PT
9
8 SANDWICH BODY 21 SUCTION STRAINER
SOL 7 AB
7
22 PRESSURE SWITCH
a b
23 9 DIRECT. CONT. VALVE
PUBLICATION OSMĆ6
6 10 10 RELIEF VALVE 23 DIRECT. CONT. VALVE
11 3 HP MOTOR 24 OIL LEVEL SWITCH
19 1
12 OIL LEVEL GAUGE 25 TEMP. SWITCH
13 GEAR PUMP
TAĆ8982ĆCG
SECTION A-A
SECTION B-B
FIGURE 6. HYDRAULIC POWER UNIT
6/6/00
repaired and the system filled to the proper level before SERVICE MANUAL for the recommended hydraulic
operating the crane. Use a filter when filling the fluid.
reservoir, with a mesh width of 0.002 in. (0.06 mm) or
better. Fill via the 10 micron system filter. Refer to PCM SYSTEM PRESSURE CHECKS
CRANE LUBRICATION SPECIFICATIONS, Figure 1 in
Publication OSMĆ4, located in the OPERATING AND Check main system pressure weekly or every 50 hours
SERVICE MANUAL, for the recommended hydraulic of operation. The system should operate at 130 psi.
fluid. Note any system pressure corrections in the crane's
permanent file. Frequent reĆadjustment indicates wear
in the pressure relief components. Pressure drops
! CAUTION should be investigated to determine the cause.
Do not operate the hydraulic system with a low
reservoir fluid level. Cavitation of the hydrauĆ OPERATION AND INSPECTION OF DC
lic pump can occur which will cause serious MOTOR HYDRAULIC BRAKE CALIPER
component damage and brake system failure. ASSEMBLIES
a. DAILY AND MONTHLY FILTER INSPECTION The DC Motor Hydraulic Brake System has a caliper
AND SERVICE assembly and spring/hydraulic actuator. Operation of
the spring/hydraulic actuator is as follows:
1. High Pressure Filters: The high pressure
filters are equipped with an indicator to a. NORMAL OPERATION -
determine when they should be replaced. The The brake in a released position
high pressure filters should be checked daily has hydraulic pressure applied to
and replaced if required. the piston opposite the spring
chamber, which keeps the spring
2. Suction Filters: The suction filters require compressed (CAGED). The brake
inspection and cleaning yearly or every 2,500 is in readiness for normal applicaĆ
hours of operation. The filters should be tion by releasing the hydraulic
cleaned with solvent and blown through with pressure from the spring chamber. NORMAL OPERATION
air to remove any buildĆup of contaminants.
3. Breather Filter: The breather filter is deĆ b. SPRING BRAKE APPLICAĆ
signed to eliminate fluid contamination resultĆ TION - The spring force, acting
ing from wet, dirty air. The breather filter has against the piston, forces the push
an indicator in its side to determine when the rod against the push rod flange nut
unit needs servicing. The breather should be by the piston tube and sets the
inspected daily and serviced when required. brake pads (The spring is now in
Refer to the PARTS CATALOG for ordering an UNCAGED position).
replacement filters. 1ĆCGĆ1576, P10Ć37
TAĆ8978ĆCG SPRING BRAKE
APPLICATION
b. HYDRAULIC FLUID REPLACEMENT
The hydraulic fluid should be replaced every five years c. INSPECTION
under normal conditions. However, fluid contaminated The brakes should be checked at regular intervals for
with water or solid particle contaminants must be normal wear condition. Inspect the brakes as follows:
replaced more often. Fluid samples should be taken
1. Land any load on the hook and properly stow
every 250 hours as part of a continuing lubricating
the boom in the boom rest. Install cable drum
analysis program. The type and size or particles should
lock pin.
be analyzed to determine imminent component failure.
Action should be taken before system failure results. 2. Inspect brake for loose or missing bolts, nuts,
Fluid that is contaminated with a water content of retaining rings or other attachments. Secure
60 ppm or greater should be replaced immediately. The or replace as required.
system should be drained and refilled when in warm
3. Inspect carrier and lining (pads) assemblies
operating condition. All filters should be cleaned or
for wear, scars or breaks.
replaced as is applicable. Use a filter when filling the
reservoir, with a mesh width of 0.002 in. (0.06 mm) or NOTE
better. Fill via the 10 micron system filter. Refer to PCM
CRANE LUBRICATION SPECIFICATIONS, Figure 1 in If adjustment is required, the brakes must be
Publication OSMĆ4, located in the OPERATING AND released.
COPYRIGHT 2002
LeTourneau, Inc. 11
6/6/00
d. ADJUSTMENT
! CAUTION
! CAUTION Install cable drum lock pin before performing
any service work to hydraulic brake system.
Install cable drum lock pin before performing Refer to CABLE DRUM LOCK PIN in
any service work to hydraulic brake system. Publication OSMĆ4.
Refer to CABLE DRUM LOCK PIN in
Publication OSMĆ4. ! CAUTION
Spring brake chambers are under comĆ
! CAUTION pressed spring force. Releasing the tension
on the brakes must be done with the use of the
Spring brake chambers are under comĆ jackbolt and nut assembly (P/N 423Ć2980 &
pressed spring force. Releasing the tension 423Ć2981) or shop air minimum 100 psi. If air is
on the brakes must be done with the use of the used to release the brake, ensure the supply is
jackbolt and nut assembly (P/N 423Ć2980 & uninterrupted or the brake will set quickly and
423Ć2981) or shop air minimum 100 psi. If air is unexpectedly possibly causing injury. Refer to
used to release the brake, ensure the supply is MANUALLY RELEASING THE HYDRAULIC
uninterrupted or the brake will set quickly, BRAKES, page 15.
possibly causing injury. Refer to MANUALLY
RELEASING THE HYDRAULIC BRAKES, a. Use the jackbolt assembly mounted externally on
page 15. the brake cylinder or shop air of 100 psi minimum to
release tension on the brake. Refer to Figure 9 for an
1. Use the jackbolt assembly mounted externalĆ illustration of the use of the jackbolt.
ly on the brake cylinder to release tension on
b. Loosen the jamnut (17) and back the stop bolt (18)
the brake or 100 psi air pressure. Refer to
into the brake mount bracket (16) to release the tension
Figure 9 for an illustration of the use of the
on the springs (32).
jackbolt.
c. Unhook the springs (30) from the clamp structure
Numbers in parentheses refer to Figure 8. (29).
2. Loosen the locknut (20) and adjust the stop d. Remove the mount bolts (33) and caliper mounts
bolt (19) to achieve a .060" clearance between (28) to allow the clamp structure (29) to be maneuvered
the floating brake pad (15, pad farthest from clear of the rotor (2).
actuator) and the rotor (2), measured at the e. Inspect the rotor. If it is badly grooved or scored,
center of the pad's I.D. have it resurfaced or replace it. Minimum thickness is
.68 inch.
3. Tighten the locknut (20).
f. Remove the lining bolts (11 and 19) to release the
4. Loosen the set screw (6) and screw the worn pads (15) from the backing plates (13 and 29).
adjusting nut (8) to achieve a .060" clearance
between the piston actuated pad (15, pad g. Loosen the setscrew (6). Then back the adjusting
closest to actuator) and the rotor (2), again, nut (8) toward the actuator (5) to allow for the increased
measured at the center of the pad's I.D. thickness of the new pads.
h. Position the new pads (15) on the backing plates
5. Tighten the set screw (6) to lock the adjustĆ
(13 and 29) and install the lining bolts (11 and 19).
ment.
i. Position the assembled caliper structure to the
NOTE rotor (2). Then position the caliper mount plates (14 and
28) on the brake mount bracket (14) and within the
Replace the brake pads if lining is less than grooves along each side of the clamp structure (29).
1/4" thick. j. Install the mount bolts (31), and as they are
tightened, continually check that the assembled caliper
structure can move freely toward and away from the
DISC PAD REPLACEMENT brake rotor. If any binding occurs, reposition the caliper
Numbers in parenthesis refer to Figure 8. mount plates (14 and 24) and retighten the mount bolts
(31). Binding of the caliper may cause the pads to
If brake pads or other parts need replacement, remove continually drag against the rotor, resulting in excessive
the brake assemblies as follows: wear.
COPYRIGHT 2002
12
LeTourneau, Inc.
6/6/00
k. Connect the springs (30) to the clamp structure To check the run out tolerance while the brake
(29). head assembly is removed, place a dial
l. Screw the stop bolt (18) out until the clearance indicator on the rotor assembly and rotate the
between the floating pad (15, pad farthest from rotor by hand one revolution. If run out should
actuator) and the rotor is .060 " measured at the center exceed .005 of an inch, it will be necessary to
of the pad. Tighten the locknut (17). check rotor installation.
m. Turn the adjusting nut (8) until the piston actuated n. Activate the brakes and check for proper moveĆ
pad (15, pad closest to actuator) has clearance of .060" ment of the caliper and actuator rod.
between it and the rotor (2). Then tighten the setĆ
screw (6).
NOTE
If excessive wear is observed on the brake
head carrier linings, the brake rotor run out
should be checked. This should be done at the
time new carrier linings are installed.
12 15 14 13
1 LOCKNUT
2 STOP BOLT
3 FLOATING PAD
8 4 ROTOR
16
5 SETSCREW
9
17 6 ADJUSTING NUT
7 PISTON ACTUATED PAD
4 8 ACTUATOR
9 SPRING
1 10 LINING BOLT
66
2 11 LINING BOLT
11 12 MOUNT BOLTS
55
3 13 CALIPER
10
10
14 CALIPER MOUNT
15 BRAKE MOUNT BRACKET
14 7 16 BACKING PLATE
17 BACKING PLATE
12
tag: air brake assy FIGURE 7. HYDRAULIC BRAKE ASSEMBLY

1ĆNGOĆ1602, P10Ć41 TAĆ8973ĆCG
COPYRIGHT 2002
LeTourneau, Inc. 13
6/6/00
1
2
3
4
6
7
16
8
9
10 13
15
17
14 18
19
12 20
11
21
30
34
22
29
33
24 32
25
31
23 26
28
27
1 BRAKE HUB 8 SLEEVE NUT 15 PAD 22 LOCKWASHER 29 CLAMP STR.

2 DISC 9 RING 16 MOUNT STR. 23 BAR 30 SPRING
3 LOCKWASHER 10 BOSS 17 JAMNUT 24 LOCKWASHER 31 BOLT
4 BOLT 11 CAPSCREW 18 BOLT 25 BOLT 32 WASHER
5 BRAKE ACTUATOR 12 LOCKWASHER 19 CAPSCREW 26 FLATWASHER 33 BOLT
6 SETSCREW 13 CLAMP PLATE STR. 20 LOCKWASHER 27 SPACER 34 LOCKWASHER
7 INSERT 14 PLATE 21 NUT 28 PLATE
FIGURE 8. BRAKE CALIPER GROUP

COPYRIGHT 2002
14
LeTourneau, Inc.
6/6/00
MANUALLY RELEASING THE HYDRAULIC BRAKES

For emergency situations requiring the release of the
brakes, adjustment, replacement of the brake pads, or
other repair requiring removal of the brake caliper
assembly, the tension on the brakes can safely be The boom must be in the stowed position and
released using a jackbolt and primary hand tools. A the cable drum lock pin installed before
jackbolt and nut assembly (P/N 423Ć2980 & 423Ć2981) is inspecting, servicing, or repairing any part of
mounted externally on the brake cylinder to allow the crane's hydraulic brake system. Also,
release or modulation of the brake (refer to Figure 9). place a DO NOT OPERATE sign on the
Refer to Figure 9 for an illustration of the jackbolt controls and lock the operator's control panel
assembly installed on the brake actuator. before performing maintenance or inspecting
the hydraulic brake system. Serious injury or
death is possible if the crane is started or
moved while maintenance or repairs are being
conducted.
Jackbolt must be bottomed into threaded

recess in cylinder rod. Use flat on jack bolt to
tighten and keep it from screwing out of
cylinder rod when jacknut is turned CCW.
1 1 2
1 SPECIAL TOOL
4
P/N 423Ć2980 & 423Ć2981
2 ACTUATOR TOP PLATE
5 3 CYLINDER ROD
4 JAMNUT
5 PISTON
FIGURE 9. MANUALLY RELEASING HYDRAULIC BRAKES

COPYRIGHT 2002
LeTourneau, Inc. 15
6/6/00
NOTES
COPYRIGHT 2002
16
LeTourneau, Inc.
6/6/00
SERVICING THE HYDRAULIC BRAKE ACTUATORS

The following instructions are provided to help techniĆ b. Disconnect hydraulic lines from the actuator (if not
cians with the replacement of the hydraulic brake done to connect shop air for releasing spring tension).
actuator seal kit.
c. Loosen the jamnut (19) and back the stop bolt (20)
into the brake mount bracket (18) to release the tension
on the springs (32).
d. Unhook the springs (32) from the clamp structure
The boom must be in the stowed position and (31).
the drum safety lock pins installed before e. Remove the mount bolts (33) and caliper mounts
inspecting, servicing, or repairing any part of (16 & 30) to allow the clamp structure (31) to be
the crane's hydraulic brake system. Also, maneuvered clear of the rotor (2).
place a DO NOT OPERATE sign on the
f. Unbolt the brake actuator (5) and take it to a
controls and lock out the operator's control
suitable workbench.
panel before performing maintenance or
inspecting the hydraulic brake system.
Serious injury or loss of life is possible if the
DISASSEMBLY
crane is started or moved while maintenance Numbers in parentheses refer to Figure 10.
or repairs are being conducted.
a. Do not remove pipe plug (24). Plug will act as guide
for press stud.
b. Position the brake actuator into brake actuator
press (P/N 423Ć5028) with the 5/8Ć18 UNF studs
NEVER attempt to disassemble the brake protruding through the bottom of the press' base plate.
actuators while mounted on the motor. The Secure with mounting nuts. Refer to Figure 10.
brake actuators are under spring pressure c. Power the press' ram down until it seats firmly
and can cause serious injury if not disasĆ against the top of the brake actuator.
sembled and assembled in the proper manner.
d. Remove the four 3/8" acorn nuts and washers (1)
Disassemble and assemble the brake actuaĆ
from the bolts (23) securing the top plate (3) of the
tors only with the proper tools and per the
actuator.
instructions in this document.
e. Slowly release hydraulic pressure. The spring
force against the inside of the cover will allow the cover
REMOVAL and internal components of the actuator to be safely
Numbers in parenthesis refer to Figure 8. removed after the ram is backed off sufficiently.
f. Remove the springs (4 & 5) and piston (7) from the
! CAUTION actuator.
g. Remove the seals and wear rings (6, 8, 9, 10 & 11)
Brake actuators are under compressed spring
from the piston (7) and actuator housing (12 & 21).
force. Releasing the tension on the brakes
must be done with the use of the jackbolt and h. Remove cylinder rod (15) and OĆring (16), bushing
nut assembly (P/N 423Ć2980 & 423Ć2981) or (17), OĆring (18), and seals (19 & 20).
shop air minimum 100 psi. If air is used to
release the brake, ensure the supply is INSPECTIONS UPON DISASSEMBLY
uninterrupted or the brake will set quickly and
Numbers in parentheses refer to Figure 10.
unexpectedly possibly causing injury. Refer to
MANUALLY RELEASING THE HYDRAULIC a. Check actuator cylinder bore (12) for scoring and
BRAKES, page 15. dents.
b. Inspect the cylinder rod (15), bushing (17) and
a. Use the jackbolt assembly mounted externally on
piston (7). Remove any nicks and scratches. If it is
the brake cylinder or shop air of 100 psi minimum to
determined that the cylinder rod and piston are
release tension on the brake. Refer to Figure 9 for an
corroded, scored, or notched, they should be replaced.
illustration of the use of the jackbolt. Attach shop air to
the inlet port of the actuator if that is your chosen c. Thoroughly clean the springs (4 & 5) and coat with
method. a light rust preventative lubricant.
COPYRIGHT 2002
LeTourneau, Inc. 17
6/6/00
NOTE f. Install the actuator onto the caliper. Tighten mount

nuts to 200 ft. lbs.
If mounting studs are removed from housing,
g. Install assembly onto motor.
use Loctite threadĆlocking compound to
reassemble. If piston is removed from h. Reconnect hydraulic lines.
cylinder rod, use Loctite threadĆlocking
compound on retaining nut. BRAKE SYSTEM LEAKAGE CHECK
a. Adjust brakes so push rod travel is as short as
ASSEMBLY possible without brake shoes dragging.
Numbers in parentheses refer to Figure 10.
! CAUTION
a. Install seal kit (P/N 423Ć2978) and lubricate with
lubricant (P/N 151Ć0360). Refer to Figure 10. Do not operate main hook, boom, or auxiliary
hook motors until you are sure there are no
b. Install piston (7), bushing (17), and springs (4 & 5)
leaks and the brakes are functioning properly.
into actuator housing (12 & 21).
c. Install actuator housing into press. Secure with b. Turn MASTER switch to the ON position to activate
nuts. hydraulic power unit.
d. Use pipe plug as centering guide. Use the c. Turn BRAKE switch to the SET position.
hydraulic ram to press the cover structure (3) until it d. Check pressure gauge. A drop is pressure indiĆ
meets the case (12). cates a leak in the plumbing.
e. Install the four 3/8" acorn nuts (1) and washers (2) e. Turn BRAKE switch to the ENABLE position
onto the bolts (23) which the secure the cover structure. (released). Check pressure gauge. A drop in pressure
Torque to 25 ft. lbs. indicates a leak in the actuator.
NOTES
COPYRIGHT 2002
18
LeTourneau, Inc.
6/6/00
WARNING 1
NEVER attempt to disassemble the brake actuators while mounted on the motor:
The brake actuators are under spring pressure and can cause serious injury if not
disassembled and assembled in the proper manner. Disassemble and assemble IF PIPE PLUG REMOVED FOR USE OF MANUAL
the brake actuators only with the proper tools and per the instructions in 2
RELEASE TOOL, REINSTALL PRIOR TO USING
SERVICING THE HYDRAULIC BRAKE ACTUATORS, page 17. PRESS FOR DISASSEMBLY
12
24
A
3
13
B
4 25 14
CYLINDER SHOWN IN RE- 15

TRACTED POSITION – 5
HAS 2” STROKE
PRESS P/N 423-5028

16
C
1 3/8" ACORN NUTS 6
2 LOCKWASHER 17
3 TOP PLATE
4 BOOST SPRING 18
5 HEAVY SPRING
6 OĆRING 7
19
PIPE PLUG USED FOR CEN- 7 PISTON
TERING TOP WITH RAM
8 OĆRING
9 WEAR RING 20
10 OĆRING 8
AFTER ACTUATOR IS SECURED 11 WEAR RING
IN PRESS WITH RAM SEATED B
AGAINST ACTUATOR, REMOVE A 12 ACTUATOR HOUSING
3/8” ACORN NUTS, BACK OFF 13 OĆRING
STUD SLOWLY TO DISAS-
SEMBLE ACTUATOR. REVERSE 14 JAMNUT 9 21
PROCEDURE FOR ASSEMBLY. 15 CYLINDER ROD
16 OĆRING 26
17 BUSHING
18 OĆRING 10
19 SEAL 22
20 SEAL
C
21 BOTTOM PLATE
22 WASHER
11 23
SECURE WITH
23 3/8" UNS X 7Ć1/2" BOLT
MOUNTING NUTS CYLINDER SHOWN IN 24 3/8" NPT PIPE PLUG
RELEASED POSITION 25 WARNING DECAL
SEAL KIT 423Ć2978 INSTALLATION 26 MOUNT STUDS
FIGURE 10. SERVICING BRAKE ACTUATOR
1ĆNGOĆ1594, Ldgr2Ć20, 2/12/98 TAĆ8931ĆCG
1ĆOSMĆ6.2b, Gorilla
6/6/00 COPYRIGHT 2002 19
LeTourneau, Inc.
PUBLICATION OSMĆ6
6/6/00
1ĆCGĆ1567, P10Ć32, 11/6/98
HOIST BRAKE AUXILIARY HOIST BRAKE BOOM HOIST BRAKE
H H
P P H
T T
6A 6B 7A 7B
H H H
P T P T
SOL. 8 SOL. 3 SOL. 9 SOL. 5
A B T A B T
1A 1B
3A 3B 5A 5B
P T SOL. 2
P T SOL. 4 P T SOL. 7
LeTourneau, Inc.
COPYRIGHT 2002
130 PSI
SOL. 1
100 PSI FUNCTIONAL DESCRIPTION:

SOLENOID 1 - ENERGIZE REQUIRED FOR ALL FUNCTIONS.
SOLENOID 2 - ENERGIZE FOR RELEASE OF HOIST BRAKE.
SOLENOID 2, 3 & 8 - ENERGIZE FOR POWER LOSS LOWER AND EMERGENCY RELEASE TENSION ON HOIST BRAKE.
SOLENOID 4 - ENERGIZE FOR RELEASE OF AUXILLIARY HOIST BRAKE.
M 5 GPM M 3 GPM SOLENOID 4, 5 & 9 - ENERGIZE FOR POWER LOSS LOWER AND EMERGENCY RELEASE TENSION ON AUXILIARY HOIST BRAKE.
AC DC
SOLENOID 4, 5 & 9 - ENERGIZE FOR CONSTANT TENSION ON AUXILIARY HOIST BRAKE.
SOLENOID 7 - ENERGIZE FOR RELEASE OF BOOM HOIST BRAKE.
NOTE:
1. THERE ARE 2 BRAKE CALIPERS ON EACH MOTOR.
RESERVOIR 2. HOLD IS SHOWN AS H, TENSION IS SHOWN AS T.
TAĆ8943ĆCG
BRAKES
FIGURE 11. HYDRAULIC BRAKE SCHEMATIC, PCM 120SS/350SS
21
22
BRAKES
E4
SOL 5
SEE NOTE
10 P
A2 A B P1
T
1ĆNGOĆ2757, P03Ć27
12
23
10 22 A2
8 24
25
E1
26
1 T1
UPPER
T3 M1 CYLINDER
5 6
SEE NOTE
7
AUXILIARY HOIST BRAKE
20 P
E1
A3 B T E3 21
21
A E7 2
E2 P2 E2 P2 E2
1 3
LOWER
E5 CYLINDER SOL 9 T4 5B 4B 3B 2B 1B
14
4 28
E4 29
M2
5A 4A 3A 2A 1A
A4 P2 P2 P2 P2 P2
18
17
A4 A4
19 13
E4
15
SOL 3 E6
10
COPYRIGHT 2002
P
A2 A B P1 16
T
12
23 T2
22
24 A2
10 25
A1
LeTourneau, Inc.
11
8 9
7
UPPER
CYLINDER M1 T3
FIGURE 12. BRAKE CONTROL DIAGRAM

E1 T1 1
BOOM HOIST BRAKE

5 6 E1 20
1 AB SOL 1
a b
UPPER
T3 M1 SOL 2
CYLINDER
P
A3 B T E3 LOWER
CYLINDER E5
A 21
HOIST BRAKE
20 3 SOL 4 AB
E1 a b
14 SEE NOTE 1
4 SOL 8
28
E4 29
1 21
LOWER
E5 SOL 7 AB
CYLINDER
a b
VALVE DETAIL
TAĆ10243Ć4
6/6/00
PUBLICATION OSMĆ6
BRAKE CONTROL DIAGRAM
1 BRAKE CONTROL UNIT ADAPTERS:

2 HYDRAULIC POWER UNIT A1 HYDRAULIC FITTING
3 SOLENOID VALVE A2 HYDRAULIC FITTING
4 LOCKWASHER A3 HYDRAULIC FITTING
A4 HYDRAULIC FITTING
5 ANGLE MOUNT
6 ANGLE MOUNT
ELBOWS:
7 HOSE E1 HYDRAULIC FITTING
14 BOLT
PLUGS:
15 MANIFOLD
P1 JIG PLUG
16 HOSE
P2 PLUG W/#12 OĆRING
17 HOSE
18 HOSE TEES:
19 HOSE T1 HYDRAULIC FITTING
20 HOSE T2 HYDRAULIC FITTING
21 KIT COVER T3 HYDRAULIC FITTING
22 VALVE T4 HYDRAULIC FITTING
23 SUBPLATE
MISCELLANEOUS FITTINGS:
24 BOLT KIT
M1 PIPE REDUCER
25 SEAL KIT
M2 CAP NUT
26 HOSE
27 PLATE MOUNT
28 SUBPLATE
29 BOLT KIT
COPYRIGHT 2002
LeTourneau, Inc. 23
6/6/00
NOTES
COPYRIGHT 2002
24
LeTourneau, Inc.
6/6/00
LUBRICATING OIL ANALYSIS

An effective preventive maintenance program will give oil (copper, iron, aluminum, silica, or chromium) indiĆ
the owner or equipment manager the ability to predict cates what part is wearing.
and control downtime. An onĆgoing oil analysis program Lubricating oil analysis is not effective unless it is
is very important in identifying components that are in done on a continual basis in order to establish a
need of replacement, overhaul or a change in their wear trend. At least two or three samples must be taken
maintenance to prevent an unscheduled breakdown or and recorded to establish this trend which reflects the
premature failure. conditions in which the crane is working. After the trend
is established, records will readily show any accelerated
THE ROLE OF LUBRICATING OIL ANALYĆ increase in this pattern. Comparisons to other cranes
SIS IN A PREVENTIVE MAINTENANCE with like components and working in similar conditions
PROGRAM can also be made and used in forecasting downtime
and production scheduling.
Service intervals for the drivers and gearboxes on the
crane are included in PREVENTIVE MAINTENANCE ANALYSIS OF LUBRICATING OIL IN
SCHEDULES located in the back of this publication. LeTOURNEAU, INC. DRIVERS AND GEARĆ
These recommendations are based on normal BOXES
conditions and a lubricating oil analysis program
LeTourneau, Inc. has done extensive research on driver
should be used to supplement these recommendaĆ
and gearbox life/maintenance programs. This research
tions. If the crane is used in extremes of temperatures,
has confirmed the value of an onĆgoing lubricating oil
prolonged operation, sandy or dusty conditions or
analysis program for obtaining maximum life from the
exposure to moisture, the lubrication intervals may have
drivers and gearboxes on the crane.
to be modified. An onĆgoing lubricating oil analysis
program can help to identify problems resulting from the a. SAMPLE COLLECTION
above mentioned conditions and others that may cause Oil samples should be drawn and analyzed every
accelerated component failure which are unique to your 250 hours of operation, again prior to an oil change
operation. A preventive maintenance program custom and more often if suspicious of component operaĆ
tailored for a specific application is the most effective tion. The crane should be operated for at least one hour
manner in which to maintain heavy equipment. with continual operation of the component prior to
taking a sample from a driver or gearbox. The oil
NOTE samples should then be taken within 10 minutes of
Lubricating oil analysis is designed to detect stopping the machine. Approximately 3Ć5 oz. is normally
only that type of failure which characteristicalĆ required for analysis. Be sure receptacle is clean.
ly begins with an increase in metal wear; that NOTE
is, worn bearings, worn gears and slowly
progressing fatigue failures. Component A suction pump should be used to draw the oil
failures which are catastrophic and instantaĆ sample, as this will result in the most accurate
neous in nature are not caught by lubricating analysis reports. BE SURE to thoroughly clean
oil analysis. the suction pump between taking samples in
several components.
PROGRAM OPERATION NOTE
With lubricating oil analysis, the wear of internal
Samples must be sent promptly to the testing
components can be determined without taking the
facility. Analysis and reporting must be
machine apart. At the recommended oil change
likewise equally prompt. Any delay could
interval or as otherwise recommended; a sample of the
negate the application of the analysis report.
oil should be collected and sent to a testing facility who
All samples must be analyzed under identical
analyzes its microscopic metal content with special
conditions or the results will not be usable.
emission or atomic absorption spectrophotometry
equipment. When this is done regularly, a record or Newly changed oil or oil recently added to a system will
wear trend is established for that component or group not give a true picture when it is analyzed. Also,
on components from several machines. If the amount of deviation from accepted procedures in taking the
certain metal or other foreign matter rises suddenly sample can invalidate the analysis results. Any of these
above the normal wear trend, it can indicate failure is conditions could have dangerous or misleading conseĆ
imminent. The type of metal or material detected in the quences because the sample analysis would be
COPYRIGHT 2002
LeTourneau, Inc. 9
4ĆOSM 4.3a, Gorilla
8/30/01
incorrect and not indicate the true condition of the 2. Viscosity test: If viscosity shows a large
component. increase or decrease, then change the oil.
The magnetic plug should also be inspected and 3. Insoluble material test: If the amount of
cleaned regularly. Record the appearance and weight insoluble material test shows a large increase,
of metal accumulated. In the event of the appearance of the oil should be changed. This could indicate
a large increase in the amount of metallic particles or the failure of a seal and the seals should be
chips, the gearbox or driver should be inspected closely examined.
internally. If no damage is readily evident, the compoĆ WEAR TREND ANALYSIS
nent should be removed from service and disasĆ
Of particular concern are the levels of silicate (contamiĆ
sembled and the source(s) of the contamination
nation) and iron (wear). The results of each sample
identified and repaired.
taken should be compared to at least two or three
b. PROPER DOCUMENTATION previous samples (from the same component) in order
to conduct wear trend analysis. A sudden increase in
Proper documentation is critical to the success of an
the amount of these contaminants in the oil would signal
ongoing lubricating oil analysis program. It is
the need for corrective action such as flushing or
especially important to maintain accurate and detailed
disassembly of the component.
records when analyzing several components on one
crane or a group of cranes. This documentation should NOTE
include:
Flushing the driver or gearbox is strongly
1. Date of sample recommended if iron content reaches 100
2. Serial or identification numbers of the compoĆ ppm. If these high levels of iron content
nent continue after flushing, disassembly and
inspection should be considered. In order to
3. Total hours of component life maximize component life, the amount of iron
4. Hours of operation since last oil change contained in the oil must be kept as low as
possible.
5. Complete results of all tests conducted
NOTE
6. Serial number of the crane and position of the
gearbox or driver (main hoist, aux. hoist, Refer to DRIVER MAINTENANCE, Page 13, for
boom luffing, swing) additional information on servicing drivers.
Service requirements for gearboxes are found
7. Appearance and weight of magnetic plug in the PREVENTIVE MAINTENANCE SCHEDĆ
accumulation ULES located in the back of this section. Also,
8. Any other applicable comments about the refer to PCM CRANE LUBRICATION SPECIFIĆ
component's operation CATIONS, Figure 1, for lubricants recomĆ
mended for use in drivers and gearboxes.
c. RECOMMENDED TESTS
a. SYNTHETIC AND SPECIALITY LUBRICANTS
1. Spectrographic analysis: This test checks Synthetic and speciality lubricants have become popuĆ
for the metal content in the oil. The amounts in lar with many equipment owners and may be beneficial
parts per million should be compared to the where temperature extremes (hot and cold) are encounĆ
previous sample. If a significant increase in tered. Contact LeTourneau, Inc. through your distributor
any of the elements appears, perform a to determine acceptable lubricants for your operation.
gearcase inspection. A sudden increase in
iron content will indicate excessive wear of ! CAUTION
one or more of the drive train components. A
sudden increase in chromium should indicate If the service intervals recommended in the
unusual wear of a bearing. If silicon content PREVENTIVE MAINTENANCE SCHEDULES
only shows a large step change, the oil should are exceeded due to the use of synthetic or
be changed. speciality lubricants, it is essential to monitor
the component with lubricating oil analysis.
NOTE The guideline of 100 ppm. of iron content will
apply and the component should be flushed if
It is important to emphasize that a large this amount is reached. Disassembly and
increase in iron or chromium content between inspection should be undertaken if wear trend
two consecutive tests indicates component analysis indicates a reoccurrence after
failure. flushing.
COPYRIGHT 2002
10
LeTourneau, Inc.
8/30/01
HYDRAULIC BRAKE OIL OPERATING AND SERVICE MANUAL for additional

information on servicing the hydraulic brake system.
The hydraulic brake system is equipped with a power
unit which has a 20 gallon reservoir. This unit is factory NOTE
equipped with fire resistant brake fluid (P/N 423Ć5122).
It is recommended that oil samples be taken for analysis The ultimate success of a lubricating oil
every 250 hours of operation or monthly. The reservoir analysis program rests with the owner or
should be drained and thoroughly cleaned every five equipment manager. If good samples are
years or when lubricating oil analysis indicates a taken, forwarded promptly, and the feedback
water or solid particle contamination of 60 ppm or used wisely, a lubricating oil analysis program
greater. Refer to Publication OSMĆ6, BRAKES, in the will be very effective.
NOTES
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NOTES
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POWER LOSS LOWERING SYSTEM INSPECTION

