SM At9120e April94

GROVE CRANE
MODEL
AT 9120E
3G
60
86
PUBLISHED: APRIL 1994

LIST OF EFFECTIVE PAGES
Original . . . . . . April 1994
Page Numbers Change in Effect Page Numbers Change in Effect
Title Page thru xi Original

1-0-1 and 1-0-2 Original
1-1-1 thru 1-1-7 Original
2-6-1 thru 2- 6-9 Original
2-10-1 thru 2-10-41
2-11-1 thru 2-11-11
2-12-1 thru 2-12-12
2-13-1 thru 2-13-10
Original
Original
Original
Original
3G
2-15-1thru 2-15-13 Original
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iii
FOREWORD
This manual has been compiled to assist you in properly operating and maintaining your Grove Crane.
The Grove Crane has been designed for maximum performance with minimum maintenance. With proper care, years
of trouble-free service can be expected.
Constant improvement and engineering progress makes it necessary that we reserve the right to make specification
and equipment changes without notice.
This manual is divided into three chapters, with Chapter One subdivided into two sections, Chapter Two subdivided
into 15 sections, Chapter Three subdivided into one or more sections, as needed. Page numbering is by chapter-sec-
tion-individual page (i.e. 2-10-5). The example indicates Chapter Two, Section 10, and the fifth page of Section 10.
Changes from the first printing of this manual that have been made in the text are marked by a vertical bar (I) on the
margin of the page opposite the change.
In the event some text is removed, and is not replaced with new or changed material, a deletion arrow is used where the
text was deleted.
occurred
3G
In the event there is a change in an illustration, a hand with a pointing finger will be used to point out where the change
A CHANGE RECORD page is included as page iii herein. It is intended that the recipient of the changes keep this
CHANGE RECORD updated as each change is received by him.
The definitions of WARNING, CAUTION, and NOTE as used in this manual apply as follows.
60
WARNING
A WARNING IS USED TO EMPHASIZE

THAT IF AN OPERATION, PROCE-
DURE,OR PRACTICE IS NOT FOL-
86
LOWED EXACTLY,DEATH OR INJURY

TO PERSONNEL MAY RESULT.
CAUTION
A CAUTION IS USED TO EMPHASIZE

THAT IF AN OPERATION, PROCE-
DURE, OR PRACTICE IS NOT FOL-
LOWED EXACTLY, EQUIPMENT DAM-
AGE MAY RESULT.
NOTE
A note is used to emphasize an impor-

tant procedure or condition.
iv
HOW TO USE THIS MANUAL
This manual consists of two separate parts: the basic Service Manual and Service Maintenance packages.
The first part of the manual covers basic maintenance and is divided into three chapters. Chapter One covers General
Description and Maintenance and is subdivided into two sections. Chapter Two covers Detailed Description, Opera-
tion, and Maintenance and is usually Subdivided into 15 sections. Chapter Three covers Optional Equipment and is
subdivided into one or more sections as necessary. Page numbering is by chapter-section-individual page (i.e.
2-10-5). The example indicates Chapter Two, Section 10, and the fifth page of Section 10. A Table of Contents in the
front of the manual lists all major headings found in all the sections of the three chapters.
The remainder of the service manual consists of Service Maintenance packages which contain detailed disassembly
and assembly information for the major components utilized on the machine. Package numbering is by category -
package number - revision level. For example, SM02-001-0, SM02 represents category (Drive Train), 001 represents
the package number in the category, and 0 represents the revision level of the package. Each Service Maintenance
Package is individually numbered and has its’ own Table of Contents. An index follows the Service Maintenance Pack-
ages tab to provide a listing of all the Service Maintenance packages included with the Service Manual.
3G
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v
WARRANTY
THERE ARE NO WARRANTIES, EXPRESS OR IMPLIED, MADE BY EITHER
THE DISTRIBUTOR OR THE MANUFACTURER ON NEW GROVE EQUIP-
MENT, EXCEPT THE MANUFACTURER’S WARRANTY AGAINST DEFECTS,
MATERIAL AND WORKMANSHIP SET OUT BELOW:
NEW EQUIPMENT WARRANTY

“The Manufacturer warrants each new product made by the Manu-
facturer to be free from defects in material and workmanship, its ob-
ligation and liability under this warranty being limited to replacing
free of charge at its factory, any part proving defective under normal
use and service within six (6) months from the date of initial sale,
lease or rental, providing the equipment is on record with the Manu-
facturer as being installed by the distributor. If the machine is not on
record as being installed by the distributor, the Manufacturer will
consider the date of shipment from the factory as the date of initial
sale, lease or rental. This warranty is in lieu of all other warranties,
express or implied and the obligation and liability of the Manufac-
turer under this warranty shall not include any transportation or
other charges or the cost of installation or any liability for direct, indi-
rect or consequential damages or delay resulting from the defect.
Any operation beyond rated capacity or the improper use or applica-
tion of the product or the substitution upon it of parts not approved by
the Manufacturer shall void this warranty. This warranty covers only
3G
the products of Grove Manufacturing Company. The products of
other Manufacturers are covered only by such warranties as are
made by their Manufacturers.”
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EX-

PRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHAN-
TABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND OF ANY OTHER
OBLIGATIONS OR LIABILITY ON THE PART OF THE MANUFACTURER, AND
60
GROVE MANUFACTURING COMPANY NEITHER ASSUMES NOR AUTHOR-
IZES ANY OTHER PERSON TO ASSUME FOR IT ANY OTHER LIABILITY IN
CONNECTION WITH SUCH EQUIPMENT.
86
NOTICE TO OWNER/USER
Should this crane become involved in an accident, please

contact your local Grove distributor immediately and relate
details of the incident so he can notify Grove Worldwide. If
the distributor is unknown and/or cannot be reached, please
contact Grove Worldwide, Product Support, (091) 5656281.
(Address: Grove Europe, Crown Works, Sunderland,
SR4 6TT, England.
vi
TABLE OF CONTENTS
CHAPTER ONE
GENERAL DESCRIPTION AND MAINTENANCE
SECTION 1 - GENERAL DESCRIPTION

General Description
SECTION 2 - GENERAL MAINTENANCE

General Maintenance
CHAPTER TWO
DETAILED DESCRIPTION, OPERATION, AND MAINTENANCE
SECTION 1 - CABS
Cabs
Carrier Cab 3G
Tachograph System
Superstructure Cab
SECTION 2 - ENGINE
Carrier Engine
Fuel System - Carrier Engine
60
Exhaust Brake - Carrier Engine
Throttle Cable and Engine Stop Setting - Carrier Engine
Water Cooling System
Air Intake System - Carrier Engine
Turntable Engine
Fuel System - Turntable Engine
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Air Intake System - Turntable Engine
SECTION 3 - DRIVE TRAIN

Drive Train
Transmission/Torque Converter
Transmission Oil Cooler
SECTION 4 -AXLES AND BRAKE SYSTEM

Axles
Wheels and Tyres
Brake System
Service Brakes
Air Valves
vii
TABLE OF CONTENTS (continued)
SECTION 5 - STEERING SYSTEMS

Steering Systems
Steering Gear
Dual Steering Bevel Gearbox
Obitrol Steering Valve
Steering Pump
Emergency Steering Pump
Steer Cylinders
Obitrol Steering Motor
Flow indicator
Flow Control Valve
Hydraulic Reservoir Steering
SECTION 6 -SUSPENSION
Suspension System
Suspension Cylinder
SECTION 7 -AIR SYSTEM

Air Systems
Air System Components
SECTION 8 - HYDRAULIC SYSTEM

3G
Hydraulic System
Supply Pressure and Return Circuit
Hydraulic Filter
60
Valve Setting Procedure
Hydraulic Reservoir
Hydraulic Pumps - Carrier, Outrigger, Suspension and Rear Steering
Hydraulic Pumps - Turntable
Hydraulic Pump Disconnect
Steering Pumps
86
Emergency Steering Pump

Valves
Cylinders
Hydraulic Oil Cooler
SECTION 9 - SWING SYSTEM

Swing System
Swing Motor
Swing Gearbox and Brake
Swing Bearing
viii
SECTION 10 - BOOM
Boom
Boom Extension and Retraction Cable
Telescope Circuit
Telescope Cylinders
Lift Circuit
Lift Cylinder
Hose Reel
Swingaway Boom Extension
Auxiliary Boom Nose
SECTION 11 - HOISTS
Hoists
Piston Type Motor
Auxiliary Hoist
Vane Type Motor
Hoist to Boom Alignment
Counterweight
SECTION 12 - OUTRIGGERS
Outriggers Circuit
Outrigger Beam Assembly
3G
Extension Cylinder
Stabilizer Cylinder
60
SECTION 13 - SWIVELS
Swivels
9 Port Air/Hydraulic Swivel
Electrical Swivel
SECTION 14 - ELECTRICAL SYSTEM

86
Electrical System
SECTION 15 - LUBRICATION
Lubrication
CHAPTER THREE
OPTIONAL EQUIPMENT
SECTION 1 - MISCELLANEOUS OPTIONAL EQUIPMENT

Miscellaneous Optional Equipment
SERVICE MAINTENANCE PACKAGES
ix
GENERAL WARNINGS
IT IS MANDATORY THAT ALL HYDRAULIC HOSES AND FITTINGS BE COR-

RECTLY TAGGED AND IDENTIFIED BEFORE THEY ARE DISCONNECTED TO
EFFECT REPAIRS OR SERVICE FAILURE TO CORRECTLY TAG AND IDENTIFY
HOSES AND FITTINGS CAN CAUSE WRONG RECONNECTION, WHICH CAN RE-
SULT IN DEATH OR INJURY TO PERSONNEL.
3G
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x
SERVICE MANUAL
CORRECTIVE ACTION REQUEST FORM
Should you have any query concerning the content or presentation of this manual please complete the following form.
All returns will be acknowledged and if approved incorporated into the next issue of the manual.
Name . . . . . . . . . . . . . . . . . . . . . . . . . . Title . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . .
Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
..........................................................................
Crane Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Production/Page No. . . . . . . . . . . . . .
Remarks
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Forward To:- Technical Publications Dept.

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Grove Worldwide
Sunderland
SR4 6TT
ENGLAND
xi
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3G
CHAPTER ONE
GENERAL DESCRIPTION AND MAINTENANCE
3G
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1-0-1, 1-0-2
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SECTION 1
GENERAL DESCRIPTION
TABLE OF CONTENTS
Page
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3
List of Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-4
Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-6
LIST OF FIGURES
Title Page
3G
Slinging Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-7
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1-1-1
WARNING SAFETY SUMMARY
Page
1-1-6
WARNING
DO NOT SLING ANY OTHER PART OF

THE MACHINE FOR THIS OPERATION,
OTHERWISE STRUCTURAL DAMAGE
MAY OCCUR.
ALWAYS ENSURE THAT SUITABLE

DUNNAGE IS USED BETWEEN THE
SLINGS AND THE OUTRIGGER
BEAMS TO ENSURE THAT NEITHER
THE SLINGS NOR THE BEAMS ARE
DAMAGED DUE TO ABRASION BE-
TWEEN THE SLINGS AND THE SHARP
EDGES OF THE BEAMS.
3G
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1-1-2
GENERAL DESCRIPTION
DESCRIPTION
This manual provides information for the maintenance enclosed cab mounted on the turntable. The crane is
personnel of the Model AT9120E Grove Crane. equipped with a five section fully powered boom. Addi-
tional reach is obtained by utilising the swingaway, lifting
The lift capacities are listed on the Load Chart in the cab. is provided by a main hoist and an optional auxiliary
hoist.
The crane carrier incorporates an all welded steel
frame, utilising one non-drive/non steer, one non-drive
NOTE
steer and three drive steer axles to provide a standard
10x6 drive. An optional 10x8 drive is available which
Throughout this manual, reference is
utilises one non-drive/non steer and four drive steer ax-
made to left, right, front, and rear when
les. Axle steering is accomplished utilising hydraulic
describing locations. When operating
steer cylinders. The carrier engine is mounted at the
the crane from the carrier, these refer-
front of the crane and provides motive power through a
ence locations are to be considered as
12 speed powershift gearbox having eight forward and
those viewed from the operator’s seat
four reverse gears. Hydraulic sliding beam outriggers
with the turntable facing forward over
are integral with the carrier frame. 3G
The carrier utilises a hydragas suspension system, with
hydraulic lockout and an automatic levelling system, op-
the front of the carrier frame. When op-
erating the crane from the turntable,
these reference locations are to be con-
erated from the cab. sidered as those viewed from the op-
erator’s seat with the turntable facing
The turntable is capable of 360 degrees rotation in either rearward with the boom directly over
60
direction. All crane functions are controlled from the fully the rear of the carrier frame.
86
1-1-3
LIST OF SPECIFICATIONS
GENERAL TRANSMISSION.
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT9120E Speeds . . . . . . . . . . . . Forward . . . . . . . . . . . Reverse

Rated Capacity . . . . . . . . . . . . . See Load chart in cab 1st Gear . . . . . . . . . . . . . . 6.83 . . . . . . . . . . . . . . . . . 6.83
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10x6 & 10x8 2nd Gear . . . . . . . . . . . . . 5.19 . . . . . . . . . . . . . . . . . 3.42
Gross Weight . . . . See lifting and transportation decal 3rd Gear . . . . . . . . . . . . . . 3.42 . . . . . . . . . . . . . . . . . 1.79
Maximum Speed . . . . . . . . . . . . . . . . . 70 kph (45 mph) 4th Gear . . . . . . . . . . . . . . 2.64 . . . . . . . . . . . . . . . . . 0.91
5th Gear . . . . . . . . . . . . . . 1.79
DIMENSIONS 6th Gear . . . . . . . . . . . . . . 1.36
7th Gear . . . . . . . . . . . . . . 0.90
8th Gear . . . . . . . . . . . . . . 0.68
NOTE
WHEELS AND TYRES.
Dimensions listed are for a crane with Size . . . . . . . . . . . . . . . . . . . . . . 16.00 R25 or 20.5 R25
all components fully retracted in the Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
travel mode. Torque . . . . . . . . . . . . . . . . . . . . . . . . . 440lb/ft (608 nm)
For roading and lifting pressures, see the Tyre Inflation
Wheel Base . . . . . . . . . . . . . . . . . . . . 5670mm (18¢ 7² )
decal in the cab for various tire sizes and lifting pres-
Overall Crane Width . . . . . . . . . . . . . . 2900mm (9¢ 6² )
Overall Crane Height . . . . . . . . . . . . . 3990mm (13¢ 1²)
Overall Crane Length . . . . . . . . . . 15500mm (50¢ 10² )
Tailswing . . . . . . . . . . . . . . . . . . . . . . . 4445mm (14¢ 7² )
3G sures.
BRAKES.
Type . . . . . . . . . . . . . . Axles 4, 5 Simplex Wedge Type
Track . . . . . . . . . . . . . . . . . . . . . . . . . . 2380mm (7¢ 10² )
. . . . . . . . . . . . . . . . . Axles 1, 2 & 3Duplex Wedge Type
CAPACITIES (US Gallons/ Litres). PUMP (EMERGENCY STEER)
60
Fuel Tank Turntable . . . . . . . . . 55 gallons (209 litres) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Fuel Tank Carrier . . . . . . . . . . . 114 gallons (432 litres) Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine Lubrication System See Engine Specifications GPM . . . . . . . . 1 - 38 gpm (144 lpm) @ 70 kph flow is
Coolant Capacity . . . . . . . . . . . . 12 gallons (45.5 litres) . . . . . . . . . . . . . . . . . . . . dependent on ground speed.
Hyd Tank (Reservoir Capacity)300 gallons (1136 litres) HYDRAULIC PUMP (4 SECTION)
86
Hydraulic Tank Steer Capacity 43.6 gallons (164 litres) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Hoist Main . . . . . . . . . . . . . . . . . . . . 1.6 gallons (6 litres) Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hoist Auxiliary . . . . . . . . . . . . . . . 3.6 gallons (14 litres) GPM . . . . . . . . . . . . . . . . . . . . . . 1 - 21.9 gpm (83 lpm),
Swing Gearbox . . . . . . . . . . . . . . . 1.6 gallons (6 litres) . . . . . . . . . . . . . . . 3 - 46.2 gpm (175 lpm) @ 2500 rpm.
Gearbox and Torque Convertor 13 gallons (50 litres)
No. 1 Axle Differential (8 x 8, 10 x 8)4.5 gallons (17 litres) HYDRAULIC PUMP (2 SECTION - STEERING)
No. 2 Axle Differential . . . . . . . . . . 4 gallons (15 litres) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
No. 4 Axle Differential . . . . . . . 4.8 gallons (18.2 litres) Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
No. 5 Axle Differential . . . . . . . . . 4.5 gallons (17 litres) GPM . . . . . . . . . . . . . . . . . . . . . . 2 - 22.4 gpm (60 lpm)
No. 1 Axle Hubs (8 x 8, 10 x 8) 0.34 gallons (1.3 litres) HYDRAULIC PUMP (OUTRIGGER / SUSPENSION)
No. 2 Axle Hubs . . . . . . . . . . . . 0.34 gallons (1.3 litres)
No. 4 Axle Hubs . . . . . . . . . . . . . 0.4 gallons (1.5 litres) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
No. 5 Axle Hubs . . . . . . . . . . . . 0.36 gallons (1.4 litres) Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GPM . . . . . . . . . . . 1 - 35 gpm (132 lpm) @ 2300 rpm.
FIRE EXTINGUISHER. SWING MOTOR.
Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BC Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vane
Weight . . . . . . . . . . . . . . . . . . . . . . . . 2.75 lbs (1.25 kg) Displacement . . . . . . . . . . 8.7cu.in (144 cu.cm) per rev
1-1-4
SWING GEARBOX. Auxiliary Hoist (Grove HO 30B)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Reduction Drum Diameter . . . . . . . . . . . . . . . . . . . . . 15² (38.1cm)
Reduction Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46:1 Drum Length . . . . . . . . . . . . . . . . . . . . . 25.6² (65.1 cm)
BOOM Cable Size . . . . . . . . . . . . . . . . . . . . . . . . 0.75² (19mm)
Length . . . . . . . . . . . 12.96m to 48.72m (42¢ 6² to 160¢) Permissilble Line Pull. Refer to Line Pull and Reeving In-
. . . . . . . . . . . . . . . . 5 section fully powered trapezoidal. formation Chart in the cab
Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -3° to +80°
Optional Extras COUNTERWEIGHT
10m (33¢) swingaway offsettable at 2°, 15°, or 30°.
10m to 14.6m or 17.7m (33¢ to 48¢ or 58¢) swingaway of- Weight . . . . . . . . (See Axle Weight Distribution Chart)
fsettable at 2°, 15°, or 30°. OUTRIGGERS.
Multi-section fixed offset lattice jib and fixed extension
7.01m (23¢) to 35.35m (116¢) jib, offsettable at 10°, 17°, Type . . . . . . . . . . Double Box Beam with Vertical Jack
or 30°. Extended Length . . . . . . . . . . . . . . . . . . 25¢ 1² (7.64m)
Partial Extended Length (Opt) . . . . . . . 18¢ 7² (5.67m)
HOISTS
AIR HYDRAULIC SWIVEL
Main Hoist
Air Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drum Diameter . . . . . . . . . . . . . . . . . . . . . 20² (50.8cm) Oil Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Drum Length . . . . . . . . . . . . . . . . . . . . . 27.6² (70.2cm) 3G
Cable Size . . . . . . . . . . . . . . . . . . . . . . . . . . . 1² (25mm)
Permissilble Line Pull. Refer to Line Pull and Reeving In-
ELECTRICAL SYSTEM.
Type . . . . . . . . . . . . . . . . . . . . . . . . . Single wire ground

formation Chart in the cab System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.
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1-1-5
SLINGING POINTS 4. The spreader beams to be positioned above the
height of the machine and slings attached to the outrig-
When it is required to lift a machine for shipment, rigging ger beams and the spreader beams as shown.
personnel shall be responsible for proper selection and
placement of all slings and load handling devices. They 5. The slings must be selected to suit the C of G to
must verify all dimensions as required for clearance and give a level lift.
weight of machine of lifting.
WARNING
Partially extended outriggers are used as lifting points.
DO NOT SLING ANY OTHER PART OF
The following procedure must be adhered to:- THE MACHINE FOR THIS OPERATION,
OTHERWISE STRUCTURAL DAMAGE
1. Ensure the parking brake is applied and the swing MAY OCCUR.
lock pin engaged with the turntable in line with the car-
rier. ALWAYS ENSURE THAT SUITABLE
DUNNAGE IS USED BETWEEN THE
2. Extend all four outrigger beams (approximately 12” SLINGS AND THE OUTRIGGER BEAMS
(30.5cm). TO ENSURE THAT NEITHER THE
SLINGS NOR THE BEAMS ARE DAM-
3. Use two spreader beams which are long enough to AGED DUE TO ABRASION BETWEEN
span the width of the machine and sufficient to give THE SLINGS AND THE SHARP EDGES
clearance to the machine for a vertical lift.
3G OF THE BEAMS.
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1-1-6
3G
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Slinging Points
1-1-7
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3G
SECTION 2
GENERAL MAINTENANCE
TABLE OF CONTENTS
Page
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Cleaning Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
Steam Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3
External Cleaning of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-4
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Pressing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
3G
Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wires and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2-5
1-2-5
1-2-5
1-2-5
Antifriction Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-5
Double Row, Tapered Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Heating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Sleeve Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
86
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6

Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6
Keep the System Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-7
Sealing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-7
Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-7
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-7
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-7
Fasteners and Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-8
LIST OF FIGURES
Title Page
Nut Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-9
Bolt Head Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-9
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-10
Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-11
1-2-1
Page
1-2-6
WARNING
EXERCISE EXTREME CARE AROUND

PRESSURIZED HYDRAULIC SYS-
TEMS.DO NOT WORK ON A HYDRAU-
LIC SYSTEM WHILE IT IS IN OPERA-
TION OR UNTIL ALL PRESSURE IS RE-
LEASED.
1-2-7
WARNING
LOCTITE TYPE ADHESIVES CONTAIN

CHEMICALS THAT MAY BE HARMFUL
IF MISUSED. READ AND FOLLOW THE
3G
INSTRUCTIONS ON THE CONTAINER.
60
86
1-2-2
GENERAL MAINTENANCE
MAINTENANCE
These general suggestions should be helpful in follow- Whenever hydraulic, fuel, lubricating oil lines, or airlines
ing the instructions in this manual. In analyzing a system are disconnected, clean the adjacent area as well as the
malfunction, use a systematic procedure to locate and point of disconnect. As soon as the disconnection is
correct the problem. made, cap, plug or tape each line or opening to prevent
entry of foreign material. The same recommendations
1. Determine the problem. for cleaning and covering apply when access covers or
inspection plates are removed.
2. List possible causes.
Clean and inspect all parts. Be sure all passages and
3. Devise checks. holes are open. Cover all parts to keep them clean. Be
sure parts are clean when they are installed. Leave new
4. Conduct checks in a logical order to determine the
parts in their containers until ready for assembly.
cause.
5. Consider the remaining service life of components

3G
against the cost of parts and labor necessary to replace
them.
Clean the rust preventive compound from all machined
surfaces of new parts before installing them.
CLEANING PRECAUTIONS
6. Make the necessary repair.
Steam Cleaning
60
7. Recheck to ensure that nothing has been over-
looked.
Whenever cranes are being steam cleaned, or cleaned
using high pressure water jets, certain precautions
8. Functionally test the failed part in its system.
should be taken to prevent ingress into susceptible com-
ponents such as general crane electrics i.e. solenoid
86
NOTE
valves, collector column electrical motors, generators
and dynamos. Direct spray on to any exposed output of
Your safety and that of others is always
input shaft seals should also be avoided.
the number one consideration when
working around machines. Safety is a
matter of thoroughly understanding Swing bearings are generally only protected by a laby-
the job to be done and the application rinth type seal which although totally adequate to pre-
of good common sense. It is not just a vent water ingress under normal circumstances, will not
matter of do’s and don’ts. Stay clear of prevent water ingress from the indiscriminate applica-
all moving parts. tion of a high pressure jet. The points to be protected on
swing bearings are the top and bottom gaps between
CLEANLINESS. the inner (fixed) and outer rotating sections.
An important item in preserving the long life of the ma- Any water entering will be trapped in the tracks and
chine is keeping dirt out of working parts. Enclosed com- cause corrosion and thereby reduce the life of the swing
partments, seals, and filters have been provided to keep bearing. Therefore it is essential that during steam
the supply of air, fuel, and lubricants clean. It is important cleaning the jet not directed to these gaps, unless they
that these enclosures be maintained. are suitably protected.
1-2-3
Commercial detergents which dissolve dust and dirt
which have been contaminated with fuel and/or lube oil
should be used. (e.g. Henkel P3/768, Nalfleet 9-040 or
equivalent). It has been proved in practice that the deter-
gent has a better effect when it is brush applied and left
for a time before being sprayed off with water. In stub-
born cases of contamination the process should be re-
peated until the parts are completely cleaned.
On completion the engine should be run up to operating

temperature so that the remaining water evaporates.
3. Cleaning with Steam Jet Device
Cleaning with a steam jet device is preferable above all

other cleaning methods. to clean the engine efficiently a
steam temperature of between 80 degrees to 90 de-
Section Through Ball Type Swing Bearing
Do Not Steam Clean Shaded Areas grees with a steam pressure of 60 bar will be required.
Again on completion the engine should be run up to op-
erating temperature to evaporate any remaining water.
External Cleaning of the Deutz Air Cooled Engine
The cooling system of the Deutz air cooled engine

3G 4. Cleaning with Diesel Fuel
Diesel fuel has only a limited dissolving effect, therefore

cleaning with diesel fuel is not recommended. Moreover
should be regularly checked (particularly in dirty condi-
the diesel fuel pollutes the environment.
tions of application) to ensure that there is no build up of
contamination on the cooling fins, etc. General
60
Deposits of dirt and dust on the cooling fins of cylinders, When cleaning with water or steam jet, care should be
cylinder head, oil coolers and charge oil coolers, espe- taken to protect the injection pumps, speed governors,
cially when contamination with fuel and/or lube oil, will regulator, starter motor and electrical equipment from
result in the cooling effect being reduced. The vertical the direct spray. Also shaft passages with seals should
cylinder head fins in particular, must be free of contami-
86
not come into direct contact with water or steam jets

nation and therefore will require careful cleaning. The (due to the risk of water ingress).
protective grills in front of the cooling blowers should
also be cleaned. Cleaning the air supply side after removal of the air cowl-
ing is particularly important.
The method of cleaning used and the types of deter-
gents required will depend on the kind of contamination, REMOVAL AND INSTALLATION.
however when cleaning the following points should be
When performing maintenance, do not attempt to manu-
observed:-
ally lift heavy parts when hoisting equipment should be
1. Dry Cleaning with Compressed Air used. Never locate or leave heavy parts in an unstable
position. When raising a portion of a crane or a complete
Cleaning with compressed air can only be applied with crane, ensure the crane is blocked securely and the
slight contamination by dry dust. Start by blowing out weight is supported by blocks rather than by lifting
dust from the exhaust side. equipment.
2. Cleaning with Detergents and Water When using hoisting equipment, follow the hoist manu-
facturers recommendations and use lifting devices that
Cleaning with water alone is not successful. will allow you to achieve the proper balance of the as-
1-2-4
semblies being lifted and to ensure safe handling.Un- pered splines and discard the part if the splines are
less otherwise specified, all removals requiring hoisting worn.
equipment should be accomplished using an adjustable
lifting attachment. All supporting members (chains and LOCKS.
cables) should be parallel to each other and as near per-
pendicular as possible to the top of the object being Lockwashers, flat metal locks, or cotter pins are used to
lifted. lock nuts and bolts.
CAUTION Flat metal locks must be installed properly to be effec-

tive. Bend one end of the lock around the edge of the
THE CAPACITY OF AN EYEBOLT DI- part. Bend the other end against one flat surface of the
MINISHES AS THE ANGLE BETWEEN nut or bolt head.
THE SUPPORTING MEMBERS AND
THE OBJECT BECOMES LESS THAN Always use new locking devices on components which
90 DEGREES. EYEBOLTS AND have moving parts.
BRACKETS SHOULD NEVER BE BENT
When installing lockwashers on housings made of alu-
AND SHOULD ONLY HAVE STRESS IN
minum, use a flat washer between the lock-washer and
TENSION.
the housing.
Some removals require the use of lifting fixtures to ob-
3G WIRES AND CABLES.
tain proper balance. The weights of some components
are given in their respective sections of the manual. Batteries should always be disconnected prior to work-
ing on the electrical system.
If a part resists removal, check to be certain all nuts and
bolts have been removed and that an adjacent part is When removing or disconnecting a group of wires or ca-
not interfering. bles, tag each one to ensure proper identification during
60
assembly.
DISASSEMBLY AND ASSEMBLY.
SHIMS.
When assembling or disassembling a component or
system, complete each step in turn. Do not partially as- When shims are removed, tie them together and identify
semble one part and start assembling some other part. them as to location. Keep shims clean and flat until they
86
Make all adjustments as recommended. Always check are reinstalled.

the job after it is completed to see that nothing has been
overlooked. Recheck the various adjustments by oper- BEARINGS.
ating the machine before returning it to the job.
Antifriction Bearings.
PRESSING PARTS.
When an antifriction bearing is removed, cover it to keep
When pressing one part into another, use an anti-seize out dirt and abrasives. Wash bearings in non-flammable
compound or a molybdenum disulfide base compound cleaning solution and allow them to drain dry. The bear-
to lubricate the mating surfaces. ing may be dried with compressed air BUT do not spin
the bearing.Discard the bearings if the races and balls or
Assemble tapered parts dry. Before assembling parts rollers are pitted, scored, or burned. If the bearing is
with tapered splines, be sure the splines are clean,dry, serviceable, coat it with oil and wrap it in clean waxed
and free from burrs. Position the parts together by hand paper.Do not unwrap new bearings until time of installa-
to mesh the splines before applying pressure. tion.The life of an antifriction bearing will be shortened if
not properly lubricated. Dirt in an antifriction bearing can
Parts which are fitted together with tapered splines are cause the bearing to lock resulting in the shaft turning in
always very tight. If they are not tight, inspect the ta- the inner race or the outer race turning within the cage.
1-2-5
Double Row, Tapered Roller. Sleeve Bearings.
Double row, tapered roller bearings are precision fit dur- Do not install sleeve bearings with a hammer. Use a
ing manufacture and components are not interchange- press and be sure to apply the pressure directly in line
able. The cups, cones, and spacers are usually etched with the bore. If it is necessary to drive on a bearing,use
with the same serial number and letter designator. If no a bearing driver or a bar with a smooth flat end. If a
letter designators are found, wire the components to- sleeve bearing has an oil hole, align it with the oil hole in
gether to assure correct installation. Reusable bearing the mating part.
components should be installed in their original posi-
GASKETS
tions.
Be sure the holes in the gaskets correspond with the lu-
Heating Bearings. bricant passages in the mating parts. If it is necessary to
make gaskets, select material of the proper type and
Bearings which require expansion for installation should thickness. Be sure to cut holes in the right places. Blank
be heated in oil not to exceed 250 degrees F(121 de- gaskets can cause serious damage.
grees C). When more than one part is heated to aid in
assembly, they must be allowed to cool and then When removed, always install new cylinder head and
pressed together again. Parts often separate as they manifold gaskets using recommended gasket com-
cool and contract. pound on head gaskets to allow uniform sealing.
Installation.
Lubricate new or used bearings before installa-

3G BATTERIES.
Clean batteries by scrubbing them with a solution of

baking soda and water. Rinse with clear water. After
tion.Bearings that are to be preloaded must have a film
cleaning, dry thoroughly and coat terminals and connec-
of oil over the entire assembly to obtain accurate pre-
tions with an anti corrosion compound or grease.
loading. When installing a bearing, spacer, or washer
60
against a shoulder on a shaft, be sure the chamfered If the machine is to be stored or not used for an extended
side is toward the shoulder. period of time, the batteries should be removed. Store
the batteries in a warm, dry place, preferably on wooden
When pressing bearings into a retainer or bore, uni- shelves. Never store on concrete. A small charge
formly apply pressure to the outer race. If the bearing is should be introduced periodically to keep the specific
pressed on the shaft, uniformly apply pressure on the in-
86
gravity rating at recommended level.

ner race.
HYDRAULIC SYSTEMS.
Preload.
WARNING
Preload is an initial load placed on the bearing at the
EXERCISE EXTREME CARE AROUND
time of assembly. Whether a tapered roller bearing
PRESSURIZED HYDRAULIC SYS-
should have preload could depend on any of several
TEMS.DO NOT WORK ON A HYDRAU-
conditions: rigidity of the housings and shaft, bearing
LIC SYSTEM WHILE IT IS IN OPERA-
spread, speed of operation, etc.
TION OR UNTIL ALL PRESSURE IS RE-
LEASED.
To determine whether a bearing requires preload or end
clearance, consult the disassembly and assembly in- Cleanliness.
structions pertaining to that bearing.
Contaminants in a hydraulic system affect operation
Care should be exercised in applying preload. Misappli- and will result in serious damage to the system compo-
cation of preload to bearings requiring end clearance nents. Dirty hydraulic systems are a major cause of
can result in bearing failure. component failures.
1-2-6
Keep the System Clean. equipment, the severity of the application, and the expe-
rience of the operators and maintenance personnel.The
When removing components of a hydraulic sys- following are known high stress areas applicable to
tem,cover all openings on both the component and the Grove machines, and a visual inspection of these areas
crane. should be made part of an owner’s planned preventive
maintenance program:
If evidence of foreign particles is found in the hydraulic
system, flush the system. a. Power Telescope Boom - wear pad retaining struc-
tures, hydraulic cylinder attaching points,boom pivot
Disassemble and assemble hydraulic components on a shaft retaining structures.
clean surface.
b. Outrigger pads, beams, boxes and attachment
Clean all metal parts in a nonflammable cleaning fluid. structures.
Then lubricate all components to aid in assembly.
c. Main frames - generally in the area of doubler
Sealing Elements. plates and crossmembers;at the junction of front and
rear frame members on truck cranes.
Inspect all sealing elements (O-ring, gaskets, etc.) when
disassembling and assembling the hydraulic system d. Turntable bearing connection (where bearing is
components. Installation of new elements is always rec- welded to the crane turntable or carrier).
ommended.
Hydraulic Lines.
3G e.
f.
Counterweight support structures.
Carrier axle and suspension mounting structures.

When installing metal tubes, tighten all bolts finger-tight.
Then, in order, tighten the bolts at the rigid end,the ad- g. Hydraulic cylinder end connections.
justable end, and the mounting brackets. After tubes are
60
mounted, install the hoses. Connect both ends of the The above is provided only as a guide, and your inspec-
hose with all bolts finger-tight. Position the hose so it tion plan should not be limited to the areas listed.A thor-
does not rub the machine or another hose and has a ough visual inspection of all weldments is good practice.
minimum of bending and twisting.Tighten bolts in both
couplings. Anyone requiring more detailed inspection instructions
86
and/or repair procedures may request same by contact-

Due to manufacturing methods there is a natural curva- ing: Grove Cranes Sunderland SR4 6TT
ture to a hydraulic hose. The hose should be installed so
any bend is with this curvature. LOCTITE.
FATIGUE OF WELDED STRUCTURES. WARNING
Experience has shown that highly stressed welded LOCTITE TYPE ADHESIVES CONTAIN
structures when repeatedly subjected to varying CHEMICALS THAT MAY BE HARMFUL
stresses caused by twisting, shock, bending, and inten- IF MISUSED. READ AND FOLLOW THE
tional and/or unintentional overloads, often become INSTRUCTIONS ON THE CONTAINER.
subject to weld cracking which may be attributed to fa-
tigue of the welded joint. This condition is not uncom- Always follow the directions on the Loctite container as
mon in construction equipment. not all Loctite types are suitable for all applications.Vari-
ous types of Loctite are specified throughout the Service
Equipment should be periodically inspected for evi- Manual.The following types of Loctite brand adhesives
dence of weld fatigue. The frequency of these inspec- are available from the Parts Department of Grove
tions should be commensurate with the age of the Cranes.
1-2-7
Loctite Number Grove Part Number When referring to the applicable torque charts, use val-
ues as close as possible to the torque values shown to
242 9999100805 allow for wrench calibration tolerance. An erratic or jerk-
545 9999100851 ing motion of the wrench can easily result in excessive
271 9999100852 torque. ALWAYS use a slow wrench movement and
516 9999100853 STOP when the predetermined value has been
reached.
FASTENERS AND TORQUE VALVES.
Use bolts of the correct length. A bolt which is too long Torque wrenches are precision instruments and are to
may bottom before the head is tight against the part it is be handled with care to ensure calibrated accuracy.
to hold. If a bolt is too short, there may not be enough Calibration checks should be made on a scheduled ba-
threads engaged to hold the part securely.Threads can sis. Whenever the wrench might be either over stressed
be damaged. Inspect them and replace fasteners, as or damaged, it should immediately be removed from
necessary. service until recalibrated.
Torque values should correspond to the type KNOW YOUR TORQUE WRENCH! Flexible beam type
bolts,studs, and nuts being used. wrenches, even though they might have a preset fea-
ture, must be pulled at right angles and the force must be
The torque tables are provided by Grove Manufacturing applied at the exact center of the handle.Force value
Company for reference when performing maintenance. readings must be made while the tool is in motion.
proper torquing can seriously affect performance and

reliability.
3G
Use of proper torque values is extremely important.Im-
Rigid handle type torque wrenches are available with
torque limiting devices that can be preset to required
values and which eliminate dial readings.
Identification of fastener grade is always neces-
sary.When marked as a high strength bolt (grade 3, NOTE
60
5,etc.), the mechanic must be aware that he is working
with a highly stressed component and the fastener To convert pounds-foot of torque to
should be torqued accordingly. kilograms meter (kgm), multiply the
pounds-foot quantity by 0.138255.
NOTE
NOTE
86
Some special applications require vari-

ation from standard torque values. Ref-
To convert pounds-inch of torque to
erence should always be made to com-
kilograms centimeter (kgcm), multiply
ponent overhaul procedures for recom-
the pounds-inch quantity by 1.152.
mendations.
Special attention should be given to the existence of lu- NOTE

bricant, plating, or other factors that might require vari-
ation from standard torque values. When multipliers and/or special tools
are used to reach hard to get at
When maximum recommended torque values have spots,ensure torque readings are pre-
been exceeded, the fastener should be replaced. cisely calculated.
1-2-8
Grade 5
No 3 Lines 1 Line 3 Dots 3 Radial 1 Radial 1 Row

Markings Spaced 1 Dot Spaced lines Line Notched
Heat 1 Dot Corners
Treated 120° 120 °
Grade 8
6 Lines 1 Line 6 Radial 6 Dots 1 Radial 2 Rows

Spaced 1 Dot lines Spaced Line Notched
° 1 Dot Corners
60 60°
0334
Nut Identification
3G
60
SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8

and Grade 2
86
Socket Socket 12 - Point

Capscrew Shoulder Flange Screw
Screw
2083
Bolt Head Identification
1-2-9
TORQUE VALUES (Pounds-Foot)
Coarse Thread 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
Capscrew
SAE Grade 1 7 10 19 30 45 66 93 150 202 300 474 659 884 1057

and Grade 2
SAE Grade 5 13 18 31 50 75 110 150 250 378 583 782 1097 1461 1748
SAE Grade 7 14 24 43 69 106 150 209 350 550 825 1304 1815 2434 2913
SAE Grade 8 15 28 46 75 115 165 225 370 591 893 1410 1964 2633 3150
Socket 15 28 46 75 115 165 225 370 591 893 1410 1964 2633 3150
Capscrew
Socket 4 10 22 - 40 - 96 167 - 333 - - - -

