LUBRICATION 500/700/900/1100/1200 SERIES CRANE DH/DEH LOCOMOTIVE CRANES GENERAL LUBRICATION INFORMATION In order to properly protect your machine and get, the best performance and longest life out of it, sched- ules of lubrication and preventive maintenance must be adhered to. All lubrication and maintenance schedules are guidelines based upon normal work cycles under average working conditions. At any time that unusually tough working conditions and operation are encountered, maintenance and lubri- cation intervals must be shortened. Operating at extreme temperatures (hot or cold), under constant, heavy load, operating intermittently, or operating in very dirty conditions consitute tougher than average working conditions and operation. Both service recommendations and actual working conditions must be taken into consideration to determine when, the machine should be serviced. Lubrication Keeping your machine properly lubricated is the most effective way to prevent part failures and con- sequent costly repairs. The iubrication chart pro- vided on page 210 shows the crane assemblies to be lubricated by interval. The pages following the chact illustrate the assemblies and their lubrication fittings. The following information contains additional recommendations. Pune mUS.A. TS R-11781) a. Keep all lubricants and iubricating equipment clean and free of contamination both while in storage and while in use. b. Clean all grease fittings and surfaces before applying a grease gun. Dirt on fittings will be forced through along with clean grease. and wil ‘cause wear and premature material failures. . Wipe off excess grease and other lubricants, Olly and greasy surfaces collect dirt which may work its way into moving parts and cause wear and failures. d. Avoid overgreasing. Excess lubricants will be thrown into clutches and brakes and will cause slipping. ¢. Always maintain a film of grease on exposed gears; however, avoid overgreasing (see “d" above and Lubrication interval Chart). IMPORTANT Under no circumstances may the recommended lubrication intervals be exceeded. Avoiding service intervals will be construed as negligence and will void the warranty on the machine. Page 200 ‘rmo14o006LUBRICATION INTERVAL CHART 900 SERIES LUBRICATION INTERVAL CHART ote DAILY means every 8 hours of operation. WEEKLY means every 40 hours of operation. MONTHLY means every 160 hours of operation. MAINTAIN means do not allow the supply to disappear; the interval will vary depending on climate and use. Check daily. SEE PAGE 213 FOR DUTY CYCLE AND TRAVEL REQUIREMENTS, ‘These intervals represent periods of time during normal operation. If the ma- chine is used more than normal or in a rough climate, it will naturally become necessary to lubricate the machine more frequently. If the machine is idled for long periods of time, lubrication will have to be done before it is put in ser- vice each time. It will also have to be lubed before storing to prevent cor- rosion and weathering. Proper lubrication will contribute to the smooth functioning of parts as well as protecting those parts from corrosion and wear. The following chart shows the assemblies to be lubricated by interval. INTERVAL LUBRICANT* ASSEMBLY LUBRICATED FITTINGS PAGE 4 Hours #2, Swing Roller Bushings TEach 237 4 Hours #2 Fairlead Bearings 4 256 Daily #2 Boom Clutch Shaft Bushings 2, 3 228 Daily #2 Boom Drum Shaft Bushings 4 228-229 Daily #2 Boom Overrunning Clutch a ay Shaft Bushings Daily MolycoteG Boom Foot Pins (Old Style) 2 252 Daily #2 Swing Roller Bearings LEach 237 Daily #2 Vertical Swing Shaft Upper ‘| eae Bushing Daily #2 Vertical Swing Shaft Lower 236 Bushing Daily #2 Center Pin Bushing 1 236 Daily #2 Third Drum Shaft Bushings 2 221 Daily #2 Vertical Travel Shaft Bushings 2 236, 244 Daily #2 Horizontal Travel Shaft A an Bushings Daily #2 Track Rollers 1 Each 245-246 Daily #2 Drive Tumblers 2 Each 245-246 Daily #2, Idler Tumblers 1 Each 245-246 Daily #2 Crawler Drive Sprocket eee eres Bushings Daily sae) A-Frame Fleeting Sheaves 2 255 Daily #2 Blocks and Hooks With 252 Bushings *Please see page 260 for product recommenda Printed in U.S.A. (OVER) | 775(N)INTERVAL LUBRICANT * ASSEMBLY LUBRICATED Daily Daily Monthly Monthly Monthly Ple: Printed in U.S.A. 676 (R1-4/96) a a #8 #8 #8 #2 #6 a a #8 #8 2 #8 8 #8 n #8 a8 a2 a Boom, Jib and Bail Sheaves With Bushings Positive Swing Lock Crawler Cranes Crawler Drive Chains Boom Clutch Lever Pins Boom Gear Shifter Pins Boom Hoist Dog Horizontal & Vertical Reverse Shaft Clutch Lever Pins Shaft Bearing -Hydrostatic Swing Swing