AND TEST PROCEDURES
The following procedures are recommended as a b. Inspect the auxiliary and hoist brake rotor thermoĆ
minimum periodic inspection and checkout of the couple for proper thermocouple to brake rotor clearĆ
Power Loss Lowering System. These procedures ance (.050 ± .002 inches, rotor cold).
should be conducted every 250 hours or monthly as c. Inspect the auxiliary hoist temperature transmitter
outlined in the PREVENTIVE MAINTENANCE for proper electrical connections and connection tightĆ
SCHEDULES, located in the back of this publication. ness.
NOTE d. Ensure that the EMERGENCY HOIST RELEASE
switch is in the OFF position.
Refer to PCM CRANE POWER LOSS LOWERĆ e. Ensure that the CONSTANT TENSION switch is in
ING SYSTEM, located in Publication ROMĆ6 in the OFF position.
the REPAIR AND OVERHAUL MANUAL, for a
f. With the MASTER switch in the ON position and
detailed explanation of the Power Loss
the HOIST SELECT switch in the AUX position, lift any
Lowering System.
convenient load to approximately 25% of full up travel.
g. Position the HOIST joystick to NEUTRAL and the
24 VDC BATTERY BANK AND CHARGER BRAKE switch to the SET position.
The crane has 24 VDC battery backĆup power available
for power loss lowering functions in the event of a power
loss situation. A bank of four 12 VDC, maintenance free
lead batteries is mounted on top of the machinery Uncontrolled load descent during test can
house. The system contains a regulated battery charĆ cause serious injury or death! BE ALERT -
ger, which operates from 120 VAC, to restore the battery OBSERVE HOOK LOWERING SPEED. If at any
bank to full charge after the unit has supplied backĆup time during this procedure it appears that the
power to the crane. After the full charge has been load is descending when it shouldn't be or is
reached, the charger continues to trickleĆcharge the descending uncontrollably, it is imperative
batteries to maintain a full charge without overcharging. that the operator immediately move the HOIST
joystick to the NEUTRAL position and release
The battery charger is operational when the 600A
the POWER LOSS HOIST LOWER pushbutton.
Feeder Breaker to the crane is closed (ON).
The following switch settings should also be
The charger has a 5Ćamp fuse on the 120 VAC input. An made:
internal ganged 15A circuit breaker protects the system D BRAKE switch in the SET position
in the event that loading exceeds ratings. The battery
D EMERGENCY HOIST RELEASE switch in the
charger is calibrated to float the battery bank at
OFF position
27.5 VDC (the optimum voltage for the battery type).
D CONSTANT TENSION switch in the OFF
The GREEN pilot light is ON when the battery charger is position
properly ON and the battery is floating at proper DC
D MASTER switch in the OFF position.
voltage. The RED pilot light comes ON when the battery
is connected to the charger in reverse polarity. If you see CAUTION
!
this RED light ON, immediately disconnect the charger
from the battery bank. The Power Loss Hoist Lower function has the
potential to generate extreme brake rotor and
The batteries are maintenance free other than it is
pad temperatures (the heavier the load, the
recommended that the connections be checked
faster the temperature will rise). Always
every two months for tightness.
station an observer in a location where the
brakes can be visually monitored when doing
POWER LOSS HOIST LOWER TEST a power loss hoist lower. Because of the brake
PROCEDURE (AUXILIARY AND MAIN dust that can be generated by dragging
HOIST) through the brakes it is advised that the
observer wear a respirator and view the
a. Inspect the Power Loss Lowering Card and the procedure from the catwalk looking through
auxiliary and main hoist Speed Sensor Filter Cards for the door into the crane machinery house. This
proper electrical connections and connection tightness. observer must be able to contact the operator
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and signal a procedure shutdown should the d. Ensure that the EMERGENCY HOIST RELEASE
temperature sensing system obviously fail (as switch is in the OFF position.
evidenced by a glowing red brake rotor, e. With the MASTER switch in the ON position and
excessive sparking, smoke, flame, etc.). the HOIST SELECT switch in the AUX position, lift an
approximately 5,000 lb load to approximately 25% of full
NOTE up travel.
The SPEED/TEMP WARNING light should be f. Position the HOIST joystick to NEUTRAL and the
out and stay out throughout this procedure BRAKE switch to the SET position.
(unless brake rotor temperature exceeds
approximately 700°F).
h. To activate power loss hoist lower mode, perform If at any time during this procedure it appears
the following steps: that the load is descending when it shouldn't
1. MASTER switch in the BAT position (POWER be or is descending uncontrollably, it is
ON light flashing). imperative that the operator move the
CONSTANT TENSION switch to the OFF
2. BRAKE switch in the ENABLE position. position. The following switch settings should
3. POWER LOSS HOIST LOWER pushbutton also be made: BRAKE switch in the SET
depressed and held. position, EMERGENCY HOIST RELEASE
switch in the OFF position, and MASTER
4. HOIST joystick moved in the LOWER direction switch in the OFF position.
(HOIST joystick contact must close).
The load should accelerate to and descend at a ! CAUTION
constant rate (300 rpm of motor speed) as the load pulls This procedure has the potential to generate
through the partially released hoist brake. When extreme brake rotor and pad temperatures
satisfied that the power loss lowering system is lowering (the heavier the load, the faster the temperaĆ
the load as expected, release the POWER LOSS HOIST ture will rise and the faster the load will
LOWER pushbutton and return the HOIST joystick to accelerate). Always station an observer in a
NEUTRAL, at which point the brake will set and the load location where the brakes can be visually
will stop. Take the BRAKE switch to SET and the monitored when doing a constant tension
MASTER switch to OFF. The crane is now ready for mode test lower operation. Because of the
normal operations. brake dust that can be generated by dragging
through the brakes, it is advised that the
Should the crane not perform as expected, refer to the
observer wear a respirator and view the
POWER LOSS HOIST LOWER section of PCM CRANE
procedure from the catwalk, looking through
POWER LOSS LOWERING SYSTEM, located in PublicaĆ
the door into the crane machinery house. This
tion ROMĆ6 in the REPAIR AND OVERHAUL MANUAL,
observer must be able to contact the operator
for a detailed explanation of how this system works.
and signal a shutdown should the temperature
i. Repeat Steps f" through h" above with a load on sensing system obviously fail (as evidenced
the main hoist and the HOIST SELECT switch in the by a glowing red brake rotor, excessive
MAIN position. sparking, smoke, flame, etc.).
NOTE
CONSTANT TENSION TEST PROCEDURE
(POWER LOSS OPERATIONS, AUXILIARY The SPEED/TEMP WARNING light should be
out and stay out throughout this procedure
HOIST ONLY)
(unless brake rotor temperature exceeds
a. Inspect the Power Loss Lowering Card and the approximately 700°F).
auxiliary and main hoist Speed Sensor Filter Cards for g. To activate constant tension mode under power
proper electrical connections and connection tightness. loss conditions, perform the following steps:
b. Inspect the auxiliary hoist brake rotor thermocouĆ 1. MASTER switch in the BAT position (POWER
ple for proper thermocouple to brake rotor clearance ON light flashing).
(.050 ± .002 inches, rotor cold). 2. BRAKE switch in the ENABLE position.
c. Inspect the auxiliary hoist temperature transmitter 3. CONSTANT TENSION switch in the BAT
for proper electrical connections and connection tightĆ position and held there (CONSTANT TENĆ
ness. SION and AUX RUN lights should come on).
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This will cause the brakes to partially release and 2. BRAKE switch in the ENABLE position.
maintain a line tension of approximately 3,300 lbs. The
3. CONSTANT TENSION switch in the ON posiĆ
suspended 5,000 lb load will begin to descend and
tion (CONSTANT TENSION and AUX RUN
accelerate. Once movement is seen, turn the
lights should come on).
CONSTANT TENSION switch to OFF, which should set
the brake and stop the load. Take the BRAKE switch to This will cause the aux hoist motor to power up and
SET and the MASTER switch to OFF. The crane is now maintain approximately 3,300 lbs of up tension on the
ready for normal operations. line. This will result in all of the slack being taken out of
the line but no movement of the load (3,300 lbs of
Should the crane not perform as expected, refer to the tension will not be enough to lift 5,000 lbs of load). Verify
CONSTANT TENSION section of PCM CRANE POWER aux hoist motor torque by reading the following values
LOSS LOWERING SYSTEM, located in Publication on the hoist motor controller tester (located in the crane
ROMĆ6 in the REPAIR AND OVERHAUL MANUAL, for a control room at the top on the column):
detailed explanation of how this system works.
4. IA = +0.62 to +0.68 (hoist motor armature
current)
CONSTANT TENSION TEST PROCEDURE
(NORMAL OPERATIONS, AUXILIARY 5. IF = +1.23 to +1.37 (hoist motor field current)
HOIST ONLY) Verify that each of the following three actions will disable
constant tension mode:
a. Inspect the Power Loss Lowering Card and the
auxiliary and main hoist Speed Sensor Filter Cards for 6. CONSTANT TENSION switch in the OFF
proper electrical connections and connection tightness. position. This will set the brake and make
tester signal IA equal zero. Put the aux hoist
b. Inspect the auxiliary hoist brake rotor thermocouĆ back into constant tension mode by taking the
ple for proper thermocouple to brake rotor clearance CONSTANT TENSION switch back to ON
(.050 ± .002 inches, rotor cold). before performing the next step.
c. Inspect the auxiliary hoist temperature transmitter 7. BRAKE switch in the SET position. This will set
for proper electrical connections and connection tightĆ the brake and make tester signal IA equal
ness. zero. Put the aux hoist back into constant
d. Ensure that the EMERGENCY HOIST RELEASE tension mode by first taking the BRAKE switch
switch is in the OFF position. to the ENABLE position and then taking the
CONSTANT TENSION switch to OFF and
e. With the MASTER switch in the ON position and back to ON before performing the next step.
the HOIST SELECT switch in the AUX position, attach
the aux hook to an approximately 5,000 lb load resting 8. HOIST joystick out of neutral (move it in the UP
on the deck of the rig, leaving a little bit of cable slack. torque direction). This disables constant tenĆ
sion mode and automatically returns load
f. Position the HOIST joystick to NEUTRAL and the control in either direction to the HOIST
BRAKE switch to the SET position. joystick.
NOTE
Once disabled by any of the three means
If at any time during this procedure it appears above, constant tension mode will stay
that the load is descending when it shouldn't disabled until the CONSTANT TENSION
be or is descending uncontrollably, it is switch is cycled from ON to OFF and back to
imperative that the operator move the ON again.
CONSTANT TENSION switch to the OFF Should the crane not perform as expected, refer to
position. The following switch settings should CONSTANT TENSION MODE OPERATION AND TROUĆ
also be made: BRAKE switch in the SET BLESHOOTING, located in Publication ROMĆ6 in the
position, EMERGENCY HOIST RELEASE REPAIR AND OVERHAUL MANUAL.
switch in the OFF position, and MASTER
switch in the OFF position. EMERGENCY HOIST RELEASE TEST
g. To activate constant tension mode when not under PROCEDURE (NORMAL OPERATIONS,
power loss conditions, perform the following steps: MAIN AND AUXILIARY HOIST)
1. MASTER switch in the ON position (POWER a. Position the hooks in a safe area. Position the
ON light ON). HOIST SELECT switch to the AUX position.
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b. Position the HOIST joystick to NEUTRAL, BRAKE The Emergency Release system uses the same circuitry
switch to the SET position. and generates the same results as does an Automatic
Overload Protection System (AOPS) activation. Visually
check that the top canister of the aux hoist motor brake
remains set, that the bottom brake canister releases
If at any time during this procedure it appears fully, and that LED3 on the hoist controller (GOL Veac
that the load is descending, it is imperative Disable, visible through the window in the hoist
that the operator move the EMERGENCY controller front cover) illuminates. The external cab
HOIST RELEASE switch to the OFF position. mounted alarm and the machinery house mounted
The following switch settings should also be alarm will sound with a pulsating tone. Clear the alarms
made: BRAKE switch in the SET position, with the ACKNOWLEDGE HORN BUTTON, take the
CONSTANT TENSION switch in the OFF EMERGENCY HOIST RELEASE switch to OFF, and take
position, and MASTER switch in the OFF the OVERLOAD PROTECTION SWITCH to RESET and
position. then back to ON.
c. To activate emergency release mode , perform the
following steps: Should the crane not perform as expected, refer to the
EMERGENCY HOIST RELEASE (NORMAL OPERAĆ
1. MASTER switch in the ON position (POWER
ON light ON). TIONS) section of PCM CRANE POWER LOSS LOWERĆ
ING SYSTEM, located in Publication ROMĆ6 in the
2. BRAKE switch in the SET position. REPAIR AND OVERHAUL MANUAL, for a detailed
3. OVERLOAD PROTECTION switch in the ON explanation of how this system works.
position (OVERLOAD PROTECTION ACTIVE
light should come on). d. Repeat steps b" and c" above with the HOIST
4. EMERGENCY HOIST RELEASE switch in the SELECT switch in the MAIN position.
ON position (GROSS OVERLOAD, EMERĆ
GENCY HOIST RELEASE, and AUX RUN e. Position the OVERLOAD PROTECTION switch to
lights should come on). RESET unless directed otherwise by a supervisor.
NOTES
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PUBLICATION ROMĆ6 SOLID STATE CONVERSION SYSTEM
PCM CRANE POWER LOSS LOWERING SYSTEM

The primary purpose of the PCM crane power loss
lowering system is to enable the operator to lower a load
! CAUTION
(main or auxiliary hoist) while suffering power loss Before initiating this procedure, inspect the
conditions to the crane's hoist system (loss of main AC main and auxiliary hoist brake rotor thermoĆ
power and/or 24 VDC power supply). This system can couples for proper thermocouple to brake
also be used to lower a load during scenarios other than rotor clearance (.050 ± .002 inches, rotor
power loss (such as failure or malfunction of the normal cold). Inspect the PLLC, the main and auxiliary
hoisting system). When the Master Switch is turned to speed sensor filter cards, and the main and
BAT, backup batteries supply 24 VDC to the power loss auxiliary hoist temperature transmitters for
lowering card (PLLC, see Figure 24) and to various other proper electrical connections and tightness.
necessary backup components. The PLLC, which
monitors operator commands, motor speed, and motor ! CAUTION
brake rotor temperature, manipulates a proportional
This procedure has the potential to generate
hydraulic relief valve to partially release the motor park
extreme brake rotor and pad temperatures
brake. This allows the load to slip through the brake and
(the heavier the load, the faster the temperaĆ
descend at a constant speed (approximately 300 rpm at
ture will rise). Always station an observer in a
the motor) via gravity. The system hydraulic pressure to
location where the brakes can be visually
the motor brake is varied in proportion to the current
monitored when doing a power loss hoist
supplied to the proportional valve's solenoid by the
lower. Because of the brake dust that can be
PLLC. This current varies based on speed feedback to
generated by dragging through the brakes, it
the PLLC from the motor's two speed sensors. A
is advised that the observer wear a respirator
thermocouple monitors brake rotor temperature and
and view the procedure from the catwalk,
halts the lowering process when the temperature
looking through the door into the crane
exceeds approximately 700°F (371°C). Lowering is
control room. This observer must be able to
allowed to resume once the rotor has cooled to
contact the operator and signal a procedure
approximately 450°F (232°C). Besides the mode of
shutdown should the temperature sensing
operation described above (Power Loss Hoist Lower),
system obviously fail (as evidenced by a
the PLLC is also responsible for backup battery
glowing red brake rotor, excessive sparking,
Constant Tension operation, and for monitoring the
smoke, flame, etc.)
status of the normal (nonĆpower loss) Emergency Hoist
Release operation (descriptions of each to follow). 1. EMERGENCY HOIST RELEASE switch must
be in the OFF position.
NOTE 2. CONSTANT TENSION switch must be in the
OFF position.
The Power Loss Lowering System should be 3. MASTER switch must be in the BAT position
inspected and tested monthly in accordance (POWER ON light flashing).
with the PREVENTIVE MAINTENANCE
SCHEDULES, located in Publication OSMĆ4 in 4. AUX or MAIN hoist position selected with the
the OPERATING AND SERVICE MANUAL. HOIST SELECT switch.
5. BRAKE switch must be in the ENABLE
NOTE position.
6. POWER LOSS HOIST LOWER button pressed
These instructions reference general electriĆ and held.
cal schematic 422Ć1678, located in the back of
7. HOIST joystick moved in the LOWER direction
Section 4, Electrical System Troubleshooting
(HOIST joystick contact must close and the
(in this manual), and general hydraulic
AUX or MAIN RUN light should come on).
schematic 422Ć3396, located in the back of
Publication OSMĆ6 in the OPERATING AND For the discussion that follows, assume that the Hoist
SERVICE MANUAL. Select switch is in MAIN. When BAT is selected with the
Master Switch, relay BTB becomes energized, which
a. POWER LOSS HOIST LOWER: Power Loss Hoist makes wire 11D hot through a set of normally closed
Lower is the normal means of lowering a suspended CR15 contacts (see electrical schematic referenced
load when operating under power loss conditions. To above). 11D becoming hot energizes SOL8 and also
activate power loss hoist lower mode, the following indicates to the PLLC that the main hoist is selected.
conditions must be met: SOL8 causes its associated hydraulic valve to shift,
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1ĆROM 6.2d, Gorilla
5/12/99 (Rev 8/30/01)
SOLID STATE CONVERSION SYSTEM PUBLICATION ROMĆ6
FIGURE 24. POWER LOSS POWERING CARD (1 of 2)

9ĆNGOĆ1876Ć1, P10Ć64
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FIGURE 24. POWER LOSS LOWERING CARD (2 of 2)

9ĆCGĆ2471Ć1, P02Ć25
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resulting in the proportional hydraulic relief valve SOL3 b. CONSTANT TENSION (AUXILIARY HOIST
being placed in series with the upper brake canister ONLY): Constant tension mode is used when the load is
(see hydraulic schematic referenced above). When the on the deck of a vessel that is pitching up and down due
Power Loss Hoist Lower push button is depressed and to wave motion. To activate constant tension mode
the hoist joystick is moved in the lower direction, wire under power loss conditions, the following conditions
EL4 to the PLLC will become hot causing CR39 and must be met:
SOL3 to be energized by the PLLC. This results in a set 1. EMERGENCY HOIST RELEASE switch must
of CR39 contacts closing, which energizes CR41 and be in the OFF position.
SOL2. A set of CR41 contacts will then close energizing
CR28, which energizes CTR15, which applies 24V 2. MASTER switch must be in the BAT position
battery power to the backup hydraulic DC pump motor. (POWER ON light flashing).
SOL2 energizing applies full system pressure (approxiĆ 3. HOIST SELECT switch must be in the AUX
mately 130 psi) to the springĆapplied lower brake position.
canister (causing it to fully release) and a variable 4. BRAKE switch must be in the ENABLE
pressure (via the PLLCĆcontrolled proportional relief position.
valve SOL3) to the springĆapplied upper brake canister.
The PLLC, which supplies approximately 14 VDC to 5. CONSTANT TENSION switch must be turned
each main hoist motor speed sensor filter card through to the BAT position and held there
wires 12MH1 and 12MH2, monitors main hoist motor (CONSTANT TENSION and AUX RUN lights
speed on wires 92MH1 and 92MH2 from the motor should come on).
speed sensors (these signals are pulse trains generĆ When BAT is selected with the Master Switch, relay BTB
ated by magnetic pickups with 1 Hz corresponding to becomes energized, which makes wire 11G hot through
1 rpm of motor speed). If the speed is less than a set of normally open CR15 contacts (see electrical
300 rpm, more current (in the form of a pulse width schematic referenced above). 11G becoming hot
modulated signal) is sent to SOL3 by the PLLC, causing energizes SOL9 and also indicates to the PLLC that the
the relief valve to bypass less fluid to tank, resulting in aux hoist is selected. SOL9 causes its associated
more pressure to the upper brake canister (and hydraulic valve to shift, resulting in the proportional
therefore less braking effort and more motor speed for a hydraulic relief valve SOL5 being placed in series with
given load). If the speed is more than 300 rpm, less the upper brake canister (see hydraulic schematic
current is sent to SOL3, causing the relief valve to referenced above). When the Constant Tension switch
bypass more fluid to tank, resulting in less pressure to is held in the BAT position, wire CT4 to the PLLC will
the upper brake canister (and therefore more braking become hot, causing CR40 and SOL5 to be energized
effort and less motor speed for a given load). This by the PLLC. This results in a set of CR40 contacts
dynamic feedback system results in a relatively closing, which energizes CR42 and SOL4. A set of CR42
constant lowering speed for a full range of loads (up to contacts will then close energizing CR28, which enerĆ
and including rated load). Auxiliary hoist operation is gizes CTR15, which applies 24V battery power to the
similar except that CR15 will be energized resulting in backup hydraulic DC pump motor. SOL4 energizing
wire 11G being hot and SOL9, CR40, SOL5, SOL4 and applies full system pressure (approximately 130 psi) to
CR42 being energized as opposed to their main hoist the springĆapplied lower brake canister (causing it to
counterparts listed above. fully release) and a reduced pressure (via the PLLCĆconĆ
trolled proportional relief valve SOL5) to the springĆapĆ
Should motor speed exceed approximately 750 rpm in plied upper brake canister. (This reduced pressure is
power loss hoist lower mode, the PLLC will set the brake constant and is set during initial calibration of the
fully (overspeed condition). Wire EL4 will have to be system by lifting a 3300Ćlb. load with the aux hook, going
deĆenergized (Power Loss Hoist Lower button released, into power loss" constant tension mode as described
hoist joystick neutral) and then reĆenergized in order to above, and then adjusting the mid" pot on component
initiate another lowering attempt. U9 (proportional valve drive card) on the PLLC until the
load just starts slipping. This effectively applies a
Temperature sensing circuitry and logic are discussed constant current to SOL5 to maintain approximately
in the Temperature Sensing section following. 3300 lbs. of line tension on the hoist cable. This
preĆadjusted pressure is dependent upon CR11 being
NOTE energized when the Constant Tension switch is turned
to BAT. This opens a set of CR11 contacts and removes
Power Loss Hoist Lower mode will be 24V from wire 43SA to the PLLC, which makes the mid
overridden by constant tension mode (wire pot setting on U9 effective. During this constant tension
CT3 hot) and emergency hoist release mode operation under power loss conditions, should the deck
(wires ER1 or ER2 hot). drop from under the load due to wave motion, the load
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will also drop if it weighs more than 3300 lbs. There will At the same time, the hoist controller also energize
be no motor power, of course, to take up the slack when CR43, which energizes either SOL2 if the main hoist is
the deck rises again. selected, or SOL4 if the aux hoist is selected. This
applies full hydraulic pressure to the selected motor's
Top motor speed allowed by the PLLC in constant
bottom brake canister, releasing it fully.
tension mode is 2665 rpm. Should motor speed exceed
this maximum, the park brake will be fully set and the The end result is that during an Emergency Release
constant tension switch will have to be cycled from OFF operation, the top brake canister of the selected hoist
back to BAT in order to resume constant tension motor will be fully set, and the bottom brake canister will
operation. be fully released, resulting in a holding force of
approximately 150% of maximum rated load. If a true
Temperature sensing circuitry and logic are discussed gross overload exists, the load will pull through the one
in the Temperature Sensing section following. brake canister without causing structural damage to the
crane.
NOTE
To reset the Emegency Release sytem, place the
Constant tension mode will be overridden by Emergency Hoist Release switch to OFF and then cycle
emergency hoist release mode (wires ER1 or the Overload Protection switch to RESET and then back
ER2 hot) and overrides power loss hoist lower to ON. The Gross Overload light should go out and the
mode (wire EL4 hot). Overload Protection Active light should illuminate.
c. EMERGENCY HOIST RELEASE (NORMAL NOTE

OPERATIONS): The emergency hoist release mode is
Emergency hoist release mode overrides
designed to be used if the hook becomes entangled in a
constant tension (wire CT4 hot) and power
vessel that is moving away from the crane. To activate
loss hoist lower (wire EL4 hot) modes.
emergency hoist release mode when not under power
loss conditions, the following conditions must be met: d. TEMPERATURE SENSING: A descending load
opposed by friction drag torque on the motor brake
1. MASTER switch must be in the ON position.
rotor will generate heat. Brake rotor temperature is
2. OVERLOAD PROTECTION switch must be in sensed by a thermocouple mounted .050 inches from
the ON position (OVERLOAD PROTECTION the radial edge of the rotor (cold). As the rotor heats up it
ACTIVE light on). expands and its heat is transmitted through the air gap
to the thermocouple. The thermocouple's millivolt
3. AUX or MAIN hoist position selected with the signal is routed to a 4Ć20mA temperature transmitter
HOIST SELECT switch. which sends a proportional current signal to the PLLC
4. EMERGENCY HOIST RELEASE switch must on wire TX1 (main hoist) or TX2 (auxiliary hoist). If the
be put in the ON position (EMERGENCY rotor temperature is sensed to be greater than approxiĆ
HOIST RELEASE and AUX or MAIN RUN mately 700°F, the PLLC will set the park brake until rotor
lights should come on). temperature drops to less than approximately 450°F, at
which point lowering will be reĆenabled.
Placing the Emergency Hoist Release Switch in ON
position causes CR9 to energize. A set of CR9 contacts NOTE
connects wire 3F to wire GOL, which initiates the same
Rotor temperature has no effect on emerĆ
chain of events that results from an Automatic Overload
gency release mode.
Protection System (AOPS) activation (refer to PublicaĆ
tion ROMĆ6 in the REPAIR AND OVERHAUL MANUAL for CAUTION
!
more information on the AOPS). Wire GOL applies 24V
to the hoist controller, which in turn energizes CR44, The thermocouple/temperature transmitter
which energizes SOL1 (Brake Master Solenoid) and combination is calibrated to measure rotor
SOL8. The hoist controller also energizes CR44A, which temperature across an air gap which
energizes SOL9. SOL8 and SOL9 route hydraulic decreases as the rotor heats up and expands.
pressure away from the top brake canisters of the main Should the thermocouple ever physically
and aux hoist motors respectively and to the proportionĆ contact the rotating brake rotor, its sensed
al relief valve solenoids SOL3 and SOL5 (see Hydraulic temperature will go up rapidly causing a
Schematic referenced above). No current is sent to premature temperature shutdown of the
SOL3 or SOL5 from the PLLC during an Emergency lowering process (refer to LED1 and LED3 in
Release operation, so all hydraulic pressure to the top PLLC LED's, below). This will also result in
canisters is bypassed to tank through SOL3 and SOL5, rapid wear and failure of the thermocouple
and the top canisters remain fully set. element, likewise causing a temperature
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shutdown (see LED1 and LED3). For these

reasons it is important to maintain proper
thermocouple to rotor clearance (.050 ± .002
inch, rotor cold). The dual speed sensor arrangement is
designed for redundancy; only one speed
NOTE sensor and its associated processing circuit
are normally necessary for power loss
Refer to Figure 25 for an illustration of the lowering. The PLLC allows lowering with the
thermocouple and installation procedures. SPEED/TEMPERATURE warning light flashing
Refer to Figure 26 for an illustration of the but the cause of the flashing light should be
temperature transmitters. investigated and rectified as soon as possible.
Should both speed sensors or PLLC speed
e. SPEED/TEMPERATURE Warning Light: The sensor signal processing circuits fail, the
SPEED/TEMPERATURE warning light (located on the PLLC will have no speed feedback and will
operator's console) comes on in the following modes sense" that the load is not moving. Should
and for the following reasons (for further information on this be the case, when a lower mode is
troubleshooting what is specifically causing a flashing initiated, the park brake will be released and
or a steady light, refer to PLLC LED'S, below): the load will descend unabated. Also, since
both speed feedback systems are disabled,
1. Steady Mode: The light will come on and the SPEED/TEMPERATURE light will not
glow steadily and the park brake will be set illuminate. It is important that the operator
(exception: in emergency release mode, the always maintain extreme caution when using
park brake will remain released regardless of the power loss lowering system (as with any
the status of this light) in the event of: lowering operation) and always be prepared
(a) The motor brake rotor reaching its maxiĆ to come out of a lowering mode (joystick
mum allowed temperature of approxiĆ neutral, POWER LOSS HOIST LOWER push
mately 700°F. The light will go out and button released, CONSTANT TENSION switch
lowering will be allowed once the rotor off, EMERGENCY HOIST RELEASE switch off)
temperature has cooled to less than should a problem be suspected. Coming out
approximately 450°F. of a lowering mode will set the park brake and
stop the load. Note that having both speed
(b) A failure of the brake rotor temperature sensors and/or speed sensor signal processĆ
sensing thermocouple. ing circuits fail at the same time is an
extremely unlikely situation. Speed sensor
(c) A failure of the brake rotor 4Ć20mA condition and PLLC speed sensor signal
temperature transmitter. processing circuitry condition are constantly
monitored during normal crane operations
NOTE (with malfunctions indicated by a flashing
SPEED/TEMPERATURE light), so any power
A failure of one hoist motor's thermocouple loss lowering situation should begin with two
and/or temperature transmitter will cause the known good speed sensors and circuitry. A
SPEED/TEMPERATURE warning light to come possible failure scenario to be aware of,
on steady but will not disable the lowering however, would be to have both of the speed
capability of the other hoist motor. For further sensors not wired or improperly wired to the
information on troubleshooting what is PLLC resulting in no speed feedback to the
specifically causing a flashing or a steady card. It is therefore important that the power
light, refer to PLLC LED's, below. loss lowering system be regularly checked for
proper installation and functioning in accorĆ
2. Flashing Mode: This light will flash in the
dance with the crane's preventive mainteĆ
event of:
nance schedule.
(a) Motor speed greater than 250 rpm and a f. PLLC LED'S: Mounted on the PLLC are eight
failure of one of the two motor speed LED's (light emitting diodes) (refer to Figure 24). These
sensors. LED's have the following labels and meanings:
(b) Motor speed greater than 250 rpm and a 1. LED1 (AH Temp Hi). If this LED comes on, the
failure of one of the two speed sensor SPEED/TEMPERATURE warning light on the
signal processing circuits on the PLLC. operator's console will also come on and glow
COPYRIGHT 2002
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LeTourneau, Inc.
5/12/99 (Rev8/30/01)
steadily. While the LED is on, the auxiliary park 4. LED4 (MH XM Open). If this LED comes on,
brake will be set and lowering will be disabled the SPEED/TEMPERATURE warning light on
(exception: emergency release mode). This the operator's console will also come on and
LED comes on if: glow steadily. This LED comes on if the main
hoist temperature transmitter is sending less
(a) The auxiliary hoist motor brake rotor than .5 VDC on wire TX1 to the PLLC (normally
temperature is sensed to be greater than it should always read a minimum of 1 VDC).
approximately 700°F (greater than This would indicate a probable miswired or
4 VDC on wire TX2). The LED goes out malfunctioning transmitter. While the LED is
when the rotor temperature is sensed to on, the main park brake will be set and
be less than approximately 450°F (less lowering will be disabled (exception: emerĆ
than 2 VDC on wire TX2). gency release mode).
(b) The auxiliary hoist temperature transmitĆ 5. LED5 (AH SS1 Fail). If the auxiliary hoist
ter senses that the thermocouple eleĆ motor speed is greater than 250 rpm and this
ment is open (approximately 5.25 VDC LED comes on, the SPEED/TEMPERATURE
on wire TX2). warning light on the operator's console will
come on and flash. This LED comes on if:
(c) The auxiliary hoist temperature transmitĆ
ter itself malfunctions (approximately (a) The auxiliary host speed sensor 1 is not
5.25 VDC on wire TX2). sending a signal to the PLLC (see NOTE
below).
2. LED2 (AH XM Open). If this LED comes on,
the SPEED/TEMPERATURE warning light on (b) The auxiliary hoist speed sensor 1 signal
the operator's console will also come on and processing circuitry on the PLLC is
glow steadily. This LED comes on if the malfunctioning (see NOTE below).
auxiliary hoist temperature transmitter is NOTE
sending less than .5 VDC on wire TX2 to the
PLLC (normally it should always read a Circuitry on the PLLC essentially compares
minimum of 1 VDC). This would indicate a the signals received from the auxiliary hoist
probable miswired or malfunctioning transĆ speed sensor 1 and auxiliary hoist speed
mitter. While the LED is on, the auxiliary hoist sensor 2 and turns on LED5 if a signal is
park brake will be set and lowering will be sensed from speed sensor 2 but not from
disabled (exception: emergency release speed sensor 1. Consequently if both speed
mode). sensors or both speed sensor signal processĆ
ing circuits are malfunctioning, no difference
3. LED3 (MH Temp Hi). If this LED comes on, between the two will be detected and LED5 will
the SPEED/TEMPERATURE warning light on not come on.
the operator's console will also come on and
glow steadily. While the LED is on, the main 6. LED6 (AH SS2 Fail). If auxiliary hoist motor
park brake will be set and lowering will be speed is greater than 250 rpm and this LED
disabled (exception: emergency release comes on, the SPEED/TEMPERATURE warnĆ
mode). This LED comes on if: ing light on the operator's console will come
on and flash. This LED comes on if:
(a) The main hoist motor brake rotor temperĆ
(a) Auxiliary hoist speed sensor 2 is not
ature is sensed to be greater than
sending a signal to the PLLC (see NOTE
approximately 700°F (greater than
below).
4 VDC on wire TX1). The LED goes out
when the rotor temperature is sensed to (b) The auxiliary hoist speed sensor 2 signal
be less than approximately 450°F (less processing circuitry on the PLLC is
than 2 VDC on wire TX1). malfunctioning (see NOTE below).
(b) The main hoist temperature transmitter NOTE

senses that the thermocouple element is
open (approximately 5.25 VDC on wire Circuitry on the PLLC essentially compares
TX1). the signals received from auxiliary hoist
speed sensor 1 and auxiliary hoist speed
(c) The main hoist temperature transmitter sensor 2 and turns on LED6 if a signal is
itself malfunctions (approximately sensed from speed sensor 1 but not from
5.25 VDC on wire TX1). speed sensor 2. Consequently if both speed
COPYRIGHT 2002
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LeTourneau, Inc.
5/12/99 (Rev 8/30/01)
sensors or both speed sensor signal processĆ malfunctioning, no difference between the two
ing circuits are malfunctioning, no difference will be detected and LED7 will not come on.
between the two will be detected and LED6 will
8. LED8 (MH SS2 Fail). If main hoist motor
not come on.
speed is greater than 250 rpm and this LED
7. LED7 (MH SS1 Fail). If main hoist motor comes on, the SPEED/TEMPERATURE warnĆ
speed is greater than 250 rpm and this LED ing light on the operator's console will come
comes on, the SPEED/TEMPERATURE warnĆ on and flash. This LED comes on if:
ing light on the operator's console will come (a) Main hoist speed sensor 2 is not sending
on and flash. This LED comes on if: a signal to the PLLC (see NOTE below).
(a) Main hoist speed sensor 1 is not sending (b) The main hoist speed sensor 2 signal
a signal to the PLLC (see NOTE below). processing circuitry on the PLLC is
(b) The main hoist speed sensor 1 signal malfunctioning (see NOTE below).
processing circuitry on the PLLC is
malfunctioning (see NOTE below). NOTE
NOTE Circuitry on the PLLC essentially compares
the signals received from main hoist speed
Circuitry on the PLLC essentially compares sensor 1 and main hoist speed sensor 2 and
the signals received from main hoist speed turns on LED8 if a signal is sensed from speed
sensor 1 and main hoist speed sensor 2 and sensor 1 but not from speed sensor 2.
turns on LED7 if a signal is sensed from speed Consequently, if both speed sensors or both
sensor 2 but not from speed sensor 1. speed sensor signal processing circuits are
Consequently, if both speed sensors or both malfunctioning, no difference between the two
speed sensor signal processing circuits are will be detected and LED8 will not come on.
NOTES
COPYRIGHT 2002
80
LeTourneau, Inc.
5/12/99 (Rev8/30/01)
3
3
4
1
1
BRACKET INSTALLATION
BRAKE CALIPER
ASSEMBLY
THERMOCOUPLE
BRACKET ASSEMBLY
THERMOCOUPLE
ASSEMBLY
OUTSIDE EDGE
OF BRAKE DISC
±.002"
OUTSIDE EDGE .050" CLEAR
OF BRAKE DISC (REF)
1. MOUNTING BRACKET
2. COMPRESSION FITTING
3. THERMOCOUPLE ASSEMBLY
4. THREAD LOADING COMPOUND - LOCTITE RC271
1. Insert compression fitting (Item 2) into bracket (Item 1) using Loctite (Item 4).
2. Install bracket onto brake caliper using caliper mount bolt as shown. Adjust bracket as necessary so
that compression fitting is perpendicular to radial edge of brake disk. Tighten caliper mount bolt.
3. Loosen compression fitting nut and insert thermocouple (Item 3) through fitting bushing and teflon
ferrule (internal to fitting) until thermocouple tip measures .050" above brake disk edge. Tighten fitting
nut using Loctite (Item 4) and recheck for .050 ±.002" clearance. Loosen nut and readjust if
necessary.
4. Route thermocouple wire as shown on machine wire layout; terminate thermocouple wire as shown
on machine schematic.
FIGURE 25. HYDRAULIC BRAKE THERMOCOUPLE INSTALLATION