Shoulder Screw
12 Point Unless otherwise specified, the mechanical properties and tightening torque for the flange screws shall be the
Flange Screw same as for the corresponding grade and size hex head capscrew listed above. See note 3.
NOTES: 1. Studs shall be torqued using capscrew figures when grade is known.
2. Sizes used for socket head shoulder screws are nominal, or basic shoulder diameter, and not the thread diameter normally
used to describe a bolt. 3G
3. Grade marking for the 12-point flange screw is the same as for the hex head capscrew.
Torque Values for Unfinished Fasteners With No Special Lubrication - Coarse Threads
60
TORQUE VALUES (Pounds-Foot)
Fine Thread 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-3/8 1-1/2
Capscrew
SAE Grade 1 8 11 21 33 50 73 104 165 221 327 514 722 992 1174
86
and Grade 2
SAE Grade 5 15 20 35 55 83 121 168 276 413 633 848 1203 1638 1942
SAE Grade 7 16 26 48 76 118 165 234 387 601 896 1408 1992 2730 3238
SAE Grade 8 17 31 51 82 128 183 251 409 646 970 1530 2154 2953 3500
Socket 17 31 51 82 128 183 251 409 646 970 1530 2154 2953 3500
Capscrew
Socket See Note 2

Shoulder Screw
12 Point Unless otherwise specified, the mechanical properties and tightening torque for the flange screws shall be the same
Flange Screw as for the corresponding grade and size hex head capscrew listed above. See note 3.
NOTES: 1. Studs shall be torqued using capscrew figures when grade is known.
2. Sizes used for socket head shoulder screws are nominal, or basic shoulder diameter, and not the thread diameter normally
used to describe a bolt.
3. Grade marking for the 12-point flange screw is the same as for the hex head capscrew
Torque Values for Unfinished Fasteners With No Special Lubrication - Fine Threads
1-2-10
TORQUE VALUE (Pounds-Foot)
Bolt
Diameter Grade 8 Grade 5
1/4 8 5
5/16 15 11
3/8 30 19
7/16 45 31
1/2 66 47
9/16 96 67
5/8 168 117
3/4 235 164
7/8 380 265
1 568 398
1-1/8
1-1/4
1-3/8
3G 805
1135
1490
563
795
1042
1-1/2 1975 1383
1-3/4 3120 2182

60
2 4690 3280
Torque Values for Unfinished Grade 5 and Grade 8 Bolts Using Cadmium Plated,
Grade C, Locknuts Having a Wax or Dichromate Coating
86
TORQUE VALUES
BOLT DIAMETER - MM
Class M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Pounds-inch Pounds-foot
8.8 24 43 79 132 193 32 56 94 142 190 277 368 479 707 967
(Grade 5)
10.9 35 62 114 192 279 46 81 133 205 269 400 520 691 996 1357
(Grade 8)
12.9 43 80 135 240 332 55 96 159 243 323 475 628 822 1205 1630
(Grade 9)
NOTE: Torque for Fine Threads can be considered 8% higher.
Torque Values for Unfinished Metric Fasteners with No Special Lubricant - Coarse Threads
1-2-11
ASSEMBLY OF J.I.C. HYDRAULIC FITTING. the tightening torque to avoid extrusion of the insert from
between the mating surfaces.
All J.I.C. type hydraulic fittings must be assembled using The correct copper insert for the size of the fitting and the
the correct cone shaped soft copper insert between the correct tightening torque to ensure optimum sealing is
mating surfaces. The use of these inserts place a limit on shown on the table below.
FITTING SIZE INSERT PART NUMBER TIGHTENING TORQUE
Æ 3/ ” J.I.C.
8
Æ 1/ ” J.I.C.
7-794-990145 13 lb ft (17.6 Nm)
2
Æ 3/ ” J.I.C.
7-794-990146 16 lb ft (21.7 Nm)
4
Æ 1” J.I.C.
7-794-990147 41 lb ft (55.6 Nm)
Æ 11/ ” J.I.C.
7-794-990148 61 lb ft (82.7 Nm)
4
Æ 11/ ” J.I.C.
7-794-990149 77 lb ft (104.4 Nm)
2 7-794-990250 95 lb ft (129 Nm)
Inserts are considered unnecessary for Æ 1/4” fittings

3G
60
86
1-2-12
CHAPTER TWO
DETAILED DESCRIPTION, OPERATION AND
MAINTENANCE
3G
60
86
2-0-1 ,2-0-2
86
60
3G
SECTION 1
CABS
TABLE OF CONTENTS
Page
CABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-9
.
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-9 .
CARRIER CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10 .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10 .
Cab Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-10 .
Direction Indicator Warning Light (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
Engine Steering Pump Failure Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
Transmission Steering Pump Failure Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-10
Torque Convertor Lock Up Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
3G
Engine Distress Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
Alternator Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
Transmission Oil Temperature Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
Gearshift Warning Light (Amber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
Suspension Locked Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
Transmission Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
Transmission Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-10
60
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Engine Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11 .
Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Tachograph or Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
86
Inter Axle Differential Lock Warning Light (Amber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11

Differential Lock Warning Light (Amber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Power Take-Off Warning Light (Blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Rear Wheels Steering Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Front Wheel Drive Warning Light (Amber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Parking Brake Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Air Pressure Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Power to Superstructure Warning Light (Amber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-11
Main Beam Warning Light (Blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Direction Indicator Warning Light (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Tachometer/Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Air Pressure Gauge (No. 1 Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-11
Engine Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 .
Lighting Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 .
Rear Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 .
2-1-1
Page
Hazard Warning Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 .

Rotary Beacon Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-12
Engine Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 .
Front Wheel Drive Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-12 .
Inter Axle Differential Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-12
Power Take-Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13 .
Dashpanel Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13 .
Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13
.
Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13
.
Slider Control - Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13 .
Slider Control - Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13 .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13.
Horn, Direction Indicator and Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-13
Windscreen Wiper and Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-13
Exhaust Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13 .
Axle Cross Differential Lock Foot Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-13
Foot Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-13 .
Foot Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
3G .
Windscreen Washer Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-14
Steering Column Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-14
Battery Isolator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14 .
Carrier/Superstructure Change Over Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-14
Gearshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14
.
Torque Convertor Automatic Lock Up Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-14
60
Gearshift Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14 .
Emergency Gearshift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-14
Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-14 .
Third Axle Raise Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 .
Suspension Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 .
Suspension On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 .
86
Auto Ride Height Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 .

Axle Nos. 1 & 2 Left Hand Suspension Cylinders Control Switch . . . . . . . . . . . . . . . . . . . . . 2-1-15
Axle Nos. 1 & 2 Right Hand Suspension Cylinders Control Switch . . . . . . . . . . . . . . . . . . . . 2-1-15
Axle Nos. 4 & 5 Left Hand Suspension Cylinders Control Switch . . . . . . . . . . . . . . . . . . . . . 2-1-15
Axle Nos. 4 & 5 Right Hand Suspension Cylinders Control Switch . . . . . . . . . . . . . . . . . . . . 2-1-15
Ride Height Warning Light (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-15
3rd Axle Load Condition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-15
Axles Raise Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 .
APC 100 Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 .
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15
.
Rear Steering Tiller Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-15 .
Rear Steer Master Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-16 .
Rear Steer Lock/Unlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-16
Rear Steer Operational Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-16
Rear Steering Alignment Light (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-16
Rear Steer Locked Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-16
Rear Steering Unlocked Light (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-16
2-1-2
Page
Smoke Emission Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-16 .

Retarder Hand Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-16
Warning Light - Retarder (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-16
Engine Overspeed Warning Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-16
TACHOGRAPH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-23 .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-23
.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-23
.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-23
.
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-23 .
SUPERSTRUCTURE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-26 .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-26
.
Cab Controls And Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-26 .
Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-26.
Fan Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-26 .
Windscreen Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-26
Roof Wiper/Washer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-26 .
Superstructure Lighting Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-26
Rotating Beacon Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-26
3G
Engine Stop Switch - Super Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-27
Cold Start Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-27 .
Main and Auxiliary Hoist Boost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-27
Swing Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-27 .
Hoist Overlower Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-27
Auxiliary Hoist Selector Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-27
60
Fuel Quantity Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-27 .
Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-27
.
Tachometer/Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-27 .
Engine Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-27
Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-27 .
Boom Tele Sequence Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-27
86
Inner Mid Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-28 .

Mid Override Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-28 .
Warning Light Inner Mid Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-28
Warning Light Mid Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-32 .
Ignition Switch - Super Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-32
Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-32 .
Engine Distress Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-32
Counterweight Not Fully Raised Warning Light (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-32
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-32 .
Ignition Switch - Carrier Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-32
Low Air Pressure Indicator Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-32
Low Oil Pressure Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-32
High Engine Temperature Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-32
Transmission Oil Temperature Warning Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-32
Front Wheel Drive Warning Light (Amber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-33
2-1-3
Page
Suspension Locked Warning Light (Green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-33
Inter Axle Differential Lock Warning Light (Amber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-33
Engine Stop Switch - Carrier Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-33
Power Take-Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-33 .
Axles Raise Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-33 .
Rear Wheels Unlocked Light (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-33
Outrigger Selector Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-33 .
Hand Throttle - Carrier Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-33
Load Moment Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-33
Rear Steering Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-33 .
Parking Brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34 .
Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
.
Hand Throttle - Super Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-34
Gear Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
.
Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34.
Telescope Control Valve - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-34
Foot Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
.
Foot Throttle Pedal - Super Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-34
Swing Lock Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-34
3G .
Swing and Telescope or Auxiliary Hoist Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-34
Boom Lift and Main Hoist Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-35
Hoist Rotation Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-35 .
Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-35
.
Arm Rest Adjustment Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-35
Heater Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-35 .
60
Heater Control Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-35
Heat Control (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-35 .
Battery Isolator Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1-36 .
LIST OF FIGURES
86
Title Page
Carrier Cab Controls and Indicators (Sheet 1 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-17
Tachograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-24
.
Tachograph Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-25.
Boom Extend Configurations (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-29
Superstructure Cab Controls and Indicators (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1-37
2-1-4
Page
2-1-13
WARNING
THE P.T.O. MUST ALWAYS BE DISEN-

GAGED FOR NORMAL ROAD TRAVEL
ORDER. THE P.T.O. MUST ONLY BE
ENGAGED OR DISENGAGED WHEN
THE CRANE IS STATIONARY AND THE
ENGINE IS SWITCHED OFF. CHECK
THE AIR PRESSURE IN THE AUXIL-
IARY AIR SYSTEM IS OVER 110 PSI (7.7
BARS) BEFORE ATTEMPTING TO EN-
GAGE OR DISENGAGE THE P.T.O.
CONTROL. THE P.T.O. WILL NOT EN-
GAGE IF THE AIR PRESSURE IN CIR-
3G
CUIT 4 IS TOO LOW.
WARNING
2-1-14
THE STEERING COLUMN MUST ONLY

BE ADJUSTED WHEN THE CRANE IS
60
STATIONARY.
2-1-14
WARNING
ALWAYS TURN OFF ENGINE AND IG-

86
NITION SWITCH BEFORE CHANGING

OVER CARRIER / SUPERSTRUCTURE
SWITCH.
2-1-14
WARNING
THE PARKING BRAKE MUST BE AP-

PLIED BEFORE LEAVING THE CAR-
RIER CAB
2-1-15
WARNING
WHEN THE THIRD AXLE IS RAISED NO

PERSON SHOULD GO UNDER THE
CARRIER UNLESS THE AXLE IS
BLOCKED UP.
2-1-5
WARNING SAFETY SUMMARY (continued)
Page
2-1-16
WARNING
DO NOT TRAVEL ON HIGHWAY WITH

REAR STEER UNLOCKED.
2-1-26
WARNING
AVOID POLYCARBONATE CONTACT

WITH ABRASIVE CLEANERS, SUCH
AS STEEL WOOL, COMET, AJAX,
ETC., HIGHLY ALKALINE CLEANERS,
SQUEEGEES, SHARP INSTRUMENTS,
RAZOR BLADES, PETROL, ACETONE,
BENZENE, CARBON TETRACHLO-
3G
RIDE, TOLUENE, MEK, ACIDS OR ANY
CLEANERS WITH AMMONIA.
DO NOT CLEAN IN HOT SUN OR AT

ELEVATED TEMPERATURE. DO NOT
STICK ANY LABELS OR STICKERS TO
60
THE POLYCARBONATED SURFACE.
USE ONLY APPROVED SOLVENTS TO

CLEAN FRAMING. SOLVENTS RESI-
DUE AND FUMES CAN DAMAGE
POLYCARBONATE EDGE AND CAUSE
86
CRACKING OF THE POLYCAR-

BONATE. ALL PRIMERS FOR FRAME
AND/OR GLASS SURFACES MUST BE
CHECKED FOR POLYCARBONATE
COMPATIBILITY FOR THE SAME REA-
SON. IF SETTING BLOCKS ARE
GLUED IN PLACE, THE GLUE SHOULD
CONTAIN ONLY THE ABOVE SOL-
VENTS, OR WATER
2-1-27
WARNING
NEVER LEAVE THE CAB WITH THE

SWING BRAKE DISENGAGED.
2-1-6
Page
2-1-27
WARNING
THE HOIST LOWER MOTION CUT

OVERRIDE SWITCH MUST ONLY BE
USED FOR SERVICING THE HOIST CA-
BLE AND NOT FOR ANY OTHER PUR-
POSE.
2-1-28
WARNING
WHEN SWITCHING TO THE RIGGING

POSITION ANY LOAD ON THE HOOK
MUST FIRST BE REMOVED.
3GWARNING
THE ENGINE CANNOT BE STARTED

2-1-32
UNLESS GEARSHIFT IS IN NEUTRAL

POSITION IN BOTH CABS.
60
2-1-33
WARNING
THE PTO MUST BE ENGAGED AND

THE REAR STEERING LOCK DISEN-
GAGED FROM THE CARRIER CAB BE-
86
FORE USING THE REAR AXLE FUNC-

TION.
2-1-34
WARNING
THE PARKING BRAKE MUST BE AP-

PLIED BEFORE LEAVING THE SUPER-
STRUCTURE CAB
2-1-7
Page
2-1-34
WARNING
THE GEARSHIFT LEVER IN BOTH

CABS MUST BE NEUTRAL POSITION
BEFORE CARRIER ENGINE CAN BE
STARTED.
3G
60
86
2-1-8
CABS
DESCRIPTION
The crane is equipped with two cabs, a carrier cab and a A symbol identification decal is located in each cab.
superstructure cab. The carrier cab contains all controls
and indicators necessary for crane travel. The super-
structure cab contains all controls and indicators neces- For detailed information of either cab, refer to either
sary to perform craning operations. Both cabs utilize in- CARRIER CAB or SUPERSTRUCTURE CAB in this
ternational symbols to label the various crane controls. section.
3G
60
86
2-1-9
CARRIER CAB
DESCRIPTION
CAB CONTROLS AND INDICATORS 5. Blank Aperture

6. Engine Distress Warning Light (Red)
NOTE
This light illuminates when the engine coolant tempera-
The following paragraphs describe the ture is too high, coolant level too low or the oil pressure is
controls and indicators located in the low. When the light illuminates a buzzer also sounds.
carrier cab. The numbers in parenthe- Stop the engine immediately the light shows and investi-
ses ( ) represent the index number from gate the cause.
the figure title Carrier Cab Controls and 7. Alternator Warning Light (Red)
Indicators.
The warning light illuminates when the ignition switch
(50) is turned to the ON position. The warning should go
1. Direction Indicator Warning Light (Green)
out when the engine starts. If the warning illuminates
when the engine is running there is a fault in the charging
This light flashes intermittently when the direction indi- system. Unless the fault is corrected the battery will run
ard warning switch is selected.

3G
cator switch is operated for LEFT HAND turn or the haz- down.
8. Transmission Oil Temperature Warning Light
(Red)
2. Engine Steering Pump Failure Warning Light
(Red) The warning light illuminates when the transmission oil
temperature is excessive (refer to item (12)).
60
If this light illuminates when the engine is running it indi- 9. Gearshift Warning Light (Amber)
cates that there is a loss of hydraulic oil flow from one of
the engine driven steering pumps. This light will illuminate if the gearshift is selected out of
sequence. Whenever a gear change is selected that
3. Transmission Steering Pump Failure Warning would not be compatible to the engine speed, the auto-
matic powershift control will delay the implementation of
86
Light (Red)
the change, until the correct conditions exist.
Illuminates when there is a loss of hydraulic oil flow from 10. Suspension Locked Warning Light (Red)
the other engine driven steering pump or from the trans-
This light illuminates when the suspension cylinders are
mission driven emergency steering pump. This light will
hydraulically locked and not connected with the suspen-
also be on when the machine is stationary or travelling
sion accumulators.
slowly.
11. Transmission Oil Pressure Gauge
4. Torque Convertor Lock Up Warning Light Normal operating pressure is 15 to 18 bar (215 to 230
psi). If pressure drops below 13 bar (190 psi) stop en-
This will illuminate when power is being supplied to gine and ascertain the cause and rectify. (Note it is nor-
energise the lock up solenoid. mal for the gauge to deflect to zero when the transmis-
sion is shifting).
This lamp is not an indication that the lock up has actu-
12. Transmission Oil Temperature Gauge
ally engaged, lock up engagement can be detected by a
‘slight kick’ in the transmission shortly after the lamp is Normal operating temperature is 175° to 230°F (80° -
illuminated. 110°C). Maximum temperature is 248°F (120°C). If ex-
2-1-10
cessive temperature is indicated by the transmission oil 21. Rear Wheels Steering Warning Light (Red)
temperature gauge and warning light (8), stop the crane
and shift to neutral. Accelerate the engine to 1200 - 1500 Illuminates to indicate the steering linkage to the rear
rpm and allow the temperature to return to normal (two wheels is not fully locked using switch (81) for road
or three minutes) before resuming operation. travel.
22. Front Wheel Drive Warning Light (Amber)

13. Engine Oil Pressure Gauge
Illuminates to indicate front wheel drive is selected.
Indicates the engine oil pressure. Refer to the Engine
Operators Manual for correct oil pressure reading. 23. Parking Brake Warning Light (Red)
14. Engine Water Temperature Gauge Illuminates when the parking brakes are ON and ignition
switch is turned ON.
Indicates the engine water temperature. Refer to the En-
gine Operators Manual for the correct water tempera- 24. Air Pressure Warning Light (Red)
ture reading.
This light will illuminate if the air pressure in the air sys-
15. Voltmeter tems as indicated by the gauges (30) to (33) falls below
87 psi (600 KPa). Stop and investigate.
With the ignition switch in the ON position and before
25. Power to Superstructure Warning Light (Am-
3G
starting the engine, the voltmeter indicates the condition
of the batteries. With the engine running the voltmeter
indicates alternator voltage.
ber) - Fitted to Cranes with Drive/Steer Controls
from the Superstructure Cab.
This illuminates when the power to superstructure

16. Fuel Quantity Gauge
switch is in the superstructure position.
Indicates the quantity of fuel in the fuel tank. 26. Blank Aperture
60
17. Tachograph or Speedometer 27. Main Beam Warning Light (Blue)
This instrument records the road speed, and distance tr- Illuminates when the headlights are switched to MAIN
avelling together with other operating data. Refer to BEAM.
Section IV in the Carrier Operators and Safety Hand-
86
book for further details. An optional speedometer may 28. Direction Indicator Warning Light (Green)
be fitted.
This light flashes intermittently when the direction indi-
cator switch is operated for RIGHT HAND turn or hazard
18. Inter Axle Differential Lock Warning Light
warning switch is selected.
(Amber)
29. Tachometer/Hourmeter
Illuminates when the Inter Axle Differential Lock is se-
lected on the 4th axle. This meter is calibrated in rpm x 100. The tacho receives
an a.c. signal from the alternator. The hourmeter portion
19. Differential Lock Warning Light (Amber) of the gauge records the total running hours of the en-
gine.
Illuminates when the axle cross differential locks are en-
gaged on all the drive axles. 30. Air Pressure Gauge (No. 1 Circuit)
20. Power Take-Off Warning Light (Blue) Indicates the air pressure in the No. 1 circuit service
brake system which should read 125 psi (860 KPa) at
This light will illuminate when the Power Take-Off is en- maximum working pressure. This operates No. 1, 3 and
gaged. 4 axles.
2-1-11
31. Air Pressure Gauge (No. 2 Circuit) 39. Blank Aperture
Indicates the air pressure in the No. 2 circuit service 40. Engine Stop Switch
maximum working pressure. This circuit operates Nos. This is a spring loaded switch biased for engine run. De-
2 and 5 axles. press the switch against the spring to stop the engine.
32. Air Pressure Gauge (No. 3 Circuit) 41. Blank Aperture
Indicates the air pressure in the parking/emergency 42. Front Wheel Drive Switch
maximum working pressure. This switch is used for selecting front wheel drive.
33. Air Pressure Gauge (No. 4 Circuit) Use this switch only when crane is stationary and in neu-
tral.
Indicates the air pressure in the auxiliary air system
which should read 125 psi (860 KPa) at maximum work- Warning light (22) will illuminate in front wheel drive. If
ing pressure. the pressure in air circuit No. 4 is too low this switch will
not select.
34. Engine Warning Buzzer 3G
When the engine coolant temperature is too high, cool-
ant level too low or oil pressure too low this warning
DO NOT SELECT FRONT WHEEL DRIVE FOR NOR-
MAL ROAD TRAVEL OPERATIONS.
43. Inter Axle Differential Lock Switch

buzzer sounds. Works in conjunction with engine dis-
tress warning light (6).
This switch controls the engagement and disengage-
60
ment of the differential inter axle lock. The tractive effort
35. Lighting Switch
of the crane is considerably improved when the lock is
engaged. It is intended to be engaged for travelling on
A two position switch. Move to first position for side, tail
surfaces that offers adverse wheel grip.
and number plate lamps ON. Further movement to sec-
ond position for headlamps ON
The lock should preferably be engaged when the crane
86
is STATIONARY but may be engaged when moving if:-