Roller Brackets Vertical Swing Shaft Splines -- & Jaw Clutch Swing-Travel Shifter Drive Shaft Sprocket Bearings Main Hoist Clutch Lever Pins Third Drum Clutch Lever Pins Auxiliary Shaft Clutch Lever Pins Controlled Load Lowering Sprockets Steering Shifter Pins and Shafts Vertical Travel Shaft Splines and Jaw Clutch Bail, Jib and Boom Point Sheaves With Bearings Blocks & Hooks With Bearings Shaft Splines On Overrunning Clutch Shaft Inner Bail and A-Frame Axle “Thrust Nuts and Bearings on The Swing Brake Boom Hoist Brake Bearing Third Drum Brake Main Hoist Brake Main & Auxiliary Hoist Brake Bearings (Truck) see page 260 for product recemmendations. Diag. does not show thrust nuts. LUBRICATION LOAD HOIST GROUP 900 Series Cranes LUBRICATION INTERVAL CHART (CONTINUED FITTINGS PAGE 252 1 241 Coat 246 Pins 232 $ Places 232 2 233 Pins 238 1 240 4 237 Oil Cup 238 Shaft 239 2 220 Pins 221 Pins = 221 Pins 222 LEach = 222 244 Oil Cup 244 252/253/254 252 229 3 2s5 3 238 1 232 Oil Shaft 224 8 223 8 224 Page 211 5LUBRICATION LOAD HOIST GROUP 900 Series Cranes LUBRICATION INTERVAL CHART (CONTINUED) INTERVAL LUBRICANT* ASSEMBLY LUBRICATED FITTINGS PAGE 6 Months #2 Boom Clutch Bearings 1 228, 232 Page 230 Boom Sprag Clutch 230, 231 6 Months #2 Horizontal & Vertical Re- A ArH verse Shaft Bearings 6 Months #2 Main Hoist Drum Shaft 6 220 Bearings 6 Months #2 Auxiliary Shaft Bearings 2 222 6 Months 42 Engine Pilot Bearings (Not Used With 3 Stage 1 214 Torque Converter) 6 Months #2 Main Drum Bearings (Truck) 6 225 6 Months #2 Front Drum Bearings (Truck) 6 225 1600 Hours #8 Chain Case . Change 223 1600 Hours #7 Deck Gear Housing Change 236 1600 Hours #8 Jaw Clutch Cases + Change 245 1600 Hours #7 Center Bevel Gear Travel. Change 248 Case Maintain #6 Exposed Gear Teeth - Coat 214 Maintain #2 Buligear and Pinion 1 236 Maintain #8 Crawler Drive Chains Coat 246 Maintain #2 Crawler Axles Coat 244 Maintain #6 Wire Ropes Coat 252 Maintain Fuel O11 Telescoping Boom Stops Coat 252 500 Hours #2 Hoist Valves-Upper Lightly 226 1000 Hours #2 Hoist Valves-Lower Lightly 226 Monthly #2 Swivel Joint Maintain 242 eve: NOTES: in off cup Use a hand grease gun on all upper deck fittings to avoid seal damage. 3 to 5 shots of grease will normally be sufficient on any grease fitting. Assemblies will vary according to crane models, and not all cranes are equipped with everything shown on the chart. We suggest that you set up a check chart complete with the items on your par- ticular machine. to establish a good lubrication program. A chart is shown on page 290. See Page 258 for McKissick lubrication recommendations. *Please see page 260 for product recommendations. Printed in U.S.A. T7TS(N) (Fi1-4/96) Page 212LUBRICATION LOAD HOIST GROUP: 900 Series Cranes DUTY CYCLE AND TRAVEL Different lubrication intervals are required for duty cycle work and operations in which the machine is continually under travel. DUTY CYCLE - LUBRICATE EVERY FOUR HOURS Fairlead--------- 7+ +--+ Page 256 All Swing Rollers - - - - vo - s+ Page 237 Center Pin Bushing - - --------- sree Page 236 Vertical Swing Shaft Lower Bushing - - = +++ = + Page 236 Vertical Swing Shaft Upper Bushing - - - 22+ + ++ Page 238 soe TRAVEL - LUBRICATE EVERY 1/2 HOUR OR 1/2 MILE Vertical Travel Shaft Bushings- - - - - = sss Page 236, 244 Horizontal Travel Shaft Bushings - - - cree Page 244 Track Rolle: sore ert Page 245-246 Drive Tumblers. - - - - Page 245-246 Idler Tumblers - - - - - Page 245-246 Crawler Drive Sprocket Bushings Page 245-246 McKissick Blocks, Sheaves & Svivels —-—--------~ Page 258 Printed in U.S.A. Page 213 ‘TS(N) (R1-4/96) Sead!GENERAL ASSEMBLY 900 SERIES CRANES LOCATIONS LAVHS GSUaAaE SNId ‘IVLNOZINOH ONY TVOLLUGA L008 : LavHs Woyd woor SHHILNTD ONTUT MOT .LSIOH WOOR VOT Ga'TTOULNOD woud avo IsIOH yoog SYVID i tr] = | | t HY axuvud GNV HOLNT9 | HOLNTS I i = : : ONIMS. Sel Lavis AUVITIXAY, Th a a ! SNIVHD ‘119 1 ' 1 | SNIONG. ae awa HY move aT) woud HT ! as a == HOLD onruvad aa aMVUG GNV HOLNTO\__ONTAS soma SNId Se 5 Cron: —— Looa i i a Wood" suvao Nado -— SLUNDOUdS TTD LaVHs aATua HOLNTS wna aye HOLNTO OVYds ONIYEMOT GVOT YSTTOULNOD auvug ONIMS YALYAANOD ANOYOL ¢ a 5 a : 2 5 ou zg eLUBRICATION LOAD HOIST GRouP 900 SERIES CRANES CHAIN DRIVE ASSEMBLY SHAFT BEARINGS ITEM #2 - WEEKLY MAIN HOIST DRUM ASSEMBLY SHAFT & DRUM BEARINGS ITEM 42 - 6 MONTHS Printed in U.S.A. 775(N) (OVER)LUBRICATION LOAD HOIST GROUP 900 SERIES CRANES MAIN HOIST CLUTCH ASSEMBLY THIRD DRUM CLUTCH ASSEMBLY CLUTCH LEVER ima ITEM #8 - WEEKLY SHAFT BUSHINGS ITEM #2 - DAILY, Printed in U.S.A. (CONTINUED) 