COPYRIGHT 2002
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LeTourneau, Inc.
5/12/99 (Rev 8/30/01)
3B
9
TX2
7 8
SET 1 SET 2
GRND
AUX HOIST
CASE
5 6
ACT2
(YEL)
ACT1
(RED)
4
3 4 7 8 9
5 6 OUT+
3
T/C , MV
TEMP XMIT
AUX HOOK
418Ć0161
TEMP XMIT PANEL
3B
9
TX1
422Ć8556
7 8
MAIN HOIST
CASE
GRND
SET 1 SET 2
MTC 1 MTC 2
(RED) (YEL)
5 6 4
3 4 7 8 9
5 6
3
OUT+
T/C , MV
TEMP XMIT
MAIN HOOK
418Ć0161
FIGURE 26. HYDRAULIC BRAKE THERMOCOUPLE TEMPERATURE TRANSMITTERS

NOTES
COPYRIGHT 2002
82
LeTourneau, Inc.
5/12/99 (Rev8/30/01)
PUBLICATION ROMĆ1
LeTOURNEAU, INC., PCM 120SS ELECTRIC DECK CRANE
REPAIR AND OVERHAUL MANUAL
STRUCTURAL COMPONENTS
Page Page
SCOPE OF THIS PUBLICATION . . . . . . . . . . . . . . . 2 PCMĆ120SS FLOATING SHEAVE HOUSING
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . 2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CRANE TESTING, EXAMINATION, AND INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 31
CERTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SURVEY AND APPROVAL . . . . . . . . . . . . . . . . . . . . 3
ANNUAL EXAMINATIONS . . . . . . . . . . . . . . . . . . . . 3 PCMĆ120SS HOOK AND BLOCK ASSEMBLY . . . . . . 33
CONTROL BOOK AND CERTIFICATE . . . . . . . . . . 3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 33
CRITICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 5
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CRITICAL MECHANICAL COMPONENTS . . . . . . . 5
CRITICAL STRUCTURAL COMPONENTS . . . . . . . 5 CABLE DRUM LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . 35
CRITICAL RIGGING COMPONENTS . . . . . . . . . . . 5
PCMĆ120SS STRUCTURAL REPAIRS . . . . . . . . . . . . 37
PCMĆ120SS MACHINERY HOUSE AND WINCH WELDING REQUIREMENTS . . . . . . . . . . . . . . . . . . 37
INSTALLATION - BOOM, MAIN HOOK AND
STRUCTURAL MATERIALS . . . . . . . . . . . . . . . . . . . 37
AUXILIARY HOOK ASSEMBLIES . . . . . . . . . . . . . . . . 7
STRUCTURAL REPAIR PROCEDURES . . . . . . . . . 37
MACHINERY HOUSE DESCRIPTION . . . . . . . . . . . 7
PCMĆ350SS/120SS ELECTRIC DECK CRANE
PCMĆ120SS COLUMN AND SWING TABLE . . . . . . . 9
PAINT RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 39
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 9
MATERIALS AND EQUIPMENT
INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 9 RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . 39
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . 39
PCMĆ120SS TURNTABLE ROLLER ASSEMBLY . . 13 PAINT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 40
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13 POST PAINT INSPECTION AND SERVICES . . . . . 40
REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13 LIST OF ILLUSTRATIONS
FIGURE Page
PCMĆ120SS SWING GEAR UNIT ASSEMBLY . . . . . . 15
1 MACHINERY HOUSE AND WINCH
SWING GEAR UNIT DC MOTOR . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 8
SWING GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 INNER COLUMN AND SWING TABLE . . . . . 10
PCMĆ120SS GANTRY ASSEMBLY . . . . . . . . . . . . . . . 19 4 SWING TABLE ROLLER ADJUSTMENT . . . 14
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 5 SWING GEAR UNIT ASSEMBLY . . . . . . . . . . 16
INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 19 6 GANTRY GROUP - PCM 120 . . . . . . . . . . . 20
REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 19 7 BOOM AND AUXILIARY HOIST - PCM 120 27
PCMĆ120 BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . 25 8 BOOM TIP INSTALLATION WITH

AUXILIARY HOIST - PCM 120 . . . . . . . . . . . 29
BOOM DISASSEMBLY AND REMOVAL . . . . . . . . . 25
9 BOOM GROUP WITH AUXILIARY HOIST
BOOM INSPECTIONS AND SERVICES . . . . . . . . . 25 PCM 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BOOM REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 25 10 FLOATING SHEAVE HOUSING ASSEMBLY 32
11 MAIN HOOK AND BLOCK ASSEMBLY -
PCMĆ120SS GANTRY SHEAVE HOUSING
PCM 120 (50ĆTON) . . . . . . . . . . . . . . . . . . . . . 34
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
12 LOCK PIN MOUNT STRUCTURE
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION - PCMĆ120SS . . . . . . . . . . . 36
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
COPYRIGHT 2002
LeTourneau, Inc. 1
1ĆROM 1.2a, 120SS (Gorilla)
4/20/99
PCM 120SS ELECTRIC DECK CRANE STRUCTURAL COMPONENTS PUBLICATION ROMĆ1

Publication ROSĆ1, STRUCTURAL COMPONENTS, is to
assist maintenance personnel and operators in the Place a DO NOT OPERATE sign on the
location, inspection, adjustment and repair or replaceĆ controls of the machine and secure the
ment of the various structural components of the crane. controls before performing any maintenance
or repair operations. Serious injury or death is
NOTE possible if the machine is started or moved
while maintenance or repair operations are
In several places in this publication, the terms being conducted.
certification of the crane and its components.
NEVER remove the DC drive motors access
covers unless the electrical system is turned
off, locked out, and grounded. Contact with
al standing or who by extensive knowledge,
high voltage terminals inside the motors will
training, and experience, has successfully
result is serious injury or loss of life.
demonstrated the ability to solve or resolve
problems relating to the subject matter and
work.
NOTE BEFORE attempting to disassemble any of the

major components of the machine BE SURE to
Mandatory rules of this publication per provide hoists or cranes and lifting devices of
ANSI/ASME are characterized by the word adequate capacity and height.
SHALL." If a provision is of an advisory NEVER stand under or place any body part
nature, it is indicated by the word under components while hoisted. Serious
SHOULD" and is recommended to be considĆ injury, loss of life could result in the event of an
ered, the advisability of which depends on the accident.
facts in each situation.
! CAUTION
WARNINGS AND CAUTIONS To prevent injury, wear hard hat, protective
glasses and other protective equipment as
Before any inspections or repairs are performed to the required by job conditions. ALWAYS wear
structural components of the crane it is critically gloves when handling wire rope.
important to read and comply with the following
warnings and cautions. These warnings and cautions ! CAUTION
will not be reiterated in the following text:
When inspecting or performing maintenance the PARTS CATALOG to order replacement
or repair operations on elevated structures of signs.
the crane, NEVER proceed beyond the safety
of handrailed platforms. Serious injury or loss ! CAUTION
of life from falling is possible outside these
areas. BEFORE welding on any structural members
of the machine refer to Publication LETĆ1,
Ladders and catwalks attached to the crane FIELD WELDING PROCEDURES, located in
are designed for servicing of the crane only the back of Section 1, of the REPAIR AND
while the crane is stopped. No personnel are OVERHAUL MANUAL. Serious damage to
allowed on any structure of the crane during electrical and electronic controls is possible
operation. Serious injury or loss of life could unless precautions described in this publicaĆ
result from falling or crushing. tion are adhered to.
COPYRIGHT 2002
2
LeTourneau, Inc.
4/20/99
PUBLICATION ROMĆ1 PCM 120SS ELECTRIC DECK CRANE STRUCTURAL COMPONENTS
CRANE TESTING, EXAMINATION, AND CERTIFICATION

The following general guidelines for the testing, exĆ Register (Control Book Ć ILO Form No. 1). A copy of this
amination and certification of the crane are included to certificate may be requested by the certifying authority.
alert the deck supervisor, operator and maintenance
personnel of these requirements and the CRITICAL ANNUAL EXAMINATIONS
IMPORTANCE of these procedures for the continued
safe operation of the crane. Cranes shall undergo a thorough examination at least
every twelve (12) months by a competent person, or
NOTE more frequently if required by the certifying authority.
It is the responsibility of the deck supervisor, a. STRUCTURAL INSPECTION

crane operator, and maintenance personnel to The annual thorough inspection shall comprise control
make sure the applicable tests and certificaĆ and function testing of the crane as well as visual control
tions required by the certifying authority under of elongation, wear and tear, corrosion, cracking and
which the crane is being operated are met. It is formation of fractures, etc. The examination shall be
also the responsibility of the above personnel carried out in such a way that it, as far as possible, will
to have the required documentation of these give a reliable knowledge of the safety of the examined
tests, examinations, and certification on hand components.
and in the format required by the certifying
authority. There are many different certifying b. INSPECTIONS FOR OVERLOADED CRANE
authorities worldwide and these guidelines A crane which has been exposed to a load moment
should not be considered all inclusive. exceeding 110% of the permitted load moment (includĆ
Certifying authorities may have the power to ing maximum calculated for dynamic load) shall be
impose fines and harsher penalties for willful thoroughly examined by a competent person before it is
or neglect violations of crane testing, again taken into use.
examination, and certification.
CONTROL BOOK AND CERTIFICATE
SURVEY AND APPROVAL
The results of initial testing, tests and examinations
Before a crane is, or crane components are, first taken every four (4) years as well as the annual examinations
into use, and later every four (4) years, a competent and all kinds of tests and examinations after repairs or
person shall have controlled constructions and calculaĆ alterations of the crane or hoisting gear, shall be entered
tions, carried out testing and examination of strength, in the Control Book (ILO Form No. 1). All controls, crane
quality of materials, workmanship and structural design functions and safety devices shall be inspected and
as well as certification in connection with this in tested annually and when found to function properly the
compliance with the requirements of the certifying results shall be entered into the Control Book. The entry
authority. shall be written by the competent person who carried
After the crane has been tested and thoroughly out the inspection and the examination. Control Book
examined with a satisfactory result by a qualified and Certificate shall both be kept on board. The Control
person, a certificate will be issued. The original test Book and certificate shall be available for the surveyor of
certificate shall be filed on board with the Cargo Gear the certifying authority.
COPYRIGHT 2002
LeTourneau, Inc. 3
4/20/99
COPYRIGHT 2002
4
LeTourneau, Inc.
4/20/99
CRITICAL COMPONENTS
The following is a list of components of the crane which CRITICAL STRUCTURAL COMPONENTS
should be considered as critical components." These
a. Boom chord members
components are ones which affect the safety of the
crane from a structural and load hoisting standpoint. b. Boom section connection components
These components should be of prime concern to the c. Boom foot pins
deck supervisor, operator and maintenance personnel
with regards to certification, inspection, maintenance d. Primary load members of gantries, masts and
and prompt repair per the appropriate guidelines. AĆframes
e. Load transfer members of the rotating upper
CRITICAL MECHANICAL COMPONENTS structure
a. All lines and linkage between the brake control f. Pedestal and swing circle transition pieces
element and the component to be controlled.
CRITICAL RIGGING COMPONENTS
b. Hoist, boom, and swing brake systems
a. All running wire ropes in hoist system
c. Drums, shafts, and gears of hoisting and swing b. All standing wire rope in load restraint and support
systems system
d. Swing bearing and gear c. Hook block assembly
e. Wire rope sheaves and sheave shafts d. Wire rope deadĆend connection devices
f. Electric drive motors for hoists, boom, and swing e. Floating harness or bridle assemblies
COPYRIGHT 2002
LeTourneau, Inc. 5
4/20/99
COPYRIGHT 2002
6
LeTourneau, Inc.
4/20/99
PCMĆ120SS MACHINERY HOUSE AND WINCH INSTALLATION

BOOM, MAIN HOOK AND AUXILIARY HOOK ASSEMBLIES
The PCMĆ120SS Electric Deck Crane is equipped with a NOTE
Winch Housing Assembly positioned on the side of the
Machinery House. The Winch Housing Assembly
consists of three major parts; the Boom Gear Drive Refer to the Troubleshooting guide in
Assembly, the Hook Gear Drive Assembly, and the Section 4 for information concerning the
Auxiliary Gear Drive Assembly. location of malfunctioning or damaged
electrical, electronic or mechanical compoĆ
nents.
Refer to WARNINGS AND CAUTIONS,

page 2, before performing any inspection or REMOVAL OF WINCH HOUSING
repair to the structural members of the crane.
ASSEMBLY DC DRIVE MOTORS AND
MACHINERY HOUSE DESCRIPTION DRIVERS
Access to the Machinery House and the electrical
It is necessary to remove the driver and DC motor for
control components, swing and hoisting machinery can
any of the Winch Housing Drive Assemblies to work on
be gained through the access door. A ventilation and
either the driver unit or motor except for minor repair or
service hatch is provided for cooling and maintenance
adjustments.
servicing. This compartment contains the Solid State
control components, relay switches, transformers, fuse
Instructions are provided in Section 2, DC MOTORS, for
boxes and other switch gear of the crane. Refer to the
an inĆplace inspection of the DC drive motors. InstrucĆ
PARTS CATALOG for location of specific control deĆ
tions are provided in Section 7, DRIVERS, for an inĆplace
vices.
inspection of the drivers' internal components and the
subsequent removal of a DC drive motor and driver as a
unit if the inspections warrant removal.
Due to the presence of potentially injurious

conditions, only qualified personnel should ! CAUTION
enter the Machinery House. Before attempting
to work on a component, make sure all Under no circumstances should the owner
electrical power is turned off and locked out attempt to disassemble the driver past the
and a DO NOT OPERATE sign is attached to removal of the cover during the inĆplace
the controls. Also, station an operator at the inspection. This is especially important if the
remote control operator's console or in the driver is in warranty. Unauthorized disassemĆ
cab if energized tests of the components are bly will void the warranty.
made.
COPYRIGHT 2002
LeTourneau, Inc. 7
4/20/99
1 3
2 4
1 3
5
3
1. CABLE DRUM STR.

2. BOLT
3. NĆ3 DRIVER
4. OĆRING
5. NĆ9 MOTOR
6. MACHINERY HOUSE
7. SWING TABLE
8. CAPSCREW
FIGURE 1. MACHINERY HOUSE AND WINCH INSTALLATION

COPYRIGHT 2002
8
LeTourneau, Inc.
4/20/99
PCMĆ120SS INNER COLUMN AND SWING TABLE ASSEMBLY

The Column and Swing Table Assembly is the turn table NOTE
and outer column structure which allows the crane to
rotate around the inner column and gear structure. Use care to prevent damage to grease seals,
Refer to Figure 2. bearings and spacer.
DISASSEMBLY PROCEDURES INSPECTIONS AND SERVICES

a. Thoroughly clean all bearings, bearing spacers,
grease seals and capscrews.
b. Examine for burrs, nicks and dress out.
page 2, before performing any inspection or NOTE
Small burrs and nicks can be dressed out, but
NOTE damaged or worn bearings and bushings
must be replaced.
A suitable hoisting device such as an auxiliary
crane will be required for disassembly and c. Examine bearings, spacers and grease seals.
reassembly procedures. Replace if damaged or worn.
a. Tighten (8) bolts, 4 in the Outer Column Structure d. Use proper lubricant on bearings, spacers and
and 4 in the Swing Table. These bolts are used to grease seals as prescribed PCM CRANE LUBRICATION
support and keep the Swing Table Assembly centered. SPECIFICATIONS, Publication OSMĆ4, Figure 1,
located in the OPERATING AND SERVICE MANUAL.
! CAUTION
REASSEMBLY
It is essential to install eight 1Ć1/4" UNF bolts,
a. Install bearings, spacer and grease seals in
as shown on Figure 3, Item (1), to support and
bearing hub.
keep the swing table centered. The bolts
should be installed four in the swing table and NOTE
four in the column structure. Failure to install
the bolts could result in damage to the crane Use care to prevent damage to grease seals
and a potentially hazardous situation. during reassembly and installation.
b. Remove (6) bolts holding seal cap to spindle on b. With a suitable hoisting device, position upper
top of inner column and gear structure. bearing assembly over spindle.
c. Remove (24) bolts that retain the upper bearing c. Remove the three jacking screws from the bearing
assembly to the Swing Table. DO NOT reuse these hub.
bolts.
d. Bolt seal cap to spindle. Refer to the CAPSCREW
d. Using (3) of the bearing hub bolts, jack entire TORQUE CHART, located in the appendix of this manual
upper structure assembly from spindle, using tapped for the proper torque.
holes in the bearing hub.
e. Relieve tension on lineĆup bolts.
e. With a suitable hoisting device, lift the upper
f. Recheck torque on bearing hub and seal cap
bearing assembly from spindle.
bolts.
NOTE NOTE
BE SURE the hoisting device is adequate and
Check to be sure lineĆup bolts have been
that the Swing Table Assembly is secured to
backed off enough to prevent any interference
the inner column structure with the lineĆup
in the cranes rotation.
bolts.
g. Refill upper bearing assembly with proper lubriĆ
f. Remove the two grease seals from the bearing
cant through pipe on side of bearing hub. Refer to the
hub.
PCM CRANE LUBRICATION SPECIFICATIONS, Figure
g. With a suitable tool, drive the thrust bearing, 1 in Publication OSMĆ4, located in the OPERATING AND
bearing spacer and roller bearing out of bearing hub. SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc. 9
4/20/99
1 2
3
4
12
5
6
11
13 9
10
18
17 17
16 16
14
19
15 20
21
22
27
28 23
29
24
30
21
31
25
26
32
FIGURE 2. INNER COLUMN AND SWING TABLE

1ĆNGOĆ2265, P12Ć34 TAĆ8992ĆCG
COPYRIGHT 2002
10
LeTourneau, Inc.
4/20/99
INNER COLUMN AND SWING TABLE
1. OIL LEVEL GAUGE

2. PIPE CAP
3. PIPE NIPPLE
4. ELBOW
5. BOLT
6. TUBE STR.
7. BOLT
8. SEAL CAP
9. BOLT
10. BEARING HUB
11. NIPPLE
12. ELBOW
13. MACHINERY HOUSE
14. OUTER COLUMN STR.
15. BOLT
16. LOCKWASHER
17. BOLT
18. GREASE FITTING
19. RETAINER PLATE
20. ROLLER PIN
21. OIL SEAL
22. ROLLER
23. BEARING ASSY.
24. RETAINER
25. SPACER & SEAL RETAINER
26. RETAINER
27. BOLT
28. THRUST BEARING
29. BEARING SPACER
30. ROLLER BEARING
31. GREASE SEAL
32. INNER COLUMN STR.
COPYRIGHT 2002
LeTourneau, Inc. 11
4/20/99
4 1
2 3 1 4
1 1
1. BOLT, 1Ć1/4" UNF 5. ELBOW STR.

2. SWING TABLE 6. WIRE TUBE STR.
3. INNER COLUMN STR. 7. UPPER BEARING ASSY.
4. BOLT, 1" UNF
FIGURE 3. PCMĆ120SS SWING BEARING REPLACEMENT - UPPER COLUMN ASSEMBLY

1ĆNGOĆ2264, P10Ć60 TAĆ9488ĆS8
COPYRIGHT 2002
12
LeTourneau, Inc.
4/20/99
PCMĆ120SS SWING TABLE ROLLER ASSEMBLY
The Swing Table Roller Assembly, located on the bottom NOTE
of the outer column allows the crane to rotate. Refer to
Figure 2. Small burrs and nicks can be dressed out, but
damaged or worn bearings and bushings
DISASSEMBLY PROCEDURES must be replaced.
c. Examine oil seals, rings and retainers. Replace if
damaged or worn.
Refer to WARNINGS AND CAUTIONS, page 2, REASSEMBLY PROCEDURES

before performing any inspection or repair to a. Install bearings, bushings and oil seals. Lubricate
the structural members of the crane. bearings.
NOTE NOTE
A suitable hoisting device such as an auxiliary Use care to prevent damage to oil seals during
crane will be required for disassembly and reassembly and installation.
reassembly procedures.
b. With Swing Table Roller Assembly completely
a. Reduce load on the rollers by removing the boom
together, use a suitable hoisting device to position roller
or raising the boom to its maximum UP position.
assembly into the roller housing structure.
b. Remove the capscrews and bolt retainer pads on
c. Install all rollers with the dimple on the roller flange
top of the roller assembly.
closest to the column.
c. With proper hoisting device lift out the entire Swing
Table Roller Assembly. NOTE
NOTE The dimple indicates the high side of the roller
pin.
Be sure that a suitable such as an auxiliary
crane is used and that the Swing Table Roller d. Adjust all rollers out until they touch the swing gear.
Position of the rollers can be seen through the viewing
Assembly is well secured to it.
access hole next to the roller flange.
d. Remove the oil seal and oil seal ring from under the
bearing and remove the bearing roller from the bearing NOTE
pin.
Large adjustment is made by rotating the
e. Remove the bearing and roller off the bearing pin. roller flange independently of the retainer
f. Remove oil seal holder, oil seal and oil seal ring pad. Smaller adjustment can be made using
from bearing pin. the slotted holes of the retainer pad.
NOTE e. Using a feeler gauge between the rollers and the

swing gear, adjust the three nonĆloaded rollers in,
Use care to prevent damage to oil seal, rings, leaving a .020 inch gap between the roller and the gear.
holder, bearing and rollers. f. Secure the bolt retainer pads to roller flanges and
roller table.
INSPECTIONS AND SERVICES
g. Place grease fitting on top on the pin roller and
a. Thoroughly clean all bearings, rollers, oil seals, lubricate the bearing thoroughly in accordance with
rings, pins, capscrews, magnetic particle test all pins Figure 1, PCM LUBRICATION SPECIFICATIONS, PubliĆ
and rollers. cation OSMĆ4, located in the OPERATING AND SERĆ
b. Examine for nicks, burrs and dress out. VICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc. 13
1ĆROM 1.2b, 120SS (Gorilla)
4/20/99
THREADED LIFTING EYES
PRYBAR
ROLLER
ACCESS
HOLE
SWING GEAR
FEELER GAUGE
.020”
FIGURE 4. SWING TABLE ROLLER ADJUSTMENT

1ĆCGĆ1845, P10Ć52 TAĆ8981ĆP
COPYRIGHT 2002
14
LeTourneau, Inc.
1ĆROM 1.2b, 120SS (Gorilla)
4/20/99
PCMĆ120SS SWING GEAR UNIT ASSEMBLY

The Swing Gear Unit Assembly controls the rotation of especially wound to provide maximum output throughĆ
the crane and is powered by a SĆ1A, DC motor driving out the full range of motor speed. A multiple disc friction
through a #5 gearbox assembly mounted out from the type spring applied electroĆmechanically released SCR
Swing Table and King Pin Structure. The Swing Gear powered motor brake is an integral part of the motor.
Unit output shaft operates on the round gear rack of the Refer to Section 2 for disassembly, inspection, repair
Swing Table to obtain crane rotation. Refer to Figure 5 and reassembly procedures for the DC swing motor.
for an illustration of the components of the Swing Gear Also, refer to the LeTourneau, Inc. Publication TAKING
Unit Assembly. CARE OF YOUR DC MOTOR, located in the back of
Section 2 for additional information on maintenance,
troubleshooting and repair of DC motors.
SWING GEAR UNIT DC MOTOR
The Swing Gear Unit DC motor when used in conjuncĆ
SWING GEARBOX
tion with the LeTourneau, Inc. power and control system Refer to Section 6, Gearboxes, for information concernĆ
provides the operator with a wide range of control of ing the disassembly, repair and replacement and
motor speed and output power. These motors are reassembly procedures for the # 5 gearbox assembly.
COPYRIGHT 2002
LeTourneau, Inc. 15
1ĆROM 1.2c, 120SS (Gorilla)
4/20/99
2 18
5
19
17
16 6
15
8 9
14
10
13
12
11
FIGURE 5. SWING GEAR UNIT ASSEMBLY

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LeTourneau, Inc.
4/20/99
SWING GEAR UNIT AS SEMBLY
1. LID STRUCTURE
2. TOGGLE LATCH
3. OĆRING
4. BOLT
5. LOCKWASHER
6. OĆRING
7. SĆ1A DC MOTOR
8. BOLT
9. BOLT
10. WASHER BAR
11. LOCKNUT
12. #5 SWING GEARBOX
13. LOCKWASHER
14. BOLT
15. TERMINAL TUBE
16. TERMINAL TUBE
17. COVER STRUCTURE
18. MACHINERY HOUSE
& WINCH GROUP
19. SWING TABLE GROUP
COPYRIGHT 2002
LeTourneau, Inc. 17
4/20/99
COPYRIGHT 2002
18
LeTourneau, Inc.
4/20/99
PCMĆ120SS GANTRY ASSEMBLY

The PCMĆ120SS Electric Deck Crane is equipped with a a. Remove bolts, keeper plates and pins from the top
rigid steel pipe assembly that is pinned to the Swing of the boom stop support. Remove bolts, keepers and
Table Structure. The Gantry Sheave Housing Assembly pins from back of boom stop assembly. Hoist Boom
is pinned to the top of the Gantry Structure to give Stop Structure away.
proper fleet angle. The Boom Positive Stop is pinned to b. Remove bolts, keeper plates and pins from base of
the Gantry Structure to stop the boom at a minimum boom stop support and hoist it away.
radius. Refer to Figure 6 for an illustration of the
components of the Gantry Assembly. c. With a suitable hoisting device secured to the top
of the front Gantry Structure, remove bolts, keeper
plates and pins from the top and bottom of the Rear
Gantry and pins from the top and bottom of the Rear
Gantry Structure and hoist away.
Refer to WARNINGS AND CAUTIONS, page 2
before performing any inspection or repair to d. Remove bolts, keeper plates and pins from base of
the structural members of the crane. Front Gantry Structure and hoist away.
NOTE INSPECTIONS AND SERVICES

A suitable hoisting device such as an auxiliary Thoroughly clean all pins, nuts and bolts with a suitable
crane will be required for disassembly and solvent and allow to air dry. Any worn parts should be
reassembly procedures. replaced.
DISASSEMBLY NOTE
Place boom in boom rest, and with a suitable hoisting All shafts and gears must be magnetic particle
device, remove the Gantry Sheave Housing Assembly. tested.
NOTE REASSEMBLY PROCEDURES

Refer to GANTRY SHEAVE HOUSING ASĆ To reassemble the Gantry Assembly, reverse the
SEMBLY, page 23. procedures in DISASSEMBLY, above.
COPYRIGHT 2002
LeTourneau, Inc. 19
4/20/99
2
1 3
25
7 6
2
24
1
7 4
5
23 7 6
22 2
1
21
20
16 17
18
17
15
15 6
7
1
2
19 8
14 10 6
6
11
13 12
FIGURE 6. GANTRY GROUP - PCM 120

COPYRIGHT 2002
20
LeTourneau, Inc.
4/20/99
GANTRY GROUP - PCM 120
1. BOLT
2. LOCKING BAR
3. PIN
4. R.H. VERTICAL GANTRY STR.
5. L.H. VERTICAL GANTRY STR.
6. PIN
7. PIN
8. CENTER PIPE STR.
9. FRONT GANTRY STR.
10. BOLT
11. GREASE FITTING
12. BOLT
13. BEARING RETAINING
14. SHEAVE PIN
15. SPACER
16. SHEAVE
17. SEAL
18. BEARING
19. SPACER
20. SUPPORT STR. - SHOCK
21. PIN
22. PUSHER STR.
23. SPRING
24. BOLT
25. BOOM STOP SUPPORT STR.
COPYRIGHT 2002
LeTourneau, Inc. 21
4/20/99
COPYRIGHT 2002
22
LeTourneau, Inc.
4/20/99
PCMĆ120SS GANTRY SHEAVE HOUSING ASSEMBLY