36. Rear Fog Light Switch
1. the crane is moving very slowly - and
This switch activates the rear fog lights, an integral 2. the wheels are NOT SPINNING at the same time of
warning light in this switch will illuminate when the switch engagement.
is ON.
When travelling with the lock engaged do not deviate
37. Hazard Warning Switch from a straight path more than it is necessary. Disen-
gage the lock immediately conditions are suitable.
This switch operates ALL direction indicator lamps si-
multaneously. The warning lamp in the switch and lamps DO NOT TRAVEL CONTINUOUSLY WITH THE LOCK
(1) and (28) will flash intermittently until the switch is ENGAGED ON A SURFACE THAT PROVIDES GOOD
cancelled. WHEEL ADHESION.
38. Rotary Beacon Switch (Optional) Should the traction not be sufficient after operating this
switch then the cross differential lock switch (54) can be
Two position on-off switch operates the rotating beacon. operated simultaneously to provide more traction.
2-1-12
44. Power Take-Off Switch switch in the run position energises all electrical compo-
nents. This key cannot be removed until the engine is
WARNING stopped.
THE P.T.O. MUST ALWAYS BE DISEN- When the ignition key is removed the steering wheel is
GAGED FOR NORMAL ROAD TRAVEL automatically locked in position.
ORDER. THE P.T.O. MUST ONLY BE EN-
GAGED OR DISENGAGED WHEN THE 51. Horn, Direction Indicator and Headlamp
CRANE IS STATIONARY AND THE EN-
GINE IS SWITCHED OFF. CHECK THE From centre position, the lever functions are as follows:-
AIR PRESSURE IN THE AUXILIARY AIR
SYSTEM IS OVER 110 PSI (7.7 BARS) HORN - push knob INWARDS to sound horns.
BEFORE ATTEMPTING TO ENGAGE DIRECTION INDICATOR - move lever FORWARD to
OR DISENGAGE THE P.T.O. CONTROL. signal RIGHT HAND turn, and BACKWARD to signal
THE P.T.O. WILL NOT ENGAGE IF THE LEFT hand turn.
AIR PRESSURE IN CIRCUIT 4 IS TOO HEADLAMPS - press lever DOWNWARD to MAIN
BEAM. Return to centre position for DIPPED main
LOW.
beam. Pull lever UPWARD for headlamp flash.
This switch controls the torque convertor power take-off
52. Windscreen Wiper and Washer Switch
which drives the outrigger, suspension and rear steering
hydraulic pump. With the engine turned OFF and gear-
reverse the movement to disengage the pump.

3G
shift lever in NEUTRAL, switch on to engage the pump,
First movement rearward of switch selects intermittent
wipe, the first forward movement selects slow wipe and
second forward movements selects fast wipe. Press
switch knob inward for windscreen washer.
45. Dashpanel Dimmer Switch
53. Exhaust Brake Control
Operate this switch to dim the dashpanel gauge lights.
60
46. Test Switch Apply to slow the crane on curves or downgrades. Maxi-
mum brake effect occurs in the lowest gear range. The
This switch is used to test the panel display and audible throttle pedal must be released when this brake is used.
alarm. When selected the lights and alarm will operate.
It cannot hold a crane stationary.
86
47. Fan Control

54. Axle Cross Differential Lock Foot Switch
Move up and down for desired fan speed.
The switch should only be used if the traction is not satis-
48. Slider Control - Heater factory after using the inter axle differential lock switch.
Do not engage unless steering is central.
Move to the right and left for desired temperature set-
ting. The lock should preferably be engaged when the crane
is STATIONARY but may be engaged when moving if:-
49. Slider Control - Heater
1. the crane is moving very slowly - and
Move to direct the flow of air to screen or cab. 2. the wheels are NOT SPINNING at the same time of
engagement.
50. Ignition Switch
55. Foot Throttle Pedal
This key operated switch with four positions acc (4), off
(0), run (1) and start (2). The switch is spring returned This foot throttle pedal is connected to an air valve that
from start to run. With the switch in the off position, all pneumatically controls the engine speed through an air
electrical power in the carrier is off. Positioning the throttle cylinder on the engine.
2-1-13
56. Foot Brake Pedal Switch turned to RIGHT - super cab operative
carrier cab isolated
This pedal operates a dual air valve and progressively
applies and releases the road wheel brakes via two 61. Gearshift
separate air brake lines. The braking effort applied to the
road wheels is proportional to the amount of pedal de- There are eight forward and four reverse speeds avail-
pression. able. For specific operating instructions refer to Section
IV in the Carrier Operators and Safety Handbook.
57. Windscreen Washer Reservoir
62. Torque Convertor Automatic Lock Up Switch
Fluid reservoir for the windscreen washer system.
This switch should be engaged in highway travel for
Torque Convertor lock up and disengaged for site condi-
58. Steering Column Lock Lever
tions.
WARNING 63. Gearshift Override Switch
THE STEERING COLUMN MUST ONLY This switch is for override of the gear selector (61). In the
BE ADJUSTED WHEN THE CRANE IS event of failure of the automatic control this switch en-
STATIONARY. ables the crane to be moved by operating switch (64) af-
ter locking this switch in the down position using the inte-
on the left hand side is moved out and downwards

through 90° to the unlocked position. When the column
3G
To adjust the steering column the release lever mounted
has been set to the desired position the lever is moved

gral locking device. The use of this switch is considered
strictly as an emergency measure.
64. Emergency Gearshift Switch

back to the vertical locked position.
This switch is used to select forward or reverse in an
59. Battery Isolator Switch emergency when the gear selector (61) is overridden.
60
This switch is used to isolate the batteries, as required, WARNING
for maintenance work and when the crane is left unat-
tended for long periods. e.g at the end of the working THE PARKING BRAKE MUST BE AP-
day. PLIED BEFORE LEAVING THE CAR-
RIER CAB
86
WARNING
65. Parking Brake Lever
ALWAYS TURN OFF ENGINE AND IGNI- Lift collar and move lever fully downwards to progres-
TION SWITCH BEFORE CHANGING sively RELEASE the brakes; reverse the movement to
OVER CARRIER / SUPERSTRUCTURE APPLY the brakes. The lever may also be used for
SWITCH. emergency application of the brakes in case of a failure
of one of the service brakes.
60. Carrier/Superstructure Change Over Switch -
Fitted to Cranes with Drive/Steer Controls from Suspension System Controls Include Item Num-
the Superstructure Cab bers 66 to 76. For Full Details of Operation See
Section IV in this Manual.
This switch is turned as required to change over control
of the electrical system from the alternative driving cabs CAUTION
as follows:-
THE SUSPENSION MUST BE LOCKED
Switch turned to LEFT - super cab isolated BEFORE OPERATING THE THIRD
carrier cab operative AXLE RAISE SWITCH
2-1-14
CAUTION 69. Auto Ride Height Switch
70. Axle Nos. 1 & 2 Left Hand Suspension Cylin-

ders Control Switch
STRUCTURAL DAMAGE WILL OCCUR
IF THE THIRD AXLE IS NOT RAISED 71. Axle Nos. 1 & 2 Right Hand Suspension Cylin-
FOR CRAB STEERING OR WHEN DRIV- ders Control Switch
ING THE CRANE DURING FREE ON
WHEELS OPERATION. 72. Axle Nos. 4 & 5 Left Hand Suspension Cylin-
ders Control Switch
73. Axle Nos. 4 & 5 Right Hand Suspension Cylin-

WARNING ders Control Switch
74. Ride Height Warning Light (Green)
WHEN THE THIRD AXLE IS RAISED NO 75. 3rd Axle Load Condition Switch
PERSON SHOULD GO UNDER THE
CARRIER UNLESS THE AXLE IS This switch is used to select a 12 or 15 tonne axle load
BLOCKED UP. condition during auto ride selection.
76. Axles Raise Switch
66. Third Axle Raise Switch

3G This two position switch is used to simultaneously raise
axles 1, 2, 4 and 5 against the axle stops. This is done if
additional clearance between the tyres and the ground
is required when the crane is on outriggers with the sus-
Operate to raise the third axle ON outrigger duties, free
pension locked.
on wheel duties or when crab steering is required. The
suspension ON/OFF switch (68) must be operated be- NOTE
60
fore the third axle raise switch is activated.
To further raise the 3rd axle against the
axle stop, switch (66) must be selected.
When lowering the third axle onto the ground, hold the NOTE
switch until the integral yellow light illuminates to indi-
86
cate the correct pressure and hence axle load has been Do not attempt to operate axle raise
reached. switches (66) and (76) together.
77. APC 100 Override Switch
67. Suspension Lock Switch This switch is used to control the override system which
allows the transmission shifter to be operated as if
equipped with a standard electric shifted transmission.
Move the switch position to lock suspension. Use only The switch is to be used to override the automatic po-
wershift control in the event of a failure in that system,
on firm level ground for Free on Wheel Duties or before
thus allowing the crane to be driven off-site for repairs.
jacking up the crane.
78. Cigar Lighter
68. Suspension On/Off Switch 79. Rear Steering Tiller Switch
This lever provides independent control of the steering

functions of the rear axles after the steering has been
This controls the power to the suspension system. unlocked using switch (81).
2-1-15
80. Rear Steer Master Switch NOTE
This switch is turned to provide supply power for opera- This label must not be removed, or
tion of the rear steer function. painted over.
87. Retarder Hand Control (Optional)

81. Rear Steer Lock/Unlock Switch
This hand control has 5 positions, position ‘0’ is off and 4
This switch is turned to change rear steer function from a control positions, each control position giving an in-
locked to unlocked condition. Switch turned to left - rear creasing strength of braking. A warning light (88) is illu-
steer lock. Switch turned to right - rear steer unlock. minated to indicate the retarder is in use. The operation
of the control should be made with a brief pause in each
WARNING position. However the return to the ‘0’ off position may be
made in a single movement. When the retarder braking
DO NOT TRAVEL ON HIGHWAY WITH is found to be sufficient, reduce the retarder power by
REAR STEER UNLOCKED. one position. Then, if necessary, move back to the
higher position and so on. It is essential to switch off the
82. Rear Steer Operational Light retarder whenever the vehicle comes to rest in order to
avoid any unnecessary discharge of the vehicle battery.
This illuminates when power is available to controls
housed in rear steering panel. CAUTION
83. Rear Steering Alignment Light (Green)

3G
This light illuminates when the steering linkages are in
THE RETARDER CANNOT BE USED AS
A PARKING BRAKE. THE DISCONNEC-
TION OF THE RETARDER ELECTRICAL
alignment. SUPPLY SHOULD BE CHECKED AT
EACH OCCASION THE VEHICLE
COMES TO A HALT BY ENSURING
60
84. Rear Steer Locked Light (Red)
THAT THE CONTROL LEVER IS MOVED
This light illuminates when the rear steer locking pin is TO THE ‘0’ OFF POSITION AND THAT
fully engaged. THE WARNING LIGHT IS EXTIN-
GUISHED.
85. Rear Steering Unlocked Light (Green)
86
88. Warning Light - Retarder (Optional)

This light illuminates when the rear steer locking pin is
This light will illuminate whenever the retarder is being
fully disengaged.
used.
86. Smoke Emission Label 89. Engine Overspeed Warning Buzzer
The smoke emission type approval label is located in the When the engine revs exceed 2300rpm a warning
cab. buzzer sounds to alert the driver.
2-1-16
3G
60
86
Carrier Cab Controls and Indicators (Sheet 1 of 6)
2-1-17
1 10 4 9 5 8 2 3 6 7
3G
60
13 14 16 15 11 12

2. Engine Steering Pump Failure Warning Light (Red)
86
3. Transmission Steering Pump Failure Warning Light (Red)

4. Torque Convertor Lock Up Warning Light (Green)
5. Blank Aperture
7. Alternator Warning Light (Red)
8. Transmission Oil Temperature Warning Light (Red)
9. Gearshift Warning Light (Amber)
10. Suspension Locked Warning Light (Red)
11. Transmission Oil Pressure Gauge
12. Transmission Oil Temperature Gauge
14. Engine Water Temperature Gauge
15. Voltmeter
2-1-18
21 25 20 26 22 18 19 24 23 27 28
3G
60
29 30 32 31 33
18. Inter Axle Differential Lock Warning Light (Amber)

19. Differential Lock Warning Light (Amber)
86
20. Power Take-Off Warning Light (Blue)

21. Rear Wheels Steering Warning Light (Red)
23. Parking Brake Warning Light (Red)
24. Air Pressure Warning Light (Red)
25. Power to Superstructure Warning Light (Amber)
26. Blank Aperture
27. Main Beam Warning Light (Blue)
29. Tachometer / Hourmeter
30. Air Pressure Gauge (No. 1 Circuit)
33. Air Pressure Gauge (No.4 Circuit)
2-1-19
35 36 37 38 39 40
3G
60
41 42 43 44 46 45
86
35. Lighting Switch

36. Rear Fog Light Switch
37. Hazard Warning Switch
38. Rotary Beacon Switch(Optional)
39. Blank Aperture
40. Engine Stop Switch
41. Blank Aperture
42. Front Wheel Drive Switch
43. Inter Axle Differential Lock Switch
44. Power Take-Off Switch
45. Dash Panel Dimmer Switch
46. Test Switch
2-1-20
78
61
65
77
76 62
64
66 63
68 75
69
70
3G 67
71
74
73
72
60
61. Gearshift
62. Torque Convertor Automatic Lock Up Switch
63. Gearshift Override Switch
86
64. Emergency Gearshift Switch

65. Parking Brake Lever
66. Third Axle Raise Switch
67. Suspension Lock Switch
68. Suspension On/Off Switch
69. Auto Ride Height Switch
70. Axle Nos. 1 & 2 LH Suspension Cyls Control Switch
71. Axle Nos. 1 & 2 RH Suspension Cyls Control Switch
72. Axle Nos. 4 & 5 LH Suspension Cyls Control Switch
73. Axle Nos. 4 & 5 RH Suspension Cyls Control Switch
74. Ride Height Warning Light (Green)
75. 3RD Axle Load Condition Switch
77. APC 100 Override Switch
78. Cigar Lighter
2-1-21
82 80 83 84 81 85
3G
60
86
79
79. Rear Steering Tiller Switch

80. Rear Steer Master Switch
81. Rear Steer Lock/Unlock Switch
82. Rear Steer Operational Light
83. Rear Steering Alignment Light
84. Rear Steer Locked Light
85. Rear Steering Unlocked Light
2-1-22
TACHOGRAPH SYSTEM
DESCRIPTION
The tachograph is a recording instrument fitted in the spaces for handwritten entries such as operator’s name,
carrier instrument panel. The tachograph is used to place of departure, date, vehicle registration number,
automatically record road speed, time groups, and dis- and odometer reading.
tance travelled. The tachograph chart also contains
OPERATION
Refer to the Operator’s and Safety Handbook for com- 4. Journey starting place.
plete operating procedures.
5. Starting date.
A new Tachograph chart should be fitted each day be-
Check that the time shown on the clock is correct. When
fore commencing work. The following details should be
necessary, open the Tachograph and adjust the clock by
recorded on the chart centre before installation.
rotating the clock setting wheel. To insert the chart, lift
the chart clamping lever and place the chart over the
1.
2.
Operator’s name.
Total odometer reading.

3G centre boss. Press the clamping lever down to retain the
chart. Close the Tachograph.
At the end of the working day open the Tachograph and

3. Registration number of machine. remove the chart.
60
MAINTENANCE
NOTE Removal and Installation

Maintenance on the tachograph is lim- Removal and installation of the tachograph is performed
ited to removal and installation. Any in the same manner as the other instruments in the front
86
other maintenance should be per- console Refer to INSTRUMENTS in Section 14-ELEC-

formed by a Kienzle tachograph agent. TRICAL SYSTEM.
Contact Grove Manufacturing Com-
pany; Customer Services for the loca-
tion of the nearest centre.
2-1-23
The Time Group Selector
can be set at:

during driving periods (selector 1
only)
This time group is not used in all

EEC countries.
during all non driving working hours,

including periods as passenger crew
member.
during breaks from work and daily
rest periods
Malfunction warning light

This light switches on for the following
3G Speed warning light
reasons:
This light switches on whenever the set
the tachograph chart is missing
the styli aren’t in contact with the maximum speed is exceeded.In tacho
chart and a recording is not being graphs with rpm registration,a maxi
60
made mum engine speed is also set
the cover is not properly closed
86
Road speed (km/h, mph)
Clock operation ”tell tale”

The chevroned disc lets you know
whether the clock is running.Be sure
that the time is correctly set before
starting a trip, as it is essential that all
recordings are correct to British time
even when abroad
TACHOGRAPH
2-1-24
Automatic tachograph recordings
Road Speed (km/h)
Time Groups
driving periods (thicker traces)
this is a working period not recogn-
ised in all EEC countries, if record-
ings are found on this track, they are
assigned to group
all other non-driving work periods, including
periods as a co-driver, even if sleeping
whilst the vehicle is moving
rest periods
kilometres travelled
(each zig-zag = 10
km peak to peak)
3G Handwritten en-
tries
(centre
Prior to field only)
departure
Name
Place of departure
19 Date
NO Vehicle registration number
60
Odometer reading
If there is a change of driver or at the
end of the work day:
Place of arrival
Odometer reading
86
km Net distance driven
TACHOGRAPH CHART
2-1-25
SUPERSTRUCTURE CAB
DESCRIPTION
CAB CONTROLS AND INDICATORS a) Butyl cellosolve

b) Aliphatic naphtha (VM & P or Super VM & P)
NOTE c) Hexane, Haptane or Cyclohexane
d) Denatures alcohol or isopropyl alcohol.
The following paragraphs describe the
controls and indicators located in the WARNING
cab. The numbers in parentheses ( )
represent the index number from the AVOID POLYCARBONATE CONTACT
figure titled Superstructure Cab Con- WITH ABRASIVE CLEANERS, SUCH
trols and Indicators AS STEEL WOOL, COMET, AJAX, ETC.,
HIGHLY ALKALINE CLEANERS,
1. Test Switch SQUEEGEES, SHARP INSTRUMENTS,
RAZOR BLADES, PETROL, ACETONE,
This switch is used to test the dash panel lighting. BENZENE, CARBON TETRACHLO-
3G RIDE, TOLUENE, MEK, ACIDS OR ANY
2. Fan Control Switch CLEANERS WITH AMMONIA.
This is a two position switch providing two speeds for DO NOT CLEAN IN HOT SUN OR AT
fresh air ventilation to the directional vents. ELEVATED TEMPERATURE. DO NOT
STICK ANY LABELS OR STICKERS TO
3. Windscreen Wiper/Washer Switch THE POLYCARBONATED SURFACE.
60
This is a dual switch. Position one operates the USE ONLY APPROVED SOLVENTS TO
windscreen wiper, position two is a spring returned CLEAN FRAMING. SOLVENTS RESI-
which operates the washer. DUE AND FUMES CAN DAMAGE
POLYCARBONATE EDGE AND CAUSE
4. Roof Wiper/Washer Switch CRACKING OF THE POLYCAR-
86
BONATE. ALL PRIMERS FOR FRAME