775(N)LUBRICATION LOAD HOIST GROUP ‘900 Series Cranes AUXILIARY SHAFT ASSEMBLY SHAFT BEARINGS ITEM #2 - 6 MONTHS. CLL CLUTCH CONTROLLED LOAD LOWERING SPROCKETS ITEM #2 - WEEKLY CLUTCH LEVER PINS ITEM #8 - WEEKLY Printed in U.S.A. Page 222 TTS(N)CHAIN CASE ASSEMBLY DIPSTICK DRAIN PLUG The chain case holds about 6 gallons (22.71 liters) of oil. Check the oil level before beginning work and keep the level at "FULL" on the dipstick. Change oil every 1600 hours of operation. Use SAE 30 or 40. MAIN HOIST BRAKES ITEM #2 - MONTHLY Page : Printed in U.S.A. T75(N) (F1-4/96)LUBRICATION LOAD HOIST GROUP ‘900 Series Cranes THIRD DRUM BRAKE ASSEMBLY THIRD DRUM BRAKE ITEM #8 - MONTHLY OIL HERE LIGHTLY HOIST BRAKES ITEM #2 - MONTHLY i ALY Brake linkage fittings are found on the right hand side of the upperworks. There are eight fittings for the linkage. Printed in U.S.A. Page 224 T7S(N)Quiet American Crane Corporation LUBRICATION AMERICAN® Wimington, North Carolina LOAD HOIST GRouP a TRUCK CRANE MAIN HOIST SHAFT & DRUM BEARINGS ITEM #2 - 6 MONTHS SHAFT & DRUM BEARINGS ITEM #2 - 6 MONTHS Page 225 Printed in U.S.A. TIS(N)LUBRICATION All Series Cranes FLEX-AIR VALVE LUBRICATION ° = =a ‘ i ‘CLEAN AND Seas < el — nad i OBGIE (Py ccar or SCREWS(S) CONTACT ENDS DESCRIPTION Flex-Air valves are commonly used on boom hoists and drum clutch control systems. The maintenance section of this write-up applies to all Fiex-Air valves wherever used. The section on adjusting the valve detent is primarily intended for the Flex-Air valve when used in a drum control system. This adjust- ment, however, can be made on the valve when used in the other above mentioned applications. MAINTENANCE ‘500 Hours—Clean and lubricate detent latch (A) and cover (B) every 500 hours of operation with #15 lithium base grease or an equivalent low tempera- ture cup grease. To do this back off collar (C) to release spring tension on cover and detent latch. Remove ring (D) and pin (E) from handle, Handle and latch cover can now be removed. Detent latch (A) can be raised by removing pin (F).. 1000 Hours—Clean and lubricate the contact ends of screws (G), handle shaft (H). the contact area of caps (I), extension (J) and inside of bearing (K). Printed in USA e778(R1-4/82) rmo1so0es Tmo 10005 ADJUSTMENT ( WARNING © A worn or poorly adjusted detent latch could vibrate out of detent when the machine is operating. This could result in a dropped load. Aproperly adjusted detent latch shouldtake at least 5 pounds of force on the handle to disengage the detent. To adjust detent force back off collar a minimum of two turns or until the latch is free. Next turn down collar 1/8 of a turn ata time until desired response is obtained. Detent action should be checked at the start of every shift. CAUTION Detent latch Is 2 wearing item. Detent latch should be replaced before worn excessively. Page 226LUBRICATION BOOM HOIST GROUP 900 SERIES CRANES BOOM HOIST CLUTCH SHAFT ASSEMBLY ' CLUTCH SHAFT BEARING | ITEM #2 - WEEKLY CLUTCH SHAFT BUSHINGS ITEM #2 - DAILY BOOM HOIST DRUM SHAFT CRAWLER CRANES DRUM SHAFT BUSHINGS ITEM #2 - DAILY Printed in U.S.A. (OVER) T75(N)LUBRICATION BOOM HOIST GROUP 900 SERIES CRANES BOOM HOIST DRUM SHAFT -LH BOOM HOIST DRUM SHAFT-RH TRUCK CRANES DRUM SHAFT BUSHINGS DRUM SHAFT BUSHINGS’ ITEM #2 - DAILY ITEM #2 - DAILY BOOM HOIST OVERRUNNING CLUTCH SHAFT ASSEMBLY CLUTCH SHAFT BUSHINGS ITEM #2 - DAILY i i K-L.| | SHAFT SPLINES ! ITEM #8 - WEEKLY Printed in U.S.A. (CONTINUED) 775(N)LUBRICATION ‘American Cranes OVERRUNNING (SPRAG) CLUTCH to your operator's manual for the location of the Saray catch This lac is connected trough a chain ‘rive, or through gears, to the boom hoist drum. (NOTE:) The sprag clutch is a precision Product; it is very important to maintain and lubricate it properly. The clutch will then provide safe and excellent performance. The above oils are equivalent to military ‘specification MIL-H-5606A and can be ‘obtained by contacting the nearest oil company sales office. (MPORTANT: De not mix one wand of from one brand t OR" SLIPPERY ADDITIVES Printed in U.S.A. (R20-3/98) 6/79 FILL pLuGs, LUBRICATION REQUIREMENTS TUF WARNING The drain plug may be located on the side of the barrel, or (on the face of the housing. IMPORTANT: Check the oil level evary 30 days Cils listed on the front of this page may be obtained in gallons by contacting the American Grane Parts ‘Department and ordering part number 1058004. CAUTION: improper lubrication maintenance may result in excessive wear. Follow maintenance ions and check oil level every 30 days. Low oll lavel may prevent Proper operation which could result in injury, death, or Property damage. INJURY, DEATH OR PROPERTY DAMAGE. THE FOR ANY MANUFACTURER IS NOT RESPONSIBLE MADE BY THEO OIL MANU- ANY CHANGES FACTURERS IN THEIR LUBRICANTS. THE USE OF ANY LUBRICANTS, OTHER THAN ‘THOSE LISTED AND/OR CONFORMING WITH MILITARY SPECIFICATIONS MIL- WILL AUTOMATICALL' H-5606A, ‘TICALLY VOID ANY WARRANTY ON THE CLUTCH. (OVER) Thay are not compatible. When switching ther. Tush ‘chutes ‘betore ‘adding new oll, 00 NOT ADD ANY EP Page 230 Two150002MAINTENANCE 1. Maintain oil tevel at one halt ful, (See illustration for location of ol ports.) 