The Gantry Sheave Housing Assembly is made up of NOTE
three (3) sheave wheels and four (4) divider plates. Its
function is to assist in the raising and lowering of the Small burrs and nicks can be dressed out, but
boom. Refer to Figure 6 for an illustration of the Gantry damaged or worn bearings and bushings
Sheave Housing Assembly. must be replaced.
NOTE
Sheaves and sheave wheel pins are to be
magnetic particle tested.
Refer to WARNINGS AND CAUTIONS, page 2,
before performing any inspection or repair to REASSEMBLY
the structural members of the crane.
a. Reassemble and lubricate wheel bearing assemĆ
NOTE blies.
b. Insert bearing assembly and spacer into first
A suitable hoisting device such as an auxiliary wheel. Put wheel into position between spacers and
crane will be required for disassembly and slide sheave wheel pin through spacers, wheel bearing
reassembly procedures. and wheel.
c. Repeat procedure in Step b" until all wheels,
DISASSEMBLY bearing assemblies and spacers are in place and the
sheave wheel pin is all the way through the sheave
a. With a suitable hoisting device attached, remove
divider plates.
the pin retainers and pin from the Gantry Sheave
Housing Assembly. This will allow the whole Gantry d. Replace retainer plates with three (3) 1/2Ćinch bolts
Sheave Housing Assembly to drop down. each side of sheave wheel pin. Refer to the CAPSCREW
TORQUE CHART in the appendix of this manual for the
b. Remove the square nuts, pins and pipe spacers. proper torque.
NOTE e. Replace sheave housing pin and at the same time
replace the three (3) spacer pipes, one between each
Only one sheave housing pin needs to be sheave housing plate. Replace square nuts on sheave
removed and if the back pin is removed a housing pins. Refer to the CAPSCREW TORQUE
complete inspection of all wire ropes can be CHART in the appendix of this manual for the proper
made. torque.
c. Remove bolts and retainer plates on sheave wheel NOTE

pin. Remove pin with caution.
Make sure all wire ropes are in proper order.
! CAUTION f. With a suitable hoisting device, raise Gantry
Sheave Housing Assembly up and connect back to top
In removing the sheave wheel pin, care should of gantry with the gantry hinge pin. Replace keeper
be taken not to drop or damage the sheave plates with two (2) 5/8Ćinch bolts in the end of each pin.
wheels, wheel bearings and spacers. Tighten bolts. Refer to the CAPSCREW TORQUE
CHART, in the appendix of this manual for the proper
INSPECTIONS AND SERVICES torque.
g. Lubricate bearing assemblies through the grease
a. Thoroughly clean all parts to the Gantry Sheave
fitting on the end of the sheave wheel pin as specified in
Housing Assembly.
Figure 1, PCM CRANE LUBRICATION SPECIFIĆ
b. Inspect all pins, wheels, bearings and spacers. CATIONS, in Publication OSMĆ4, located in the OPERĆ
Replace if damaged or worn. ATING AND SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc. 23
4/20/99
COPYRIGHT 2002
24
LeTourneau, Inc.
4/20/99
PCMĆ120SS BOOM ASSEMBLY

The PCMĆ120SS Electric Deck Crane is equipped with a g. Spool boom wire rope onto the cable drum.
rigid steel boom made up of four sections. The lower
h. Attach suitable hoisting device to boom structure
structure is 20 feet in length. There are two middle
and lower to a prepared work surface. Remove locking
sections; one of 40 feet and one of 20 feet in length. The bars, base pins, and self aligning bushings.
upper boom section is 20 feet in length. Sections are
connected using bolt plates, bolts and nuts. Each joint i. In succession, remove the capscrews and nuts
of the boom has a male and a female fit for additional that hold the upper, middle and lower boom sections
safety. Refer to Figures 7, 8 and 9 for illustrations of the together and remove each with a suitable hoisting
Boom Assembly. device.
j. Remove pin retainers, sheave pins, bearings and
30Ćinch sheave wheels from boom tip and boom tip
extension structure.
Refer to WARNINGS AND CAUTIONS, page 2, k. Remove cotter pin and sheave pin from guide
before performing any inspection or repair to sheave housing assembly.
the structural members of the crane.
l. Remove bolts, lockwashers and lock plate from
NOTE guide sheave housing assembly and drive out sheave
housing pin. Remove the 22Ćinch sheave wheel.
A suitable hoisting device such as an auxiliary Remove bearing seal and bearing assembly.
crane will be required for disassembly and
reassembly procedures. BOOM INSPECTIONS AND SERVICES
BOOM DISASSEMBLY AND REMOVAL a. Thoroughly clean all bearings, bushings, spacers,
nuts, pins and grease fittings in a solvent and allow to air
a. Hoist the Main Hoist and Auxiliary Hoist Hook dry.
(optional) and block assemblies close enough to the tip
to prevent the wire ropes from fouling when the boom is b. Inspect all components for excessive wear and/or
lowered. damage. Replace or repair when necessary.
b. Above a flat working surface, lower the boom until
the tip almost touches.
! CAUTION Replace ALL nuts and bolts for boom

connections every four years of operation,
DO NOT lower the boom below a parallel with
also bolts and nuts are to be replaced if any
the base of the boom. Do not let the tip touch
boom sections must be replaced. Failure to
the deck surface because it might bend or
comply with this instruction could result in
damage the boom structure.
serious injury or death and damage to the
c. Remove the Main Hoist Hook and Block Assembly crane.
and the Auxiliary Hoist Hook and Block Assembly
(optional). NOTE
d. Spool Main Hook and Auxiliary Hook (optional) ALL pins and critical welds are to be magnetic
lines on to the drums. particle tested.
e. With a suitable lifting device, lower the Floating
Sheave Assembly on top of boom and secure. BOOM REASSEMBLY
f. Remove boom wire rope dead end for gantry To reassemble the Boom Assembly, reverse the proceĆ
sheave assembly. dures in Boom Dissassembly and Removal, above.
COPYRIGHT 2002
LeTourneau, Inc. 25
4/20/99
COPYRIGHT 2002
26
LeTourneau, Inc.
4/20/99
1 2 3 4 5 6
12 13 19
20 20
14 22
11 21
18 A
10
16 15
21 18
9
17
7
A
VIEW - D
VIEW – A
8 VIEW – B
VIEW – C
SECTION A-A
C
B B
1 2 3 4 5
6
1. BOOM BASE STR. 7. PLATE 12. BOLT 17. IDLER MOUNT STR.
2. BOOM MID SECTION, 40 FT. 8. BOLT 13. NUT 18. BASE PIN
3. BOOM MID SECTION, 20 FT. 9. CAP PLATE 14. IDLER 19. BUSHING
4. BOOM TOP STR. 10. GREASE FITTING 15. WASHER 20. LOCK BAR
5. CABLE SHEAVE INSTALLATION 11. LUFFING CABLE 16. NUT 21. BOLT
6. BOOM TIP EXTENSION STR. 22. SLEEVE
FIGURE 7. BOOM AND AUXILIARY HOIST - PCM 120

1ĆCGĆ1860, LdgrĆ22 TAĆ8999ĆCG
1ĆROM 1.2, FOĆ1, 120SS (Gorilla)

4/20/99
COPYRIGHT 2002 27
LeTourneau, Inc.
COPYRIGHT 2002
28
LeTourneau, Inc.
4/20/99
11 12 14
1 2
5
6 4
3
7 16
13
12
11
12
5 14 4
13
12
5
6 11
7 17
6
4
8
7
16
6 9
5 4
10
7 5
6
4
15 4 11
6 12
13 14
12 11
5
12 13
7
14
11
12
14
13
12
11 12
11
1. BOLT 6. GREASE FITTING 10. GREASE FITTING 14. SHEAVE

2. LOCKWASHER 7. BOLT 11. BOLT 15. SHEAVE PIN
3. TOP PLATE 8. PLATE 12. PLATE 16. SHEAVE PIN
4. PIN RETAINER 9. PLATE 13. PLATE 17. BOOM TIP EXT. STR.
5. BOLT
FIGURE 8. BOOM TIP INSTALLATION WITH AUXILIARY HOIST - PCM 120
COPYRIGHT 2002
LeTourneau, Inc. 29
4/20/99
2
1
10
4
5
5
9
7
1. BRIDLE LINE ASSY. 8

2. WIRE ROPE ASSY.
3. SINGLE SHEAVE DYNAMETER
4. MAIN HOOK LINE ASSY.
5. ANTI TWOĆBLOCK SENSOR
6. CLAMP
7. OPEN WEDGE SOCKET
8. OVERHAUL BALL ASSY.
9. HOOK & BLOCK ASSY.
10. LINE LOAD CELL
FIGURE 9. BOOM GROUP WITH AUXILIARY HOIST - PCM 120

COPYRIGHT 2002
30
LeTourneau, Inc.
4/20/99
PCMĆ120SS FLOATING SHEAVE HOUSING ASSEMBLY

The Floating Sheave Housing Assembly is a pulley NOTE
made up of three (3) 30Ćinch sheave wheels. Its function
is the raising and lowering of the crane's boom. Refer to Magnetic particle tests should be conducted
Figure 10 for an illustration of the components of the on all critical welds and pins during
Floating Sheave Housing Assembly. disassembly or every four (4) years.

a. Thoroughly clean all parts of the Floating Sheave
Housing Assembly.
Refer to WARNINGS AND CAUTIONS, page 2,
before performing any inspection or repair to b. Inspect all pins, wheels, bearings and spacers.
the structural members of the crane. Replace if damaged or worn.
NOTE
NOTE
Small burrs and nicks can be dressed out, but
A suitable hoisting device such as an auxiliary damaged or worn bearings and bushings
crane will be required for disassembly and must be replaced.
REASSEMBLY
DISASSEMBLY a. Reassemble and lubricate wheel bearing assemĆ
blies.
a. Lower the Floating Sheave Housing Assembly into
the cradle provided on the top of the boom. Remove the b. Insert bearing assemblies and spacers into
two (2) 1/2Ćinch bolts and retainer plate that holds the sheave wheels. Put into position and slide sheave wheel
bridal connector pin in place. With proper hoisting pin through spacers, wheel bearings and sheave
device remove pin. wheels.
c. Replace the retainer plates and 5/8Ćinch bolts.
b. Lower Floating Sheave Housing Assembly to a
Refer to the CAPSCREW TORQUE CHART in the
prepared working surface.
appendix of this manual for the proper torque.
c. Remove the square nuts, bolts and pipe spacers d. Replace spacers and sheave housing pins, one
that hold the 4 side and inner plates together. spacer between each sheave housing plate. Replace 2
inch square nuts.
NOTE
NOTE
Only one sheave housing pin needs to be
removed and if the back pin is removed a Make sure all wire ropes are in proper order.
complete inspection of all wire ropes can be e. Replace bridle connector and secure into place
made. with bridal connector pin and spacers. Replace retainer
plates with 5/8Ćinch bolts. Refer to the CAPSCREW
d. Remove 5/8Ćinch bolts and retainer plates that
hold the sheave wheel pin. Remove pin with caution.
proper torque.
NOTE f. Lubricate bearing assemblies through the grease
fitting on the end of sheave housing wheel pin as
In removing the sheave wheel pin care should specified in Figure 1, PCM CRANE LUBRICATION
be taken not to drop or damage the sheave SPECIFICATIONS, in Publication OSMĆ4, located in the
wheels, wheel bearings and spacers. OPERATING AND SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc. 31
4/20/99
3
4
5
6
7
8
8 11
22 23
15 10
12
21 9 9
7
8
13
20
11
14
15
19
19 15
14
17
18
16
17
1. UPPER BRIDLE STR. 9. NUT 17. BEARING SPACER

2. LOWER BRIDLE STR. 10. RETAINER 18. BEARING
3. PIN 11. GREASE FITTING 19. BOLT
4. RETAINER 12. BOLT 20. CENTER PIN
5. BOLT 13. SHEAVE 21. PIN
6. SPACER 14. BEARING SPACER 22. SIDE PLATE
7. RETAINER PLATE 15. SPACER 23. INNER PLATE
8. BOLT 16. SEAL
FIGURE 10. FLOATING SHEAVE HOUSING ASSEMBLY

COPYRIGHT 2002
32
LeTourneau, Inc.
4/20/99
PCMĆ120SS HOOK AND BLOCK ASSEMBLY

The Hook and Block Assembly is in two parts. The Hook measure the same as original, if not, discard
Assembly itself and the Sheave Housing Assembly. The the hook.
Hook and Block Assembly is used for hoisting materials.
Refer to Figure 11 for an illustration of the components of REASSEMBLY
the Hook and Block Assembly.
a. In reassembling the Sheave Housing Assembly,
DISASSEMBLY first reassemble an lubricate all bearing assemblies.
a. Lower the Hook and Block Assembly to a prepared b. Insert bearing assemblies and spacers into the
working surface. first wheel. Put wheel into position between spacers,
bearing seals, wheel bearings and sheave wheel.
b. The Hook Assembly itself is disassembled by first
removing the keeper plates that retain the swivel block. NOTE
c. With a suitable hoisting device attached to the Outside sheave plates are wider than the two
Hook Assembly, remove the tie bolts and tie pins that divided plates, so the two wider bearings
hold the Sheave Housing Assembly together. spacers must go to the outside.
d. Remove the bolts that hold the retainer plates on
c. Place Hook Assembly between sheave housing
the sheave wheel pin. Remove the pin with caution.
plates.
NOTE d. Repeat procedure b" in this section until all
wheels, bearing assemblies, spacers and seals are in
In removing the sheave wheel pin, care should
place and the sheave wheel pin is all the way through
be taken not to drop or damage the sheave
sheave and divider plates.
wheels, wheel bearings, spacers, seals and
Hook Assembly. e. Replace sheave wheel pin retainer plates and
bolts. Refer to the CAPSCREW TORQUE CHART in the
e. Remove Hook Assembly to a prepared working
surface.
f. Replace sheave housing tie bolts and tie pins and
f. Remove the cotter pin and 4Ćinch hook nut and
at the same time replace the 3Ćinch spacer pipes. Refer
carefully remove the hook itself so as not to damage the
to the CAPSCREW TORQUE CHART in the appendix of
bearing assembly.
this manual for the proper torque.
g. Remove the bearing assembly.
NOTE
Make sure all wire ropes are in proper order.
a. Thoroughly clean all parts of the Hook and Block
Assembly. g. Lubricate bearing assemblies through the grease
fitting on the end of the sheave housing wheel pin as
b. Inspect all pins, wheels, bearing assemblies,
specified in Figure 1, PCM CRANE LUBRICATION
spacers and seals. Replace if damaged or worn.
SPECIFICATIONS, in Publication OSMĆ4, located in the
NOTE OPERATING AND SERVICE MANUAL.
h. Lubricate the hook thrust bearing located on the
Hook wheels and pins are to be Magnetic
side of the swivel bearing block as specified in Figure 1,
Particle Tested every four (4) years or if
PCM CRANE LUBRICATION SPECIFICATIONS, in PubĆ
disassembled, to A.P.I. 2C 1983.
lication OSMĆ4, located in the OPERATING AND SERĆ
NOTE VICE MANUAL.
i. Perform a No Load Test" prior to putting back in
Check crane hooks for deformation or cracks.
service.
Hooks will be discarded where cracks exist or
throat opening is 15 percent more than the NOTE
original throat opening. Hooks will also be
discarded where they are bent or twisted more The Auxiliary Hook Assembly is a vendor
than 10° from the plane of the original hook supplied item. Refer to the Parts Catalog for
configuration. The shank of the hook shall ordering information.
COPYRIGHT 2002
LeTourneau, Inc. 33
1ĆROM 1.2d, 120SS (Gorilla)
4/20/99
1
2
3
29 4 5
28
6 3
1
7
27
10
11
14
1
26 15
25
3 16
2
11
24
10
17
13
23
18 12
22
19
20
21
1. SPACER 8. RETAINER ROD 15. LOCKWASHER 22. FELT SEAL

2. KEEPER PLATE 9. SHEAVE 16. COVER STR. 23. NUT
3. BOLT 10. BEARING SPACER 17. COTTER PIN 24. OĆRING
4. BEARING RETAINER 11. BEARING SPACER 18. THRUST BEARING 25. TIE PIN
5. GREASE FITTING 12. SEAL 19. BEARING BLOCK 26. MOUNT PLATE
6. BOLT 13. BEARING 20. HOOK 27. SHEAVE PIN
7. NUT 14. BOLT 21. LATCH KIT 28. SIDE PLATE
29. DIVIDER PLATE
FIGURE 11. MAIN HOOK AND BLOCK - PCM 120 (50ĆTON)
COPYRIGHT 2002
34
LeTourneau, Inc.
4/20/99
CABLE DRUM LOCK PIN

The cable drums for the main and auxiliary hooks and should be installed anytime these operations or any
boom luffing are equipped with a safety lock pin mount other operation which requires the drum to remain
structure to prevent the cable drum from turning if the stationary are being conducted. Refer to Figures 12 for
brake is released for service or repair or if the DC drive illustrations of the lock pin mount structure for the PCM
motor must be removed. The pin for the applicable drum 120SS.
NOTES
COPYRIGHT 2002
LeTourneau, Inc. 35
4/20/99
A A
5
6 4
4
6
5
7
VIEW A-A
1. MACHINERY HOUSE
2. KING PIN & SWING TABLE STR.
3. CABLE DRUM STR.
4. LOCK PIN STR.
5. BOLT
VIEW B-B
6. LOCK PIN MOUNT STR.
7. BOLT
8. PLATE
FIGURE 12. LOCK PIN MOUNT STRUCTURE INSTALLATION - PC 120

1ĆNGOĆ1591, P10Ć31, 6/1/98 TAĆ8950ĆCG
COPYRIGHT 2002
36
LeTourneau, Inc.
4/20/99
PCMĆ120SS STRUCTURAL REPAIRS

The following instructions pertain to structural repairs of BOOM DIAGONAL PIPES: 3" XĆHVY. X .300 wall
the crane and welding procedures which relate to safety thickness and are made from AĆ53 Gr.B or equal.
and integrity of the load bearing members.
STRUCTURAL REPAIR PROCEDURES
WELDING REQUIREMENTS
Before any structural repairs are made magnetic
Certain materials are manufactured exclusively by particle and dye penetrant tests shall be conducted.
LeTourneau, Inc. Substitution of these materials is not to
be attempted without prior approval by LeTourneau, ! CAUTION
Inc. due to the possible incompatibility of alternate
BEFORE proceeding with any structural
materials. Should the owner desire, LeTourneau, Inc.
repairs and/or replacements, BE SURE that
will provide personnel and materials for repairs and/or
there is no load on the crane and power has
replacements if requested.
been disconnected from the crane.
Instructions for welding of LeTourneau, Inc. structural
steel are included in LeTourneau, Inc. Publication LeTĆ1, ! CAUTION
FIELD WELDING PROCEDURES, located in the back of
Section 1, in the REPAIR AND OVERHAUL MANUAL. It is It is essential to isolate the Load Moment
ESSENTIAL to review these procedures and contact Indicator system from the crane's electrical
both your distributor and LeTourneau, Inc. prior to system prior to welding repairs or damage will
attempting ANY structural repairs to this crane. Anyone result.
performing structural repairs to the crane shall meet the The boom should be supported in either the boom rest
following qualifications: or temporary supports.
NOTE NOTE
Anyone performing structural repairs to the No repairs and/or replacements shall be
crane shall meet the following qualifications: undertaken without prior approval from
American Welding Society Specifications for LeTourneau, Inc. and the certifying authority
Welding Machinery and Equipment ClassificaĆ under which the crane is operating. Any
tion and Application of Welded Joints for AWS repairs shall be witnessed by an attending
D14.4 Ć 77. surveyor of the certifying authority.
STRUCTURAL MATERIALS If emergency repairs and/or replacements are necesĆ

sary, the certifying authority shall be provided with a
COLUMN PLATES: 1" thick and made from NĆ20 BHT detailed description of the extent of the repair and/or
MAIN BOOM PIPES: 6Ć5/8" O.D. LET. X .375 wall replacement, materials and procedures used, plus any
thickness and are made from high strength steel other pertinent data, at the earliest possible time.
(70,000 minimum yield, 100,000 minimum tensile Arrangements shall also be made for an inspection by
charpy of 20 lb. at -40). the certifying authority's representative.
NOTES
COPYRIGHT 2002
LeTourneau, Inc. 37
4/20/99
NOTES
COPYRIGHT 2002
38
LeTourneau, Inc.
4/20/99

PAINTING RECOMMENDATIONS
These instructions cover surface preparation, coating b. EQUIPMENT RECOMMENDED
system and inspection requirements to be used in the Sandblast Equipment: Pangborn Blast System or
painting of LeTourneau, Inc. Electric Deck Cranes. The equivalent
recommended two coat system with two part inorganic
zinc silicate primer combats corrosion by the elimination Paint Equipment: Devilbiss Air Spray Gun - Model MBC
of rust creep" or undercutting of all blasted steel 510 with air cap AUĆ1239Ć704; 10 gallon Pressure Feed
surfaces including the crane's Machinery House, ColĆ Tank with Air Motor Agitator Q.S.A. 503 or equivalent
umn, Gantry, Boom and other structural components. NOTE
These instructions are minimal requirements for normal
conditions. Local conditions and overall condition of the Materials and equipment listed above are
crane's painted surfaces may require additional meaĆ used successfully by LeTourneau, Inc. in the
sures to ensure quality paint work. manufacturing process. Substitute items that
meet specifications listed are acceptable.
NOTE
SURFACE PREPARATION
Refer to paint manufacturer's specification
a. Securely seal the ventilator fan, access door and
sheets for physical properties, performance
any other place blasting sand or paint overspray might
limitations, additional instructions for surface
enter the Machinery House or Operator's Cab (optionĆ
preparation, application and safety precauĆ
al). Cover the glass and weatherstripping on the
tions specific to the application of their
Operator's Cab (optional). Use masking tape or other
products. Specification sheets for the original
suitable material to seal these areas.
equipment paint are provided at the end of this
article. b. Cover or remove the wire rope as necessary to
prevent contamination from blasting sand and paint.
! CAUTION c. Cover and seal the swing gear and swing pinion to
be sure no contamination from sand or paint occurs.
Surface preparation and painting requires
d. Protect any exposed electrical wiring or terminals
working in close proximity with chemicals and
from damage by sandblasting.
vapors which can cause skin and respiratory
injury. Read and follow all safety precautions e. Sandblast to a commercial blast clean finish
mentioned in paint manufacturers specificaĆ (almost near white) per Steel Structures Paint Council,
tions. Surface Preparation Specification SSPCĆSPĆ10Ć63T.
The grit size should be Mesh/U.S. Sieve Series and be
Also, follow these additional safety precauĆ clean, washed silica such as Lone Star #1 or equal.
tions: Nozzle velocity of the abrasive should not be less than
1. Wear the appropriate respirators, eye 100 psi.
protection and protective clothing to prevent
injury. Do not use solvents or thinners to clean ! CAUTION
skin. Use caution to not damage seals when
2. Do not smoke, eat or drink in the surface sandblasting in close proximity to swing
preparation and painting area. Also, keep gearbox and drivers.
sparks, heat and open flames away from the NOTE
these areas.
Do not reuse blasting sand. Oil and grease
should be removed by hosing or by wiping
with a suitable solvent.
RECOMMENDATIONS
a. MATERIALS RECOMMENDED
NOTE
After sandblasting, ALL welds should be
Sandblast Media: Lone Star #1 Bulk Blast Media or
inspected by a qualified person and any that
equivalent
are suspected of being cracked are to be dye
Paint and Primer: Refer to manufacturer's product penetrant and magnetic particle tested. Refer
information following this article. to STRUCTURAL REPAIRS, and publication
COPYRIGHT 2002
LeTourneau, Inc. 39
4/20/99
LeTĆ1, FIELD WELDING PROCEDURES, locaĆ

ted in Section 1 in the REPAIR AND
! CAUTION
OVERHAUL MANUAL before attempting ANY Care must be taken to minimize surface
welding repairs to the structural components contamination from atmospheric pollution
of the crane. such as dust, industrial fallout etc.
f. All rough welds, burrs, weld splatter and other
sharp surface projections should be ground smooth. NOTE
Any grinding done after sandblasting should be reĆ
A color contrast has been purposely estabĆ
blasted to obtain a surface like the remainder of the area
lished between the primer and the finish coat.
to be painted.
The color contrast is designed to act as an
g. Sandblasting and painting operations should be indicator to insure complete coverage with
scheduled so that they will not be in progress at the both primer and finish coat. The contrast is not
same time or so that blasting is not in progress while to be so great as to markedly influence the
there is wet paint within the range of sandblasting appearance of the top coat.
contamination. The blast cleaned surface should be
coated with one coat of primer as specified during the POST PAINTING INSPECTION AND
same day as blasted and also before any visible rust
occurs. Sandblasted steel wet by rain or moisture prior
SERVICES
to priming should be reĆblasted. Post painting inspection and servicing should be
conducted by a qualified person to be sure the
NOTE requirements listed the paint manufacturer's specificaĆ
Surfaces which do not require painting should tions are met and that no damage to crane components
be masked or otherwise protected during the by contamination from sandblasting and painting will
painting of adjacent work. Also, be aware of occur. The following inspections and services should be
possible damage to surrounding rig compoĆ performed:
nents from overspray and take appropriate a. Inspect the paint to be sure that a film thickness as
measures to protect them. listed in Figure 13 is met. Measurement should be made
by Dry FilmĆMikrotest or equivalent gauge.
PAINT APPLICATION
b. Inspect Machinery House, control panels, motors,
a. Primer and paint used should be the original used wiring, and terminals for contamination from sandblastĆ
in the manufacturing process or equivalent, conform to ing and painting. Vacuum out any contamination.
the paint manufacturers specifications and be applied
listed in Figure 13. c. Inspect the slewing bearing, gear, gearbox pinion
and lubricant to be sure no contamination from
b. Painting should be done in a neat and workmanĆ
sandblasting and painting is present. Clean and
like manner and all joints and crevices should be filled
lubricate as required.
where necessary and thoroughly painted. Paint should
be applied only on surfaces that are completely dry. d. Inspect the wire rope to be sure no contamination
from sandblasting and painting is present. Clean and
c. Painting should only be permitted within a range of
lubricate as required.
temperature and humidity recommended by the paint
manufacturer as published in specifications for the e. Inspect pins and bushings for contamination from
particular product. sandblasting and painting and clean as required.
COPYRIGHT 2002
40
LeTourneau, Inc.
4/20/99
Component Metal Prep Primer Tie Coat Top Coat

Outer Column and Gear Str. Near white One coat inorganic One coat red One Coat Grey
(PC 350); Inner Column and shot or zinc primer 2Ć1/2 expoxy 1 MIL DFT HiĆSol expoxy
Gear Str. (PC 120) sand blast to 3 MLS DFT 4-6 MILS DFT
SSPCĆ10
Swing Table, Gantry Boom One Coat Yellow
(except tip), Machine House HiĆSolids epoxy
Exterior, Other crane structures 4-6 MILS DFT
Boom Tip One Coat Orange

HiĆSolids epoxy
4-6 MILS DFT
Machine House Wire brush to One coat epoxy None One Coat Whle
Interior remove rust primer 4 MILS DFT Polyurethane
and loose 1.5 to 2 MILS DFT
scale. Wash
to remove oil,
Welded Hand grease and None None Two coats cold
Railjoints foreign matter. galv. compound,
2-3 MILS
total DFT
YELLOW ORANGE
FIGURE 13. PCM CRANE PAINT REQUIREMENTS

COPYRIGHT 2002
LeTourneau, Inc. 41
4/20/99
PUBLICATION ROMĆ1
LeTOURNEAU, INC., PCM 350SS ELECTRIC DECK CRANE
REPAIR AND OVERHAUL MANUAL
STRUCTURAL COMPONENTS

Page Page
SCOPE OF THIS PUBLICATION . . . . . . . . . . . . . . . 2 PCMĆ350SS BOOM ASSEMBLY . . . . . . . . . . . . . . . . . 23
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . 2 BOOM DISASSEMBLY AND REMOVAL . . . . . . . . . 23
CRANE TESTING, EXAMINATION, AND BOOM INSPECTIONS UPON DISASSEMBLY . . . . 23
CERTIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BOOM REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 23
SURVEY AND APPROVAL . . . . . . . . . . . . . . . . . . . . 3
PCMĆ350SS FLOATING SHEAVE HOUSING
ANNUAL EXAMINATIONS . . . . . . . . . . . . . . . . . . . . 3 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CONTROL BOOK AND CERTIFICATE . . . . . . . . . . 3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CRITICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 5 INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 29
CRITICAL MECHANICAL COMPONENTS . . . . . . . 5 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CRITICAL STRUCTURAL COMPONENTS . . . . . . . 5 PCMĆ350SS HOOK AND BLOCK ASSEMBLY . . . . . . 31
CRITICAL RIGGING COMPONENTS . . . . . . . . . . . 5 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PCMĆ350SS MACHINERY HOUSE AND WINCH INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 31
INSTALLATON BOOM, MAIN HOOK, AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
AUXILIARY HOOK ASSEMBLIES . . . . . . . . . . . . . . . . 7
MACHINERY HOUSE DESCRIPTION . . . . . . . . . . . 7 CABLE DRUM LOCK PIN . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL OF WINCH HOUSING ASSEMBLY PCMĆ350SS STRUCTURAL REPAIRS . . . . . . . . . . . . 35
DC DRIVE MOTORS AND DRIVERS . . . . . . . . . . . . 7
WELDING REQUIREMENTS . . . . . . . . . . . . . . . . . . 35
PCMĆ350SS SWING TABLE AND KING PIN STRUCTURAL MATERIALS . . . . . . . . . . . . . . . . . . . 35
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
STRUCTURAL REPAIR PROCEDURES . . . . . . . . . 35
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 9
INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 9 PCMĆ350SS/120SS ELECTRIC DECK CRANE
PAINTING RECOMMENDATIONS . . . . . . . . . . . . . . . . 37
REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 9
PCMĆ350SS LOWER BEARING AND SOCKET RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . 37
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . 37
DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13 PAINT APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . 38
INSPECTIONS AND SERVICES . . . . . . . . . . . . . . . 13 POST PAINTING INSPECTION AND SERVICES . . 38
REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 13
PCMĆ350SS SWING GEAR UNIT ASSEMBLY . . . . . . 15
FIGURE Page
SWING GEAR UNIT DC MOTOR . . . . . . . . . . . . . . . 15
1 WINCH INSTALLATION . . . . . . . . . . . . . . . . 8
SWING GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 SWING TABLE ROLLER ASSEMBLY . . . . 10
PCMĆ350SS GANTRY ASSEMBLY . . . . . . . . . . . . . . . 17 3 SWING TABLE ROLLER ADJUSTMENT . 11
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4 SWING GEAR UNIT INSTALLATION
INSPECTIONS UPON DISASSEMBLY . . . . . . . . . . 17 5 GANTRY ASSEMBLY
REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . 17 6 BOOM AND AUXILIARY HOIST . . . . . . . . 25
PCMĆ350SS GANTRY SHEAVE HOUSING 7 FLOATING SHEAVE HOUSING
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 30
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 8 MAIN HOOK AND BLOCK -
PCM 350SS (75ĆTON) . . . . . . . . . . . . . . . . 32
9 LOCK PIN MOUNT STRUCTURE
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION - PCM 350SS . . . . . . . . . 34
10 PCM CRANE PAINT REQUIREMENTS . . 39
COPYRIGHT 2002
LeTourneau, Inc. 1
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)