This is a dual switch. Position one operates the roof AND/OR GLASS SURFACES MUST BE
wiper, position two is a spring returned which operates CHECKED FOR POLYCARBONATE
the washer. COMPATIBILITY FOR THE SAME REA-
SON. IF SETTING BLOCKS ARE
Instructions for Cleaning Polycarbonate Roof Win-
GLUED IN PLACE, THE GLUE SHOULD
dow
CONTAIN ONLY THE ABOVE SOL-
VENTS, OR WATER
Avoid all cleaners that contain ammonia. Using a soft
100% cotton cloth or clean sponge wash surface with a 5. Superstructure Lighting Switch
mild liquid soap or domestic household detergent and
lukewarm water. Follow cleaning with a thorough water This is a dual switch. Position one operates the cab spot-
rinse. Dry with a chamois, moist cellulose sponge or soft lamp and worklights, position two operates the boom
100% cotton cloth. floodlights when fitted.
Remove fresh paint, grease and glazing compounds 6. Rotating Beacon Switch (Optional)
with any of the following solvents, followed by a thor-
ough water rinse. This switch controls the rotating beacon.
2-1-26
7. Engine Stop Switch - Super Engine Hoist Motion: If the hoist motion is operated to its over
lower limit, the switch activates the hoist lower dump
This is a spring loaded switch biased for engine run. De- valve which dumps hoists lower. Move lever to hoist
press the switch against the spring to stop the engine. raise to restore motion within the limits.
8. Cold Start Switch This switch is used to override the over lower limit switch
for servicing the hoist cable.
Whilst cranking the engine this two position switch is
used to inject measured amounts of starting aid into the 12. Auxiliary Hoist Selector Switch (Optional)
intake manifold of a cold engine. Do not hold the switch
in for more than 5 seconds. Select when using auxiliary hoist.
Intervals between starting attempts should be 2 min- 13. Fuel Quantity Gauge
utes. Indicates the quantity of fuel in the fuel tank.
9. Main and Auxiliary Hoist Boost Switch 14. Voltmeter
Engaging this switch will provide hoist boost mode on With the engine switch in the on position and before
main and auxiliary hoist. Use the switch in conjunction starting the engine, the voltmeter indicates the condition
with control lever only when LIGHT LOADS are being of the batteries. With the engine running the voltmeter
handled or when hoisting/lowering an unloaded indicates alternator voltage.
motion.
10. Swing Brake Switch

3G
hookblock. The switch can be engaged with the hoist in
This meter is calibrated in rpm x 100. The tacho receives

its signal from a sending unit on the engine. The hour-
WARNING meter portion of the gauge records the total running
hours of the engine.
60
NEVER LEAVE THE CAB WITH THE
SWING BRAKE DISENGAGED. 16. Engine Water Temperature Gauge
This two position switch controls the swing brake. With Indicates the engine water temperature. Refer to the en-
the switch positioned to ENGAGED, the solenoid valve gine operators manual for normal operating tempera-
is de-energised removing hydraulic pressure and allow- ture.
86
ing spring pressure to apply the swing brake. With the

switch positioned to DISENGAGE, the solenoid valve is
energized and closes the circuit allowing hydraulic pres- Indicates the engine oil pressure. Refer to the engine
sure to overcome the mechanical spring pressure in the operators manual for normal operating pressure.
brake thus causing the brake to be released.The swing
is then controlled by the swing control lever (58) and the 18. Boom Tele Sequence Select
swing brake pedal (53). An integral light illuminates with
This is a three position switch which is used to select the
the brake in the DISENGAGE position.
following modes of boom telescoping as follows:
11. Hoist Overlower Override Switch
MODE A (FOUR SECTION BOOM OPERATION)
WARNING
NOTE
THE HOIST LOWER MOTION CUT In Mode A the Inner Mid boom section is
OVERRIDE SWITCH MUST ONLY BE not in use.
USED FOR SERVICING THE HOIST CA-
BLE AND NOT FOR ANY OTHER PUR- To select MODE A switch (18) is turned to the left. On se-
POSE. lection of the telescoping control the MID, OUTER MID
2-1-27
and FLY boom sections will extend in the sequence as RIGGING POSITION
shown in the Boom Extend Configurations (Sheet 1 of
3). The MID section extends to full extension (warning WARNING
light (22) illuminates) first, followed by the OUTER MID
and FLY sections synchronised. The load moment indi- WHEN SWITCHING TO THE RIGGING
cator monitors the position of the INNER MID section POSITION ANY LOAD ON THE HOOK
and will prevent telescoping of the boom if it detects the MUST FIRST BE REMOVED.
INNER MID section has extended, it will then be neces-
sary to switch to the RIGGING POSITION to retract the To select the rigging position, switch (18) is turned to the
INNER MID section and correct the error. Retracting of centre position. This position is used for servicing the
the boom is the reverse order of extending. boom and for overriding the ‘A’ and ‘B’ modes by use of
switches (19) and (20).
MODE B (FIVE SECTION BOOM OPERATION - The load moment indicator will not allow the boom to
MAIN BOOM CAPACITIES SELECTED ON THE telescope if the INNER MID or MID sections have incor-
L.M.I.). rectly extended. To proceed the operator must remove
any load from the hook, switch to the rigging position and
by using appropriate switches (19) or (20) extend or re-
To select MODE B turn switch (18) to the right and then tract the sections to correct the error.
select the appropriate code on the load moment indica-
tor. On selection of the telescoping control the INNER
3G The operator can also use the rigging position to change
MID, MID, OUTER MID and FLY boom sections will ex- modes without having to fully retract the boom. With the
tend in the sequence as shown in the Boom Extend Con- load removed from the hook, switch (18) is turned to the
figurations (Sheet 2 of 3). The INNER MID and MID sec- rigging position, this allows the INNER MID or MID sec-
tions extend in sequence first to 75% (warning lights tions to be retracted or extended by means of override
(21) and (22) illuminate) then to full extension followed switches (19) or (20) to achieve desired mode. The op-
by the OUTER MID and FLY sections synchronised. The erator MUST then turn switch (18) back to the desired
60
load moment indicator constantly monitors the telescop- mode allowing the load moment indicator to determine
ing of the INNER MID and MID sections and will prevent the safe load condition.
further telescoping if an error occurs in the telescoping
sequence, it will then be necessary to remove any load 19. Inner Mid Override Switch
from the hook and switch to the RIGGING POSITION to
correct the error. Retracting of the boom is the reverse In the event of a malfunction in the telescoping se-
86
order of extending. quence of the above modes or to necessitate the

change of modes the INNER MID section can be ind-
ependantly selected by depressing this switch after first
MODE B (FIVE SECTION BOOM OPERATION - selecting the rigging position by switch (18), warning
BOOM EXTENSION AND/OR JIB CAPACITIES SE- light (21) is illuminated.
LECTED ON THE L.M.I.).
20. Mid Override Switch
To select MODE B turn switch (18) to the right and then In the event of a malfunction in the telescoping se-
select the appropriate code on the load moment indica- quence of the above modes or to necessitate the
tor. On selection of the telescoping control the INNER change of modes the MID section can be independantly
MID, MID, OUTER MID and FLY boom sections will ex- selected by depressing this switch after first selecting
tend in the sequence as shown in the Boom Extend Con- the rigging position by switch (18), warning light (22) is
figurations (Sheet 3 of 3). The INNER MID and MID sec- illuminated.
tions extend in sequence to full extension (warning
lights (21) and (22) illuminate) followed by the OUTER 21. Warning Light Inner Mid Select
MID and FLY sections synchronised. Retracting of the
boom is the reverse order of extending. This light illuminates to indicate inner mid is selected
2-1-28
Mode A Tele Sequence
(Inner Mid not in use)
12.96M BOOM
T1(I/MID) 0%
T2(MID) 0%
12.96 metres T3(O/MID) 0%
T3(FLY) 0%
21.90M BOOM
T1(I/MID) 0%
T2(MID) 100%
3G 21.90 metres T3(O/MID) 0%
T3(FLY) 0%
30.84M BOOM
T1(I/MID) 0%
60
T2(MID) 100%
T3(O/MID) 50%
30.84 metres
T3(FLY) 50%
86
35.31M BOOM
T1(I/MID) 0%
T2(MID) 100%
T3(FLY) 75%
39.78M BOOM
T1(I/MID) 0%
T2(MID) 100%
T3(O/MID) 100%
39.78 metres
T3(FLY) 100%
Boom Extend Configurations (Sheet 1 of 3)
2-1-29
12.96M BOOM
Mode B Tele Sequence (Main Boom Use Only) T1(I/MID) 0%
(Inner Mid in use) T2(MID) 0%
T3(FLY) 0%
19.67M BOOM
T1(I/MID) 75%
T2(MID) 0%
T3(FLY) 0%
21.90M BOOM
T1(I/MID) 75%
T2(MID) 25%
T3(FLY) 0%
THIS IS NOT A CAPACITY
LENGTH BUT A MANDATORY 26.37M BOOM
TELESCOPING SEQUENCING T1(I/MID) 75%
LENGTH REQUIRED BY THE T2(MID) 75%
CONTROL SYSTEM 26.37 metres T3(O/MID) 0%
T3(FLY) 0%
3G 28.60 metres
28.60M BOOM
T1(I/MID) 100%
T2(MID)
T3(O/MID)
T3(FLY)
75%
0%
0%
30.84M BOOM
T1(I/MID) 100%
T2(MID) 100%
60
T3(FLY) 0%
35.31M BOOM
T1(I/MID) 100%
T2(MID) 100%
86

T3(FLY) 25%
39.78M BOOM
T1(I/MID) 100%
T2(MID) 100%
T3(FLY) 50%
44.25M BOOM
T1(I/MID) 100%
T2(MID) 100%
T3(FLY) 75%
48.72M BOOM
T1(I/MID) 100%
T2(MID) 100%
T3(FLY) 100%
2-1-30
Mode B Tele Sequence (Boom Extension and Jib Only)
(Inner Mid in use)
12.96M BOOM
T1(I/MID) 0%
T2(MID) 0%
T3(FLY) 0%
21.90M BOOM
T1(I/MID) 100%
T2(MID) 0%
T3(FLY) 0%
3G 30.84 metres
30.84M BOOM
T1(I/MID) 100%
T2(MID)
T3(O/MID)
T3(FLY)
100%
0%
0%
35.31M BOOM
T1(I/MID) 100%
60
T2(MID) 100%
T3(FLY) 25%
39.78M BOOM
T1(I/MID) 100%
86
T2(MID) 100%
T3(FLY) 50%
44.25M BOOM
T1(I/MID) 100%
T2(MID) 100%
T3(FLY) 75%
48.72M BOOM
T1(I/MID) 100%
T2(MID) 100%
T3(FLY) 100%
2-1-31
22. Warning Light Mid Select Item numbers 29 to 46 are fitted to Cranes with
Drive/Steer Controls from the Superstructure Cab.
This light illuminates to indicate mid is selected WARNING
23. Ignition Switch - Super Engine THE ENGINE CANNOT BE STARTED

UNLESS GEARSHIFT IS IN NEUTRAL
POSITION IN BOTH CABS.
This key operated switch with four positions acc (4), off
(0), run (1) and start (2). The switch is spring returned 29. Ignition Switch - Carrier Engine
from start to run. With the switch in the off position, all
electrical power in the super is off. Positioning the switch This key operated switch with four positions acc (4), off
to the run position energises all electrical components. (0), run (1) and start (2). The switch is spring returned
from start to run. With the switch in the off position, all the
electrical power in the carrier is off. Positioning the
24. Warning Horn switch to the acc position energizes the electrical com-
ponents.
Press to sound audible warning.
25. Engine Distress Warning Light (Red) The warning light illuminates when the ignition switch
This light illuminates when the engine coolant tempera-

3G
ture is too high, coolant level too low or the oil pressure is
(29) is turned to the ON position. The warning should go
out when the carrier engine starts. If the warning illumi-
nates when the engine is running there is a fault in the
charging system. Unless the fault is corrected the bat-
low. When the light illuminates a buzzer also sounds.
teries will run down.
Stop the engine immediately the light shows and investi-
gate the cause. 31. Low Air Pressure Indicator Warning Light
60
(Red)
The indicator is a red light that illuminates when the
pressure in the air system(s) is below 75 psi (517 kPa).
The warning light illuminates when the ignition switch
86
(23) is turned to the ON position. The warning should go 32. Low Oil Pressure Warning Light
out when the engine starts. If the warning illuminates
when the engine is running there is a fault in the charging This light illuminates in the event of low oil pressure.
system. Unless the fault is corrected the batteries will Stop the carrier engine immediately, ascertain cause
run down. and rectify the fault before continuing operations.
33. High Engine Temperature Warning Light

27. Counterweight Not Fully Raised Warning
Light (Optional) This light illuminates in the event of high engine tem-
perature. Stop the carrier engine immediately, ascertain
cause and rectify the fault before continuing operations.
This light illuminates when the counterweight is not fully
raised and could foul the carrier if not corrected. 34. Transmission Oil Temperature Warning Light
(Red)
28. Cigar Lighter
This light illuminates when the oil temperature in the
transmission system increases above normal operating
Push the knob in - it will pop out when the element is hot limits. If this occurs stop the carrier engine and rectify the
enough. fault before continuing operations.
2-1-32
35. Blank Aperture 42. Axles Raise Switch
36. Front Wheel Drive Warning Light (Amber) This two position switch is used to simultaneously raise
all axles against the axle stops. This is done if additional
Illuminates to indicate front wheel drive is selected. clearance between the tyres and the ground is required
when the crane is on outriggers.
37. Blank Aperture
43. Blank Aperture
38. Suspension Locked Warning Light (Green)
44. Rear Wheels Unlocked Light (Red)
This light illuminates when all the suspension cylinders
Illuminates to indicate the rear wheels are fully unlocked
are hydraulically locked and not connected with the sus-
and tiller steering is operational.
pension accumulators.
45. Outrigger Selector Panel
39. Inter Axle Differential Lock Warning Light
(Amber) For operational use of the outrigger switches refer to the
OUTRIGGER CONTROLS in the Carrier Operators and
Illuminates when the Inter Axle Differential Lock is se- Safety Handbook.
lected.
46. Hand Throttle - Carrier Engine
40. Engine Stop Switch - Carrier Engine 3G Move the handle rearwards to set the carrier engine
This is a spring loaded switch biased for engine run. De- speed (rpm).
press the switch against the spring to stop the engine.
47. Load Moment Indicator Panel
Refer to manufacturers handbook for operational use of
the Load Moment Indicator.
60
This switch controls the torque convertor power take-off
which drives the outrigger, suspension and rear steering
WARNING
hydraulic pumps. With the engine turned OFF and gear-
shift lever in NEUTRAL, switch on to engage the pumps, THE PTO MUST BE ENGAGED AND
reverse the movement to disengage the pumps. An inte- THE REAR STEERING LOCK DISEN-
gral light will illuminate when the power take off is en- GAGED FROM THE CARRIER CAB BE-
86
gaged. FORE USING THE REAR AXLE FUNC-

TION.
CAUTION
48. Rear Steering Control - Fitted to Cranes with
THE P.T.O. MUST ALWAYS BE DIS- EN- Drive/Steer Controls from the Superstructure Cab.
GAGED FOR NORMAL ROAD TRAVEL
ORDER. THE P.T.O. MUST ONLY BE EN- The rear steer control is a three position, spring cen-
GAGED OR DISENGAGED WHEN THE tered to off, toggle switch. By positioning the switch to
CRANE IS STATIONARY AND THE EN- the right, a control valve is actuated to turn the rear
GINE IS SWITCHED OFF. CHECK THE wheels to the left, which causes the crane to turn to the
AIR PRESSURE IN THE AUXILIARY AIR right. By positioning the switch to the left, a control valve
SYSTEM IS OVER 110 PSI (7.7 BARS) is actuated to turn the rear wheels to the right, which
BEFORE ATTEMPTING TO ENGAGE causes the crane to turn to the left. Releasing the switch
OR DISENGAGE THE P.T.O. CONTROL. allows it to spring centre to the off position.
2-1-33
WARNING 53. Swing Brake Pedal
THE PARKING BRAKE MUST BE AP- Depress this pedal progressively to apply the swing
brake when the swing park brake has been released by
PLIED BEFORE LEAVING THE SUPER-
means of switch (10).
STRUCTURE CAB
54. Telescope Control Valve - Optional
49. Parking Brake Control - Fitted to Cranes with
Drive/Steer Controls from the Superstructure Cab. Telescope control is provided by a floor mounted pedal
only if the optional auxiliary hoist is fitted. The standard
To apply pull the knob full out. Push the knob fully in to telescope control is by means of a control lever (58).
release. Apply only when machine is stationary, this
This foot operated valve is biased to centre (OFF) posi-
control is not proportional. tion and controls the telescoping motion of the boom as
under:
50. Level Indicator
Telescope OUT - depress the toe of the pedal
This indicator is used to check that the crane is LEVEL Telescope IN - depress the heel of the pedal
prior to and at intervals during craning operations. The
If optional ’motion cut’ occurs due to an overload condi-
crane is level when the bubble in the indicator is
tion arising when telescoping OUT, reverse the pedal
centralised.
movement immediately to restore the crane to a safe
51. Hand Throttle - Super Engine 3G condition.
55. Foot Brake Pedal - Fitted to Cranes with

The hand throttle is mechanically connected to the foot Drive/Steer Controls from the Superstructure Cab
throttle and provides the operator with a means of main-
taining specified engine rpm for crane operation. To use This pedal operates a dual air valve, it progressively ap-
the hand throttle, depress the foot throttle to obtain the plies and releases the road wheel brakes via two sepa-
desired engine rpm, push the button on the hand throttle rate air brake circuits. The braking effort applied to the
60
control knob and pull out on the knob. When pressure is road wheels is proportional to the amount of pedal de-
felt, release the button and turn the locknut in a clock- pression.
wise direction to lock the throttle at the desired rpm. To
56. Foot Throttle Pedal - Super Engine
release the throttle, rotate the locknut counterclockwise,
depress the button and push in on the cable. Fine ad- The throttle pedal is used to control the super engine
86
justment of engine speed is accomplished by turning the rpm for proper hydraulic pump output. The engine
control knob. speed is proportional to the foot pressure applied which
actuates the engine governor by means of a cable.
WARNING
57. Swing Lock Lever
THE GEARSHIFT LEVER IN BOTH Used to lock the superstructure in the over front or over
CABS MUST BE NEUTRAL POSITION rear position. The lock should always be engaged ex-
BEFORE CARRIER ENGINE CAN BE cept for operating over side duties or using the swing
STARTED. motion.
52. Gear Shift Lever - Fitted to Cranes with Drive/ Push lever forward (away from the operator) to lock the
Steer Controls from the Superstructure Cab superstructure. Pull lever back (towards the operator) to
unlock the superstructure.
Used to select range of gears in power-shift transmis-
58. Swing and Telescope or Auxiliary Hoist Con-
sion. Move lever progressively as required. For shift pro-
trol Lever
cedures see instructions under Operation of Transmis-
sion in Section IV of the Carrier Operators and Safety The Swing and Telescope or Auxiliary Hoist Control
Handbook. Lever (SWING/TELE or SWING/AUX) is located at the
2-1-34
end of the left armrest. The lever controls the swing and 61. Fire Extinguisher
telescope functions when the crane is not equipped with
an auxiliary hoist. When equipped with an auxiliary Located below the seat is a fire extinguisher for emer-
hoist, the lever controls swing and auxiliary hoist func- gency use.
tions and telescope functions are controlled through a 62. Arm Rest Adjustment Lever
foot pedal (54).
63. Heater Switch (Optional)
The lever, when positioned to the left or right, actuates a The switch unit consists of an ON/OFF and a rotary heat
control valve through hydraulic pilot pressure to provide control with integral thermostat. A green indicator light in
360 degree continuous rotation in the desired direction. the unit will illuminate when switched on and the fan will
Positioning the lever forward actuates the control valve start after about 45 seconds of pre heat.
to telescope the boom out and pulling the lever back ac-
tuates the boom to telescope in. If equipped with an aux- The fan will continue to run for about 250 seconds when
iliary hoist, positioning the lever forward actuates the the switch is turned off.
control valve to lower the hoist cable and pulling the
lever back reels the cable in. Moving the lever in a diago- 63. Heater Control Panel (Optional)
nal direction actuates the two functions simultaneously.
With the heat control (64) pulled out to high move the
switch on the control panel to ‘START’ and hold at that
Ensure the swing lock lever (57) is disengaged and the position, the green light will illuminate. When the amber
fore attempting to swing.