2. Change ol every 6 months 3. Flush clutch in the Spring and in the Fall ofthe year when oils changed. 4. Itis recommended that clutches which have been out ot service or on machines being switched to booming, ‘operation be flushed to remove any wax or gum formation resuiting from vaporization of the cil in the unit and recited prior to committing the crane to ‘operation. FLUSHING PROCEDURE 1. Drain clutch, then fil clutch 3/4 full with suitable ‘mineral spirits, such as ESSO *Varsat No. 1° or Shell “Sol No. 340". Kerosene may be used as a substitute, 2. Pun clutch tor 15-20 minutes to break up and dissolve ‘ly residue which may have formed inside. 3. Drain clutch completely and rekiicte with any ofthe lubricants recommended on Page 230. PREVENTATIVE MAINTENANCE itis recommended that ater two (2) years or five thousand hours (5,000) of machine operation, whichever comes. first, this clutch be replaced. Contact the nearest ‘American Crane distributor for all replacement clutch requirements. CLUTCH RECONDITIONING SERVICE ‘Some clutches may be reconditioned by the manufacturer while others may not. Contact an American Crane distor tor information conceming chach reconatioiog jilable. Reconditioned clutches cary a new ctnch warren, NOTE: These instructions cannot cover all detaits nor provide every LUBRICATION ‘American Cranes AAWARNING Failure to strictly tollow the maintenance procedures set forth herein may cause the boom to fail and impose a satety danger to Personnel and property. or $,000 hours of machine use. Failure to follow proper lubrication and replacement procedures could affect any rights to warranty claims, WARRANTY The manufacturer of the clutch guarantes rocucta wil leave the factory in good warrant ei products agunet defects ‘material for a period of 365, ajustmants under tis warranty wil be made ony ater ‘completion of inspectign of the part or product in manufacturers factory. The manufacturer's liability uncer ‘this warranty shall extend only to the ‘eplacement or correction of any detective part cr product determined by inspection as not conforming to this warranty. This warranty shall not apply to any product which shall hhave been repaired or altered without the manutacturers knowledge and consent or operated or installed contrary to the manufacturers instruction or subjected to misuse, improper maintenance or is damaged by accident 0 negiigence.. ‘This warranty is made in eu of ail warranties express or implied, including but not limited to warranties of ‘merchantability or fitness for a particular purpose, and there are no other warranties that extend beyond this ‘express warranty. ‘The manutacturer reserves the right to discontinue models ‘oF to change specifications at any time without notice. No iscontinuance or change shall create any liabiity on the part of the manulacturer in reapect to its products in the hands of its customers or products on order not incorporating such change even though delivered after any such change. that its condition. They ‘contingency which may be met in installation. possibie ‘operation or maintenance. Should further information be needed, contact American Crane Corporation. Printed in U.S.A. (20-2798) 670 Page 231 ‘TworsooceLUBRICATION BOOM HOIST GROUP 900 SERIES CRANES BOOM GEAR SHIFTER PINS ‘BOOM HOIST CLUTCH PINS | SHIFTER PINS | ‘ ITEM #8 - WEEKLY CLUTCH LEVER PINS CLUTCH SHAFT BEARINGS ITEM #8 - WEEKLY ITEM #2 - WEEKLY BOOM HOIST BRAKE ASSEMBLY BRAKE BEARING ITEM #2 - MONTHLY Printed in.U. S.A. (OVER) ‘Page 232 T75(N)BOOM HOIST DOG ASSEMBLY SHAFT BEARING ITEM #2 - WEEKLY LUBRICATION BOOM HOIST GROUP 900 SERIES CRANES Piinted in U.S.A. 775(N)Quem American Crane Corporation LUBRICA AMERICAN?