Publication ROMĆ1, STRUCTURAL COMPONENTS, is
to assist maintenance personnel and operators in the NEVER remove the DC drive motors access
location, inspection, adjustment and repair or replaceĆ covers unless the electrical system is turned
ment of the various structural components of the crane. off, locked out, and grounded. Contact with
high voltage terminals inside the motors will
NOTE result is serious injury or loss of life.
In several places in this publication, the terms
certification of the crane and its components. Do not perform welding on hooks.
al standing or who by extensive knowledge, BEFORE attempting to disassemble any of the
training, and experience, has successfully major components of the machine BE SURE to
demonstrated the ability to solve or resolve provide hoists or cranes and lifting devices of
problems relating to the subject matter and adequate capacity and height.
work. NEVER stand under or place any body part
under components while hoisted. Serious
NOTE injury, loss of life could result in the event of an
accident.
Mandatory rules of this publication per
ANSI/ASME are characterized by the word
SHALL." If a provision is of an advisory
nature, it is indicated by the word Ladders and catwalks attached to the crane
SHOULD" and is recommended to be considĆ are designed for servicing of the crane only
ered, the advisability of which depends on the while the crane is stopped. No personnel are
facts in each situation. allowed on any structure of the crane during
operation. Serious injury or loss of life could
WARNINGS AND CAUTIONS result from falling or crushing.
Before any inspections or repairs are performed to the
structural components of the crane it is critically
! CAUTION
important to read and comply with the following To prevent injury, wear hard hat, protective
warnings and cautions. These warnings and cautions glasses and other protective equipment as
will not be reiterated in the following text: required by job conditions. ALWAYS wear
gloves when handling wire rope.
! CAUTION
When inspecting or performing maintenance
or repair operations on elevated structures of
the crane, NEVER proceed beyond the safety
of handrailed platforms. Serious injury or loss
of life from falling is possible outside these
the PARTS CATALOG to order replacement
areas.
signs.
! CAUTION
BEFORE welding on any structural members
Place a DO NOT OPERATE sign on the of the machine refer to Publication LETĆ1,
controls of the machine and secure the FIELD WELDING PROCEDURES, located in
controls before performing any maintenance the back of Section 1, of the REPAIR AND
or repair operations. Serious injury or death is OVERHAUL MANUAL. Serious damage to
possible if the machine is started or moved electrical and electronic controls is possible
while maintenance or repair operations are unless precautions described in this publicaĆ
being conducted. tion are adhered to.
COPYRIGHT 2002
2
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
CRANE TESTING, EXAMINATION, AND CERTIFICATION

The following general guidelines for the testing, exĆ Register (Control Book Ć ILO Form No.1). A copy of this
amination and certification of the crane are included to certificate may be requested by the certifying authority.
alert the deck supervisor, operator and maintenance
personnel of these requirements and the CRITICAL ANNUAL EXAMINATIONS
IMPORTANCE of these procedures for the continued
safe operation of the crane. Cranes shall undergo a thorough examination at least
every twelve (12) months by a competent person, or
NOTE more frequently if required by the certifying authority.
It is the responsibility of the deck supervisor, a. STRUCTURAL INSPECTION

crane operator, and maintenance personnel to The annual thorough inspection shall comprise control
make sure the applicable tests and certificaĆ and function testing of the crane as well as visual control
tions required by the certifying authority under of elongation, wear and tear, corrosion, cracking and
which the crane is being operated are met. It is formation of fractures, etc. The examination shall be
also the responsibility of the above personnel carried out in such a way that it, as far as possible, will
to have the required documentation of these give a reliable knowledge of the safety of the examined
tests, examinations, and certification on hand components.
and in the format required by the certifying
authority. There are many different certifying b. INSPECTIONS FOR OVERLOADED CRANE
authorities worldwide and these guidelines A crane which has been exposed to a load moment
should not be considered all inclusive. exceeding 110% of the permitted load moment (includĆ
Certifying authorities may have the power to ing maximum calculated for dynamic load) shall be
impose fines and harsher penalties for willful thoroughly examined by a competent person before it is
or neglect violations of crane testing, again taken into use.
examination, and certification.
CONTROL BOOK AND CERTIFICATE
SURVEY AND APPROVAL
The results of initial testing, tests and examinations
Before a crane is, or crane components are, first taken every four (4) years as well as the annual examinations
into use, and later every four (4) years, a competent and all kinds of tests and examinations after repairs or
person shall have controlled constructions and calculaĆ alterations of the crane or hoisting gear, shall be entered
tions, carried out testing and examination of strength, in the Control Book (ILO Form No.1). All controls, crane
quality of materials, workmanship and structural design functions and safety devices shall be inspected and
as well as certification in connection with this in tested annually and when found to function properly the
compliance with the requirements of the certifying results shall be entered into the Control Book. The entry
authority. shall be written by the competent person who carried
After the crane has been tested and thoroughly out the inspection and the examination. Control Book
examined with a satisfactory result by a qualified and Certificate shall both be kept on board. The Control
person, a certificate will be issued. The original test Book and certificate shall be available for the surveyor of
certificate shall be filed on board with the Cargo Gear the certifying authority.
COPYRIGHT 2002
LeTourneau, Inc. 3
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
4
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
CRITICAL COMPONENTS
The following is a list of components of the crane which CRITICAL STRUCTURAL COMPONENTS
a. Boom chord members
components are ones which affect the safety of the
crane from a structural and load hoisting standpoint. b. Boom section connection components
These components should be of prime concern to the c. Boom foot pins
deck supervisor, operator and maintenance personnel
with regards to certification, inspection, maintenance d. Primary load members of gantries, masts and
and prompt repair per the appropriate guidelines. AĆframes
e. Load transfer members of the rotating upper
CRITICAL MECHANICAL COMPONENTS structure
a. All lines and linkage between the brake control f. Pedestal and swing circle transition pieces
element and the component to be controlled.
CRITICAL RIGGING COMPONENTS
b. Hoist, boom, and swing brake systems
a. All running wire ropes in hoist system
c. Drums, shafts, and gears of hoisting and swing b. All standing wire rope in load restraint and support
systems system
d. Swing bearings and gear c. Hook block assembly
e. Wire rope sheaves and sheave shafts d. Wire rope deadĆend connection devices
f. Electric drive motors for hoists, boom, and swing e. Floating harness or bridle assemblies
COPYRIGHT 2002
LeTourneau, Inc. 5
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
6
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS MACHINERY HOUSE AND WINCH INSTALLATION

BOOM, MAIN HOOK, AND AUXILIARY HOOK ASSEMBLIES
The PCMĆ350SS Electric Deck Crane is equipped with a be gained through the access door. A ventilation and
Winch Housing structure positioned on the side of the service hatch is provided for cooling and maintenance
Machinery House. The Winch Housing structure conĆ servicing. This compartment contains the Solid State
sists of three major parts; the Boom Gear Drive control components, relay switches, transformers, fuse
Assembly, the Hook Gear Drive Assembly, and the boxes and other switch gear of the crane. Refer to the
Auxiliary Gear Drive Assembly. PARTS CATALOG for location of specific control deĆ
vices.
REMOVAL OF WINCH HOUSING

Refer to WARNINGS AND CAUTIONS, page ASSEMBLY DC DRIVE MOTORS AND
2, before performing any inspection or repair DRIVERS
to the structural members of the crane. It is necessary to remove the driver and DC motor for
any of the Winch Housing Drive Assemblies to work on
either the driver unit or motor except for minor repair or
adjustments.
Due to the presence of potentially injurious Instructions are provided in Section 2, DC MOTORS, for
conditions, only qualified personnel should an inĆplace inspection of the DC drive motors. InstrucĆ
enter the Machinery House. Before attempting tions are provided in Section 7, DRIVERS, for an inĆplace
to work on a component, make sure all inspection of the drivers' internal components and the
electrical power is turned off and locked out subsequent removal of a DC drive motor and driver as a
and a DO NOT OPERATE sign is attached to unit if the inspections warrant removal.
the controls. Also, station an operator at the
remote control operator's console or in the ! CAUTION
cab if energized tests of the components are
Under no circumstances should the owner
made.
attempt to disassemble the driver past the
removal of the cover during the inĆplace
MACHINERY HOUSE DESCRIPTION inspection. This is especially important if the
Access to the Machinery House and the electrical driver is in warranty. Unauthorized disassemĆ
control components, swing and hoisting machinery can bly will void the warranty.
COPYRIGHT 2002
LeTourneau, Inc. 7
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
1
3
2
1
3
3 5
1. CABLE DRUM STR.

2. BOLT
3. NĆ3 DRIVER
4. OĆRING
5. NĆ9 MOTOR
6. MACHINERY HOUSE
7. SWING TABLE & KING PIN STR.
8. CAPSCREW
FIGURE 1. WINCH INSTALLATION - PCM 350SS

COPYRIGHT 2002
8
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS SWING TABLE AND KING PIN ASSEMBLY
The Swing Table King Pin Assembly, located on top of NOTE

the pyramid, is the upper portion of the whole Swing
Table Assembly which allows the crane to rotate. Small burrs and nicks can be dressed out, but
damaged or worn bearings and bushings
DISASSEMBLY PROCEDURES must be replaced.
c. Examine oil seals, rings and retainers. Replace if
damaged or worn.
REASSEMBLY PROCEDURES
a. Install bearings, bushings and oil seals. Lubricate
page 2, before performing any inspection or
bearings.
NOTE
NOTE
Use care to prevent damage to oil seals during
A suitable hoisting device such as an auxiliary reassembly and installation.
b. With Swing Table Roller Assembly completely
together, use a suitable hoisting device to position roller
a. Reduce load on the rollers by removing the boom assembly into the Roller Housing Structure.
or raising the boom to its maximum UP position. c. Install all rollers with the dimple on the roller flange
b. Remove the capscrews and bolt retainer pads on closest to the column.
top of the roller assembly.
NOTE
c. With proper hoisting device lift out the entire Swing
Table Roller Assembly. The dimple indicates the high side of the roller
pin.
NOTE d. Install two threaded lifting eyes into two of the
holes on the roller. Leave an empty hole between the
Be sure that a suitable such as an auxiliary two lifting eyes. Insert a long pry bar through the lifting
crane is used and that the Swing table Roller eyes to turn the rollers. Refer to Figure 3.
Assembly is well secured to it.
e. Adjust all rollers out until they touch the swing gear.
d. Remove the oil seal and oil seal ring from under the Position of the rollers can be seen through the viewing
bearing and remove the bearing roller from the bearing access hole next to the roller flange.
pin.
NOTE
e. Remove the bearing and roller off the bearing pin.
Large adjustment is made by rotating the
f. Remove oil seal holder, oil seal and oil seal ring roller flange independently of the retainer
from bearing pin. pad. Smaller adjustment can be made using
the slotted holes of the retainer pad.
NOTE
f. Using a feeler gauge between the rollers and the
Use care to prevent damage to oil seal, rings, swing gear, adjust the three nonĆloaded rollers (oppoĆ
holder, bearing and rollers. site the boom) in, leaving a .020 inch gap between the
roller and the gear (refer to Figure 3).
INSPECTIONS AND SERVICES g. Secure the bolt retainer pads to roller flanges and
roller table.
a. Thoroughly clean all bearings, rollers, oil seals,
h. Place grease fitting on top on the pin roller and
rings, pins, capscrews, and magnetic particle test all
pins and rollers. lubricate the bearing thoroughly in accordance with
Figure 1, PCM CRANE LUBRICATION SPECIFIĆ
b. Examine for nicks, burrs and if any are noted, use a CATIONS, Publication OSMĆ4, located in the OPERATĆ
hand grinder to remove them. ING AND SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc. 9
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
1 2 23
22
3
4 21
20
7
19
5
1. GREASE FITTING
9 2. BOLT
3. PAD
10 4. ROLLER PIN
5. OIL SEAL
6. ROLLER
7. BEARING
8. OIL SEAL RING
9. OIL SEAL HOLDER
10. RETAINER RING
11
11. OIL SEAL
12. BUSHING
13. BEARING
12
14. SOCKET STR.
15. OIL SEAL
16. HEX NUT
13 18 17. BOLT
18. COLUMN & GEAR STR.
19. SWING TABLE &
KING PIN STR.
14
20. BOLT
21. OĆRING
22. MANHOLE COVER
23. BOLT
15
17
16
FIGURE 2. SWING TABLE ROLLER ASSEMBLY

COPYRIGHT 2002
10
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
THREADED LIFTING EYES
PRYBAR
ROLLER
ACCESS
HOLE
SWING GEAR
FEELER GAUGE
.020”
FIGURE 3. SWING TABLE ROLLER ADJUSTMENT

1ĆCGĆ1845, P10Ć52 TAĆ8981ĆP
COPYRIGHT 2002
LeTourneau, Inc. 11
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
12
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS LOWER BEARING AND SOCKET ASSEMBLY

The Lower Bearing And Socket Assembly, located at the NOTE
bottom of the pyramid, is the lower portion of the whole
Swing Table Assembly which allows the crane to rotate. Small burrs and nicks can be dressed out, but
Refer to Figure 2. damaged or worn bearings and bushings
must be replaced.
DISASSEMBLY PROCEDURES c. Examine oil seals and replace if damaged or worn.
d. Use proper lubricant on bearings, bushing and oil
seals as specified in PCM CRANE LUBRICATION
SPECIFICATIONS, Figure 1, Publication OSMĆ4, loĆ
cated in the OPERATING AND SERVICE MANUAL.
page 2, before performing any inspection or NOTE
Magnetic particle tests should be conducted
NOTE on all gears and shafts every four (4) years or
when disassembled for repairs.
A jack and a hoisting device such as an
auxiliary crane of sufficient size and capacity REASSEMBLY PROCEDURES
will be required for disassembly and reasĆ a. Install bearings, bushing and oil seals.
sembly procedures.
NOTE
a. Remove nut on the bottom of the swing table tube.
Use care to prevent damage to oil seals during
b. With a suitable jacking device placed between the reassembly and installation.
swing gear and bottom of the swing table, jack upward
to relieve the load on the thrust bearing. b. With a suitable hoisting device, lift the Lower
Bearing and Socket Assembly up the pyramid structure.
c. Remove capscrews from bearing socket structure.
NOTE
d. With a suitable hoisting device, attach a sling to
bearing socket structure. BE SURE the Lower Bearing and Socket
Assembly is well secured before hoisting.
e. Rotate bearing socket structure to 45°. This will
allow bearing socket to pass column base plate. c. Rotate bearing socket structure 45° to allow it to
pass up through the column base plate and into place.
NOTE d. Replace capscrews into bearing socket structure.
BE SURE that a suitable hoisting device is e. Relieve tension on jacking device to put load back
used and the Lower Bearing socket Assembly on the thrust bearing.
is well secured before removal. f. Replace the nut on the bottom of the swing turn
table.
INSPECTIONS AND SERVICES g. Lubricate the bearing through the fitting on the
side of the assembly as specified in Figure 1, PCM
a. Thoroughly clean bearings, bushing, oil seals and
CRANE LUBRICATION SPECIFICATIONS in Publication
capscrews.
OSMĆ4, located in the OPERATING AND SERVICE
b. Examine for burrs and nicks. MANUAL.
COPYRIGHT 2002
LeTourneau, Inc. 13
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
14
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS SWING GEAR UNIT ASSEMBLY

The Swing Gear Unit Assembly controls the rotation of type spring applied electroĆmechanically released moĆ
the crane and is powered by a S1A, DC motor driving tor brake is an integral part of the motor. Refer to
through a #5 gearbox assembly mounted out from the Section 2 for disassembly, inspection, repair, and
swing table and king pin structure. The Swing Gear Unit reassembly procedures for the DC swing motor. Also,
output shaft operates on the round gear rack of the refer to the LeTourneau, Inc. Publication TAKING CARE
swing table to obtain crane rotation. Refer to Figure 4 for OF YOUR DC MOTOR, located in the back of Section 2
an illustration of the components of the Swing Gear Unit for additional information on maintenance, troubleĆ
Assembly. shooting, and repair of DC motors.
SWING GEAR UNIT DC MOTOR

The Swing Gear Unit DC motor when used in conjuncĆ SWING GEAR BOX
tion with the LeTourneau, Inc. power and control system
provides the operator with a wide range of control of Refer to Section 7, SWING GEARBOX, for information
motor speed and output power. These motors are concerning the disassembly, repair and replacement
especially wound to provide maximum output throughĆ and reassembly procedures for the #5 swing gearbox
out the full range of motor speed. A multiple disc friction assembly.
COPYRIGHT 2002
LeTourneau, Inc. 15
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
17
16
15 7
14 8
13
10
12
11
1. LID STR. 10. WASHER BAR

2. TOGGLE LATCH 11. LOCKNUT
3. OĆRING 12. #5 SWING GEARBOX
4. BOLT 13. LOCKWASHER
5. LOCKWASHER 14. BOLT
6. OĆRING 15. TERMINAL TUBE
7. SĆ1A DC MOTOR 16. TERMINAL TUBE
8. BOLT 17. COVER STR.
9. BOLT
FIGURE 4. SWING GEAR UNIT INSTALLATION

COPYRIGHT 2002
16
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS GANTRY ASSEMBLY

The PCMĆ350SS Electric Deck Crane is equipped with a b. Remove bolts, keeper plates and pins from the top
rigid steel pipe assembly that is pinned to the swing of the Boom Stop Support. Remove bolts, keepers and
table structure. The Gantry Sheave Housing Assembly pins from back of Boom Stop Assembly. Hoist Boom
is pinned to the top of the Gantry Structure to give Stop Structure away.
proper fleet angle. The Boom Positive Stop is pinned to c. Remove bolts, keeper plates and pins for base of
the Gantry Structure to stop the boom at a minimum Boom Stop Support and hoist it away.
radius. Refer to Figure 5 for an illustration of the
components of the Gantry Assembly. d. With a suitable hoisting device secured to the top
of the Front Gantry Structure, remove bolts, keeper
plates and pins form the top and bottom of the Rear
Gantry and pins from the top and bottom of the Rear
Gantry Structure and hoist away.
Refer to WARNINGS AND CAUTIONS, page
2, before performing any inspection or repair e. Remove bolts, keeper plates and pins from base of
to the structural members of the crane. Front Gantry Structure and hoist away.
NOTE INSPECTIONS UPON DISASSEMBLY

A suitable hoisting device such as an auxiliary a. Thoroughly clean all pins, nuts and bolts with a
crane will be required for disassembly and suitable solvent and allow to air dry. Any worn parts
reassembly procedures. should be replaced.
DISASSEMBLY NOTE
a. With a suitable hoisting device, remove the Gantry All shafts and gears must be magnetic particle
Sheave Housing Assembly. tested.
NOTE REASSEMBLY PROCEDURES

Refer to GANTRY SHEAVE HOUSING ASĆ To reassemble the Gantry Assembly, reverse the
SEMBLY, page 18. procedures in DISASSEMBLY, above.
COPYRIGHT 2002
LeTourneau, Inc. 17
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
1
2
3
3
22
21
20
3
19
23
18
4
2
17
1
15
16
15
14
8
4
1
5
14
2
13
4
3 2
11
12 10
1
7 1
FIGURE 5. GANTRY ASSEMBLY
COPYRIGHT 2002
18
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
GANTRY ASSEMBLY
1. BOLT
2. KEEPER PLATE
3. PIN
4. PIN
5. LOWER GANTRY STR.
6. REAR GANTRY STR.
7. LOWER GANTRY STR.
8. FRONT GANTRY STR.
9. GREASE FITTING
10. BOLT
11. RETAINER PLATE
12. SHEAVE PIN
13. BEARING SPACER
14. BEARING SPACER
15. SEAL
16. BEARING
17. SHEAVE
18. SLEEVE
19. PUSHER STRUCTURE
20. BOOM STOP SPRING
21. BOLT
22. BOOM STOP STR.
23. BOOM STOP SUPPORT STR.
COPYRIGHT 2002
LeTourneau, Inc. 19
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
20
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS GANTRY SHEAVE HOUSING ASSEMBLY

The Gantry Sheave Housing Assembly is made up of six NOTE
(6) sheave wheels and seven (7) divider plates. Its
function is to assist in the raising and lowering of the Examine for burrs and nicks. With a hand
boom. Refer to Figure 5 for an illustration of the Gantry grinder, remove any that are noted.
Sheave Housing Assembly.
NOTE
Sheaves and sheave wheel pins are to be
magnetic particle tested.
page 2, before performing any inspection or REASSEMBLY
repair to the structural members of the crane. a. Reassemble and lubricate wheel bearing assemĆ
NOTE blies.
b. Insert bearing assembly and spacer into first
A suitable hoisting device such as an auxiliary wheel. Put wheel into position between spacers and
crane will be required for disassembly and slide sheave wheel pin through spacers, wheel bearing
reassembly procedures. and wheel.
DISASSEMBLY c. Repeat procedure b" until all wheels, bearing
assemblies and spacers are in place and the sheave
a. With a suitable hoisting device attached, remove wheel pin is all the way through the sheave divider
the three (3) capscrews from the end of the gantry hinge plates.
pins. Remove the two gantry hinge pins. This will allow
the whole Gantry Sheave Housing Assembly to drop d. Replace retainer plates with three (3) 1/2Ćinch bolts
down. each side of sheave wheel pin. Refer to the CAPSCREW
b. Remove the two 1/2Ćinch bolts that hold the sheave proper torque.
housing pin keeper plates. Remove sheave housing pin
and six (6) spacers. e. Replace sheave housing pin and at the same time
replace the six (6) spacer pipes, one between each
NOTE sheave housing plate. replace keeper plates with
1/2Ćinch bolts, each side of sheave housing pins. Refer
Only one sheave housing pin needs to be
to the CAPSCREW TORQUE CHART in the appendix of
removed and if the back pin is removed a
this manual for the proper torque.
complete inspection of all wire ropes can be
made. NOTE
c. Remove retainer plates on sheave wheel pin. Make sure all wire ropes are in proper order.
Remove pin with caution.
f. With a suitable hoisting device, raise gantry
! CAUTION sheave housing unit up and connect back to top of
gantry with the two gantry hinge pins. Replace keeper
In removing the sheave wheel pin, care should plates with three (3) 1/2Ćinch bolts in the end of each pin.
be taken not to drop or damage the sheave Tighten capscrews. Refer to the CAPSCREW TORQUE
wheels, wheel bearings and spacers. CHART in the appendix of this manual for the proper
torque.
g. Lubricate bearing assemblies through the grease
a. Thoroughly clean all parts to the Gantry Sheave fitting on the end of the sheave wheel pin as specified in
Housing Assembly. Figure 1, PCM CRANE LUBRICATION SPECIFIĆ
b. Inspect all pins, wheels, bearings and spacers. CATIONS, in Publication OSMĆ4, located in the OPERĆ
replace if damaged. ATING AND SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc. 21
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
22
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS BOOM ASSEMBLY

The PCMĆ350SS Electric Deck Crane is equipped with a h. Attach suitable hoisting device to boom structure
rigid steel boom made up of four sections. The lower and lower to a prepared work surface.
structure is 43 feet 6 inches in length. There are two i. In succession, remove the capscrews and nuts
middle sections; one of 20 feet and one of 40 feet in that hold the upper, middle and lower boom sections
length. With the Auxiliary Hoist System (optional), the together and remove each with a suitable hoisting
top boom section has a length of 25 feet. Sections are device.
connected using bolt plates, bolts and nuts. Each joint
of the boom has a male and a female fit for additional j. Remove pin retainers, idler sheave pin, bearing
safety. Refer to Figure 6 for an illustration of the Boom and 30 inch sheave wheel from auxiliary hoist boom tip
Assembly. weldment.
k. Remove cotter pin and sheave pin form guide
sheave housing assembly.
l. Remove bolts, lockwashers and lock plate from
Refer to WARNINGS AND CAUTIONS, guide sheave housing assembly and drive out sheave
page 2, before performing any inspection or housing pin. Remove the 22 inch sheave wheel.
repair to the structural members of the crane. Remove bearing seal and bearing assembly.
NOTE m. Remove bolts, retainer plates and sheave wheel

pins from boom housings. Secure sheave in place and
A suitable hoisting device such as an auxiliary drive out sheave pins. Roll out the sheaves onto a
crane will be required for disassembly and prepared surface. remove all bearing seals, spacers
reassembly procedures. and bearings.
BOOM DISASSEMBLY AND REMOVAL BOOM INSPECTIONS UPON

a. Hoist the Main Hoist and Auxiliary Hoist Hook DISASSEMBLY
(optional) and block assemblies close enough to the tip a. Thoroughly clean all bearings, bushings, spacers,
to prevent the wire ropes from fouling when the boom is nuts, pins and grease fittings in a solvent and allow to air
lowered. dry.
b. Above a flat working surface, lower the boom until b. Inspect all components for excessive wear and/or
the tip almost touches. damage. Replace or repair when necessary.
! CAUTION
DO NOT lower the boom below a parallel with
the base of the boom. Do not let the tip touch Replace ALL nuts and bolts for boom
the deck surface because it might bend or connections every 4 years of operation, also
damage the boom structure. bolts and nuts are to be replaced if any boom
c. Remove the Main Hoist Hook and Block Assembly sections must be replaced. Failure to comply
and the Auxiliary Hoist Hook and Block Assembly with this instruction could result in serious
(optional). injury or death and damage to the crane.
d. Spool Main Hook and Auxiliary Hook (optional) NOTE

lines on to the drums.
ALL pins and critical welds are to be magnetic
e. With a suitable lifting device, lower the floating particle tested.
sheave assembly on top of boom and secure.
f. Remove boom wire rope dead end for gantry BOOM REASSEMBLY
sheave assembly. To reassemble the Boom Assembly, reverse the proceĆ
g. Spool boom wire rope onto the cable drum. dures in BOOM DISASSEMBLY AND REMOVAL, above.
COPYRIGHT 2002
LeTourneau, Inc. 23
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
24
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
1 2 3 4 5 6
14
15
8
12 13 16
7 9
10 E E
19
17
VIEW – C
VIEW – A 11 VIEW – B 20 21
14 18
SECTION E–E
1 2 3 4 5 6
1. LOWER BOOM SECTION 8. BOLT 15. PIN RETAINER

2. MID BOOM SECTION - 40' 9. CAP PLATE 16. BUSHING, SELFĆALIGNING
3. MID BOOM SECTION - 20' 10. GREASE FITTING 17. BUSHING, PIN
4. TOP BOOM SECTION 11. LUFFING ATTACHMENT STR. 18. GREASE FITTING
5. BOOM TIP W/AUXILIARY HOIST 12. BOLT 19. HINGE PIN
6. BOOM TIP EXTENSION 13. NUT 20. IDLER
7. BRIDLE CABLE ASSEMBLY 14. BOLT 21. NUT
NOTE: REFER TO FIGURE 6, PARTS 2 AND 3, FOR ILLUSTRATIONS OF THE BOOM TIP ASSEMBLY.
FIGURE 6. BOOM AND AUXILIARY HOIST (1 of 3)

1ĆCGĆ1848, Ldgr2Ć21 TAĆ8991ĆCG
1-ROM 1.1, 350SS, FOĆ1

6/25/98 COPYRIGHT 2002 25
LeTourneau, Inc.
COPYRIGHT 2002
26
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
1
4
3
1ĆROM 1.1, 350SS

5 19 2
6/25/98 (Rev 8/31/01)

1ĆCGĆ1849, P10Ć54
11
6
PUBLICATION ROMĆ1
12
14
13 1. BOLT
12 2. TOP PLATE
11
3. PIN RETAINER
12 4. BOLT
4 14 3 5. GREASE FITTING
13
6. BOLT
12
4 7. CUFFING ATTACHMENT
5 11
18 8. CAP PLATE
5
9. BOLT
6 6 10. GREASE FITTING
11. BEARING SPACER
4 3
12. BEARING SEAL
7
13. BEARING ASSY.
5 17 10 8 14. SHEAVE
15. BOOM TIP EXTENSION STR.
16. IDLER SHEAVE PIN
9
COPYRIGHT 2002
6 17. SHEAVE PIN
4
18. BOOM TIP STR.
3 3 19. SHEAVE PIN
5
6
LeTourneau, Inc.
16 4 11 12
13
15
14
12

3 5 11
6
12
BOOM TIP INSTALLATION WITH AUXILIARY HOIST - PCM 350SS

13
11
12 14
14 12 12
13 13
12 11
11 14
12
11
TAĆ8993ĆCG
27
PCM 350SS ELECTRIC DECK CRANE STRUCTURAL COMPONENTS
10
6
4
5
5
9
7
8
1. BRIDLE LINE CABLE ASSY.
2. WIRE ROPE ASSY., 550'
3. SINGLE SHEAVE DYNAMOMETER
4. MAIN HOOK LINE ASSY., 1" X 2225'
5. ANTIĆTWO BLOCK SENSOR
6. CLAMP, WIRE ROPE - 1"
7. OPEN WEDGE SOCKET, 1"
8. OVERHAUL BALL ASSY., 10T
9. HOOK AND BLOCK ASSY.
10. LINK LOADCELL
BOOM GROUP WITH AUXILIARY HOIST

COPYRIGHT 2002
28
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS FLOATING SHEAVE HOUSING ASSEMBLY

The Floating Sheave Housing Assembly is a pulley NOTE
made up of six (6) 30 inch sheave wheels. Its function is
the raising and lowering of the crane's boom. Refer to Magnetic particle tests should be conducted
Figure 7 for an illustration of the components of the on all critical welds and pins during
Floating Sheave Housing Assembly. disassembly or every four (4) years.

a. Thoroughly clean all parts of the Floating Sheave
Housing Assembly.
b. Inspect all pins, wheels, bearings and spacers.
page 2, before performing any inspection or
Replace if damaged or worn.
NOTE
NOTE
Examine for burrs and nicks. With a hand
A suitable hoisting device such as an auxiliary grinder, remove any that are noted.
reassembly procedures. REASSEMBLY
a. Reassemble and lubricate wheel bearing assemĆ
DISASSEMBLY blies.
b. Insert bearing assemblies and spacers into
a. Lower the Floating Sheave Housing Assembly into sheave wheels. Put into position and slide sheave wheel
the cradle provided on the top of the boom. Remove the pin through spacers, wheel bearings and sheave
three (3) 1/2Ćinch bolts on the end of the pin that holds wheels.
the bridal connector structure in place. With proper
hoisting device remove pin. c. Replace the retainer plates and 1/2Ćinch bolts.
b. Remove the two (2) 1/2Ćinch bolts and keeper appendix of this manual for the proper torque.
plates on the end of sheave housing pins that holds the
d. Replace sheave housing pins and spacers, one
five (5) sheave divider plates together. remove pin and
between each sheave housing plate. replace keeper
six (6) spacer pipes.
plates and 1/2Ćinch bolts and tighten to proper torque.
NOTE appendix of this manual for the proper torque.
Only one sheave housing pin needs to be NOTE
removed and if the back pin is removed a
complete inspection of all wire ropes can be Make sure all wire ropes are in proper order.
made. e. Replace bridle connector and secure into place
with bridal pin structure and cap plate with 1/2Ćinch
c. Remove 1/2Ćinch bolts and retainer plates that
hold the sheave wheel pin. Remove pin with caution.
NOTE f. Lubricate bearing assemblies through the grease
fitting on the end of sheave housing wheel pin as
In removing the sheave wheel pin care should specified in Figure 1, PCM CRANE LUBRICATION
be taken not to drop or damage the sheave SPECIFICATIONS, in Publication OSMĆ4, located in the
wheels, wheel bearings and spacers. OPERATING AND SERVICE MANUAL.
COPYRIGHT 2002
LeTourneau, Inc. 29
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
18
2
17
1. 3" PIPE SPACER

2. 30" SHEAVE WHEEL
16
3. 1Ć1/8" BEARING SPACER
4. KEEPER PLATE
5. 1/2" NC X 1" BOLT
6. 5/8" O/S PLATE
7. RETAINER PLATE
8. 1/8" GREASE FITTING
9. 1/2" NC X 1Ć1/4" BOLT
10. SHEAVE HOUSING PIN
11. SHEAVE WHEEL PIN
12. CAP PLATE
13. FLOATING HOUSING STR.
14. BRIDLE CONN. STR.
15. BRIDLE PIN STR.
15 16. BEARING SEAL
17. BEARING ASSY.
18. 3/4" BEARING SPACER
4
5
6 7
14 13
12
5
11
10
FIGURE 7. FLOATING SHEAVE HOUSING ASSEMBLY
COPYRIGHT 2002
30
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS MAIN HOOK AND BLOCK ASSEMBLY