3G
swing brake switch (10) is in the disengaged position be- light illuminates release the switch to the ‘RUN’ position,
the amber light must stay on. The green light will cycle
on when the fuel valve opens.
59. Boom Lift and Main Hoist Control Lever NOTE
The Boom Lift and Main Hoist Control lever (LIFT/MAIN) When switching the heater OFF do not
60
is located at the end of the right armrest. The lever, when immediately switch off the battery cir-
positioned to the left, actuates the control valve through cuit switch. This would effectively in-
hydraulic pilot pressure to raise the boom. Positioning terrupt the purging cycle of the feed to
the lever to the right lowers the boom. Pushing the lever the cooling fan. The residual heat
forward will let out the hoist cable and pulling the lever within the unit would then be sufficient
to activate the thermal trip.
86
back reels the cable in. Moving the lever in a diagonal

direction actuates two functions simultaneously. When the heater is switched off wait at
least 5 minutes before switching off the
60. Hoist Rotation Indicators battery circuit switch.
64. Heat Control (Optional)

The Hoist Rotation Indicators are located on the top of
each hoist control lever. The indicators are electronically The heat control is a pull - push cable controlling the flow
driven by a signal from an electronic transmitter at- of hot water to the heater. When pushed in the flow is cut
tached to each hoist frame. A pulsating signal is sensed off. When the cable is pulled out the flow (and heat) is at
by the operators thumb during operation. a maximum.
2-1-35
65. Battery Isolator Switch
This switch is used to isolate the batteries, as required,

for maintenance work.
65
3G
60
86
2-1-36
3G
60
45. Outrigger Selector Panel
46. Hand Throttle - Carrier Engine
47. Load Moment Indicator Panel
48. Rear Steering Control
49. Parking Brake Control
50. Level Indicator
86
51. Hand Throttle

52. Gear Shift Lever
53. Swing Brake Pedal
54. Telescope Control Valve - Optional
55. Foot Brake Pedal
56. Foot Throttle Pedal - Super Engine
57. Swing Lock Lever
58. Swing and Telescope or Auxiliary Hoist Control Lever
59. Boom Lift and Main Hoist Control Lever
60. Hoist Rotation Indicators
61. Fire Extinguisher
62. Arm Rest Adjustment Lever
63. Heater Switch (Optional)
63. Heater Control Panel (Optional)
64. Heat Control (Optional)
Superstructure Cab Controls and Indicators (Sheet 1 of 5)
2-1-37
1 2 3 4 5 6
3G
60
7 8 9 10 11 12
86
1. Test Switch
2. Fan Control Switch
3. Windscreen Wiper/Washer Switch
4. Roof Wiper Switch
5. Superstructure Lighting Switch
6. Rotating Beacon Switch (Optional)
7. Engine Stop Switch - Super Engine
8. Cold Start Switch
9. Main & Auxiliary Hoist Boost Switch
10. Swing Brake Switch
11. Hoist Overlower Override Switch
12. Auxiliary Hoist Selector Switch (Optional)
2-1-38
13 15 16
3G
60
86
14 17

14. Voltmeter
16. Engine Water Temperature Gauge
2-1-39
25
26
22 18
3G
60
19 21 20 27 24 23
86
18. Boom Tele Sequence Select

19. Inner Mid Override Switch
20. Mid Override Switch
21. Warning Light Inner Mid Select
22. Warning Light Mid Select
23. Ignition Switch - Super Engine
24. Warning Horn
27. Counterweight Not Fully Raised Warning Light (Opt)
2-1-40
36 38 39 40 41 42 43
37
44
34
31 29
33
30
3G 28
32
35
60
28. Cigar Lighter

29. Ignition Switch - Carrier Engine
86

31. Low Air Pressure Indicator Warning Light (Red)
32. Low Oil Pressure Warning Light
33. High Engine Temperature Warning Light
34. Transmission Oil Temperature Warning Light (Red)
35. Blank Aperture
37. Low Gear Range Warning Light
38. Suspension Locked Warning Light (Green)
39. Blank Aperture
40. Engine Stop Switch - Carrier Engine
43. Blank Aperture
44. Rear Wheels Unlocked Light (Red)
2-1-41
86
60
3G
SECTION 2
ENGINES
TABLE OF CONTENTS
Page
CARRIER ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-4
FUEL SYSTEM - CARRIER ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-5
EXHAUST BRAKE - CARRIER ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7
3G
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-7
THROTTLE CABLE AND ENGINE STOP SETTING - CARRIER ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-8
WATER COOLING SYSTEM - CARRIER AND TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-9
60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-10
AIR INTAKE SYSTEM - CARRIER ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-11
TURNTABLE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-12
FUEL SYSTEM - TURNTABLE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-14
AIR INTAKE SYSTEM - TURNTABLE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-15
LIST OF FIGURES
Title Page
Fuel Filter - Water Separator (Carrier Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2-6
2-2-1, 2-2-2
86
60
3G
CARRIER ENGINE
DESCRIPTION
The standard carrier engine for this crane is Mercedes Engine speed is controlled pneumatically from a foot op-
Benz OM 442 LA. This Service Manual does not include erated pedal valve in the cab to the throttle air slave cyl-
detailed information on the engine itself. A separate inder on the engine. The cylinder is connected to the en-
manual is prepared in detail by the engine manufacturer, gine throttle by linkage to control engine rpm.
and can be supplied on request. However, a short de-
scription and maintenance of certain components of the The engine and its components are enclosed in a hood
fuel system is provided in this Section. Refer to the appli- assembly with a grill in the sides and rear of the hood for
cable SM package for detailed information on the air inadequate air circulation. Access to the engine is gained
take system and water cooling system. through doors in the hood assembly.
MAINTENANCE
NOTE CAUTION
The Engine and Torque Convertor

should be removed as a complete unit.
3G MARK THE UNIVERSAL(S) SO THEY
CAN BE ASSEMBLED AS TAKEN
APART, OTHERWISE SEVERE DRIVE
LINE VIBRATION MAY OCCUR.
Removal
9. Disconnect and remove the drive shaft(s) between
60
the transmission/torque converter and the axles. Refer
1. Set the outriggers and position the boom over-the-
to DRIVE LINES in Section 3 - DRIVE TRAIN.
side.
10. Tag and disconnect all lines from the oil cooler.
2 Disconnect the air filter tubing at the engine.
11. Tag and disconnect all electrical leads from the en-
86
gine and engine components.

3. Disconnect the muffler exhaust piping at the en-
gine. 12. Tag and disconnect all lines and tubing from the en-
gine, transmission, and all other components.
4. Remove the jib rest,
13. Remove the hydraulic pump and disconnect from
the torque converter.
5. Remove the engine hood assembly from the ma-
chine. NOTE
The engine assembly, with compo-

6. Drain the engine lubrication system. nents installed, weighs approximately
4730 pounds (2150 kg).
7. Drain the transmission/torque converter oil sys-
14. Attach to the engine a lifting device capable of sup-
tem.
porting the weight of the engine and torque converter.
8. Drain the radiator, tag and disconnect the heater 15. With the lifting device supporting the weight of the
hoses, radiator hoses and air hoses. engine, remove the bolts, nuts and washers from the
2-2-3
mounting brackets on the engine torque converter 7. Connect the drive shafts as marked during re-
which secure them to the carrier frame. moval. Refer to the DRIVE LINES in Section 3 - DRIVE
TRAIN.
CAUTION
8. Install radiator and charged cooler assembly.
ENSURE THE WEIGHT OF THE ENGINE
IS NOT RESTING ON PULLEYS, FUEL 9. Connect the heater, radiator and charge cooled air
LINES, ELECTRICAL WIRING, ETC. hoses to the engine.
WHICH COULD BE DAMAGED.
10. Service the transmission and engine lubrication
system.
16. Using the lifting device, lift the engine from the
crane and place it on firm, stable blocking.
11. Install the engine hood assembly.
17. If a new engine is to be installed, remove all compo- 12. Install the jib rest.
nents, fittings etc. from the old engine and install them
on the new engine in the same locations. 13. Connect the muffler exhaust piping and the air filter
tubing.
Ensure that the same grade hardware, torque values,
and loctite as were installed by the factory are used. 14. Check the engine stop solenoid for operation and
correct adjustment.
Installation 3G 15. Loosen the primer pump on the fuel pump by turn-
1. With all components and fittings installed on the ing the knurled nut and operate the pump until an in-
new engine, lift the engine into the crane. creased resistance can be felt (Note it is necessary to
switch to ignition on in order to energise the fuel shut off
2. With the engine in position secure each side of the valve) continue pumping for several strokes. Back of the
transmission/torque converter with the bolts, nuts and bleed screws on the filter and injectors by one or two
60
washers. Torque the bolts to correct torque figure as turns. Operate pump until fuel emerging from the bleed
listed in Section 1. Secure the front of the engine with the screws is free of air bubbles. Tighten the bleed screws in
bolts, nuts and washers. the following sequence pre-filter, fine filter, injector
pump. Finally lock the primer pump in position by push-
3. Remove the lifting device. ing it down and turning the knurled nut clockwise.
86
4. Install the hydraulic pump and disconnect. 16. Energise the engine stop solenoid by engaging the
rocker switch on the dash panel. At the same time crank
5. Connect all lines and tubing to the engine, torque the engine with the starter until the oil pressure gauge
converter, and all other components in accordance with indicates pressure. Note: the starter should be operated
the identification marks made during REMOVAL. for no longer than 20 seconds at a time with a pause of
one minute between cranking.
6. Connect all electrical leads to the engine and en-
gine components in accordance with the identification 17. Start the engine. Check all hoses and fittings for
marks made during REMOVAL. leaks. Shut down the engine and check all fluid levels.
2-2-4
FUEL SYSTEM
CARRIER ENGINE
DESCRIPTION
The fuel system consists of the fuel tanks, fuel filter-wa- FUEL PUMP
ter separator, filters and/or strainer, fuel pump, and the
fuel injectors. All components except the fuel tanks and Surplus fuel, returning from the injectors, is bypassed
the fuel filter-water separator are installed on the engine back to the fuel tank of to the inlet side of the pump. The
or supplied with the engine for remote mounting. continuous flow of fuel through the injectors helps to
cool the injectors and to bypass air from the system.
FUEL FILTER - WATER SEPARATOR

FUEL TANK
The fuel filter-water separator removes water from the
fuel before it reaches the engine. It is mounted on the left
side of the crane adjacent to the fuel tank.
The fuel tank is a steel cylinder-type tank located on the
left side of the machine. The fuel tank has a capacity of
3G FUEL FILTERS AND STRAINER
114 gallons (432 litres). Three connections on top of the
tank provide for fuel supply to the engine and return of The engine uses a replaceable element-type fuel filter in
surplus fuel from the engine. The tank is equipped with a the fuel system to remove inpurities from the fuel. The
screw-type filler cap and a fuel quantity sender unit filter is installed in the system between the fuel filter-wa-
which provides a signal to a quantity indicator on the inter separator and the fuel pump and operates under suc-
strument panel in the cab. tion.
60
MAINTENANCE
86
FUEL TANK 4 Support the weight of the tank and loosen and re-
move the nuts securing the straps to the mounting
The fuel tank should be kept filled, especially overnight, brackets. Remove the tank.
to reduce condensation to a minimum. Refer to the ap-
plicable engine manual for the recommended schedule 5. If a new tank is to be used, remove the fittings and
for draining any water or sediment from the tanks. install them in the new tank.
Installation
Removal
1. Position the tank on the mounting brackets and in-

1. Position suitable containers under the fuel tank and
stall the nuts on the two straps.
drain all fuel from the tank.
2. Connect the electrical lead to the fuel quantity
2. Tag and disconnect the two lines from the top of the sender unit.
tank.
3. Connect the two lines to the fittings on top of the
3. Disconnect the electrical lead from the fuel quantity tank in accordance with the identification marks made
sender unit. during removal.
2-2-5
FUEL FILTERS AND STRAINER
7 1
Refer to the applicable engine manual for maintenance
of fuel filters and strainers.
FUEL FILTER-WATER SEPARATOR
Draining
The sump of the fuel filter water separator should be 2

drained daily, 30 minutes after the engine is shut down,
3
to remove any water and sediment. Adhere to the follow-
4
ing procedure.
1. Open the drain plug.
2. Drain until fuel appears.
3. Close the drain plug.
Removal
around the fuel line connections.

3G
1. Clean all dirt from the filter, especially the areas
6
5
8
2. Tag, disconnect, and cap the fuel lines to the filter.
3. Remove the two mounting nuts and washers.

60
4. Remove the filter. 1. Head
2. Sealing Ring
3. Element
Installation 4. Body
5. Drain Plug
1. Position the filter assembly on the mounting brack- 6. Washer
86
et. 7. Screw
8. Ring Clamping
2. Install the washers and nuts.
Fuel Filter - Water Separator
3. Connect the fuel lines as tagged prior to removal.
2-2-6
EXHAUST BRAKE
CARRIER ENGINE
DESCRIPTION
The principle of the exhaust brake, is to use the engine air to a sealed exhaust system.
as a single stage low pressure compressor, delivering
THEORY OF OPERATION
The exhaust pipe is fitted with a brake valve unit, con- the exhaust brake switch is released, returning the throt-
taining a butterfly valve, by means of which the exhaust tle to normal operation.
pipe may be closed.
When the exhaust brake is applied, the considerable en-
ergy to drive the engine now acting as a compressor is
derived from the kinetic energy of the ‘vehicle’ move-
The valve is operated by a foot switch located in the car- ment this reducing the speed of the vehicle. The absorp-
rier cab. When the switch is operated it energises two tion of the energy of the momentum in this way avoids
synchronised solenoid valves. One solenoid valve then
3G the intense and localised production of heat that takes
operates the exhaust brake cylinder, which closes the places in friction brakes. This means that the exhaust
butterfly valve, shutting off the exhaust outlet. The sec- brake can remain in operation for long periods without
ond solenoid valve closes the air supply to the throttle any fall off in efficiency and it thus relieves the wheel
cylinder, preventing the flow of fuel to the engine, until brakes of much of their most ardous duty.
60
86
2-2-7
THROTTLE CABLE AND ENGINE STOP SETTING - CARRIER ENGINE
DESCRIPTION
THROTTLE SETTING arm to the high idle position (full throttle) and fit spring
link.
1. Set travel of slave cylinder clevis pin centre to 3. Connect air supply to slave cylinder and check op-
match that of the top tapped hole in the engine throttle eration, ensuring that at the high idle position (full throt-
lever. tle) the linkage does not lock and at the low idle position
the engine lever comes to rest against its stop.
2. Set both engine throttle lever and slave cylinder Adjust where necessary.
Throttle Spring Link

3G IDLE FULL
View with engine stop

60
solenoid removed for
Slave Cylinder
clarity
ENGINE STOP SETTING 3. Adjust and fit link rod.

86
1. Set engine stop lever to the stop position. 4. Connect electrical supply and operate solenoid,
ensuring linkage does not lock and that the engine stop
2. Fully retract solenoid. lever comes to rest against its stop.
Spring Swivel
Link Rod
STOP RUN
Engine Stop
Solenoid
2-2-8
WATER COOLING SYSTEM
CARRIER AND TURNTABLE
DESCRIPTION
Under normal operating conditions the pressure in the case. The required operating pressure is also reached
system is under 0.4 and the system is protected up 1.1 very quickly. Even if a valve fails, the basic function of
bar. The coolant temperature is approx. 121°C in this the expansion tank and its pressure buildup is retained.
THEORY OF OPERATION
The first chamber is the filler section with filler neck and seal on this tank. A control line leads from this cap to the
cover. This section is designed in such a way that the third section, the additional expansion tank. The valve
specified minimum coolant quantity is available under opens at a gauge pressure of < 0.4 bar. This third section
all operating conditions. From the upper part of the tank features again a screw cap with a 0.7 bar pressure relief
an overflow connection leads to the second section; the valve and integrated 0.07 to 0.1 bar vaccum valve which
expansion tank. A screw cap with a 0.4 bar pressure re- is permanently screwed on or secured by a lead seal.
lief valve and an integrated 0.007 to 0.1 bar vaccum 3G The valve opens at a system pressure of 1.1 bar (0.4 +
valve is permanently screwed on or secured by a lead 0.7 bar) and water escapes via the overflow line.
1 2 3 4 5 6
0.7 bar 0.4 bar
1
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86
5 4 3 2
FILLER CAP AND VENTILATION FUNCTION
1. Disc spring sealed against atmosphere with

pressure > 1.2 bar.
THREE CHAMBER SYSTEM 2. Radiator ventilation with thermostat open or
cap removed (when charging system).
Water/air radiator with mounted
3. Sealed from min, over pressure to system
plastic expansion water.
pressure.
Volume of expansion tank: 4. Return flow with the thermostat closed is
1. Additional expansion volume, protected avoided by closing the vaccum valve with 0.07 ...
by 0.4 + 0.7 = 1.1 bar valve. 0.1 bar.
2. Expansion volume, protected by 0.4 bar. 5. In the case of leaks between filler neck cap
3. Filling volume. and disc spring seal the cooling system dis-
4. Filler neck. charges via the radiator vent. Increasing the sys-
5. Venting connection. tem pressure is not possible either in this case.
6. Expansion/filler line.
2-2-9
MAINTENANCE
NOTE
For more detailed information refer to

the applicable SM package.
Renew coolant every two years. It is not permitted to use an anti-corrosion/anti freeze portion of 50% by volume.
water alone, the anti freeze/anti corrosion agent in the Do not use more than 55% as this will impair the heat
coolant must not drop below 40% by volume. dissipation.
When replenishing the system it is essential to ensure
3G
60
86
2-2-10
AIR INTAKE SYSTEM
CARRIER ENGINE
DESCRIPTION
The engine air intake system consists of an air cleaner striction indicator to indicate a dirty air cleaner.
and associated piping for channeling the air from the at-
mosphere to the engine intake manifold. The intake pipe
also provides the necessary connections for starting aid The air cleaner is the dry-type with a replaceable ele-
to be injected into the air intake for quick start and a re- ment. It is usually located on the engine hood assembly.
MAINTENANCE
NOTE

PERIODIC MAINTENANCE 3G
Change element every 30,000 km or every 1 year or
when indicated, whichever comes first.
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86
2-2-11
TURNTABLE ENGINE
DESCRIPTION
The turntable engine is a Mercedes Benz OM366LA En- valve, starting aid container, atomizer and the connect-
gine. ing tubing. Depressing the quick start button while turn-
ing the engine over will inject starting fluid from the bottle
Engine speed is controlled by a hand or foot pedal oper-
through the atomizer into the air intake pipe where it
ated cable to the engine throttle lever.
mixes with the intake air.
The cold start system consists of a switch, solenoid
MAINTENANCE
Removal 14. If necessary for additional clearance, remove the

hydraulic pumps from the pump drive by removing the
1. Fully extend and set the outriggers. bolts and lockwashers.
2. Drain the engine lubricating system and pump NOTE

drive.
3G The Engine weighs approximately 1130
3. Drain the engine coolant system. lbs (510 kg).
4 Disconnect and remove the exhaust piping from 15. Attach an adequate lifting device to the engine.
the muffler and the engine.
16. With the lifting device supporting the weight of the
engine, remove the bolts, washers, locknuts, and
5. Disconnect the piping to the air cleaner and the
bonded mounting centres.
60
quick start tubing at the engine.
17. Remove the engine and pump drive from the crane
6. Remove the engine hood assembly.
and move them to a clean work area. Place the engine
and pump drive on adequate supports so the pump drive
7. Tag and disconnect the fuel lines to the engine. Cap
can be removed if necessary.
or plug all lines and openings.
86
18. If a new engine is to be installed, remove the pump

8. Tag and disconnect the heater hoses. Cap or plug
disconnect and all engine installed components, fittings,
all lines and openings.
etc. from the old engine and install them on the new en-
gine as removed. Refer to HYDRAULIC PUMP DIS-
9. Tag and disconnect the header tank, and charge
CONNECT in Section 8 for pump disconnect removal
cooler hoses.
and installation.
10. Tag and disconnect the lines to the hydraulic
Installation
pumps. Cap or plug all lines and openings.
1. With all components and fittings installed on the
11. Remove header tank, radiator and charge cooler. engine, attach an adequate lifting device and lift the en-
gine into position on the turntable.
12. Tag and disconnect the batteries and the electrical
leads to the engine and engine installed components. 2. With the lifting device still supporting the weight of
Tape all electrical leads and contacts. the engine, install the mounting bolts, washers and lock
nuts.
13. Tag and disconnect all linkages and/or cables to
the engine. 3. Remove the lifting device.
2-2-12
4. If removed, install the hydraulic pumps with the 9. Connect the heater, radiator and charged air cooler
bolts and lockwashers. Ensure a new pump to discon- hoses and vent line as tagged during removal.
nect oil.
10. Connect the fuel lines as tagged during removal.
5. Connect the lines to the hydraulic pumps as tagged 11. Install the engine hood assembly.
during removal.
12. Connect the exhaust piping and air cleaner piping
6. Contact all linkages and/or cables to the engine as as removed. Connect the quick start tubing.
tagged during removal.
13. Service the pump disconnect, engine cooling and
lubricating systems.
7. Connect all electrical wires to the engine as tagged
during removal. Connect the batteries. 14. Prime the fuel system and start the engine. Check
all hoses and lines for leakage and all systems for proper
8. Install Heater Tank, Radiator and charged air operation. Shut down the engine and check all fluid lev-
cooler. els.
3G
60
86
2-2-13
FUEL SYSTEM
TURNTABLE ENGINE
DESCRIPTION
The fuel system consists of the fuel tank, filters, fuel ply to the engine and return of surplus fuel from the en-
pump, fuel shut-off valve and the fuel injectors. All com- gine. The tank is equipped with a lockable filler cap and
ponents except the fuel tank are installed on the engine fuel quantity sender unit which provides a signal to the
or supplied with the engine for remote mounting. quantity indicator on the instrument panel.
FUEL TANK
The fuel tank is a steel cylinder-type tank located on the
right side of the turntable in front of the engine compart- The fuel filter-water separator removes water from the
ment. The tank has a capacity of 55 gallons (209 litres). fuel before it reaches the engine. It is mounted in the en-
Two connections on top of the tank provide for fuel sup- gine compartment.
MAINTENANCE
FUEL TANK
3G
The fuel tank should be kept filled, especially overnight,
Installation
1. Position the tank on the mounting brackets and in-

stall the nuts on the two straps.
to reduce condensation to a minimum. Refer to the ap-
plicable engine manual for the recommended schedule
2. Connect the electrical lead to the fuel quantity
for draining any water or sediment from the tank.
sender unit.
60
Removal
3. Connect the two lines to the fittings on top of the
tank in accordance with the identification marks made
1. Position a suitable container under the fuel tank
during removal.
and drain all fuel from the tank.
4, Install the sheet metal.
86
2. Remove the sheet metal covering the tank.