® Wilmington, North Carolina ‘SWING ‘GROUP —7 900 Series Cranes ROTATING MACHINERY BASE ASSEMBLY VERTICAL SWING SHAFT ERTICAL * VERTICAL UPPER BUSHING BULLCEAR en — TRAVEL ITEM #2 - DAILY POON LOWER SUSHI UPPI seam semen DECK GEAR HOUSING: (Approximately 60 Gallon Capacity) (227 liters). Oil should be maintained at full mark on dipstick, Use SAE 140 E.P. for Temp, above 70° F (21°). Use SAE 90 E.P. for Temp. 70° to -10° F (21°C to -23°C). Change oil every 1600 Hrs. (4'' (10,2cm) Drain Plug in Oil Well). Drain moisture weekly, (There is a petcock for thie purpose in the 2" (5. lcm) hex plug in the center rear of the machinery deck. ) BULLGEAR AND PINION. USE ITEM #2 Wipe the roller path occa- mame sionally with a cloth saturated in fuel oil, Use a minimum film of lubricant on the verti- cal face of the bullgear. VERTICAL FACE: Printed in U.S.A. Page 236 77S(N) (R1-2/82, h2-4/96)LUBRICATION SWING GROUP 900 SERIES CRANES SWING ROLLER AND BRACKET ASSEMBLIES American Crane Corporation Wilmington, North Carolina ROLLERS WITH BUSHINGS /(— ITEM #2 - 4 HOURS _ ROLLERS WITH BEARINGS ITEM #2 - DAILY ™M0000199 thrust washers wet. The swing roller brackets are to be lubricated weekly. Over-grease the rollers suffictently to keep the bra HORIZONTAL AND VERTICAL REVERSE SHAFT ASSEMBLY SHAFT BEARINGS ITEM #2 - 6 MONTHS. TM0060026-2 Printed in U.S.A. (CONTINUED) 775(N) T™M0060026LUBRICATION SWING GROUP 900 SERIES CRANES VERTICAL SWING SHAFT SWING CLUTCHES ON REVERSE SHAFT SHAFT UPPER BUSHING ITEM #2 - DAILY RIGHT HAND DECK FITTING (SEE PAGE 236) JAW CLUTCH & SPLINES CLUTCH LEVER PINS ITEM 48 - WEEKLY ITEM #8 - WEEKLY SWING BRAKE ASSEMBLY BRAKE BEARINGS ITEM #2 - MONTHLY Printed in U.S.A. (OVER) 775(N)LUBRICATION SWING GROUP 900 SERIES CRANES SWING-TRAVEL SHIFTER ASSEMBLY NOTE: IF MACHINE Is NOT TRAV- > ELLED OFTEN, OCCASIONALLY SHIFT SWING-TRAVEL SHIFTERS BACK AND FORTH TO KEEP THE SPLINES AND JAW CLUTCH OILED AND FREELY MOVING. = SHAFTS ITEM #8 - WEEKLY INDEPENDENT SWING ASSEMBLY x SHAFT BEARINGS ITEM #2 - 6 MONTHS DO NOT OVER- GREASE THESE FITTINGS USING AN AIR GUN * DRAIN PLUG *See Page 236 for correct lubricants for deck gear hous Printed in U.S.A. (CONTINUED) 277 2B.LUBRICATION SWING GROUP 900 SERIES CRANES INDEPENDENT SWING CLUTCH HYDROSTATIC SWING BRAKE ITEM 42 - 6 MONTHS CLUTCH PINS ITEM #8 - WEEKLY SHAFT BEARING ITEM #2 - WEEKLY LEVEL PLUG ON CASE OIL cuP ITEM #8 - WEEKLY FILL PLUG & BREATHER SHAFT BUSHING ITEM #2 - DAILY HYDROSTATIC SWING GEAR BOX: (Approx. 15 Gallons) (46.78 liters) (Oil should be maintained at full mark on dipstick Use SAE 140 E.P. for Temp. above 70°F (21°C) Use SAE 90 E.P. for Temp, 70°F to -10°F (21°C to -23°C), Printed in U.S.A. (OVER) 775(N)LUBRICATION SWING GROUP 900 SERIES CRANES " POSITIVE SWING LOCK-CRAWLER CRANES > —_——————— Printed in U.S. A. ‘Page 241 | IN) f 476(LUBRICATION SWING GROUP 900 SERIES CRANE SWIVEL JOINT ASSEMBLY TOP VIEW OF SWIVEL JOINT ON MACH. BASE ITEM #2 MONTHLY MAINTAIN OIL LEVEL IN OIL CUP Printed in U.S.A. 876(N)LUBRICATION TRAVEL GROUP 900 SERIES CRANES FITTINGS LOCATED ON THE CARBODY HORIZONTAL TRAVEL SHAFT BUSHINGS MAINTAIN GREASED 1 VERTICAL TRAVEL SHAFT ! LOWER BUSHINGS VERTICAL TRAVEL SHAFT. Ol CUP ITEM #8 - WEEKLY SPLINES AND JAW CLUTCH OIL HERE SHIFTER ON PAGE 239 == -ARBODY pe Add 2-1/2 gallons \(9. 46 liters) of waste oil to the 8 holes in the car- body periodically >. ©/ to lubricate the +) // crawler axles. NORMAL DIRECTION OF FORWARD TRAVEL iG SHIFTER ASSEMBLY SHIFTER SHAFTS ITEM #8 - WEEKLY ALSO OIL LINKAGE FROM AIR CHAMBERS. Printed in U.S.A. (OVER) 775(N)LUBRICATION TRAVEL GROUP 900 SERIES CRANES JAW CLUTCH AND BEVEL GEAR CASES JAW CLUTCH. fP— y JAW CLUTCH CASE CASE #30 #90 #30 CENTER BEVEL GEAR TRAVEL CASE JAW CLUTCHES: (Approximately 14 gallon (52. 99liters) capacity each.) Oil should be maintained at full mark (level plug). Use SAE 30 in both jaw clutch cases Change oil every 1600 HRS 4" (10. 16cm) drain plug in oil well.” Add required amount of kerosene to jaw clutch wells for proper shifting in cold weather, Drain moisture monthly 3/4" (1. 91cm) plug in bottom side. CENTER BEVEL GEAR TRAVEL CASE: (Approximately 17 gallon (64. 36liters) Capacity). Use SAE 140 E.P. for temperature above 70°F (21°C). Use SAE 90 E.P. for temperature 70°F (21°C) to -10°F (-23°C). Change oil every 1600 HRS 4" (10. 