The Hook and Block Assembly is in two parts. The Hook measure the same as original, if not, discard
Assembly itself and the Sheave Housing Assembly. The the hook.
Hook and Block Assembly is used for hoisting materials.
Refer to Figure 8 for an illustration of the components of REASSEMBLY
the Hook and Block Assembly.
a. In reassembling the Sheave Housing Assembly,
first reassemble an lubricate all bearing assemblies.
DISASSEMBLY
b. Insert bearing assemblies and spacers into the
a. Lower the Hook and Block Assembly to a prepared
first wheel. Put wheel into position between spacers,
working surface.
bearing seals, wheel bearings and sheave wheel.
b. The hook Assembly itself is disassembled by first
removing the keeper plates that retain the swivel block. NOTE
c. With a suitable hoisting device attached to the Outside sheave plates are wider than the two
Hook Assembly, remove the tie bolts and tie pins that divided plates, so the two wider bearings
hold the Sheave Housing Assembly together. spacers must go to the outside.
d. Remove the bolts that hold the retainer plates on c. Place Hook Assembly between sheave housing
the sheave wheel pin. Remove the pin with caution. plates.
NOTE d. Repeat procedure b" in this section until all
wheels, bearing assemblies, spacers and seals are in
In removing the sheave wheel pin, care should place and the sheave wheel pin is all the way through
be taken not to drop or damage the sheave sheave and divider plates.
wheels, wheel bearings, spacers, seals and
Hook Assembly. e. Replace sheave wheel pin retainer plates and
e. Remove Hook Assembly to a prepared working appendix of this manual for the proper torque.
surface.
f. Replace sheave housing tie bolts and tie pins and
f. Remove the cotter pin and 4Ćinch hook nut and at the same time replace the 3Ćinch spacer pipes.
carefully remove the hook itself so as not to damage the replace 1Ć1/2 inch nuts and keeper plates. Refer to the
bearing assembly. CAPSCREW TORQUE CHART in the appendix of this
g. Remove the bearing assembly. manual for the proper torque.
NOTE
a. Thoroughly clean all parts of the Hook and Block Make sure all wire ropes are in proper order.
Assembly. g. Lubricate bearing assemblies through the grease
b. Inspect all pins, wheels, bearing assemblies, fitting on the end of the sheave housing wheel pin as
spacers and seals. Replace if damaged or worn. specified in Figure 1, PCM CRANE LUBRICATION
SPECIFICATIONS, in Publication OSMĆ4, located in the
NOTE OPERATING AND SERVICE MANUAL.
Hook wheels and pins are to be Magnetic h. Lubricate the hook thrust bearing located on the
Particle Tested every four (4) years or if side of the swivel bearing block as specified in Figure 1,
disassembled. PCM CRANE LUBRICATION SPECIFICATIONS, in PubĆ
lication OSMĆ4, located in the OPERATING AND SERĆ
NOTE VICE MANUAL.
i. Perform a No Load Test" prior to putting back in
Check crane hooks for deformation or cracks.
service.
Hooks will be discarded where cracks exist or
throat opening is 15 percent more than the NOTE
original throat opening. Hooks will also be
discarded where they are bent or twisted more The Auxiliary Hook Assembly is a vendor
than 10° from the plane of the original hook supplied item. Refer to the Parts Catalog for
configuration. The shank of the hook shall ordering information.
COPYRIGHT 2002
LeTourneau, Inc. 31
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
1
2
3
24
23
6
23 7
1 5
4
22
6
10
7
11
8
21 1
20
3 14
2 19
11
18
10 13
12
17
16
15
1. SPACER PIPE 9. SHEAVE WHEEL 17. SWIVEL BLOCK

2. KEEPER PLATE 10. BEARING SPACER 18. THRUST BEARING
3. CAPSCREW 11. BEARING SPACER 19. NUT
4. RETAINER ROD 12. SEAL 20. TIE PIN
5. NUT 13. BEARING 21. MOUNT PLATE
6. RETAINER PLATE 14. COTTER PIN 22. SHEAVE PIN
7. GREASE FITTING 15. SAFETY LATCH 23. SIDE PLATE
8. BOLT 16. HOOK 24. DIVIDER PLATE
FIGURE 8. MAIN HOOK AND BLOCK - PCM 350SS (75ĆTON)

COPYRIGHT 2002
32
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
CABLE DRUM LOCK PIN

The cable drums for the main and auxiliary hooks and should be installed anytime these operations or any
boom luffing are equipped with a safety lock pin mount other operation which requires the drum to remain
structure to prevent the cable drum from turning if the stationary are being conducted. Refer to Figure 9 for
brake is released for service or repair or if the DC drive illustrations of the lock pin mount structure.
motor must be removed. The pin for the applicable drum
COPYRIGHT 2002
LeTourneau, Inc. 33
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
A A
2
4 3
7 4
5
8
6
VIEW A-A
1. MACHINERY HOUSE
2. KING PIN AND SWING TABLE STR.
3. CABLE DRUM STR.
4. LOCK PIN STR.
5. BOLT
6. LOCK PIN MOUNT STR VIEW B-B
7. BOLT
8. PLATE
FIGURE 9. LOCK PIN MOUNT STRUCTURE INSTALLATION - PCM 350SS
1ĆNGOĆ1592, P10Ć31, 6/1/98 TAĆ8949ĆCG
COPYRIGHT 2002
34
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
PCMĆ350SS STRUCTURAL REPAIRS

The following instructions pertain to structural repairs of BOOM DIAGONAL PIPES: 3" XĆHVY. X .300 wall
the crane and welding procedures which relate to safety thickness and are made from AĆ53 Gr.B or equal.
and integrity of the load bearing members.
STRUCTURAL REPAIR PROCEDURES
WELDING REQUIREMENTS Before any structural repairs are made magnetic
particle and dye penetrant tests shall be conducted.
Certain materials are manufactured exclusively by
LeTourneau, Inc. Substitution of these materials is not to ! CAUTION
be attempted without prior approval by LeTourneau,
Inc. due to the possible incompatibility of alternate BEFORE proceeding with any structural
materials. Should the owner desire, LeTourneau, Inc. repairs and/or replacements, BE SURE that
will provide personnel and materials for repairs and/or there is no load on the crane and power has
replacements if requested. been disconnected from the crane.
Instructions for welding of LeTourneau, Inc. structural ! CAUTION
steel are included in LeTourneau, Inc. Publication LeTĆ1,
FIELD WELDING PROCEDURES, located in the back of It is essential to isolate the Load Moment
Section 1, in the REPAIR AND OVERHAUL MANUAL. It is Indicator system from the crane's electrical
ESSENTIAL to review these procedures and contact system prior to welding repairs or damage will
both your distributor and LeTourneau, Inc. prior to result.
attempting ANY structural repairs to this crane. The boom should be supported in either the boom rest
or temporary supports.
NOTE
NOTE
Anyone performing structural repairs to the
crane shall meet the following qualifications: No repairs and/or replacements shall be
American Welding Society Specifications for undertaken without prior approval from
Welding Machinery and Equipment ClassificaĆ LeTourneau, Inc. and the certifying authority
tion and Application of Welded Joints for AWS under which the crane is operating. Any
D14.4 Ć 77. repairs shall be witnessed by an attending
surveyor of the certifying authority.
STRUCTURAL MATERIALS If emergency repairs and/or replacements are necesĆ
sary, the certifying authority shall be provided with a
COLUMN PLATES: 1" thick and made from NĆ20 BHT
detailed description of the extent of the repair and/or
MAIN BOOM PIPES: 6Ć5/8" O.D. LET. X .375 wall replacement, materials and procedures used, plus any
thickness and are made from high strength steel other pertinent data, at the earliest possible time.
(70,000 minimum yield, 100,000 minimum tensile Arrangements shall also be made for an inspection by
charpy of 20 lb. at -40). the certifying authority's representative.
COPYRIGHT 2002
LeTourneau, Inc. 35
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
COPYRIGHT 2002
36
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)

PAINTING RECOMMENDATIONS
These instructions cover surface preparation, coating Sandblast Equipment: Pangborn Blast System or
system and inspection requirements to be used in the equivalent
painting of LeTourneau, Inc. Electric Deck Cranes. The Paint Equipment: Devilbiss Air Spray Gun - Model MBC
recommended two coat system with two part inorganic 510 with air cap AUĆ1239Ć704; 10 gallon Pressure Feed
zinc silicate primer combats corrosion by the elimination Tank with Air Motor Agitator Q.S.A. 503 or equivalent
of rust creep" or undercutting of all blasted steel
surfaces including the crane's Machinery House, ColĆ NOTE
umn, Gantry, Boom and other structural components. Materials and equipment listed above are
These instructions are minimal requirements for normal used successfully by LeTourneau, Inc. in the
conditions. Local conditions and overall condition of the manufacturing process. Substitute items that
crane's painted surfaces may require additional meaĆ meet specifications listed are acceptable.
sures to ensure quality paint work.
SURFACE PREPARATION
NOTE
a. Securely seal the ventilator fan, access door and
Refer to paint manufacturer's specification any other place blasting sand or paint overspray might
sheets for physical properties, performance enter the Machinery House or Operator's Cab (optionĆ
limitations, additional instructions for surface al). Cover the glass and weatherstripping on the
preparation, application and safety precauĆ Operator's Cab (optional). Use masking tape or other
tions specific to the application of their suitable material to seal these areas.
products. Specification sheets for the original b. Cover or remove the wire rope as necessary to
equipment paint are provided at the end of this prevent contamination from blasting sand and paint.
article.
c. Cover and seal the swing gear and swing pinion to
! CAUTION be sure no contamination from sand or paint occurs.
d. Protect any exposed electrical wiring or terminals
Surface preparation and painting requires from damage by sandblasting.
working in close proximity with chemicals and
vapors which can cause skin and respiratory e. Sandblast to a commercial blast clean finish
(almost near white) per Steel Structures Paint Council,
injury. Read and follow all safety precautions
Surface Preparation Specification SSPCĆSPĆ10Ć63T.
mentioned in paint manufacturers specificaĆ
The grit size should be Mesh/U.S. Sieve Series and be
tions.
clean, washed silica such as Lone Star #1 or equal.
Also, follow these additional safety precauĆ Nozzle velocity of the abrasive should not be less than
tions: 100 psi.
1. Wear the appropriate respirators, eye
protection and protective clothing to prevent
! CAUTION
injury. Do not use solvents or thinners to clean Use caution to not damage seals when
skin. sandblasting in close proximity to swing
2. Do not smoke, eat or drink in the surface gearbox and drivers.
preparation and painting area. Also, keep NOTE
sparks, heat and open flames away from the
these areas. Do not reuse blasting sand. Oil and grease
should be removed by hosing or by wiping
MATERIALS AND EQUIPMENT with a suitable solvent.
RECOMMENDATIONS NOTE
a. MATERIALS RECOMMENDED After sandblasting, ALL welds should be
Sandblast Media: Lone Star #1 Bulk Blast Media or inspected by a qualified person and any that
equivalent are suspected of being cracked are to be dye
penetrant and magnetic particle tested. Refer
Paint and Primer: Refer to manufacturer's product
to STRUCTURAL REPAIRS, and publication
information following this article. LeTĆ1, FIELD WELDING PROCEDURES, loĆ
b. EQUIPMENT RECOMMENDED cated in Section 1 in the REPAIR AND
COPYRIGHT 2002
LeTourneau, Inc. 37
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
OVERHAUL MANUAL before attempting ANY

welding repairs to the structural components
! CAUTION
of the crane. Care must be taken to minimize surface
f. All rough welds, burrs, weld splatter and other contamination from atmospheric pollution
sharp surface projections should be ground smooth. such as dust, industrial fallout etc.
Any grinding done after sandblasting should be reĆ NOTE
blasted to obtain a surface like the remainder of the area
to be painted. A color contrast has been purposely estabĆ
lished between the primer and the finish coat.
g. Sandblasting and painting operations should be
The color contrast is designed to act as an
scheduled so that they will not be in progress at the
indicator to insure complete coverage with
same time or so that blasting is not in progress while
both primer and finish coat. The contrast is not
there is wet paint within the range of sandblasting
to be so great as to markedly influence the
contamination. The blast cleaned surface should be
appearance of the top coat.
coated with one coat of primer as specified during the
same day as blasted and also before any visible rust
POST PAINTING INSPECTION AND
occurs. Sandblasted steel wet by rain or moisture prior
to priming should be reĆblasted. SERVICES
Post painting inspection and servicing should be
NOTE conducted by a qualified person to be sure the
Surfaces which do not require painting should requirements listed the paint manufacturer's specificaĆ
be masked or otherwise protected during the tions are met and that no damage to crane components
painting of adjacent work. Also, be aware of by contamination from sandblasting and painting will
possible damage to surrounding rig compoĆ occur. The following inspections and services should be
nents from overspray and take appropriate performed:
measures to protect them. a. Inspect the paint to be sure that a film thickness as
listed in Figure 10 is met. Measurement should be made
PAINT APPLICATION by Dry FilmĆMikrotest or equivalent gauge.
a. Primer and paint used should be the original used b. Inspect Machinery House, control panels, motors,
in the manufacturing process or equivalent, conform to wiring, and terminals for contamination from sandblastĆ
the paint manufacturers specifications and be applied ing and painting. Vacuum out any contamination.
listed in Figure 10. c. Inspect the slewing bearing, gear, gearbox pinion
b. Painting should be done in a neat and workmanĆ and lubricant to be sure no contamination from
like manner and all joints and crevices should be filled sandblasting and painting is present. Clean and
where necessary and thoroughly painted. Paint should lubricate as required.
be applied only on surfaces that are completely dry. d. Inspect the wire rope to be sure no contamination
c. Painting should only be permitted within a range of from sandblasting and painting is present. Clean and
temperature and humidity recommended by the paint lubricate as required.
manufacturer as published in specifications for the e. Inspect pins and bushings for contamination from
particular product. sandblasting and painting and clean as required.
COPYRIGHT 2002
38
LeTourneau, Inc.
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
Component Metal Prep Primer Tie Coat Top Coat

Outer Column and Gear Str. Near white One coat inorganic One coat red One Coat Grey
(PC 350); Inner Column and shot or zinc primer 2Ć1/2 expoxy 1 MIL DFT HiĆSol expoxy
Gear Str. (PC 120) sand blast to 3 MLS DFT 4-6 MILS DFT
SSPCĆ10
Swing Table, Gantry Boom One Coat Yellow
(except tip), Machine House HiĆSolids epoxy
Exterior, Other crane structures 4-6 MILS DFT
Boom Tip One Coat Orange

HiĆSolids epoxy
4-6 MILS DFT
Machine House Wire brush to One coat epoxy None One Coat Whle
Interior remove rust primer 4 MILS DFT Polyurethane
and loose 1.5 to 2 MILS DFT
scale. Wash
to remove oil,
Welded Hand grease and None None Two coats cold
Railjoints foreign matter. galv. compound,
2-3 MILS
total DFT
YELLOW ORANGE
FIGURE 10. PCM CRANE PAINT REQUIREMENTS

COPYRIGHT 2002
LeTourneau, Inc. 39
1ĆROM 1.1, 350SS
6/25/98 (Rev 8/31/01)
FIELD WELDING PROCEDURE PUBLICATION LeT-1
NOTES
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COPYRIGHT 2001
2 7-LeT-1.3 GEN. EQUIP. (MSWord)
LeTourneau, Inc.
11-29-01
PUBLICATION LeT-1 FIELD WELDING PROCEDURE
WARNINGS AND CAUTIONS

! CAUTION
To ensure that no damage occurs to solid-
Place a DO NOT OPERATE sign on the state components, the welding ground clamp
controls while welding, maintenance or should be as close as possible to the area to
repair work is being completed. Serious be welded.
injury or death is possible if the machine is
started or moved while maintenance or
repair operations are being conducted. For
! CAUTION
the welder’s safety, always disconnect the Under NO circumstances should a bearing or
battery ground near the battery box to movable joint be between the grounding
prevent the machine from being started point and the area to be welded.
while the welder is working.
! CAUTION
Isolate ALL DDEC components before
beginning welding procedures. Damage to
If inspecting the welds of making welding components could otherwise result.
repairs on the elevated structures of a Jib
Crane, Straddle Hoist, or Marine Crane NOTE
NEVER proceed beyond existing platforms.
Moving beyond the safety of hand-railed Machines with Detroit Diesel engines
platforms could cause injury or loss of life. equipped with the DDEC system (instead of
Wear a hard hat when performing any the governor system) are also equipped with
inspections, maintenance operations or an electronic battery equalizer. To avoid
welding repairs on a Jib Crane, Straddle reverse polarity damage when disconnecting
Hoist or Marine Crane. Be sure all power is battery terminals, always remove the
turned off before touching any electrical equalizer ground terminal first and replace
connections or terminal. Only qualified and the equalizer ground terminal last.
experienced personnel should enter the
electrical control room of a Jib Crane or 1. For machines with an articulating joint,
Marine Crane. make certain that the ground strap in the
pivot area is left firmly connected
because this cable electrically “ties” the
two frame sections together.
2. If the welding unit is connected to
BEFORE working in the pivot or “pinch” area
commercial power such as in a shop
of an articulated machine, securely attach
area, the machine must be isolated from
the frame lock or steering locking pin to
all other contacts to ground other than
prevent the machine from turning. Enter this
the welding ground clamp if possible.
area only when necessary. Before operating,
Machine attachments must not contact
be sure steering locking pin is disconnected
any steel wear rails in the floor. If an
and properly stowed.
overhead crane is used to support any
part of the machine, a nonconductive
sling should be used.
3. Do not disconnect the neutral from
NEVER, under any circumstances, weld or
ground in the master junction box.
use a cutting torch on a wheel with an
Machines fitted with the optional ground
inflated tire. This could cause a tire
fault system have this connection at the
explosion resulting in serious injury or loss
fault current limiting resistors.
of life.
COPYRIGHT 2001
7-LeT-1.3 GEN. EQUIP. (MSWord) 3
11-29-01
LeTourneau, Inc.
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
GENERAL WELDING PRACTICES

PREHEAT AND INTERPASS After the electrodes have been re-baked, they may be
TEMPERATURES re-issued. Electrodes shall be re-baked no more than
once. Electrodes that have been wet shall not be used.
Preheat and interpass temperature controls are crucial
elements in making a quality weld. Preheat is defined CERTIFIED WELDERS AND APPROVED
as the temperature of the base metal in the WPS
surrounding area of the starting point of welding
immediately before welding begins. Preheat is to be All welding done shall be performed by a certified
applied using an oxy-fuel torch with a rosebud welder following an approved Welding Procedure
attachment. The minimum preheat temperature shall Specification (WPS). The WPS and welder must be
be maintained within 3” of the welding area. To qualified according to AWS D 1.1 Structural Welding
determine the proper minimum preheat temperature Code - Steel or other recognized governing code
and the maximum interpass temperature, follow the requirements.
information on. Where possible, preheat on opposite
WELDING TECHNIQUES
side of the area in which welding is being done to
insure that the temperature has soaked through the For multiple pass welds, starts and stops should
part. Temperature of the part shall be checked with stagger for each weld pass. All starts and stops should
temperature crayons to ensure correct preheat. occur before or after the corner of a structure. No slug
Interpass temperature is defined as the temperature of welding will be permitted. Where possible, use run-off
the weld between weld passes. The interpass tabs. All stops and starts should be on the tabs.
temperature shall be checked between each Remove all tabs by oxy-fuel cutting or arc gouging and
successive weld pass with temperature crayons. The grind flush. No weave welding is allowed.
start of another weld pass shall not begin until the
temperature of the part is below the maximum
CLEANING REQUIREMENT
interpass temperature at the arc initiation site. Prior to welding, all lose scale, cutting dross, grease,
oil, water, paint, rust, dirt and other contaminants are
ELECTRODE STORAGE AND HANDLING to be removed at least 2” from the edge of the joint.
All SMAW electrodes shall be removed from a fresh During welding, all individual passes are to be cleaned.
hermetically sealed canister or from baking or storage No slag welding is allowed. After welding, remove slag
ovens. Electrodes shall be issued and held in quivers and spatter from the weld and welding area by
or other small open containers by the welder until appropriate means. Excessive grinding should be
used. After hermetically sealed containers are opened avoided, but blend grind all repairs.
or after electrodes are removed from baking or storage
ovens, the electrode exposure to the atmosphere shall
WELDING DEFECTS
not exceed the values shown in Figure 1. Electrodes The following discontinuities will cause the weld to be
exposed to the atmosphere for periods less than those deemed defective and will require for the discontinuity
permitted by Figure 4 may be returned to a holding and/or the defective weld to be removed.
oven maintained at 250°F minimum for a minimum · Porosity (Pinholes) - any cavity type
hold time of four hours. Electrodes exposed to the discontinuity.
atmosphere for periods greater than those permitted in · Overlap (Cold lap) - protrusion of weld metal
Figure 4 shall be re-baked as follows: beyond the weld toe or weld root.
· All electrodes having low-hydrogen coverings · Crack - a fracture of the weld metal and/or the
conforming to ANSI/AWS A5.1 shall be baked for base metal characterized by a sharp tip and high
at least two hours between 500°F and 800°F. length to width ratio.
· All electrodes having low-hydrogen coverings · Undercut - Removal of parent material at the toes
conforming to ANSI/AWS A5.5 shall be baked for of the weld.
at least one hour at temperatures between 700°F
and 800°F.
COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
PROPER ELECTRODE SELECTION d. Prepare the joint as defined by engineering. Repair

(refer to Figure 1 to determine class) all excessive gouges and nicks up to 3/16” by blending
the metal by grinding. All discontinuities about 3/16”
Class Electrode are to be restored to the original joint profile using the
approved WPS for the structure.
1 E7018-1 e. Clean the joint as defined above.
2 E7018-1 f. Preheat the joint using guidelines defined in Figure
3 E8018C3 1, Figure 2 and Figure 3.
g. Weld using requirements and techniques as
4 E9018-M
described above.
5 E9018-M h. Visually inspect the weld during and after welding.
If a defect is noted, refer to FIELD REPAIR OF A
FIELD WELDING DEFECTIVE WELD to make the repair.
Defined as any welding done outside of the original
fabrication environment in which an item is being FIELD REPAIR OF A DEFECTIVE WELD
welded to the structure for the first time. Defined as any welding done outside of me original
a. Check with the engineering print to ensure fabrication environment in which a structure is being
dimensional accuracy. welded on to repair a defective weld or base material.
b. Determine the base metals being joined to a. Determine the extent of the defect by using Non-
determine the proper preheat and interpass Destructive Examinations (NDE) such as Magnetic
temperatures (refer to Figure 1, Figure 2, Particle Inspection (MT) or Liquid Penetrant Testing
Figure 3). (PT).
c. Preheat the weld joint. b. Preheat the area of the defect to be removed to
d. Weld using requirements and techniques 250°F.
described above. c. Use Air Carbon Arc Gouging to remove the defect.
e. Visually inspect the weld during and after welding. If the defect is a crack, remove the crack plus one inch
If a defect is noted, refer to FIELD REPAIR OF A past the termination of the crack.
DEFECTIVE WELD to make the repair. d. MT or PT the area to ensure the defect has been
removed.
FIELD REPLACEMENT WELD e. Clean the weld joint as defined above.
Defined as any welding done outside of me original f. Preheat the joint using guidelines defined in Figure
fabrication environment in which an item is being 1, Figure 2 and Figure 3.
welded to the structure to replace a worn or defective g. Weld using requirements and techniques
item. described above.
a. Before removing the old item, make any h. MT or PT and visually inspect the completed weld.
dimensional markings as needed. If a defect is still detected, repeat Steps “a” through “h”.
b. Preheat the area to be gouged to 250°F.
c. Use Air Carbon Arc Gouging to remove the old
item. Be sure not to damage the permanent items in
the structure.
COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
Class 1 Class 2 Class 3 Class 4 Class 5

A-36 C23M (1506) 4820H 8630M N40 FSC (1510)
EH36 NC23M (1517) N20 Cl-1 (1518) NN30 (1508) A514-Q
A-106-B C1035 N20 Cl-2 (1518) N20 HS (1503) N30 FSC (1508)
A500 A572 Gr-50 N20 Cl-3 (1518) NN-20HS (1503) N30 LVR (1508)
1026 N20 Cl-5 (1518) N20 Hi Moly (1504) N30 HN (1509)
C1010 M&M Class 2 (1512) N20 HMRB (1505) N25HN HTF S1 (1516)
CMS10 M&M A/R (1512) NN25 (1507) 4340
Mild .33 Max Carbon A516-70 M&M Class 3 (1512)
8720-H M&M Tubing (1511)
4130 N-20 Cl-6 (1518)
A710 Class 1
A710 Class 3
Figure 1. MATERIAL WELDABILITY GROUPING
Material Thickness Class 1 Class 2 Class 3 Class 4 Class 5

< or = 3/4” 100°F 100°F 125°F 175°F 200°F
>3/4” to 1-1/2” 125°F 150°F 225°F 225°F 250°F
>1-1/2” to 2-1/2” 150°F 225°F 250°F 275°F 300°F
>2-1/2” 225°F 300°F 300°F 325°F 350°F
Figure 2. PREHEAT REQUIREMENTS
Material Thickness Class 1 Class 2 Class 3 Class 4 Class 5

< OR = 3/4” 500°F 500°F 500°F 450°F 450°
>3/4” to 1-1/2” 500°F 500°F 500°F 450°F 450°F
>1-1/2” to 2-1/2” 500°F 500°F 500°F 450°F 450°F
>2-1/2” 500°F 500°F 500°F 450°F 450°F
Figure 3. INTERPASS MAXIMUM
Electrode Maximum Electrode Maximum

Exposure Exposure
Time (hours) Time (hours)
E70XX 4 E70XX-X 4
E70XXR 9 E80XX-X 2
A5.1 E70XXHXR 9 A5.2 E90XX-X 1
E7018M 9 E100XX-X 1/2
E110XX-X 1/2
Figure 4. MAXIMUM EXPOSURE TIME
COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
STRUCTURAL WELDING OF HIGH STRESS JOINTS

The following procedure is provided as a generic
procedure for the repair of cracks that may appear in
the load bearing components of LeTourneau, Inc.
Material Handling Equipment.
NOTE
This procedure applies only to crack repairs.
Replacement of a ball or socket should be
done in accordance with the Lower Ball,
Pivot Ball and Pivot Ball Socket Field
Replacement Procedures.
Figure 5. GRINDERS
PREPARATION
a. Steam clean the area to remove all contamination
on weld joints.
b. Clean the area to be welded of all rust, paint, oil,
grease, dirt and/or mill scale. ELECTRODE
c. Before any cutting or air carbon arc gouging is GREATER THAN 3X

DIAMETER WEAVE
performed, ensure the area is dry.
d. Preheat the area around the crack to at least
250°F (121°C).
NOTE NOT ACCEPTABLE FOR STRUCTURAL REPAIRS

WEAVE WELD
1-NGO-2859, P03-53 TA-10310
If the crack is in a casting or a weld attached
to a casting, the preheat is 350°F (177°C).
The preheat area should extend 3” from the
crack. Maintain the preheat temperature Figure 6. WEAVE WELD
during the repair procedure.
e. Use air carbon gouging to remove the crack. d. Bake previously opened packages of electrodes in
a ventilated oven at 500°F (260°C) for two hours
f. Test the area after arc air has been completed with before using.
die penetrant or mag particle to assure that the entire
crack has been removed. Continue to air carbon arc e. Electrodes taken from cardboard boxes or a non-
gouge until the crack has been removed. airtight container should also be baked at 500°F
(260°C) for two hours in a ventilated oven. Then they
g. Grind the entire gouged area (100%) so that the should be placed immediately in a ventilated holding
steel is free of any slag and carbon deposits. Shiny oven set at 225°F (107°C).
steel material should be visible in all parts. This can be
done with either air powered or electric powered f. Any electrode exposed to the air for more than four
grinders as shown in Figure 5. hours should be re-baked per the instructions above.
g. Preheat the area to be welded with a heat blanket
WELDING or torch to a temperature of 250°F (121°C).
a. Use AWS Class E7018-1 low hydrogen electrodes
for the repair. These electrodes must be clean and dry. NOTE
b. Control the moisture in low hydrogen electrodes by If the crack is in a casting or a weld attached
purchasing electrodes in 10 pound (4.5 kg) sealed to a casting, the preheat is 350°F (177°C).
packages.
The preheat area should extend 3” from the
c. Remove only one hour’s supply of electrodes at a crack. Check periodically and maintain the
time. Keep the remainder in a ventilated holding oven preheat temperature during the repair
at 225°F (107°C). procedure. The temperature should be
checked using heat crayons or heat sticks.
COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
h. When welding use stringer beads. The bead width

ELECTRODE
must be no wider than 3 times the rod diameter. Refer
to Figure 7.
WELD BEADS
ELECTRODE
STRINGER BEAD WIDTH

MAXIMUM 3X ELECTRODE
DIAMETER
BACKUP STRIP ROOT PASS BEAD

MAX STRINGER BEADS
3X
ELECTRODE
GREATER THAN 3X
DIAMETER WEAVE
WELD BEADS
STRINGER BEAD
WIDTH OF BEAD = MAXIMUM 3X ELECTRODE DIAMETER
1-NGO-2860, P03-53 TA-10309
Figure 7. STRINGER BEAD

THIS WELD IS UNACCEPTABLE
1-NGO-2861, P03-53 TA-10311
i. No weave welds are permitted. Refer to Figure 6. Figure 8. BACKUP STRIP

j. Use a backup strip made from 1/4” thick mild steel
(when practical) if the crack penetrates completely
through the plate. Refer to Figure 8.
k. Weld the root pass bead for the complete length of
the bottom of the crack area.
l. Remove the slag from the root pass with an air
scaler or air chisel.
m. To ensure that the root pass has no cracks,
visually check the root pass weld. Use die penetrant or
mag particle if a crack is suspected. If cracks are
found, the root should be gouged out, edges ground
smooth with a grinder and re-welded. EACH PASS MUST BE COMPLETED FOR THE
FULL LENGTH OF THE REPAIR AREA PRIOR
NOTE TO BEGINNING THE NEXT PASS.
1-NGO-2862, P03- TA-10312
If there are problems with cracks in the root
pass using the 7018 electrode, then it is Figure 9. FULL PASS WELD
permissible to use either 6013 or 6011
450°F (232°C). Use heat crayons or heat sticks
electrodes to make the root pass. adjacent to the weld to check temperatures. Refer to
n. Continue the bead for a full pass the length of the Figure 10.
weld prior to beginning a second pass. Refer to Figure p. Starts and stops on each pass should each be in
9. different locations from the previous passes. Refer to
o. Interpass temperature (temperature in the base Figure 11.
material 1” away from the weld) should not exceed
COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
INTERPASS TEMPERATURE
HEAT CRAYON 1" AWAY FROM THE WELD
OR GRINDING TO BE ACROSS
HEAT STICK GRINDER THE WELD DIRECTION
SMOOTH FINISH
NO GRINDING
MARKS
1-NGO-2863, P03-53
TA-10313
Figure 10. INTERPASS TEMPERATURE
1-NGO-2866, P03-53 TA-10316
Figure 13. WELD FINISHING
STARTS AND STOPS FOR EACH BEAD

ARE STAGGERED IN DIFFERENT LOCATIONS
1-NGO-2864, P03-53 TA-10314
Figure 11. WELD STARTS AND STOPS

q. Remove the slag after each pass with an air
powered needle scaler or chipper. Refer to Figure 12.
GRINDING DIRECTION
ACROSS THE WELD
MUST BE SMOOTH POLISH FINISH
AFTER COMPLETION
1-NGO-2867, P03-53 TA-10317
Figure 14. WELD POLISHING
r. Peen each bead, except for the root and cap

passes, with the scaler or chipper to reduce stress
concentrations.
s. Grind the weld-repaired area to blend in with the

adjacent base material. No undercut is allowed. Grind
feed marks should not be visible when the grinding is
finished. If necessary, polish with an emery wheel or
disk. Refer to Figure 13 and Figure 14.
t. If surrounding air is above 40°F (5°C), post-heating

after welding is NOT necessary. If surrounding air is
below 40°F (5°C), post-heat the entire repaired area
1-NGO-2865, P03-53 TA-10315 uniformly at 350°-400°F (177°-204°C) then air cool.
Figure 12. NEEDLE SCALER KIT, SCALERS
COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
UPPER BALL
FIELD REPLACEMENT PROCEDURE
For upper ball field replacement, perform the following accomplished by laying a straight edge on the ball
procedures: base and measuring out from the side plate ring to the
straight edge (refer to Detail “1”, Figure 15).
a. Before removing the damaged ball, a locating
dimension must be established so that the new ball b. Scribe a mark around the weld joint 1/4” out from
can be located properly. This dimension is taken from the side plate ring. This scribe mark is to be used when
the shoulder of the ball base, across the weld joint, to cutting off the ball base (refer to View “A”, Figure 15).
the face of the side plate ring. Make three or four c. Scribe a mark around the base of the ball 1-3/4” in
measurements around the ball (refer to View “A”, from the outer diameter of the ball base. This scribe
Figure 15). The shoulder of the ball base may have its mark is to be used when cutting off the ball base (refer
corners beveled, as shown in Detail “1”. Make sure the to View “A”).
locating dimension is taken from the original shoulder
corner and not from the beveled corner. This can be
SCRIBE LINE
STEP "b"
TUBE
DO NOT CUT
PAST THIS LINE BALL BASE
WHILE CUTTING
REMOVE THIS SECTION BASE OFF SHIMMING
WITH AIR ARC DIMENSION
1/4" ORIGINAL STEP "h"
STEP "e"
1-3/4" WELD AREA
DETAIL 2
B
1/4"
SCRIBE LINE
STEP "c" GRIND THE
END OF THE
TUBE CLEAN
ADDITIONAL WELD
WILL BE REQUIRED
TO FILL THE ID OF
TUBE WHERE AIR ARC
UNDER CUT THE TUBE VIEW C
CUT B
STEP "d"
CUTS FOR
LOCATING
DIMENSION AREA STEP "f" & "I"
REMOVED LOCATION
DIMENSION
STEP "a"
STEP "e"
VIEW A VIEW D
1-3/4" AREA CUT