5. Service the tank.
3. Tag and disconnect the two lines from the top of the
tank. FUEL FILTERS AND STRAINER
4. Disconnect the electrical lead from the fuel quantity Refer to the applicable engine manual for maintenance
of fuel filters and strainers.
sender unit.
5. Support the weight of the tank and loosen and re-
move the nuts securing the straps to the mounting Draining
brackets. Remove the tank.
The sump of the fuel filter-water separator should be
6. If a new tank is to be used, remove the fittings and drained daily, 30 minutes after the engine is shut down,
install them in the new tank. to remove any water and sediment
2-2-14
AIR INTAKE SYSTEM
TURNTABLE ENGINE
DESCRIPTION
The engine air intake system consists of an air cleaner The air cleaner is the dry-type with a replaceable ele-
and associated piping for channeling the air from the at- ment. It is located on the engine hood assembly. A serv-
mosphere to the engine intake manifold. The intake pipe ice indicator, designed to indicate red when servicing is
also provides the necessary connections for a restric- required, is used on this system.
tion indicator to indicate a dirty air cleaner.
MAINTENANCE
NOTE

3G
60
86
2-2-15
86
60
3G
SECTION 3
DRIVE TRAIN
TABLE OF CONTENTS
Page
DRIVE TRAIN
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-3
Drive Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-3
TRANSMISSION/TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-4
3G
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-6
Transmission Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-8
60
Servicing the System after a Transmission Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-9
Towing or Push Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-9
TRANSMISSION OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
86
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-10
LIST OF FIGURES
Drive Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-3

Torque Converter Drive Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-7
Hydraulic System Transmission Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3-11
2-3-1, 2-3-2
86
60
3G
DRIVE TRAIN
DESCRIPTION
The drive train consists of a Clark 6823 remote mounted verter, with automatic lock-up for highway travel is fitted.
powershift gearbox with eight forward and four reverse The carrier is fitted with either four or five axles which
speeds. An engine mounted Clark CL8652 torque con- use alternative drives 8x6, 8x8, 10x6 or 10x8.
MAINTENANCE
DRIVE LINES NOTE
Removal It is essential that the drive shaft be-

tween the gearbox and the No. 3 axle (4
axle crane) No.4 axle (5 axle crane) be
1. Scribe a timing mark across the flanges on the fitted with the tubed end of the shaft
drive shaft(s) to be removed. connected to the gearbox and the slip
joint end fitted to the axle as shown oth-
when disconnected.
3G
2. Support the shaft being removed so it does not fall
erwise excessive vibration will occur.
2. Install the retaining bolts and nuts to secure the

drive shaft. Torque the bolts to the correct torque figure.
Lubrication
3. Remove the nuts and bolts from each of the
60
flanges. The universal joints should be lubricated with any good
grade of type CG or EP-MPG (refer to Section 10-LU-
BRICATION). The interval between lubrications is gen-
4. Remove the drive shaft. erally satisfactory for normal service.
When subjected to extremely severe conditions, more

86
Installation frequent lubrication may be required.
Lubrication must be done with a low pressure hand type

1. Position the drive shaft aligning the timing marks grease gun or a high pressure gun with a low pressure
made during removal. adaptor only. High pressure will rupture the cork seals.
Gearbox Propshaft Tube End

To Be Fitted To Gearbox
No 1 Axle No 2 Axle No 4 Axle No 5 Axle

10 x 8 Drive Train
2-3-3
TRANSMISSION/TORQUE CONVERTER
DESCRIPTION
The purpose of the gearbox and torque converter is to CONVERTER RANGE switch in the carrier cab holds
transfer the power created by the engine and transfer it the lockup mode to a much lower rpm disengagement
to the axles. Torque from the transmission/torque con- level. This provides more economical partial throttle op-
verter is transferred to the axles via driver shafts con- eration by keeping the torque converter out of the power
nected between the two. flow circuit and allowing the more efficient direct connec-
tion of the engine to the power train. It also allows the op-
erator to take fuller advantage of the defueled engine as
The torque converter is equipped with automatic lockup
a brake in downgrade conditions.
capabilities. This allows the torque converter to change
from a fluid coupling to a direct mechanical link between
the engine and transmission at a predetermined rpm The hydraulic pump is mounted on an driven by the con-
level. The lockup function is controlled by the lockup verter. The emergency steer pump is mounted on and
control unit located in the junction box. An extended driven by the transmission.
With the engine running, the converter charging pump

3G
THEORY OF OPERATION
oil inlet on the transmission, then through a series of

draws oil from the transmission sump and directs it tubes to the transmission, bearings, and clutches. The
through oil filters to the regulating valve located on top of oil then returns to the transmission sump.
60
the transmission. From the regulating valve it is then di-
rected through the control cover on the transmission to A safety valve is built in the transmission control cover
the converter and to the transmission clutches. The and will open to bypass oil only if an excessive pressure
pressure regulating valve mounted on the top of the is built up due to a blocked passage.
transmission remains closed until required pressure is
delivered to the transmission for actuating the direction The rear compartment of the converter unit also houses
86
and speed clutches. This regulator valve consists of a the converter output shaft. A flexible hoses provides an
hardened valve spool operating in a closely fitted bore. overflow to the transmission sump.
The valve spool is backed up by a spring to hold the
valve spool against its seat until the oil pressure builds The three members of the torque converter are com-
up to the specified pressure. The valve spool then poses of a series of blades. The blades are curved in
moves towards the spring until a port is exposed along such a manner as to force the oil to circulate from the im-
the side of the bore. The oil can then flow through this peller to the turbine, through the reaction member again
into the impeller. This circulation causes the turbine to
port into a distributor which directs the oil into the con-
verter inlet port. turn in the same direction as the impeller. Oil enters the
inner side of the impeller and exits from the outer side
into the outer side of the turbine. It then exits from the
After entering the converter, the oil is directed through inner side of the turbine and after passing through the
the stator support to the converter cavity and exists be- reaction member, again enters the inner side of the im-
tween the turbine shaft and converter support. The oil peller.
then passes through an oil distributor which directs the
oil out of the converter by way of a down stream regula- Converter, ‘Stall’ is achieved whenever the turbine and
tor valve and then to the oil cooler. After leaving the turbine shaft are stationary and the engine is operating
cooler the oil is directed through a hose to the lubricating at full power or wide open throttle.
2-3-4
CAUTION draulically actuated piston. A piston is inserted into the
bore of the drum. The piston is ‘oil tight’ by the use of
DO NOT MAINTAIN ‘STALL’ FOR MORE sealing rings. A friction disc with internal teeth is inserted
THAN 30 SECONDS AT A TIME. EXCES- into the drum and rests against the piston.
SIVE HEAT WILL BE GENERATED AND
MAY CAUSE CONVERTER OR TRANS- Next, a disc with splines at the outer diameter is in-
MISSION SEAL DAMAGE. serted. Discs are alternated until the required total is
achieved. After inserting the last disc, a series of springs
In converters equipped with Lock-up clutches, a hydrau- and pins are assembled in such a manner that these
lic clutch, similar to the transmission clutches is used to springs rest on teeth of the piston. A heavy back-up plate
‘lock’ the engine mechanically to the output shaft. This is is then inserted and secured by a snap ring. A hub with
accomplished by hydraulic pressure actuating the lock- I.D/ and O.D. splines is inserted into the splines of discs
up clutch which in turn locks the impeller cover to the tur- with teeth on the inner diameter and a splined shaft ex-
bine hub. During lock-up the converter turns at 1 to 1 tending through the clutch support. This hub is retained
speed ratio. by a snap ring. The discs and inner shaft are free to in-
crease in speed or rotated in the opposite direction as
The down stream regulator valve on the converter con-
long as no pressure is present in the direction of speed
sists of a valve body and regulator spool. The spool is
clutch. To engage the clutch, as previously stated, the
backed up by a spring to hold the valve until converter oil
control valve is placed in the desired position. This al-
pressure builds up to specified pressure. The valve is
lows oil under pressure to flow from the control cover
used to maintain a given converter pressure to insure 3G valve, through a tube in the transmission case, to a cho-
proper performance under all conditions.
sen clutch. Once into the drum, oil is directed through a
The control valve assembly on the transmission con- drilled hole into the rear side of the piston bore. Pressure
sists of a valve body with selector valve spools con- of the oil forces the piston and discs over against the
nected to the steering column by exterior linkage. A heavy back-up plate. The discs, with teeth on the outer
detent ball and spring in the selector spool provides four diameter, clamping against discs, with teeth on inner di-
ameter, enables the clutch drum and drive shaft to be
60
positions for each speed range. A detent ball and spring
in the direction spool provides three positions, one each locked together and allows them to turn as a unit. There
for forward, neutral, and reverse. are bleed balls in the clutch drums which allow quick es-
cape for oil when the pressure to the piston is released.
On certain models, this valve also contains a shut-off
valve spool operated by an air or hydraulic cylinder lo- The transmission gear train consists of six shafts: (1) In-
86
cated on the control cover. This valve is connected to the put Shaft (2) Reverse Shaft (3) Idler Shaft, (4) First and
brake system by a hose line. When the wheel brakes are Third Shaft, (5) Second and Fourth Shaft (6) Output
applied, air or hydraulic fluid enters the valve and over- Shaft.
comes a spring force. This forces the spool to shift over
and block pressure from entering the directional A screen mounted in a frame is positioned on the bottom
clutches. In this manner a ‘neutral’ is established without of the transmission case, to screen out any foreign ma-
moving the control levers. terial. This screen is covered by the sump pan. This pan
is provided with magnets to catch any metallic particles.
With the engine running and the directional control lever
in neutral position, oil pressure is blocked a the control Some transmissions may have an axle declutching unit
valve, and the transmission is in neutral. Movement of as optional equipment, this unit consists of a split output
the forward and reverse spool will direct oil, under pres- shaft with a sliding splined sleeve to engage or disen-
sure, to either the forward or reverse direction clutch as gage the axle. This is accomplished by manually shifting
desired, and the opposite one is open to relieve pres- a lever in the operator’s compartment which is mechani-
sure. cally connected to the shift fork on the clutching unit slid-
ing sleeve. This unit, of course, is only used on the four
The direction or speed clutch assembly consists of a wheel drive machine. On the front drive only or the rear
drum with internal gear teeth and a bore to receive a hy- wheel drive only, the output shaft is on one piece type
2-3-5
and an output flange assembled only on the required
end.
MAINTENANCE
TORQUE CONVERTER NOTE
NOTE The torque converter must be fully sup-

ported to allow aligning of the located
For more detailed information refer to studs.
the Clark Service Manual.
NOTE
REMOVAL Ensure all burrs have been removed
from the flywheel mounting face and pi-
1. Refer to Section 2 - ENGINE and remove the en- lot bore and that the drive plate surface
gine and torque converter assembly.
is clean. Measure and record the en-
gine crankshaft end play.
2. Refer to Section 8 - HYDRAULIC SYSTEM and re-
move the hydraulic pump and emergency steering 3. Install two 3.5² long guide studs in the engine fly-
pump. 3G wheel housing as shown, rotate the engine flywheel to
align a dive plate mounting screw hole with the flywheel
CAUTION housing access hole.
ENSURE THE ENGINE AND TORQUE 4. Install a 4² long drive plate locating stud 7/16²-20
CONVERTER ARE FULLY SUPPORTED UNF in a drive plate nut. Align the locating stud in the
BEFORE REMOVING THE ATTACH- drive plate with the flywheel drive plate mounting screw
60
MENT BOLTS. hole positioned in step No. 3.
3. Remove bolts and washers securing the torque 5. Locate converter on flywheel housing aligning
converter to the engine housing. drive plate to flywheel and converter to flywheel hous-
ing.
4. Remove stop nuts, belleville washers and backing
86
6. Remove drive plate locating stud.

rings.
7. Install drive plate attaching screw. Snug screw but
5. Remove the flywheel mounting studs. do not tighten. Rotate the flywheel and install the re-
maining seven flywheel to drive plate attaching screws.
6. Remove the ring gear. Snug screws but do not tighten. After all eight screws
have been installed. Torque each screw to 25-30 lb.ft
7. Remove torque converter to a clean work area.
(33.9-40.6 Nm). This will require torquing each screw
and rotating the flywheel until all eight screws have been
INSTALLATION
tightened.
1. Remove all burrs from the flywheel mounting face 8. Measure the engine crankshaft end play after the
and pilot bore and clean with solvent. transmission/torque converter has been completely in-
stalled on the engine flywheel. This value must be within
2. Check the engine flywheel and housing for confor- 0.001-inches (0.025 mm) of the end play recorded ear-
mance to standard S.A.E. No. 1-S.A.E. J-927 tolerance lier.
specifications for pilot bore eccentricities, and mounting
face deviations. Measure and record engine crankshaft 9. Secure torque converter in position using the ap-
end play. propriate bolts and washers.
2-3-6
10. If necessary, refer to Section 8 - HYDRAULIC SYS- 11. Refer to Section 2 - ENGINE and install the engine
TEM and install the hydraulic pump and emergency and transmission/torque converter assembly.
steering pump.
5, 6, 7
3
3G
10
60
9
86
1. Spacer TORQUES
2. Adaptor Ring
Item 4 - 88.5 lbs ft (122 Nm)
3. Bushing
4. Screw M12
5. Stud M10
6. Nut M10
7. Washer Spring M10
8. Drive Plates
9. Screw 7/16²
10. Flywheel
Torque Converter Drive Installation
2-3-7
TRANSMISSION GEARBOX tween the engine and the wheels. The proper operation
of either unit depends greatly on the condition and op-
NOTE eration of the other; therefore, whenever repair or over-
haul of one unit is performed, the balance of the system
For more detailed information refer to must be considered before the job can be considered
the Clark Service Manual. completed.
REMOVAL After the overhaul or repaired transmission has been in-

stalled in the machine, the oil cooler, and connecting hy-
1. Disconnect the three drive lines from the transmis-
draulic system must be thoroughly cleaned. This can be
sion and from the torque converter and axles. Refer to
accomplished in several ways and a degree of judge-
DRIVE LINES in this section.
ment must be exercised as to the method employed.
The following are considered the minimum steps to be
2. Remove the drain plug from the transmission and
taken.
drain the oil.
3. Tag and disconnect the all electrical leads from the 1. Drain the entire system thoroughly.
transmission.
2. Disconnect and clean all hydraulic lines. Where
4. Tag and disconnect the hydraulic lines from the feasible, the hydraulic lines should be removed from the
transmission control valves, rear axle disconnect, and machine for cleaning.
transmission range shift.
3G
5. Tag and disconnect all oil lines from the torque con-
3. Replace oil filter elements, cleaning out the filter
cases thoroughly.
verter and oil cooler going to the transmission.
4. The oil cooler must be thoroughly cleaned. The
NOTE cooler should be back flushed with oil and compressed
60
air until all foreign material has been removed. Flushing
The transmission weighs approxi- in the direction of normal oil flow ill not adequately clean
mately 1786 pounds (810kg) dry. the cooler. If necessary, the cooler assembly should be
removed from the machine for cleaning, use oil, com-
6. Position a transmission jack or some other means pressed air, and steam cleaner for cleaning. Do not use
of support, capable of supporting the weight of the trans- flushing compounds for cleaning purposes.
86
mission, under the transmission.

5. Remove the drain plug from the torque converter
7. With the weight of the transmission on the support-
and inspect the interior of the converter housing, gears,
ing device, remove the four bolts, shock mounts, and
etc. If the presence of considerable foreign material is
end caps securing the transmission mounts to the
noted, it will be necessary for the converter to be re-
frame.
moved, disassembled, and cleaned thoroughly. It is re-
alized this entails extra labor, however, such labor is a
8. Remove the washers and bolts that secure the
minor cost compared to the cost of difficulties which can
transmission mounts to the transmission.
result from the presence of such foreign material in the
9. Using the supporting device, lower and remove the system.
transmission.
6. Assemble all components and use only the type oil
SERVICING THE SYSTEM AFTER A TRANSMIS- recommended. Fill the transmission as outlines under
SION OVERHAUL Lubrication Fill Procedure.
The transmission torque converter, and its associated 7. Recheck all drain plugs, lines, connections, etc. for
hydraulic system are important links in the drive line be- leaks and tighten as necessary.
2-3-8
Lubrication Fill Procedure NOTE
Fill transmission through filler opening until fluid cranes

The transmission weighs approxi-
to LOW mark on dipstick. Remove LOWER check plug
mately 1786 pounds (810 kg) dry.
until oil runs from LOWER oil hole, replace plug.
2. Run the engine for two (2) minutes at idle to prime 2. Using a transmission jack or suitable device capa-
the torque converter and hydraulic lines. ble of supporting the transmission weight, position the
transmission under the frame and raise it into position.
3. Check the level of fluid in the transmission with the
engine running at idle and if necessary add fluid to bring 3. Position the transmission mounts onto the trans-
the level to LOW mark on dipstick or oil runs freely from mission. Secure with the bolts and washers. Torque the
LOWER oil level. bolts to 479 pounds-foot (66 kgm).
4. Check the oil level again with the transmission oil

hot (180 to 200 degrees)F ( 82 to 93 degrees C). Bring oil 4. Secure the transmission mounts to the frame using
level to FULL mark on dipstick or runs freely from UP- the four bolts, shock mounts, and end caps.
PER oil level.
5. Remove the supporting device from under the
5. Recheck all plugs, lines etc. for leaks and tighten transmission.
where necessary. 3G 6. Connect all the transmission oil lines to the torque
converter and oil cooler in accordance with the identifi-
cation marks made during removal.
7. Connect the hydraulic lines to the transmission

60
control valve, rear axle disconnect, and transmission
range shift in accordance with the identification marks
made during removal.
8. Connect the electrical leads to the transmission as

86
9. Connect the three drive lines to the transmission

and to the torque converter and axles. Refer to DRIVE
LINES in this section.
10. Install the transmission drain plug and service the

Low Oil Level transmission as outlined in the Torque Converter and
Full Oil Level Transmission Specifications and Service Data under
TORQUE CONVERTER.
Lubrication Fill Procedure

TOWING OR PUSH STARTING
INSTALLATION
Before towing the vehicle, disconnect both front and
1. if a new transmission is to be installed, remove all rear drive lines. Because of the design of the hydraulic
fittings from the old one and install them in the same lo- system, the engine cannot be starter by pushing or tow-
cations on the new transmission. ing.
2-3-9
TRANSMISSION OIL COOLER
DESCRIPTION
The transmission oil cooler assembly consists of a mo- the transmission. The switch is located at the rear of the
tor driven fan and a hydraulic radiator. The fan directs transmission.
cool air through the cooling fan on the cooler.
The oil cooler is mounted on the carrier platform behind
A temperature switch is fitted in the hydraulic oil line to the carrier cab adjacent the engine compartment.
THEORY OF OPERATION
An engine driven hydraulic pump circulates oil from the (176°F) the temperature switch actuates the unloader
reservoir through the fan motor via a solenoid operated valve which allows full oil pressure to drive the motor fan.
unloader valve.
The fan remains operational until the oil cools to safe op-
When the hydraulic oil reaches a temperature of 80°C erating temperature.
MAINTENANCE
3G
REMOVAL 3. Secure the oil cooler unit with a lifting device.
1. Tag and disconnect hydraulic lines to cooler and 4. Remove nuts, studs, washers and anti-vibration
hydraulic motor. mountings to release cooler from carrier platform.
60
5. Remove oil cooler to clean work area.
2. Remove bolts anti-vibration mounting, nuts, wash-
ers and stay.
INSTALLATION
NOTE 1. Installation is the reverse of removal.