16cm) drain plug in oil well Drain the water from the machinery deck well once or twice weekly to prevent having the vertical swing shaft bushing run in water from condensation. CRAWLER ASSEMBLY - 999, 9260, 9270, 9280, 9299 DRIVE SPROCKETS ITEM #2 - DAILY (INNER & OUTER BUSHINGS) DRIVE TUMBLERS IDLER TUMBLERS ROLLER AXLES 2 - DAILY ITEM #2 - DAILY = Printed in U.S.A. (CONTINUED) Page 245 775(N) ITEM #2 - DALLYLUBRICATION RAVEL GROUP 900 SERIES CRANES CRAWLER ASSEMBLY - 9300, 9310 DRIVE SPROCKETS ITEM #2 - DAILY (INNER & OUTER BUSH! 6 FO) INGS) ROLLER AXLES DRIVE TUMBLERS ITEM 42 - DAILY IDLER TUMBLERS ITEM #2 - DAILY ITEM #2 - DAILY DRIVE CHAINS Lubricate the crawler drive chains weekly under normal operating conditions. When working in water or dust, lubricate more often. Lubricate the chains thoroughly at all moving joints. Use item #8. Remove excess dirt accumulation. Printed in U.S.A. 775(N)LUBRICATION RIGGING GROUP 900 SERIES CRANES 5 SHEAVE HAMMERHEAD TIP ITEM #2 - WEEKLY LUBE on LUBE LUBE HERE HERE HERE LUBE |HERE 1 4 SHEAVE BOOM TIP ITEM #2 - WEEKLY Printed in U.S.A, (CONTINUED) 775(N)LUBRICATION RIGGING GROUP 900 Series Cranes RIGGING The following guidelines are to be followed for lubricating the rigging sheaves and bails. A. Blocks and hooks with bushings 8 Hours B. A-Frame fleeting sheaves (bushings) 8 Hours C. Boom and bail sheaves with bushings 8 Hours D. Blocks and hooks with bearings 40 Hours E. Boom and bail sheaves with bearings 40 Hours See Page 258 for McKissick lubrication recommendations. These assemblies should be lubricated as follows: Boom Stops Maintain a coating of fuel oil. Rope Roller Guides Weekly with Item #2 if equipped with fittings. A-Frame Area between inner bail and backlegs should be coated with Item #9. Wire Ropes Maintain a film of Item #6 to prevent corrosion and ab- normal sheave groove wear. Tagline Winder Use SAE 90 weight gear lubricant. Remove the fill and level plugs and fill to the level of the level plug. Fill every three months or at the beginning of a job. Boom Foot Pins —Lubricate every 8 hours using special Molycote G lubricant. Boom foot pins with fiberglide bearing inserts require no lubrication. See page 802 for installation instructions. The following pages contain illustrations of various parts of the rigging. Thes illustrations are intended to guide you but do not represent all of the considerable options available. Older and special machines may vary from the illustrated parts. Printed in U.S.A. Page 252 77S(N) (R1-4/96)The following guide and bails. LUBRICATION RIGGING GROUP 900 Series Cranes RIGGING lines are to be followed for lubricating the rigging sheaves A. Blocks and hooks with bushings & Hours B. A-Frame fleeting sheaves (bushings) 8 Hours C. Boom and bail sheaves with bushings 8 Hours D. Blocks and hooks with bearings 40 Hours E. Boom and bail sheaves with bearings 40 Hours See Page 258 for McKissick lubrication recommendations. These a Boom Stops Rope Roller Guides A-Frame Wire Ropes Tagline Winder Boom Foot Pins The following page mblies should be lubricated as follow Maintain a coating of fuel oil. Weekly with Item #2 If equipped with fittings. Area between inner bail and backlegs should be coated with Item #9. Maintain a film of Item #6 to prevent corrosion and ab- normal sheave groove w Use SAE 90 weight gear lubricant. Remove the fill and level pluge and fill to the level of the level plug. Fill every three months or at the beginning of a job. Lubricate every 8 hours using special Molycote G lubricant. Boom foot pins with fiberglide bearing inserts require no lubrication. See page 802 for installation instruction contain illustrations of various parts of the rigging. These illustrations are intended to guide you but do not represent all of the considerable options available parts. Printed in U.S.A. T7S(N) (R1-4/96) Older and special machines may vary from the illustrated Page 252LUBRICATION RIGGING GROUP 900 SERIES CRANES 5 SHEAVE HAMMERHEAD TIP ITEM #2 - WEEKLY LUBE LUBE HERE 4 SHEAVE BOOM TIP ITEM #2 - WEEKLY j LUBE HERE | iN i Printed in U.S.A. (CONTINUED) T75(N)See eee RIGGING GROUP 900 SERIES CRANES 6 SHEAVE TIP ITEM #2 - WEEKLY BOOM POINT SHEAVE ASSEMBLY, 1 OR 2 SHEAVES ITEM #2 - WEEKLY Printed in U.S.A. (OVER) ‘T75(N)RETRACTABLE USE ITEM #2 LUBRICATION RIGGING GROUP 900 SERIES CRANES RAME, INNER BAIL INNER BAIL AXLE FITTINGS WEEKLY FLEETING SHEAVE 8 HOURS (BUSHING) BAIL SHEAVES 8 HOURS FOR BUSHINGS 40 HOURS FOR BEARINGS OUTER BAIL, 77" (1. 96m) BOOM ITEM #2 - WEEKLY (BEARING)., « Printed in U.S.A. (CONTINUED) 775(N)LUBRICATION RIGGING GROUP 900 SERIES CRANES GUIDE SHEAVE ASSEMBLY GUIDE SHEAVE ASSEMBLY FOR 77" (1. 