SCRIBE LINE STEP "d"
BALL BASE VIEW B 16,965

1/8" RADIUS - BOTH ENDS
ORIGINAL
SHOULDER TOOL DRAWING GAGE ROD - MAT. 1/4" ROUND
CORNER
6 TO 8 FT. HEIGHT OF
1"
LOCATING NEW BALL + 2" DRILL 7/16" DIA. HOLE
DIMENSION
LIFTING LUG MUST BE IN THE SAME
1/2" PLATE PLANE AS THE LIFTING
STEP "a"
1/4" LUG. INSERT 3/8" x 2"
SIDE PLAE BOLT FROM THIS SIDE
RING
DETAIL 1 LOCATION FOR

BALL INSTALLATION TOOL 1" FLAT WASHER
1" DIA. ROD
1-NGO-1281, P08-24 TA6075CG
Figure 15. UPPER BALL FIELD REPLACEMENT
COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
d. Use air-arc to cut the ball off at the neck, as shown 2. Place the ball in liquid nitrogen and freeze for
in View “A”. 30 to 40 minutes. Watch the position of the
e. Use air-arc to cut the ball weld joint out. The lifting lug on the ball installation tool so that the
intersection of the 1/4” and 1-3/4” scribe marks is used 3/8” X 2” bolt does not fall out.
to locate the approximate root of the weld joint. Do not m. TUBE EXPANSION:
undercut past the 1/4” scribe mark (refer to View “A”, 1. Heat is required to enlarge the tube bore. The
Figure 15). five-inch slab around the tube is to be heated
f. Make two air-arc cuts 90° from each other as first to about 300°F (149°C), and then the tube
shown in View “B”. Be careful not to cut into the tube. can be heated to 300°F (149°C).
g. Remove the pie shaped section of the ball base. 2. Use the gage rod to check expansion of the
h. Before cutting and removing the other ball base tube. If gage rod will not go into tube, then
section, determine the dimension between the bottom increase slab and tube temperature by 25°F (-
of the ball and the machined recess in the tube (refer 4°C) and recheck with gage rod.
to Detail “2”). A shim of this dimension will be used n. BALL INSTALLATION PROCEDURE:
when installing the new ball. This dimension should be
1. Be sure the shim install in Step “j”, 3 is still in
approximately 0.125”.
place. Hoist the frozen ball into position and
i. Cut and remove the rest of the ball base section insert into the heated tube. You will have three
(refer to View “B”, Figure 15). to four minutes to locate the ball. The ball
j. TUBE WELDING PREPARATION: should bottom against the shim. Check the
1. The end of the tube is to be replaced by locating dimension obtained in Step “a”. This
grinding clean and welding up any air-arc should be checked in three or four places
undercut of the tube below the 1/4” scribe line. around the ball. Reposition, as necessary, to
Preheat the weld area to 300° F (149°C) and hold this dimension until the ball temperature
weld with material listed in Step “o”, 1 (refer to increases to the point that the ball is held
View “C”). snugly in place within the tube. This dimension
2. Grind the end of the tube and, if necessary, must be held for proper ball location (refer to
grind the I.D. as the machine surface of the View “D” of Figure 15).
tube (refer to View “C”). 2. Allow the ball and tube to return to room
3. Install a shim, of your making, in the bottom of temperature.
the machined recess in the tube. The 3. Rotate the ball installation tool until the 3/8” X
thickness for this shim was determined in Step 2” bolt falls out. Remove the installation tool.
“h”. o. BALL WELDING PROCEDURE:
k. INSTALLATION TOOL FABRICATION: 1. Preheat the weld area to 300°F (149°C) and
1. Fabricate the ball installation tool, as shown in maintain this temperature while welding out
tool drawings on Figure 15. the joint. Arc weld with 1/8” diameter
2. Make gage rod tool, as shown in tool drawing E-8018C1 electrodes or MIG weld with Tri-
on Figure 15. Mark TM-911N2 flux cored wire. The
l. BALL FREEZING PROCEDURE: electrodes must have been stored in a sealed
container and heated in a 250°F (121°C) oven
1. Insert the installation tool through the new ball.
for 30 minutes before welding. Do not weave
Place a 1” flatwasher over the 1” rod and put a
weld.
3/8” X 2” bolt through the 7/16” hole. Do not
put a nut on the 3/8” bolt. 2. The cap passes must be blended smooth. If
not, they must be ground smooth.
3. Paint the repair area.
COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
LOWER BALL
The following procedure is set forth for the field f. Grind the end of the tube clean and if necessary
replacement of the lower ball structure. grind the I.D. of the tube to the same I.D. as the
a. Before removing the damaged ball, a locating machined surface of the tube. See View “B”, Figure 16.
dimension must first be established so that the new g. Install spacer ring in the tube bore to provide
ball can be located. This dimension is taken from the positive stop when installing ball.
edge of the side plate ring to the shoulder of the base h. Install new ball. It should be loose fit into the tube.
ball. If heat is required to enlarge the tube bore, the side
b. Scribe a mark around the weld joint one inch out plate is to be heated first to about 300°F (149°C) and
from the side plate ring. Do not cut past this line when then the tube can be heated to 300°F (149°C).
cutting the ball off. See View “A”, Figure 16. i. Use the dimension obtained in Step “a” to locate
c. Scribe a mark around the base of the ball the new ball in the end of the tube. Tack weld in place
1-13/16” in from the outer diameter of the ball base. four places. See View “C”, Figure 16.
d. Use air-arc to cut the ball weld joint out. Do not cut j. Preheat the area to 300°F (149°C) and maintain
past the one-inch reference line at the surface. The 1- this temperature while welding out the joint.
13/16” reference line and the 2-9/16” depth dimension k. Use 1/8” diameter E-8018C1 electrodes that have
can be used to locate the root of the weld joint. been stored in a sealed container and heated in a
e. The end of the tube is to be repaired by grinding 250°F (121°C) oven for 30 minutes to weld the joint.
clean and welding up the air-arc undercut with Do not weave the electrode more than 1-1/2” times the
E-8018C1 electrodes. Preheat to 300°F (149°C) before diameter of the rod.
welding. Do not over weld I.D. or it will have be ground l. The cap passes must be blended smooth. If not,
by hand. they must be ground smooth.
m. Paint the repair area.
Figure 16. LOWER BALL FIELD REPLACEMENT
COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
PIVOT BALL FIELD REPLACEMENT PROCEDURE

For replacement of the pivot ball, perform the following first three root passes. Finish the weld by completing
procedures: each layer all the way around the ball before starting
on the next layer. (Rod size is not important after the
a. Separate the pivot ball from the pivot socket as
first three passes). Tri-Mark TM-911N2 gas shielded
described in the FRONT FRAME REMOVAL, in
flux cored wire may be used for all welding.
Section 1, STRUCTURAL, in the REPAIR AND
OVERHAUL MANUAL. i. Do not exceed 400°F (204°C) in the neck area of
the ball at any time and never contact the carburized
b. Clean the repair area free of dirt and grease.
area with the torch. Do not allow the heat transference
c. Preheat cross-member to 200°F (93°C) and cut off to cause the temperature of the ball to exceed 300°F
old ball. (149° C).
d. Repair any gouges or cracks in the slab while it is j. Extend the weld out from the edge of the ball
still hot, using dry E-8018C electrodes. (If E-8018C 1-3/8” and blend smooth the slab by grinding.
electrodes are not available, E-70l8 electrodes are
k. Wrap the ball and cross-member to extend the
acceptable, but only for slab repairs.
cool down time. Ball must cool down to at least 100°F
e. Grind cross-member surface smooth. (38°C) before reassembling.
f. Place a 1/16” diameter copper wire around the ball l. Follow the PIVOT BALL SOCKET
base. Space wire away from the edge of the ball base REPLACEMENT PROCEDURE. One socket must be
so the wire does not melt into the weld. Refer to Figure removed and reinstalled to insure correct alignment
17. and preload with the new ball.
g. Preheat the slab around the perimeter of the ball m. Clean and paint the repaired area.
base until the ball base temperature is 300°F (149°C).
n. Follow the re-assembly procedures outlined in
Do not exceed this temperature.
Section 1, STRUCTURAL, in the REPAIR AND
h. Weld the ball base to the cross-member using dry OVERHAUL MANUAL.
E-8018C electrodes. Use a 1/8” diameter rod for the
BEVEL AROUND BALL BASE
3/8 in. MINIMUM
PILOT STUD
1-NGO-1284, P08-25 TA8246CG

1/16 in. DIA. WIRE
WIRE PART #151-0182
Figure 17. PIVOT BALL REPLACEMENT
COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
PIVOT BALL SOCKET

To replace the pivot ball socket, perform the following k. Heat the socket and cross-member area adjacent
procedures: to the socket to 250°-350°F (121°-177°C) and tack
firmly into place using dry E–8018C1 electrodes or Tri-
a. Separate the front and rear halves of the machine
Mark TM-911N2 gas-shielded flux cored wire.
as described in FRONT FRAME REMOVAL, in Section
1, STRUCTURAL, in the REPAIR AND OVERHAUL l. E-8018C1 electrodes, 1/8” diameter, should be
MANUAL. If the pivot ball is also being replaced, used to make the first three root passes. Finish each
replace the pivot ball first. Refer to PIVOT BALL FIELD root pass by completing each pass all the way around
REPLACEMENT PROCEDURE. the socket before starting the next pass. Rod size may
be increased after the first three root passes are
b. Clean the repair area free of dirt and grease.
completed. Welds are to be stringer beads, not weave
c. Preheat the cross member to 200°F (93°C). Cut welds. Tri-Mark TM-911N2 gas-shielded flux cored
the weld from around the socket using air-arc. Refer to wire may also be used for all welding.
Figure 18 and dimensions of the new socket for depth
m. Wrap the cross-member and the socket to extend
and angle of cut in cross-member.
the cool-down time. Allow to cool to at least 100°F
d. Bevel slab as shown in Figure 18. (38°C) before proceeding further.
e. Repair cracks and gouges in slab while it is still n. Disassemble the ball cap and socket to install
hot, using dry E-8018C1 electrodes. (If E-8018C1 shims. Follow the re-assembly procedure outlined in
electrodes are not available, E-7018 electrodes are ASSEMBLY OF REAR FRAME TO FRONT FRAME
acceptable). AND BALL CAP SHIMMING PROCEDURES, located
f. Clean up notch in slab for re-welding. in Section 1, STRUCTURAL, in the REPAIR AND
OVERHAUL MANUAL. Be sure to check the steering
g. Measure and record the dimension between the
pivot ball cap shim tolerance as indicated in this
upper and lower cross-members that the pivot balls
section.
mount to. The measurement should be as close to ball
centerline as possible. The measurement must be .001
inch.
h. Hoist the ball cap and socket up to the ball base
and install around ball base using new liners. Omit the
spacer and shims between the ball cap and socket,
and snug up the capscrews.
i. Join the machine halves together allowing the
socket to seat firmly against the rear of the notch in the
slab.
j. Using a jack underneath the lower ball and socket,
push until the cross-member deflects to .010-inch
minimum and .015 inch maximum. Reference
dimensions in Step “g”.
Figure 18. PIVOT BALL SOCKET

REPLACEMENT
COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
NOTES
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COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
JC-40SS A-FRAME TIE PLATE INSTALLATION

The following procedure is for installing tie plates to 1. The tie plate slots (1-5/8”) may require
repair loose A-frame pin bores on JC-40SS Cranes. trimming to fit the ears of the base beam. After
trimming, grind smooth all torch marks and
NOTE bevel edges as required. Refer to Figure 19.
Ensure plates are installed on the correct
Before beginning these repairs, review
sides of A-frame legs.
WARNINGS AND CAUTIONS. All weld and
heat treat procedures used in these repairs 2. Weld tie plates on the counterweight boom
should be per the welding instructions, side according to welding installation
located in STRUCTURAL WELDING OF HIGH procedures shown in Figure 20, Figure 21 and
STRESS JOINTS. Use 7018 electrodes. Figure 22.
3. The weld areas in the center of the plate
INSTALLATION OF A-FRAME TIE PLATES should be free of flaws and imperfections.
a. Move trolley to the outer end of the boom. This Grind if necessary.
places the counterweight boom cables in tension and
places the A-frame pins in a partially loaded ! CAUTION
configuration. DO NOT WELD TO THE TOP FLANGE OF
1. After positioning trolley, lock out control THE BASE BEAM.
systems to prevent accidental crane operation.
4. Grind smooth all repaired areas and check for
2. Position ground leads close to repair area to
cracks.
prevent possible damage to crane electronics.
5. Paint all repaired areas.
3. Inspect A-frame ears and I-beam areas for any
cracks to be repaired before proceeding. Use 6. Inspect at P.M. intervals.
non-destructive test methods.
NOTE
b. Install two tie plates, P/N 413-9717 (inside) and
413-4779 (outside) on each A-frame leg. Refer to Although not expected to be required, the
Figure 19. same procedure applies to the boom side A–
frame pin configurations.
NOTE
USE SINGLE WELD PASS ONLY. DO NOT
USE WEAVE WELDS.
NOTES
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COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
A-Frame
Boom
A-Frame Pin
Locations
Counterweight Boom
1-NGO-2070, P10-94
TA-9347-CG
Figure 19. A-FRAME PIN LOCATIONS
COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
The 1-5/8" slot will be fitted to

the crane. Grind smooth any
torch marks. Prepare a 3/4"
bevel for weld.
P/N 413-9717
Tie Plate, Inside A-Frame
The 1-5/8" slot will be fitted to

the crane. Grind smooth any
torch marks. Pepare a 3/4"
bevel for weld.
1-CG-2071, P10-94
P/N 413-4779
TA-9348-CG
Tie Plate, Outside A-Frame
Figure 20. A-FRAME TIE PLATES
COPYRIGHT 2001
11-29-01
LeTourneau, Inc.
PUBLICATION LeT-1
LETOURNEAU, INC.
FIELD WELDING PROCEDURE
MATERIAL HANDLING EQUIPMENT
TABLE OF CONTENTS LIST OF ILLUSTRATIONS

PAGE PAGE
SCOPE OF THIS PUBLICATION.................................................. 1 Figure 1. MATERIAL WELDABILITY GROUPING ..................7
WARNINGS AND CAUTIONS ...................................................... 3 Figure 2. PREHEAT REQUIREMENTS ..................................7
GENERAL WELDING PRACTICES.............................................. 5 Figure 3. INTERPASS MAXIMUM ..........................................7
PREHEAT AND INTERPASS TEMPERATURES...................... 5
Figure 4. MAXIMUM EXPOSURE TIME .................................7
ELECTRODE STORAGE AND HANDLING .............................. 5
Figure 5. GRINDERS .............................................................9
CERTIFIED WELDERS AND APPROVED WPS....................... 5
Figure 6. WEAVE WELD ........................................................9
WELDING TECHNIQUES......................................................... 5
Figure 7. STRINGER BEAD ................................................. 10
CLEANING REQUIREMENT .................................................... 5
Figure 8. BACKUP STRIP .................................................... 10
WELDING DEFECTS ............................................................... 5
Figure 9. FULL PASS WELD................................................ 10
PROPER ELECTRODE SELECTION ....................................... 6
FIELD WELDING...................................................................... 6 Figure 10. INTERPASS TEMPERATURE............................... 11
FIELD REPLACEMENT WELD................................................. 6 Figure 11. WELD STARTS AND STOPS................................ 11

FIELD REPAIR OF A DEFECTIVE WELD ................................ 6 Figure 12. NEEDLE SCALER KIT, SCALERS ........................ 11
STRUCTURAL WELDING OF HIGH STRESS JOINTS................ 9 Figure 13. WELD FINISHING ................................................. 11
PREPARATION ........................................................................ 9 Figure 14. WELD POLISHING................................................ 11
WELDING................................................................................. 9 Figure 15. UPPER BALL FIELD REPLACEMENT .................. 13
UPPER BALL FIELD REPLACEMENT PROCEDURE ............... 13 Figure 16. LOWER BALL FIELD REPLACEMENT ................. 15
LOWER BALL FIELD REPLACEMENT PROCEDURE ............. 15
Figure 17. PIVOT BALL REPLACEMENT............................... 17
PIVOT BALL FIELD REPLACEMENT PROCEDURE................. 17
Figure 18. PIVOT BALL SOCKET REPLACEMENT .............. 19
PIVOT BALL SOCKET FIELD REPLACEMENT
PROCEDURE ............................................................................. 19 Figure 19. A-FRAME PIN LOCATIONS .................................. 22
JC-40SS A-FRAME TIE PLATE INSTALLATION....................... 21 Figure 20. A-FRAME TIE PLATES ......................................... 23
INSTALLATION OF A-FRAME TIE PLATES........................... 21 Figure 21. WELDING INSTALLATION.................................... 24
Figure 22. WELDING INSTALLATIONS ................................. 24
Publication LeT-1, FIELD WELDING PROCEDURES,

provides instructions for welding structural components
on all LeTourneau, Inc. Log Stackers, Straddle Hoists,
Side Porters, Jib Cranes, Marine Cranes and Letro-Pik
Aircraft Cranes. To avoid personal injury or damage to
machine components, it is essential to follow the
instructions in this publication.
COPYRIGHT 2001
7-LeT-1.3 GEN. EQUIP. (MSWord)
1
LeTourneau, Inc.
11-29-01
A-Frame
Structure
Tie Plate
P/N 413-9717
Tie Plate
P/N 413-4779
Weld Areas
(both sides of eye)
I Beam Typ
1-NGO-2072, P10-94 TA-9349-CG
Figure 21. WELDING INSTALLATION
A-FRAME
TYP
413-4779
TIE PLATE
413-9717
TIE PLATE
TYP
NO WELD
TYP
1-NGO-2073, P10-94
TA-9350-CG
Figure 22. WELDING INSTALLATIONS
COPYRIGHT 2001
LeTourneau, Inc.
11-29-01
AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS)

DESCRIPTION OF OPERATION
The purpose of the Automatic Overload Protection This system is required by Norwegian Petroleum
System (AOPS) is to automatically (no operator interĆ Directorate (NPD) regulations for North Sea operations,
vention required) relieve hoist line tension in the event of and may be disabled for other operations by positioning
a sensed gross overload on the hook. the Overload Protection switch to Reset, and positionĆ
ing the rightmost circuit breaker in the cab junction box
If the crane experiences an overload of 140% (user (CB28) to the open (down) position.
adjustable) or more of maximum rated load, the Wylie
loadĆmoment system termination unit board will signal
the Gross Overload Sense card (mounted on the upper OVERLOAD PROTECTION SWITCH - Leave in Reset
rightĆhand side wall of the cab relay box) to apply 24V to (AOPS disabled) unless told otherwise.
wire GOL. Wire GOL applies 24V to the hoist controller,
If told otherwise:
which turns on the Gross Overload Light and causes the
hoist motor to automatically come to a stop (if moving), • Overload Protection Switch ................................ON
regardless of operator control inputs. The hoist controlĆ • Overload Protection Active Light (Green) ...........ON
ler then energizes CR44, which energizes SOL1 (Brake To Reset the AOPS after an Activation:
Master Solenoid) and SOL8. The hoist controller also
• Overload Protection Switch ..................Reset
energizes CR44A, which energizes SOL9. SOL8 and
SOL9 route hydraulic pressure away from the top brake • Gross Overload Light............................OFF
canisters of the main and auxiliary hoist motors • Overload Protection Active Light ...........OFF
respectively and to the proportional relief valve soleĆ
• Overload Protection Switch ...................ON
noids, SOL3 and SOL5 (see machine hydraulic scheĆ
matic). Since no current is sent to energize SOL3 or • Overload Protection Active Light.............ON
SOL5 (these are only energized during Power Loss NOTES:
Lowering System (PLLS) events), all hydraulic pressure
to the top canisters is bypassed to tank through SOL3 a. A flashing Gross Overload Light indicates that the
and SOL5, and the top canisters remain fully set. AOPS has malfunctioned and has disabled itself. Clear
the malfunction indication by taking the Overload
At the same time, the hoist controller will also energize Protection Switch to Reset and back to On.
CR43, which energizes either SOL2 if the main hoist is b. A flashing Hoist Brakes Light indicates that a brake
selected, or SOL4 if the auxiliary hoist is selected, This is dragging. This indication is generated by pressure
applies full hydraulic pressure to the selected motor's switches mounted on each hoist brake canister. Stop
bottom brake canister, releasing it fully. hoisting until proper release of both hoist brake
The end result is that when the AOPS is triggered by the canisters has been verified.
Wylie system, the top brake canister of the selected c. The AOPS needs to be tested every six months.
hoist motor will be fully set, and the bottom brake Refer to Publication OSMĆ4 (Preventive Maintenance
canister will be fully released, resulting in a holding force Requirements and Recommendations) in the Operating
of approximately 150% of maximum rated load. If a true and Service Manual. The AOPS needs to be recaliĆ
gross overload exists, the load will pull through the one brated if the Wylie loadĆmoment system is recalibrated.
brake canister without causing structural damage to the See AOPS TEST AND CALIBRATION PROCEDURE of
crane. this document.
COPYRIGHT 2002
83
LeTourneau, Inc.
4ĆROM 6.2e, Gorilla
9/25/01
AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS)

TEST AND CALIBRATION PROCEDURE
TEST PROCEDURE resistance until the Gross Overload Light comes on
(approximately 900 ohms, start with high resistance and
To fully operationally test the AUTOMATIC OVERLOAD
work down). This should happen at approximately
PROTECTION SYSTEM (AOPS) would require actually
140% of maximum rated load (28,000 lbs. on the display
grossly overloading the crane, which is not a desirable
for both the PCM350 and PCM120 (maximum rated load
situation. The best alternative is to simulate a gross
= 20,000 lbs)). Visually check that the top canister of the
overload and confirm that the proper system response
aux hoist motor brake remains set, that the bottom
take place.
canister releases fully, and that LED 3 on the hoist
a. Position the hooks to a safe area. Remove the controller (GOL Veac Disable, visible through the
cover from the Wylie load moment box in the cab. window in the hoist controller front cover) illuminates.
Position the hook select switch to MAIN. Connect a The external cab mounted alarm and the machinery
potentiometer (5k ohm ideal) or decade resistance box house mounted alarm, which should already be soundĆ
across terminals T2 and T6 on the Wylie circuit board. ing from an overload greater than 100%, will change
Varing the resistance across these terminals will from their normal tones to a pulsating tone, indicating an
artificially cause the load readout on the Wylie display to AOPS activation. Clear the alarms with the AcknowlĆ
change. Turn the Overload Protection Switch and the edge Horn Button, remove the added resistance, and
Master Switch to ON. Adjust the resistance until the take the Overload Protection Switch to RESET.
Gross Overload Light comes on (approximately 2.8k
CALIBRATION PROCEDURE
ohms, start with high resistance and work down). This
should happen at approximate 140% of maximum rated If necessary, the gross overload trip point for each hook
load (210,000 lbs. on the display for the PCM350 can be adjusted by pots on the Gross Overload Sense
(maximum rated load = 150,000 lbs.); 140,000 lbs. for Card (P/N 422Ć7381). This card is mounted on the inside
the PCM120 (maximum rated load = 100,000 lbs)). rightĆhand wall of the cab junction box; bottom pot
Visually check that the top canister of the main hoist calibrates the main hook, top pot calibrates the aux
motor brake remains set, that the bottom canister hook.
releases fully, and that LED 3 on the hoist controller Adjusting a pot CW raises the trip point, CCW lowers the
(GOL Veac Disable, visible through the window in the trip point. To calibrate the AOPS trip point for a given
hoist controller front cover) illuminates. The external cab hook, turn the appropriate pot on the Gross Overload
mounted alarm and the machinery house mounted Sense Card fully CW (maximum trip point). Adjust the
alarm, which should already be sounding from an appropriate load readout with a variable resistor as
overload greater than 100%, will change from their described in the test procedure above to the desired
normal tones to a pulsating tone, indicating an AOPS gross overload trip level (factory recommendation is
activation. Clear the alarms with the Acknowledge Horn 140% of maximum rated load). Adjust the Gross
Button, remove the added resistance, switch to Aux Overload Sense Card pot CCW until the Gross Overload
Hoist, and take the Overload Protection Switch to Light comes on and the Gross Overload alarms sound.
RESET and then back to ON. The AOPS for this hook is now calibrated. Reset the
b. To test the AOPS on the Auxiliary hook, connect the AOPS, and test the calibration for accuracy as deĆ
resistance across terminals T8 and T6 on the Wylie scribed in the test procedure above.
circuit board. Increase the displayed load by varing the
COPYRIGHT 2002
85
LeTourneau, Inc.
4ĆROM 6.2e, Gorilla
9/25/01
14
1 2 3 4
1ĆCGĆ2458, P02Ć22
OFF
OFF ON
BLK BAT
AMB RED RED RED ONCONSTANT AMB
SS8 LT3 PB8 SS6 TENSION LT6 LT7
LIMIT
LIGHTS SPEED/TEMP POWER LOSS BOOM LOWER
OFF ON SWITCHES
WARNING HOIST LOWER LIMIT OVERRIDE
RED RED RED EMERGENCY AMB

LT8 LT4 HOOK RELEASE LT24 LT5
SS7
SLACK WIRE
DRIVE SYSTEM SWING BRAKE MAIN AUX
ROPE
FAIL ENGAGE
GREEN GREEN GREEN
RUN RUN
GREEN LT1 LT34 LOWER LT2
RUN
LT3
ELECTRIC DECK CRANE SAFETY INSTRUCTIONS
LEFT RIGHT
SWING HOIST RAISE BOOM

OFF
SET ENABLE MAIN AUX
BAT ON
BLK BLK BLK RED RED
PB9 PB3 LT9 LT23 PB2
SS1 SS3 SS2
ACKNOWLEDGE HORN POWER ON MASTER BRAKE HOIST BRAKE HOIST SELECT EMERGENCY
WARNING HYD. PRESS. STOP
COPYRIGHT 2002
LeTourneau, Inc.
8
FIGURE 1. IDENTIFICATION GROUP (Sheet 1 of 7)

9
6 7
TAĆ9580Ć6
7/13/99
1ĆOSM 2.2a, 120SS Gorilla
PUBLICATION OSMĆ2
PUBLICATION OSMĆ2 ELECTRIC DECK CRANE SAFETY INSTRUCTIONS
14
13
12
WALL “G”
WALL “M”
10
11

1ĆCGĆ2459, P02Ć22 TAĆ9734Ć6
COPYRIGHT 2002
LeTourneau, Inc. 15
7/13/99
ELECTRIC DECK CRANE SAFETY INSTRUCTIONS PUBLICATION OSMĆ2
18
19
18
17
19
WALL “B”
16
18
É
14
É
14
15
8

1ĆCGĆ2460, P02Ć22 TAĆ9581Ć6
COPYRIGHT 2002
16
LeTourneau, Inc.
7/13/99
23
22
22
14
18
10
21
10
20
FIGURE 1. IDENTIFICATION GROUP-120SS (4 of 7)

9ĆCGĆ2454-1, Ldgr2Ć39Ć1 TAĆ9739Ć6
9ĆOSM 2.2 (FOĆ1) 120SS Gorilla

09/20/01 COPYRIGHT 2002 17
LeTourneau, Inc.
23
23
23
23
FIGURE 1. IDENTIFICATION GROUP (5 of 7)

1ĆCGĆ2462, LdgrĆ40 TAĆ9738Ć6
9ĆOSM 2.2, FOĆ2, 120SS Gorilla

09/20/01 COPYRIGHT 2002 19
LeTourneau, Inc.
1
Constant Tension Switch:
Master Switch:
POWER LOSS HOIST LOWER OPERATION
For use during crane power loss situations to lower load at a constant speed.
Emergency Hoist Release Switch: OFF
OFF
BAT
Before activating :
(1) Inspect Power Loss Lowering Card, thermocouples
and temperature transmitters as per OSM-4.
WARNING
DO NOT USE THE BOOM
Power On Light: FLASHING
(2)Place a man in the machinery house to monitor
Brake Switch: ENABLE
Power Loss Hoist Lower Button: PRESS and HOLDthe brakes and notify the operator to stop if
Hoist Joystick: LOWER brakes begin overheating.
LOWER LIMIT OVERRIDE
BUTTON WITH LOAD IN
CONSTANT TENSION OPERATION
For use (AUX HOIST ONLY) when a load is on the deck of a vessel that POWER
6 THE HOOK(S)
2 is pitching up and down due to wave motion. NORMAL LOSS
Emergency Hoist Release Switch: OFF OFF
Master Switch: ON BAT
Power On Light:
Hoist Select Switch:
Brake Switch:
ON
AUX
ENABLE
FLASHING
AUX
ENABLE
7 !
Constant Tension Switch: ON BAT BEFORE OPERATING MACHINE, STUDY THE
OPERATING AND SERVICE MANUALS.
Constant Tension Light: ON ON
READ ALL SAFETY SIGNS ON MACHINE.
CLEAR THE AREA OF THE OTHER PERSONS.
LEARN AND PRACTICE SAFE USE OF
EMERGENCY HOIST RELEASE CONTROLS BEFORE OPERATING.
3 OPERATION It is the operator’s responsibility to understand and follow
For use if the hook becomes entangled in a vessel the manufacturer’s instructions on machine operation,
that is moving away from the crane. POWER
service and to observe pertinent laws and regulations.
Maintenance Manuals and Operating & Service manuals,
NORMAL LOSS may be obtained through your equipment dealer.
LeTourneau, Inc. P/N 422–1605
Power On Light: ON FLASHING
Emergency Hoist Release Switch: ON ON
Emergency Hoist Release Light: ON ON
8
4
KG KIPS
45359.7 100 NEUTRAL BUS (BLOCK)
40823.7 90 IS NOT USED WITH
36287.7 80 TWO–POLE BREAKERS
120VAC
31751.7 70
27215.8 60 LeTourneau, Inc P/N 622–8869

CAPACITY
22679.8 50
18143.8 40
9
13607.9 30
9071.9 20
4535.9 10
0
REACH FEET 20 30 40 50 60 70 80 90 100 110
103108
REACH CM 762.0 914.4 1219.2 1524.0 1828.8 2133.6 2438.4 2743.2 3048.0 3352.8
10
MAIN HOIST (4)(2)(1)
LeTOURNEAU PCM–120 CRANE LINE LIFT
W/100 FOOT BOOM MIN– REACH 22.0 FT
5 MAX SWL 98,400 LBS.
BOOM REACH SWL (LBS.) SWL (LBS.) SWL (LBS.)

ANGLE FEET 4 PART LINE 2 PART LINE 1 PART LINE
___ ____ _____ _____ _____

ELECTRICAL EQUIPMENT
___ ____ _____ _____ _____ AUTHORIZED PERSONNEL
___ ____ _____ _____ _____
___ ____ _____ _____ _____

ONLY
___ ____ _____ _____ _____
___ ____ _____ _____ _____
___ ____ _____ _____ _____
___ ____ _____ _____ _____ 11

___ ____ _____ _____ _____
___
___
____
____
_____
_____
_____
_____
_____
_____
EQUIPMENT
OPERATED BY
REMOTE CONTROL

1ĆCGĆ2463, P02Ć22 TAĆ9736Ć6
COPYRIGHT 2002
LeTourneau, Inc. 21
7/13/99
!
12 API SPEC 2C
FIFTH EDITION 1995 DATE MANUFACTURED
18
MANUFACTURER’S MODEL NO.
DESIGN SERVICE TEMPERATURE DEG.C.
MANUFACTURER SERIAL NUMBER
MANUFACTURED
BY
ADDRESS P.O. BOX 2307 LONGVIEW,TEXAS 75606

HAZARDOUS VOLTAGE
Can shock, burn, or cause death.
Turn power off before servicing motor.
! Hazardous A.C. voltage can be at

terminals when motor is stopped.
13
HAZARDOUS VOLTAGE
CAN CAUSE SHOCK, BURN
OR DEATH
OPEN 600 VOLT DRIVE !

MOTOR FEEDER CIRCUIT 19
BRAKE DISC ON
BREAKERS IN POWER ELECTRIC MOTORS
DISTRIBUTION PANEL MAY BE HOT. BRAKE
LeTourneau, Inc P/N 422–8870 DISC WILL ROTATE IF
MOTOR IS ENGAGED
LeTourneau, Inc P/N 423–5159
14
CRANE SN PC1
20 SWL 7.43 T 6.7°
SWL 49.20 T 80.3°
600 VOLTS
MANUFACTURED BY:
LeTourneau, Inc.
21
DATE
15
PC 120 SN
SWL REACH BOOM
THIS EQUIPMENT IS TONS FEET ANGLE
SUPPLIED BY MORE THAN 49.20 22 80.3°
7.43 103 6.7°
ONE POWER SOURCE
22
16 LOW
DO NOT OPERATE CRANE HEADROOM
WITH HATCH CLOSED LeTourneau, Inc. P/N 423–7045
LeTournean, Inc P/N 422–8868
!
23
! LADDERS:
FALLING HAZARD
ALWAYS face ladder
when climbing up
Can cause serious or down.
HIGHLY LOADED SPRING INSIDE THIS injury or death.
17 HOUSING CAN CAUSE SERIOUS
Keep one hand firmly
on ladder or handhold
PHYSICAL WATCH YOUR STEP. at all times.
INJURY OR DEATH Keep ladder rungs,
DO NOT REMOVE SCREWS WATCH FOR WIND steps and platforms
GUSTS. clean – free of grease,
LeTourneau, Inc P/N 422–3262 oil, etc.

1ĆCGĆ2464, P02Ć22 TAĆ9737Ć6
COPYRIGHT 2002
22
LeTourneau, Inc.
7/13/99
CRITICAL COMPONENTS
The following is a list of components of the crane which D Electric drive motors for hoist, boom, and swing
components are ones which affect the safety of the CRITICAL STRUCTURAL COMPONENTS
crane from a structural and load hoisting standpoint. D Boom chord members
These components should be of prime concern to the
deck operators supervisor, operator and maintenance D Boom section connection components
personnel with regards to certification, inspection, D Boom foot pins
maintenance and prompt repair per the appropriate D Primary load members of gantries, masts and
guidelines. Instructions for the maintenance and repair AĆframes
of these components are included in the OPERATING
AND SERVICE MANUAL and the REPAIR AND OVERĆ D Load transfer members of the rotating upper strucĆ
HAUL MANUAL for the crane. ture
D Pedestal and swing circle transition pieces
CRITICAL MECHANICAL COMPONENTS
D All linkage between the brake control element and CRITICAL RIGGING COMPONENTS
the component to be controlled. D All running wire ropes in hoist system
D Hoist, boom and swing brake systems D All standing wire rope in load restraint and support
D Drums, shafts, and gears of hoisting and swing system
systems D Hook block assembly
D Slewing or swing bearing and gear D Wire rope deadĆend connection devices
D Wire rope sheaves and sheave shafts D Floating harness or bridle assemblies
NOTES
COPYRIGHT 2002
LeTourneau, Inc. 13
7/13/99
FORM H"
LOAD DIAGRAM
SEE CERTIFICATE NO. _____________________________ FOR THE APPROVED CONDITIONS FROM
THE ATTACHED LOAD CHART, WHICH HAVE BEEN SURVEYED AND TESTED AS A UNIT AFTER
INSTALLATION ONBOARD THE _____________________________.
AUX. HOIST SB
1 INCH WIRE ROPE
BRIDLE PENDANTS 57.5 TONS BREAKING STR.
1Ć3/4 INCH WIRE ROPE DYFORM 18 HSLR
6 X 26 IWRC EIPS ROTATION RESISTANT
168 TONS BREAKING STR. SINGLE SHEAVE
TWO
SHEAVES
LUFFING THREE SINGLE
1 INCH WIRE ROPE SHEAVE
62.5 TONS BREAKING STR.
SHEAVES
CONSTRUCTEX T.B., SWL
R
D.B.
S.W.L.
TWO
SHEAVES
THREE
SHEAVES
HOOK LOAD
SINGLE 20,000 LB
SHEAVE UNDER HOOK
SINGLE
SHEAVE HOOK LOAD
98,400 LB.
UNDER HOOK
MAIN HOIST DB, 1 INCH WIRE ROPE

Lw 70.03 B.S., DYFORM 34 LR, GR 2160
ROTATION RESISTANT
Lw
Lw
(1) The attached load chart indicates the approved
hook safe working loads and the approved rigging
arrangements which may be certificated under the
requirements of the American Bureau of Shipping.
(2) Where sheaves are built into the structure they shall
be treated as structural parts and need not be
tested and certificated as loose gear.
(3) The S.W.L. to be marked on the blocks should be

indicated on this diagram.
(4) S.W.L. = SAFE WORKING LOAD

S.B. = SINGLE BLOCK
D.B. = DOUBLE BLOCK
T.B. = TRIPLE BLOCK
R = RESULTANT LOAD
Lw = LINE PULL TO THE WINCH
HOOK AND BLOCK WT OF 1600 LB HAS BEEN

DEDUCTED FROM THE MAIN HOIST HOOK LOAD.
PCM 120SS CRANE

1ĆCGĆ1585, P10Ć30, 5/8/00 TAĆ8878ĆCG
COPYRIGHT 2001
InsertĆ1
LeTourneau, Inc.
9ĆOSMĆ2.2b.1, 120SS Gorilla
8/21/01
ELECTRIC DECK CRANE SAFETY INSTRUCTIONS PUBLICATION OSM-2
COPYRIGHT 2002
Insert -2 7-OSM-2.2b.1, 120SS Gorilla (MSWord)
LeTourneau, Inc. REVISION: 05-01-02

COPYRIGHT 2001
InsertĆ3
LeTourneau, Inc.
8/21/01
1" WIRE ROPE

1375' LONG
70.03 TONS B.S.
HOOK SHEAVE WHEELS
HOOK CABLE DRUM
PCM 120SS CRANE

1ĆCGĆ1586, P10Ć30, 5/4/00 TAĆ8926ĆCG
COPYRIGHT 2001
LeTourneau, Inc.
InsertĆ4 8/21/01
6 FLOATING SHEAVE HOUSING
DEAD END
3
1” WIRE ROPE (9 x 40 CONSTRUCTEX)

460” LONG, 62.5 TONS B.S.
1
GANTRY SHEAVE HOUSING
BOOM UP CABLE DRUM
PCMĆ120SS CRANE
BOOM UP CABLE REEVING SCHEMATIC
1ĆNGOĆ1588, P10Ć30, 5/8/00 TAĆ8928ĆCG
COPYRIGHT 2001
InsertĆ5
LeTourneau, Inc.
8/21/01
GUIDE SHEAVE WHEEL
JIB BOOM
SHEAVE WHEEL
1” WIRE ROPE (19 X 19)

550’ LONG, 57.5 TONS B.S.
10 TON HOOK
AUX. HOOK CABLE DRUM
PCM 120SS CRANE

AUXILIARY HOOK CABLE REEVING SCHEMATIC
COPYRIGHT 2001
LeTourneau, Inc.
InsertĆ6 8/21/01
PUBLICATION OSMĆ2
8/21/01
LeTOURNEAU PCMĆ120SS
MAIN HOIST CAPACITY CHART-100 FT. BOOM
STATIC AND DYNAMIC PERSONNEL
SAFE WORKING LOAD IN KIPS SAFE WORKING LOAD IN KIPS
WORKING BOOM
RADIUS ANGLE 4ĆPART LINE 4ĆPART LINE 2ĆPART LINE 2ĆPART LINE 1ĆPART LINE 1ĆPART LINE
(FT.) (DEG.) STATIC DYNAMIC STATIC DYNAMIC STATIC DYNAMIC 4ĆPART LINE 2ĆPART LINE 1ĆPART LINE
1.33 2.00 1.33 2.00 1.33 2.00
22.0 80.3 98.40a 65.06h 48.40a 48.40a 23.40a 23.40a 32.32f 23.60a 11.00a
25.0 78.5 94.24f 62.29f 48.40a 48.40a 23.40a 23.40a 30.34f 23.60a 11.00a
30.0 75.6 79.10g 52.20g 48.40a 48.40a 23.40a 23.40a 25.30g 23.60a 11.00a
35.0 72.6 67.46g 44.44g 48.40a 48.40a 23.40a 23.40a 21.42g 23.41g 11.00a
40.0 69.5 58.95g 38.77g 48.40a 41.72g 23.40a 23.40a 18.58g 20.06g 11.00a
45.0 66.4 52.38g 34.39g 48.40a 36.66g 23.40a 23.40a 16.39g 17.53g 11.00a
LeTourneau, Inc.
50.0 63.2 47.08g 30.85g 48.40a 32.49c 23.40a 23.40a 14.63g 15.45c 11.00a
55.0 59.9 42.67g 27.91g 44.36c 29.04c 23.40a 23.40a 13.16g 13.72c 11.00a
60.0 56.5 38.88g 25.39g 40.05c 26.16c 23.40a 23.40a 11.89g 12.28c 11.00a
COPYRIGHT 2001
65.0 53.0 35.56g 23.19g 36.39c 23.73c 23.40a 23.40a 10.79g 11.06c 11.00a
70.0 49.2 32.58g 21.19g 33.26c 21.64c 23.40a 21.64c 9.79g 10.02c 11.02c
75.0 45.3 29.85g 19.36g 30.54c 19.83c 23.40a 19.83c 8.88g 9.11c 9.11c
80.0 41.0 27.29g 17.66g 28.13g 18.22g 23.40a 18.24c 8.03g 8.31g 8.32c
85.0 36.3 24.84g 16.02g 25.53g 16.49g 23.40a 16.85c 7.21g 7.44g 7.62c
90.0 31.0 22.41g 14.41g 22.97g 14.78g 23.40a 15.57g 6.40g 6.59g 6.99g

95.0 24.7 19.89g 12.73g 20.32g 13.01g 21.24g 13.62g 5.56g 5.71g 6.01g
100.0 16.1 16.94g 10.76g 17.25g 10.96g 17.89g 11.39g 4.58g 4.68g 4.90g
103.0 6.7 14.07d 8.90g 14.27d 9.04g 14.69d 9.32g 3.65g 3.72g 3.86g
NOTES
D This load chart meets API Spec. 2C (Fifth Edition, 1995) D Bridle Line - 1Ć3/4", 6 x 26 Class, IWRC,
D Safe Working Load (SWL) - Load which may be carried below the hook. EIPS, B.S. = 168 tons
D API Static Rated Load = SWL plus 1.6 kip hook block. D BoomĆup Line - 1", Bridon CONSTRUCTEX = 62.5 tons
D A 1600Ćlb. maintenance hook and block weight has been deducted from the total allowable D Ratings followed by a" are limited by the hoist line limit.
loads on the 4Ćpart, 2Ćpart and 1Ćpart lines. D Ratings followed by c" are limited by the foundation limit.
D The design capacity of the crane is based on 50 tons at a 22Ćft. working radius. D Ratings followed by "d"are limited by the luffing line limit.
D Main Hoist Line - 1" Bridon Dyform 34 LR GR 2160, rotation resistant, B.S. = 70.03 tons D Ratings followed by f" are limited by the boom axial load limit.
D Aux. Hoist Line - 1" Bridon Dyform 18 HSLR, rotation resistant, B.S. = 57.5 tons D Ratings followed by g" are limited by luffing system on gantry limit.
InsertĆ7
D Ratings followed by h" are limited by lifted load limit.

D This chart is to be used for mild sea conditions only.
PUBLICATION OSMĆ2
8/21/01
LeTOURNEAU PCMĆ120SS
MAIN HOIST CAPACITY CHART-120 FT. BOOM
STATIC AND DYNAMIC PERSONNEL
SAFE WORKING LOAD IN KIPS SAFE WORKING LOAD IN KIPS
WORKING BOOM
RADIUS ANGLE 4ĆPART LINE 4ĆPART LINE 2ĆPART LINE 2ĆPART LINE SINGLE LINE SINGLE LINE
(FT.) (DEG.) STATIC DYNAMIC STATIC DYNAMIC STATIC DYNAMIC 4ĆPART LINE 2ĆPART LINE SINGLE LINE
1.33 2.00 1.33 2.00 1.33 2.00
25.0 80.4 98.40a 57.13 48.40a 48.40 23.40a 23.40 32.30f 23.40e 11.00e
30.0 78.0 84.40c 46.42 48.40a 48.40 23.40a 23.40 29.40f 23.40e 11.00e
35.0 75.6 70.15c 39.25 48.40a 42.74 23.40a 23.40 27.09f 23.40e 11.00e
40.0 73.1 59.45c 34.06 48.40a 36.65 23.40a 23.40 25.19f 23.40e 11.00e
45.0 70.5 51.14c 30.1 48.40a 32.09 23.40a 23.40 23.58f 22.24f 11.00e
50.0 68.0 44.48c 26.95 44.48c 28.53 23.40a 23.40 22.20f 20.97f 11.00e
LeTourneau, Inc.
55.0 65.4 39.03c 24.36 39.03c 25.65 23.40a 23.40 20.99f 19.85f 11.00e
60.0 62.7 34.49c 22.18 34.49c 23.24 23.40a 23.40 19.91f 18.86f 11.00e
65.0 59.9 30.65c 20.29 30.65c 21.19 23.40a 23.00 18.94f 17.95f 11.00e
27.36c 27.36c 23.40a 18.04f 17.13f 11.00e
COPYRIGHT 2001
70.0 57.1 18.64 19.39 20.91

75.0 54.2 24.50c 17.16 24.50c 17.80 23.40a 19.10 17.22f 16.35f 11.00e
80.0 51.2 22.00c 15.81 22.00c 16.36 22.00c 17.52 16.44f 15.63f 11.00e
85.0 48.0 19.80c 14.57 19.80c 15.04 19.80c 16.05 15.69f 14.93f 11.00e
90.0 44.7 17.83c 13.41 17.83c 13.81 17.83c 14.67 14.97f 14.26f 11.00e
95.0 41.1 16.08c 12.31 16.08c 12.64 16.08c 13.37 14.26f 13.59f 11.00e
100.0 37.2 14.49c 11.24 14.49c 11.52 14.49c 12.13 13.55f 12.93f 11.00e
105.0 33.0 13.06c 10.19 13.06c 10.42 13.06c 10.93 12.83f 12.24f 11.00e

110.0 28.2 11.75c 9.11 11.75c 9.30 11.75c 9.71 11.75c 11.51f 10.55f
115.0 22.5 10.56c 7.96 10.56c 8.11 10.56c 8.43 10.56c 10.56c 9.80f
120.0 14.7 9.46c 6.58 9.46c 6.69 9.46c 6.91 9.46c 9.46c 8.84f
123.0 6.1 8.33d 5.23 8.33d 5.30 8.33d 5.45 8.33g 8.33g 7.80f
NOTES
D This load chart meets API Spec. 2C (Fifth Edition, 1995) D Bridle Line - 1Ć3/4", 6 x 26 Class, IWRC, EIPS, B.S. = 168 tons
D Safe Working Load (SWL) - Load which may be carried below the hook. D BoomĆup Line - 1", Bridon CONSTRUCTEX = 62.5 tons
D API Static Rated Load = SWL plus 1.6 kip hook block. D Ratings followed by a" are limited by the hoist line limit.
D A 1600Ćlb. maintenance hook and block weight has been deducted from the total allowable D Ratings followed by c" are limited by the foundation limit.
loads on the 4Ćpart, 2Ćpart and 1Ćpart lines. D Ratings followed by "d"are limited by the luffing line limit.
D The design capacity of the crane is based on 50 tons at a 22Ćft. working radius. D Ratings followed by e" are limited by the hoist line limit.
D Main Hoist Line - 1" Bridon Dyform 34 LR GR 2160, rotation resistant, B.S. = 70.03 tons D Ratings followed by f" are limited by the boom limit.
InsertĆ9
D Aux. Hoist Line - 1" Bridon Dyform 18 HSLR, rotation resistant, B.S. = 57.5 tons D Ratings followed by g" are limited by the luffing line limit.
D This chart is to be used for mild sea conditions only.
LeTOURNEAU, INC.
PCM 120SS CRANE W/120' BOOM
AUXILIARY HOIST SYSTEM
DYNAMIC, STATIC AND PERSONNEL
LOAD RATING CHART, SINGLE LINE LIFT
API Spec 2C, Fifth Edition (1995)
PERSONNEL
WORKING BOOM STATIC LIFT DYNAMIC SWL
LIFT
RADIUS (FT.) ANGLE (DEG.) SWL (KIPS) 1.33 (KIPS) 2.00
SWL (KIPS)
30.0 79.9 20.00a 13.33 9.80e
35.0 77.5 20.00a 13.33 9.80e
40.0 75.2 20.00a 13.33 9.80e
45.0 72.8 20.00a 13.33 9.80e
50.0 70.3 20.00a 13.33 9.80e
55.0 67.8 20.00a 13.33 9.80e
60.0 65.3 20.00a 13.33 9.80e
65.0 62.7 20.00a 13.33 9.80e
70.0 60.1 20.00a 13.33 9.80e
75.0 57.4 20.00a 13.33 9.80e
80.0 54.5 20.00a 13.33 9.80e
85.0 51.6 20.00a 13.33 9.80e
90.0 48.5 19.28c 13.33 9.80e
95.0 45.3 17.49c 13.33 9.80e
100.0 41.8 15.87c 13.33 9.80e
105.0 38.1 14.41c 13.23 9.80e
110.0 34.1 13.08c 12.15 9.80e
115.0 29.5 11.85c 10.96 9.80e
120.0 24.0 10.72c 9.70 9.80e
125.0 16.7 9.66c 8.23 9.63f
128.0 9.6 9.04c 6.93 8.81f
NOTES
D This load chart meets API Spec. 2L, Fifth Edition (1995). Safe Working Load (SWL) = Load which may be
carried below the hook. API Static Rated Load = SWL plus 500 lb. overhaul ball.
D Ratings followed by a" are limited by the auxiliary hoist line limit.
D Ratings followed by c" are limited by the foundation limit.
D Ratings followed by e" are limited by the auxiliary hoist line limit.
D Ratings followed by f" are limited by the boom limit.
D Main Hoist Line - 1" dia. Bridon Dyform 34 LR, GR 2160, rotation
resistant. B.S. = 70.03 tons.
D Aux. Hoist Line - 1" dia. Bridon Dyform 18 HSLR rotation resistant. B.S. = 57.5 tons.
D Bridle Line - 1Ć3/4" dia., 6 x 26 Class, IWRC, EEIPS, B.S. = 168 tons.
D BoomĆUp Line - 1" dia., Bridon CONSTRUCTEX = 62.5 tons
COPYRIGHT 2001
LeTourneau, Inc.
InsertĆ10 8/21/01
CRITICAL COMPONENTS
The following is a list of components of the crane which D Electric drive motors for hoist, boom, and swing
components are ones which affect the safety of the CRITICAL STRUCTURAL COMPONENTS
crane from a structural and load hoisting standpoint. Boom chord members
These components should be of prime concern to the
deck operators supervisor, operator and maintenance D Boom foot pins
personnel with regards to certification, inspection, D Boom section connection components
maintenance and prompt repair per the appropriate D Primary load members of gantries, masts and
guidelines. Instructions for the maintenance and repair AĆframes
of these components are included in the OPERATING
AND SERVICE MANUAL and the REPAIR AND OVERĆ D Load transfer members of the rotating upper strucĆ
HAUL MANUAL for the crane. ture
D Pedestal and swing circle transition pieces
CRITICAL MECHANICAL COMPONENTS
D All linkage between the brake control element and CRITICAL RIGGING COMPONENTS
the component to be controlled. D All running wire ropes in hoist system
D Hoist, boom and swing brake systems D All standing wire rope in load restraint and support
D Drums, shafts, and gears of hoisting and swing system
systems D Hook block assembly
D Slewing or swing bearing and gear D Wire rope deadĆend connection devices
D Wire rope sheaves and sheave shafts D Floating harness or bridle assemblies
NOTES
COPYRIGHT 2002
LeTourneau, Inc. 13
7/13/99
14
1 2 3 4
1ĆCGĆ2458, P02Ć22
OFF
OFF ON
BLK BAT
AMB RED RED RED ONCONSTANT AMB
SS8 LT3 PB8 SS6 TENSION LT6 LT7
LIMIT
LIGHTS SPEED/TEMP POWER LOSS BOOM LOWER
OFF ON SWITCHES
WARNING HOIST LOWER LIMIT OVERRIDE
RED RED RED EMERGENCY AMB

LT8 LT4 HOOK RELEASE LT24 LT5
SS7
SLACK WIRE
DRIVE SYSTEM SWING BRAKE MAIN AUX
ROPE
FAIL ENGAGE
GREEN GREEN GREEN
RUN RUN
GREEN LT1 LT34 LOWER LT2
RUN
LT3
LEFT RIGHT
SWING HOIST RAISE BOOM

OFF
SET ENABLE MAIN AUX
BAT ON
BLK BLK BLK RED RED
PB9 PB3 LT9 LT23 PB2
SS1 SS3 SS2
ACKNOWLEDGE HORN POWER ON MASTER BRAKE HOIST BRAKE HOIST SELECT EMERGENCY
WARNING HYD. PRESS. STOP
COPYRIGHT 2002
LeTourneau, Inc.
8

9
6 7
TAĆ9580Ć6
7/13/99
PUBLICATION OSMĆ2
14
13
12
WALL “G”
WALL “M”
10
11

1ĆCGĆ2459, P02Ć22 TAĆ9734Ć6
COPYRIGHT 2002
LeTourneau, Inc. 15
7/13/99
18
19
18
17
19
WALL “B”
16
18
É
14
É
14
15
8

1ĆCGĆ2460, P02Ć22 TAĆ9581Ć6
COPYRIGHT 2002
16
LeTourneau, Inc.
7/13/99
23
22
46
10
10
46
22
21
20
14
18
9ĆCGĆ9869-1, LdgrĆ40-1 TAĆ9869Ć6
9ĆOSM 2.3, (FOĆ1) 350SS Gorilla

09/20/01 COPYRIGHT 2002 17
LeTourneau, Inc.
23
23
23
23

1ĆCGĆ2462Ć1, LdgrĆ40-1 TAĆ9870Ć6
9ĆOSM 2.3, FOĆ2, 350SS Gorilla

09/20/01 COPYRIGHT 2002 19
LeTourneau, Inc.
1
Constant Tension Switch:
Master Switch:
POWER LOSS HOIST LOWER OPERATION
For use during crane power loss situations to lower load at a constant speed.
Emergency Hoist Release Switch: OFF
OFF
BAT
Before activating :
(1) Inspect Power Loss Lowering Card, thermocouples
and temperature transmitters as per OSM-4.
WARNING
DO NOT USE THE BOOM
Power On Light: FLASHING
Brake Switch: ENABLE (2)Place a man in the machinery house to monitor
Power Loss Hoist Lower Button: PRESS and HOLDthe brakes and notify the operator to stop if
Hoist Joystick: LOWER brakes begin overheating.
LOWER LIMIT OVERRIDE
BUTTON WITH LOAD IN
CONSTANT TENSION OPERATION
For use (AUX HOIST ONLY) when a load is on the deck of a vessel that POWER
6 THE HOOK(S)
2 is pitching up and down due to wave motion. NORMAL LOSS
Emergency Hoist Release Switch: OFF OFF
Power On Light:
Hoist Select Switch:
Brake Switch:
ON
AUX
ENABLE
FLASHING
AUX
ENABLE
7 !
Constant Tension Switch: ON BAT BEFORE OPERATING MACHINE, STUDY THE
OPERATING AND SERVICE MANUALS.
Constant Tension Light: ON ON
READ ALL SAFETY SIGNS ON MACHINE.
CLEAR THE AREA OF THE OTHER PERSONS.
LEARN AND PRACTICE SAFE USE OF
EMERGENCY HOIST RELEASE CONTROLS BEFORE OPERATING.
3 OPERATION It is the operator’s responsibility to understand and follow
For use if the hook becomes entangled in a vessel the manufacturer’s instructions on machine operation,
that is moving away from the crane. POWER
service and to observe pertinent laws and regulations.
Maintenance Manuals and Operating & Service manuals,
NORMAL LOSS may be obtained through your equipment dealer.
Power On Light: ON FLASHING
Emergency Hoist Release Switch: ON ON
Emergency Hoist Release Light: ON ON
8
4
NEUTRAL BUS (BLOCK)
KG KIPS
68039.5 150
IS NOT USED WITH
63503.5 140 TWO–POLE BREAKERS
58967.6 130 120VAC
54431.6 120
49895.6 110 LeTourneau, Inc P/N 622–8869
45823.7 100
CAPACITY
40823.7 90
36287.7 80
9
31751.7 70
27215.8 60
22679.8 50
18143.8 40
13607.9 30
9071.9 20
VENDOR:
4535.9 10
VENDOR:
VENDOR:
FEET 30 35 40 50 60 70 80 90 100 110 120 130135
CM 914.4 1219.2 1524.0 1828.8 2133.6 2438.4 2743.2 3048.0 3352.8 3657.6 3962.4
REACH 4114.8
10
5
LETOURNEAU PCM–350 CRANE MIN– REACH 30.0 FT
WITH 123.5 FT. BOOM MAX SWL 146800 LBS.
BOOM REACH SWL (LBS.) SWL (LBS.) SWL (LBS.) ELECTRICAL EQUIPMENT
ANGLE FEET 6 PART LINE 4 PART LINE 2 PART LINE
___ ____ _____ _____ _____ AUTHORIZED PERSONNEL

___ ____ _____ _____ _____
ONLY
___ ____ _____ _____ _____
___ ____ _____ _____ _____
___ ____ _____ _____ _____
___ ____ _____ _____ _____

11
___ ____ _____ _____ _____
___ ____ _____ _____ _____
___
___
____
____
_____
_____
_____
_____
_____
_____
EQUIPMENT
___ ____ _____ _____ _____
OPERATED BY
REMOTE CONTROL
FIGURE 1. IDENTIFICATION GROUP-350SS (Sheet 6 of 7)

1ĆCGĆ2463Ć1, P02Ć22Ć1 TAĆ9868Ć6
COPYRIGHT 2002
LeTourneau, Inc. 21
7/13/99
!
12 API SPEC 2C
FIFTH EDITION 1995 DATE MANUFACTURED
18
MANUFACTURER’S MODEL NO.
DESIGN SERVICE TEMPERATURE DEG.C.
MANUFACTURER SERIAL NUMBER
MANUFACTURED
BY
ADDRESS P.O. BOX 2307 LONGVIEW,TEXAS 75606

HAZARDOUS VOLTAGE
Can shock, burn, or cause death.
Turn power off before servicing motor.
! Hazardous A.C. voltage can be at

terminals when motor is stopped.
13
HAZARDOUS VOLTAGE
CAN CAUSE SHOCK, BURN
OR DEATH
OPEN 600 VOLT DRIVE !

MOTOR FEEDER CIRCUIT 19 BRAKE DISC ON
BREAKERS IN POWER ELECTRIC MOTORS
DISTRIBUTION PANEL MAY BE HOT. BRAKE
LeTourneau, Inc P/N 422–8870 DISC WILL ROTATE IF
MOTOR IS ENGAGED
14
CRANE SN PC3
20 SWL 17.95 T 0.0°
SWL 73.40 T 79.5°
600 VOLTS
MANUFACTURED BY:
LeTourneau, Inc.
21
DATE
15
PC 350 SN
SWL REACH BOOM
THIS EQUIPMENT IS TONS FEET ANGLE
SUPPLIED BY MORE THAN 73.40 30 79.5°
17.95 129 0.0°
ONE POWER SOURCE
22
16 LOW
DO NOT OPERATE CRANE HEADROOM
WITH HATCH CLOSED LeTourneau, Inc. P/N 423–7045
LeTournean, Inc P/N 422–8868
!
23
! LADDERS:
FALLING HAZARD
ALWAYS face ladder
when climbing up
Can cause serious or down.
HIGHLY LOADED SPRING INSIDE THIS injury or death.
17 HOUSING CAN CAUSE SERIOUS
Keep one hand firmly
on ladder or handhold
PHYSICAL WATCH YOUR STEP. at all times.
INJURY OR DEATH Keep ladder rungs,
DO NOT REMOVE SCREWS WATCH FOR WIND steps and platforms
GUSTS. clean – free of grease,
LeTourneau, Inc P/N 422–3262 oil, etc.
FIGURE 1. IDENTIFICATION GROUP-350SS (Sheet 7 of 7)

1ĆCGĆ2464Ć1, P02Ć22Ć1 TAĆ9867Ć6
COPYRIGHT 2002
22
LeTourneau, Inc.
7/13/99

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LETOURNEAU, INC.

QUALIFIED CRANE INSPECTOR

PREVENTIVE MAINTENANCE SCHEDULES AND CRANE

PUBLICATION ROM-1 “STRUCTURAL COMPONENTS” 5

PUBLICATION LET-1 “FIELD WELDING PROCEDURES” 6

EXCERPTS FROM PUBLICATION ROM-6 7

EXCERPTS FROM PUBLICATION OSM-2 “SAFETY” 8

MONTHLY INSPECTION AND LUBRICATION REQUIREMENTS

NOTE: Numbers in parentheses refer to lubrication points indicated on Figure 1.

2. Lubricate main hook sheaves. (1)

3. Lubricate main hook swivel bearing. (1)

4. Lubricate auxiliary hook bearings (optional). (2)

5. Lubricate auxiliary sheaves (optional). (3)

6. Lubricate boom sheaves (optional). (4)

7. Lubricate floating block and equalizer sheave. (5)

8. Lubricate boom selfĆaligning bushing (until new grease appears). (6)

9. Lubricate swing roller bearings. (7)

10. Lubricate swing gear and gearbox pinion. (8)

11. Lubricate gantry sheave. (9)

12. Lubricate swing bearing (PCM 350SS). (10)

13. Lubricate spherical and thrust bearing (PCM 120SS). (10)

CAUTION: PROPERLY STOW BOOM BEFORE LUBRICATING CRANE.

FIGURE 1. LUBRICATING POINTS PCM 350 AND PCM 120

NOTE: The quarterly inspections includes an inspection of electric motors, servicĆ

QUARTERLY INSPECTION AND LUBRICATION REQUIREMENTS

NOTE: Numbers in parentheses refer to lubrication points indicated on Figure 2.

2. Lubricate main hook sheaves. (1)

3. Lubricate main hook swivel bearing. (1)

4. Lubricate auxiliary hook bearings (optional). (2)

5. Lubricate auxiliary sheaves (optional). (3)

6. Lubricate boom sheaves (optional). (4)

7. Lubricate floating block and equalizer sheave. (5)

8. Lubricate boom selfĆaligning bushing (until new grease appears). (6)

9. Lubricate swing roller bearings. (7)

10. Lubricate swing gear and gearbox pinion. (8)

11. Lubricate gantry sheave. (9)

12. Lubricate swing bearing (PCM 350SS). (10)

13. Lubricate spherical and thrust bearing (PCM 120SS). (10)

CAUTION: PROPERLY STOW BOOM BEFORE LUBRICATING CRANE.

FIGURE 2. LUBRICATING POINTS PCM 350 AND PCM 120

MAIN HOOK, BOOM, AUXILIARY HOOK (OPTIONAL):

CRANE SWING COMPONENTS

HYDRAULIC BRAKE SYSTEM

WIRE ROPE - INSPECTION AND LUBRICATION REQUIREMENTS:

CABLE DRUM DEAD END INSPECTION:

1. Check boom angle/radius indicators over full range for accuracy.

SWING, BOOM, MAIN HOOK AND AUXILIARY HOOK (OPTIONAL):

4. Check for damage or leakage in hydraulic brake systems.

5. Check speed sensors mounting, tightness and condition of leads.

POWER LOSS LOWERING SYSTEM

QUARTERLY ELECTRICAL P.M.

ELECTRICAL CONTROLS GROUP:

5. Check circuit breakers.

6. Blow out the cabinet with clean, dry compressed air.

QUARTERLY DC MOTOR BRUSH INSPECTION

POSITION BRUSH IN GAUGE SAME WAY

NOT ALL LEADS SHOWN

HIGH POINT ON BRUSH

1ĆCGĆ1088, P01Ć112 TA8010CG

SIMPLIFIED AND EXAGGERATED ILLUSTRATION OF ARMATURE AND COMMUTATOR

MOTOR TRACK # TIR MAX. BARĆTOĆBAR SURFACE CONDITION - SEE NOTE

QUARTERLY STRUCTURAL INSPECTIONS

AUTOMATIC OVERLOAD PROTECTION SYSTEM (AOPS):