96m) TAPER TIP Se ITEM #2 - WEEKLY 4 SHEAVES ITEM #2 - WEEKLY FAIRLEAD ASSEMBLY ITEM #2 - 4 HOURS BUSHING ITEM #2 - 8 HOURS BEARING ITEM #2 WEEKLY Printed in U.S.A. T75(N)LUBRICATION AMERICANS Cranes McKISSICK BLOCKS, SHEAVES & SWIVEL ASSEMBLIES In addition to normal maintenance for stee! surfaces, the following lubrication is recommended. Blocks, Sheaves & Swivel Assemblies With Tapered Roller Bearings Lubricate all bearings every 40 hours of continuous ‘operation or 30 days if use is intermittent with a lithium based grease of medium consistency. See Item #2. Lubrication Recommendations chart Blocks, Sheaves & Swivel Assemblies With Bronze Bushings Lubricate all bushings every 8 hours of continuous use or 14 days if use is intermittent. Use a lithium- base grease of medium consi Printed in USA. e76(R17760) Blocks, Sheaves & Swivel Assemblies With Roller Bearings Lubricate all bearings every 24 hours of continuous ‘operation or 14 days if use is intermittent. Use Item #2, Page 258LUBRICATION ALL SERIES RECOMMENDED LUBRICANTS NOTE: The presence or omission of a brand name on this list is not necessarily a guarantee of any petroleum product by American Crane Corporation. Responsibility for quality assurance and performance lies with the oil supplier. Strict observation of lubrication requirements, cleanliness and proper application will assure good lubrication which contributes to longer machinery life. Lube Item #1 or #2: For plain, ball or roller bearings. Apply arctic (shaded column) or temperate lubricant (unshaded column), as conditions require. ‘Must conform to Industry standards: ‘Must conform to industry standards: 1) NLGINo. 2 1) NLGINo. 1 4) MikG-10924C 2) Mi-G-3278A, 5) AAR:M-842-75 Rykon Premium Grease #1 EP} Beverol Copal Grease or Unidoz EP2 BP (British Energrease LS Petroleum) EP2 Chevron Duralith EP2 Conoco EP Conolith #2 SRI Grease Esso Beacon EP2 Exxon Ronnex WB Fina Marson ELP2 Gult Gulfcrown Grease EP2 Kendall Super Blu-Grease L-427 Lubriplate 1200-2 Mobil Mobilgrease XHP-222 Shell Alvania EP2 SKF Aifalub LGEP2 ‘Sun Prestige 742=P ‘Texaco Multfak EP2/ ‘Starplex 2 Code 1935 Mutts EP2 : i Anti-Friction Composition : oe (AFC) No. 3W Bef i ee "The above listed lubricants are for service In “The above listed lubricants are for service in ARCTIC TEMPERATE climates, in ambient temperatures | climates, in ambient temperatures from -45°F to 32°F from 20°F to 110°F (-7°C to 43°C). (49°C 10 0°C). Printed in U.S.A. (Continued) Page 260 06/94 (1-3/0)‘Must conform to industry standards: 1) Agma SEP 3) ASTM Gr. 1000 1) Mi-PRF-2105E 2) 180.2204) MikL-2105 B/C NL Gear Cmpnd 220 Citgo Citgo EP Compound Conoco Gear Oil 220 Exxon Spartan EP220 Fina Giran 220 Kendall Super Three Star 80W/140 Lubriplate ‘APG 90 Mobi Mobilgear 630 Shell Spirax 85W/140 Texaco Meropa 220 Whitmore 47-HD‘Must conform to industry standards: 1) Agma15R__2) NLGINo. 2,3 Pinion Grease MS-CB (Open Gear No. 44 Surett N 26K ‘Open Gear Compound SR-12K Gear Shield Extra Heavy Mobittac 375 NC Aivania EP2 Crater 5X LGC Medium S “The above listed lubricants are for service “The above listed lubricants are for service in ARCTIC ‘TEMPERATE climates, in ambient temperatures} climates, in ambient temperatures from ~45°F to 32°F from 20°F to 110°F (-7°C to 43°C). | €48°C 100°C).conditions require. ‘Must conform to industry standards: 1) AGMA SEP 5) ASTM Gr. 465, 2) ISO 32, ISO 100, ISO 4000 3) Mil-H-4600 IB Gr. 100 Citgo Kendall Lubriplate Chain & Cable Fluid Mobil Mobilube HD 85-140 Shell ‘Omala 100 Texaco Crater 2X Fluid Whitmore Wire Rope Lubelubricant (unshaded column), as conditions require. ‘Must conform to industry standards: ‘Must conform to industry standards: 1) ASTM Gr. 465 4) 180 100 1) MilL-46152 3) Mil-L-46167 2) MikH-4600 1B Gr.4 5) SAE 30/40 2) MiLL-21058, 3) MikL-2104B Manufacturer Brand Name Manufacturer Brand Name “Amalie Manual Transmission Lube 600 ‘Amoco ‘Amoco 100 Motor Oil No. 30 Citgo Pacemaker 100 Conoco Rednind Oil 100 Exxon Coray 100 Mobil Mobilube 80W-90 Texaco URSA Oil Extra Duty SAE 30 or 40 : Whitmore 20-HD wa i The above listed lubricants are for service in “The above listed lubricants are for service in ARCTIC TEMPERATE climates, in ambient temperatures | climates, in ambient temperatures from -45°F to 32°F from 20°F to 10°F (-7°C to 43°C). (43°C to 0°C).LUBRICATION ALL SERIES Lube Item #13: For railroad journal boxes, axle gear case bearings. Apply arctic (shaded column) or temperate lubricant (unshaded column), as conditions apply. ‘Superia AAR All-Weather Car Oil Veedol Arvella 82 All Year Car Oil 35 All Year Car Oil 33 Engine Oil No. 30 Motoreze 40 “The above listed lubricants are for service in ‘TEMPERATE climates, in ambient temperatures from 20°F to 110°F (-7°C to 43°C). Lube Item #0: For special applications, such as low speed/medium-to-high load flexible gear couplings. Use ‘where specified only. This light viscosity grease may be used in either temperate or arctic ambient temperatures, depending upon specific requirements for lubricant viscosity, adsorption and cohesiveness, as well as bearing load/speed conditions "Amooo Oi Company Fiykon Grease #0 EP Chevron U.S.A,, Inc. Dura-Lith Grease EPO Exxon Company, USA Lidok EP-0 Gulf Oi Company Gutfcrown Grease EP #0 Kendall Refining Co. Kendall L-406 Grease Keystone Div. Pennwalt Corp. Zeniplex #0 Mobil Oil Company Mobilux EPO Phillips Petroleum Co. Philube EP-O Shell Oil Company ANvania EP RO Standard Oil Co. (Ohio) Bearing Gard LT-0 ‘Sun Oil Co. Sun Prestige 740 EP Texaco Oil Company Muttifak EPO Union Oil Co. (Calit.) Union Unoba EPO Printed in U.S.A. Page 260.3 06/94 (1-3/0)FLEXIBLE SHAFTS Always keep shaft and shaft casing clean and tree from contaminants. Wher: dirt and grit combine with lubricants they form an abrasive paste which causes rapid and excessive wear of flexible shatts Frequent lubrication of flexible shafts is not always necessary except with large diameter shafts. Shafts should always have a thin coating of grease to pre~ vent corrosion. The following are different types of flexible shafts found on AMERICAN cranes: Tailshatt governor; Ro- tation Indicator and Motorcycle Throttle Control LUBRICATION 1. Remove the shaft from the casing. Clean both the shaft and inside of the casing thoroughly by washing in kerosene or spirits. 2. Dry the shaft 3. Coat the entire shatt lightly with ube item #2 as shaft is assembled into the casing. See Necom- memded Lubricants (found in this tab). Never force grease into the casing with grease guns or pressure lubricators. Printed in US.A. 7180 LUBRICATION AMERICANE Cranes Page 270LUBRICATION CHECK LIST 900 SERIES CRANES LUBRICATION CHECK LIST We suggest that you make use of a check list to keep an accurate record of lubrication performed on the machine. Keeping the chart right on the crane will help insure that all assemblies are lubricated at the correct intervals. The following chart covers all the assemblies available on the general 900 series cranes, both crawler and truck. These assemblies are arranged by their hourly lubrication intervals. SEE THE LUBE CHART FOR COMPLETE LUBRICATION INSTRUCTIONS. Some items must be lubricated at different intervals during duty cycle and travel operations. See page 213 of the lube chart for these items. ASSEMBLY INTERVAL] DATE AND INITIAL OF OILER ‘Swing Rollers Fairlead ASSEMBLY INTERVAL DATE AND INITIAL OF OILER Boom Clutch Shaft 8 Hrs. Boom Drum Shaft Burs. | Boom Overrunning Shaft 8 Hrs. Boom Foot Pins 8 Hrs. Swing Roller 8 Hrs. E Vert. Swing Shaft-Upper @ Hrs. Vert. Swing Shaft-Lower @ Hes. Center Pin Sirs. Third Drum Shaft Vert. Travel Shaft Horiz. Travel Shaft Track Rollers Drive Tumblers Idler Tumblers Crawler Drive Sprocket ‘A-Frame Fleeting Sheaves Blocks & Hook (Bushings) ‘Boom, Jib & Bail Sheaves (Bushings) 8 Hrs. Positive Swing Lock- Crawlers 8 Hrs. [Exposed Gear Teeth Maintain Bullgear and Pinion Maintain + ‘Crawler Drive Chains Maintain, | feseie Brite Manian Wire Ropes Maintain Boom Stops [Maintain Printed in U.S.A. Page 290 676LUBRICATION CHECK LIST ASSEMBLY INTERVAL] _D. D INITIAL OF OILER 40 ATE AN. ‘Crawler Drive Chains {|}; fF psa fear Boom Clutch Pins Boom Gear Shifter Pins 40 Hrs. Boom Hoist Dog 40 Hrs. Swing Shaft Clutch Pins [Shaft Bearing-Hydrostatic Swing Roller Brackets Vert. & Jaw Clutch 40 Hrs. Swing-Travel Shifter | 40 Hrs. | [Drive Shaft Sprocket Bearings 40 Hrs, Third Drum Clutch Pins ‘Aux, Shaft Clutch Pins 40 Hrs. C.L.L. Sprockets _| 40 Hrs. teering Shifter Pins and H Shafts 40 Hrs. Vert. Travel Shaft Splines & Jaw Clutch 40 Hrs. Bail, Jib and Boom Point Sheaves (Bearings) 40 Hrs. Blocks & Hooks (Bearings) | 40 Hrs. ‘Shaft Splines/Overrunning Shaft 40 Hrs. Inner Bail & A-Frame Axle | 40 Hrs. [ASSEMBLY INTERVAL] DATE AND INITIAL OF OILER ‘Swing Brake ‘Boom Hoist Brake ‘Third Drum Brake Main Hoist Brake Main & Aux. Hoist Brake (Truck) Printed in U.S.A. Page 292mim oenevewame me ie 900 SERIES CRANES LUBRICATION CHECK LIST ASSEMBLY INTERVAL] DATE AND INITIAL OF OILER 7 [ne BATE AND INTIS S ‘Hoist Valves-Upper Parts 500 Hrs. ASSEMBLY INTERVAL] D INITIAL OF OILER 1000 Fr: ASSEMBLY INTERVAL] DATE AND INITIAL OF OILER ‘Boom Clutch ‘Months ‘Boom Sprag Clutch 6 Months [Swing Shaft Bearings 6 Months: [Main Hoist Drum Shaft 6 Months: [Auxiliary Shaft 6 Months | Pilot Bearings 6 Months (Main Drum (Track) 6 Months [Front Dram (Truck) 6 Months ASSEMBLY Chain Case Deck Gear Housing INTERVAL, 1600 Hrs. 1600 Hrs. DATE AND INITIAL OF OILER Jaw Clutch Cases Center Travel Case Printed in U.S.A. 775(N) 1600 Hrs. ‘Page 294