86
The oil cooler unit weighs approxi- 2. When the oil cooler is fully installed check trans-
mately 130kg (287 lbs). mission oil level to ensure it is at the correct level.
2-3-10
Transmission Oil Cooler Hydraulic Tank
3G
Solenoid Operated
Unloading Valve
60
86
Engine
Hydraulic System Transmission Oil Cooler
2-3-11
86
60
3G
SECTION 4
AXLE AND BRAKE SYSTEM
TABLE OF CONTENTS
Page
AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-3
Wheel Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-4
Steering Box Setting Locks Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-8
WHEELS AND TYRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-10
3G
Mounting Wheel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-10
Wheel Studs and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-10
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-12
SERVICE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Initial Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Operational Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
86
Brake Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13

Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Brake Chamber Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-13
Brake Actuator (Expander Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-14
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-14
AIR VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-15
LIST OF FIGURES
Title Page
Wheel Alignment Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-7
Steering Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-9
Lug Nut Tightening Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-11
Brake Actuator (Expander Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4-14
2-4-1
Page
2-4-3
WARNING
ENSURE ANY LIFTING DEVICE USED

IS CAPABLE OF SUPPORTING THE
WEIGHT OF THE AXLE.
2-4-3
WARNING
DO NOT ALLOW THE AXLE TO TWIST

OR TILT WHEN REMOVING THE
MOUNTING HARDWARE.
2-4-10
WARNING
3G
DO NOT ATTEMPT TO DEMOUNT OR
MOUNT TYRES WITHOUT PROPER
TRAINING. THE HIGH PRESSURES IN-
VOLVED CAN CAUSE TYRE AND RIM
PARTS AND TOOLS TO FLY WITH EX-
PLOSIVE FORCE, IF PROPER PROCE-
60
DURES ARE NOT USED, CAUSING SE-
VERE INJURY OR DEATH TO PERSON-
NEL AND DAMAGE TO THE CRANE
AND SURROUNDING AREA.
86
2-4-2
AXLES
DESCRIPTION
The crane is equipped with either four or five axles. To be controlled from either the carrier or turntable cab. The
provide maximum maneuverability, all but the third axle axles are mounted to the carrier frame by means of sus-
on the five axle machine are drive/steer axles and can pension cylinders located at each end of each axle.
MAINTENANCE
NOTE 6. Remove the cotter pin and hex nut securing the
drag link to the steering arm and disconnect the drag link
For more detailed information refer to from the axle.
7. Tag and disconnect the air lines to the brake cham-
REMOVAL bers. Cap or plug all lines and openings.
8. Tag and disconnect the hydraulic lines to the steer

NOTE
cylinders. Cap or plug all lines and openings
The axles do not have to be removed
from the crane to remove the planetary
wheel ends of the drive units.
3G WARNING
ENSURE ANY LIFTING DEVICE USED

IS CAPABLE OF SUPPORTING THE
1. Fully extend and set the outriggers. Install blocking WEIGHT OF THE AXLE.
under the frame at the outboard ends of the outrigger
WARNING
60
boxes.
DO NOT ALLOW THE AXLE TO TWIST
2. Deplete the air pressure in the brake system. OR TILT WHEN REMOVING THE
MOUNTING HARDWARE.
NOTE
NOTE
86
Each tyre and wheel assembly weighs

The axles weigh approximately
approximately 403 to 453kg (888 to 909
No 1 Axle 650kg (1433 lbs)
lbs) depending on tyre size.
3. Remove the tyre and wheel assemblies from the No 3 Axle 560kg (1234 lbs)
axle to be removed No 4 Axle 1010kg (2226 lbs)
4. Remove the drive lines. Refer to DRIVE LINES in 9. With an adequate lifting/supporting device sup-
Section 3 - DRIVE TRAIN. porting the weight of the axle, remove the bolts, wash-
ers, and pins securing the shock absorber to the axle
5. Place adequate blocking beneath the axle(s) to be
removed. 10. Remove any torque or panhard rods from the axle.
NOTE 11. Remove the axle and move it to a clean work area.
INSTALLATION
Wheel and axle alignment will be easier
if the tie rods are not removed from the 1. Using an adequate lifting/supporting device, posi-
axle. tion the axle under the crane.
2-4-3
2. Install the shock absorber on the axle using the 2. Assemble frame gauges and fit to carrier, rear
pins, bolts and washers. gauge to hang from rear number plate brackets and
front gauge to hang from cab support frame.
3. Install any torque or panhard rods which were re-
moved. 3. Fit and secure adaptors to the centre axle (if 10 x 8
configuration) and the two rear axles using the wheel nut
4. Secure the drag link to the steering arm with the type fixings.
hex nut and cotter pin.
4. Fit and secure wheel adaptors to the front two axles
using the long stud fixings and washers having first re-
5. Install the drive lines. Refer to DRIVE LINES in
moved the 3 road wheel nuts.
Section 3 - DRIVE TRAIN.
5. Lock the suspension and using the outrigger jacks
6. Install the air lines to the brakes as tagged during with beams partially extended, jack the machine up until
removal. all road wheels are clear of the ground and free to rotate.
7. Install the hydraulic lines to the steer cylinders as 6. Starting at the foremost front axle, hang the laser
tagged during removal. Bleed the steering system if on the wheel adaptor spindle at the groove and turn it on.
necessary.
7. Place a measuring scale approximately 4 to 5
8. Install the tyre and wheel assemblies. Torque the metres away from the laser, in such a position so that the
nuts to 59 kgm (440 pounds-foot).
9. Build up pressure in the air system.

3G laser dot hits the scale at the 200 mark.
8. Rotate the wheel, note the highest and lowest num-

bers indicated by the laser dot. Add these numbers and
divide by 2. This is the number to aim for using the ad-
10. Refer to LUBRICATION in this section and service
justment knobs on the wheel adaptor.
the axle.
60
9. Rotate the wheel until one knob points at the meas-
11. Remove the blocking. uring scale and the other knobs align vertically, adjust
the front knob to obtain the target number.
12. Retract and stow the outriggers.
10. Rotate the wheel one third of a turn and repeat op-
WHEEL ALIGNMENT PROCEDURE eration no. 9 for the two remaining knobs, aiming for the
86
same number.
1. Before attempting to make any wheel alignment
adjustments, ensure that the crane conforms to the fol- 11. Rotate the wheel completely to verify that the laser
lowing. dot remains on the same number. Fine tuning is ob-
tained by splitting the difference and repeating the same
a. The rear steer hydraulic circuit has been purged to procedure. The laser is now mounted at 90° to the axle.
exclude any air as part of the initial start and run up pro-
12. Repeat operations 6 through 11 for the remaining 9
cedure.
or 7 wheels.
b. All major components are fitted, e.g. swingaway, 13. Lower the machine back down onto the ground and
hoist unit (s), outrigger beams, hookblocks, etc. unlock the suspension. Re-check that the crane is at
ride height. Drive the crane back at least 1 full revolution
c. All counterweights, depending upon customer of the road wheels and drive it forwards again, bringing it
specification, are on the machine in their stowed and to rest without applying the footbrake and bringing the
road going positions. road wheels into a straight ahead position.
d. Hydraulic oil tank is full and the fuel tanks are at 14. Position and tack weld the bosses in place behind
least 50% full on the carrier and 75% on the turntable. the 3 steering/relay levers. Remove the lock bolts and
2-4-4
turn the road wheel to gain access to fully weld the 23. Adjust top and bottom torque arms, to move the
bosses. centre axle in the required direction.
15. Shunt the crane backwards and forwards to re- 24. Mark a datum line with chalk on the outer wall of the
align the steering/relay levers with the bosses, bringing nearside tyre and a corresponding line on the floor.
the crane to a stop without applying the footbrake. Install Drive the crane backwards at least 1 full revolution of the
the lockbolts and washers and secure. At this stage re- road wheels then drive it forwards again until the two da-
move the steering wheel from the carrier cab steering tum lines are in line, bringing the crane to a stop in both
column (to prevent accidental movement of the steering directions, without applying the footbrake. Apply the
linkage which will result in damage). Switch off engine parking brake and switch off the engine.
and apply parking brake. 25. Mount the lasers on the centre axle wheel adaptor
spindles and re-take the readings front and back, noting
16. Mount the laser onto a wheel adaptor on the front
them on the sheet. Calculate ‘toe-in’ and wheel align-
axle (near side). Aim it at the front target so that the laser
ment.
dot can be seen on the scale. Using a blank wheel align-
ment sheet, record the reading at A1, on the record 26. Repeat operations 23 through to 25 as required un-
sheet. til axle is in correct alignment. Using the clino, re-check
castor angle of the axle and adjust if required.
17. Rotate the laser 180° on the wheel adaptor spindle
and aim the laser dot at the rear target, recording the 27. Using the results obtained from the alignment re-
cord sheet, decide which wheels need adjusting to align
reading at B1.
18. It is advisable to have one person positioning and

aiming the laser and a second person to take the read-
3G the steering (‘toe-in and toe-out’ is adjusted when fine
tuning the steering).
NOTE
ings and record them, as this will eliminate unnecessary
walking up and down the length of the crane. When adjusting the steering, use bot-
tom steering drag rods only. No other
60
19. Repeat operations 16 and 17 for remaining wheels drag rods should be adjusted.
on the crane, moving either clockwise or anti-clockwise
around the crane. 28. Turn the bottom drag rods in the required direction
on those axles which require coarse adjustments.
20. Having taken all the readings, and noted them in
29. Shunt the crane backwards and forwards, re-align-
boxes A1, B1, A2, B2 on the wheel alignment sheet
ing the datum marks, bringing the crane to a halt in both
86
complete the remaining boxes on the sheet to establish

directions without applying the footbrake. Apply the
wheel alignment and ‘toe-in/toe out’.
parking brake and switch off the engine.
21. It is extremely unlikely that the wheel alignment fig- 30. Take a complete set of readings from all wheels by
ures will be within acceptable limits, and therefore ad- repeating operations 16 through to 20. Analyse the re-
justments are almost certain to be required. If, due to mi- sults obtained to confirm that all wheels are reasonably
salignment, it was not possible to obtain a reading on the aligned and do not have a distinct right or left hand steer-
front or rear scales from a particular wheel, adjustments ing bias. If any wheels are still greatly misaligned, repeat
must be made to this (these) wheel(s) first. operations 28 and 29 as required, taking readings from
those wheels only after each adjustment cycle.
22. The centre axle (when fitted) is non-steering. If the
initial axle installation has been correctly carried out, i.e. 31. At this stage, all the wheels should be reasonably
the amount of ‘toe-in’ or ‘toe-out’ as recorded on the aligned and fine adjustment including toe in and toe out
sheet is approximately equal on both wheels and the can be carried out.
axle does not have a pronounced right hand or left hand
NOTE
lock, then no adjustment to the axle installation is re-
quired, in which case go to operation 27. If adjustment is The final wheel alignment figures to be
required, continue as follows, operation 23. aimed for are as follows:-
2-4-5
Axle Nos. 1, 2 - steering/non drive - no gap of 5mm between the axle and the stop. Do this on all
right hand or left hand steering bias, four axles.
toe-in 0 to 3 mm/m.
40. Switch off the engine and adjust the steering stop in
Axle Nos. 4 & 5 - driving/steering - no the steering worm box in compliance with the steering
right hand or left hand steering bias, box setting locks procedure in this section.
toe-out 0 to 3 mm/m.
41. Still holding the same left hand lock position, drive
32. Starting with No. 1 axle, make fine adjustments to the crane in reverse at least 1 full revolution of the road
bottom steering drag rod and/or axle track rod as re- wheels.
quired. Shunt the crane backwards and forwards, re-
aligning datum marks on the floor, bringing the crane to 42. Check that the gap between the axle and the stop is
a halt without using the footbrake. Apply the parking still at least 5mm on all four axles and adjust as required.
brake and switch off the engine.
43. Drive the crane forwards again at least 1 full revolu-
33. Re-take a set of alignment readings for the axle in tion of the road wheels, still maintaining the left hand
question and note them on alignment sheet, calculating lock. Re-check that the gap between the axle and the
toe-in/toe-out. stop is at least 5mm, adjust if required.
34. Repeat operations 32 and 33 until the alignment 44. Repeat operations 39 through to 43 as required un-
31.
35. Repeat operations 32 through to 34 for each axle in

3G
readings are within the limitations as stated in operation til the steering stops are set correctly.
45. Drive the crane forwards and turn the steering

wheel onto a right hand lock until the gap between the air
turn missing out the centre axle, until all the axles have tank mounting bracket and the rear offside tyre is 19mm
been adjusted to within the acceptable limits. at the rear axle.
60
36. Take a complete set of readings from all wheels as 46. With the engine running, hold the steering wheel in
in operations 16 through to 20. Assuming that these final this position and adjust the axle stops until there is a gap
readings are within acceptable limits, enter the com- of 5mm between the axle and the stop. Do this on all four
pleted wheel alignment sheet onto the crane log book. If axles.
any of the wheels are still misaligned, adjust and re-take
86
readings accordingly, until the acceptable alignment fig- 47. Switch off the engine and adjust the steering stop in
ures are achieved. the steering worm box in compliance with the steering
box setting locks procedure in this section.
37. Remove lockbolts and washers from the steering/
relay levers and reinstall steering wheel in carrier cab. 48. Still holding the right hand lock position, drive the
Remove and dismantle front and rear frame gauges, re- crane in reverse at least 1 full revolution of the road
move wheel adaptors, replace and re-torque wheel wheels.
nuts. Ensure all drag rod and track rod clamps are fully
tightened. All alignment equipment should be stowed in 49. Check that the gap between the axle and the stop is
the trolley and the lasers should be re-charged. still at least 5mm on all four axles and adjust as required.
38. Drive the crane forwards and turn the steering 50. Drive the crane forwards at least 1 full revolution of
wheel onto a left hand lock until the gap between the the road wheels, still remaining the right hand lock. Re-
brake actuator and the bottom steering drag rod is check that the gap between the axle and the stop is still
12mm at the front axle. at least 5mm, adjust if required.
39. With the engine running hold the steering wheel in 51. Repeat operations 46 through to 50 until the steer-
this position and adjust the axle stop bolts until there is a ing stops are set correctly.
2-4-6
A1 A1 A2 A2
....... .......
B1
- + - + B2
C1 /
....... .......
C1 ±. . . . . . :Dm . . . . . .= DM ... ± = D.m. . . . .

: ±. . . . . . C2
/
....... .......
C2 ... ±
CAMBER
DM CAMBER
C1 +TOE-IN+ C2
±...... ±. . . . . .
-TOE-OUT-
A1 ....... ....... A2
- + + -
B1 .......
C3 /
DM ... ±
....... B2
/
....... .......
C3 ± . . . . . . :Dm . . . . . .= C4 = D.m. . . . .
: ±. . . . . . C4
DM ... ±
CAMBER KPl CAMBER KPl
STURZ Spreizung +TOE-IN+ STURZ Spreizung
CARROSSAGE C3 C4 CARROSSAGE
±...... ± ...... -TOE-OUT- ± . . . . . . . . . . . ±. . . . . . .

CASTER CASTER
± . . . . . . . . . . NACHLAUF
CHASSE
NACHLAUF
CHASSE ..........
±
A1 ....... .......
A2
B1 - + 3G + - B2
C5 /
....... .......
C5 ±. . . . . . :Dm . . . . . .= DM ... ± = D.m. . . . .

: ±. . . . . . C6
CAMBER
+
C6 /
DM ... ± + CAMBER
STURZ
+TOE-IN+ + STURZ
CARROSSAGE C5 C6 CARROSSAGE
±...... -TOE-OUT-
......
-
±
. . . . .. . . . . .
60
......
- -
A1 ....... .......
A2
B1 - + - + B2
C7 /
....... .......
C7 ±. . . . . . :Dm . . . . . .= DM ... ± = D.m. . . . .

: ±. . . . . . C8
/
....... .......
C8 ... ±
DM
KPl KPl
86
CAMBER CAMBER
STURZ Spreizung
C7 +TOE-IN+ C8
STURZ Spreizung
CARROSSAGE CARROSSAGE
±...... ± ...... -TOE-OUT- ±...... ± ......

CASTER CASTER
± . . . . . . . . . . NACHLAUF
CHASSE
NACHLAUF
CHASSE ..........
±
A1 ....... .......
A2
B1 - + - + B2
C9 /
....... .......
C9 ±. . . . . . :Dm . . . . . .= DM . . . ± = D.m. . . . .
: ±. . . . . . C10
/
....... .......
C10
DM . . ±
CAMBER KPl CAMBER KPl
STURZ Spreizung
C9 +TOE-IN+ C10
STURZ Spreizung
CARROSSAGE CARROSSAGE
±...... ± ...... -TOE-OUT- ±...... ± ......

CASTER CASTER
± . . . . . . . . . . NACHLAUF
CHASSE
NACHLAUF
CHASSE ..........
±
B1 B2
Wheel Alignment Sheet
2-4-7
STEERING BOX SETTING LOCKS PROCEDURE 5. Turn steering wheel to achieve correct position for
right lock.
1. Turn steering wheel to achieve correct position for
left lock (if this is unattainable, as close as possible). 6. Remove rearmost cap on adjusting box.
2. Remove foremost cap on adjusting note. NOTE
NOTE Oil may exude.
Oil may exude. 7. Adjust ring in manner described in (3) above noting
that in this case turning the ring anti-clockwise will re-
3. Using a small, clean screwdriver, pinpunch or simi- duce travel on right lock.
lar, turn adjusting ring until required lock is available.
Note that turning the ring clockwise (as viewed on end of 8. Replace cap and check operation of both steering
input shaft) will reduce steering travel on left lock. Ring lock stops, adjust if necessary and finally tighten caps.
may require several turns initially.
9. Set steering stops on axles 3mm clear of hubs
4. Replace cap and check operation of left lock stop. when steering is stopped by steering box, i.e. turn steer-
Note that the cap acts as a locking device for the adjusting to full left lock as allowed by steering box stops, then
ing ring; therefore the lock cannot be checked unless the fix axle stops with 3mm clearance. Repeat with right
caps are in place. 3G hand stops.
ADJUSTING BOX
60
INPUT SHAFT
CAP HOLE THROUGH

WHICH ADJUSTMENTS
ARE MADE
86
INPUT SHAFT
ADJUSTING RING
Scrap View Showing Adjusting Ring
2-4-8
TURNING THE ADJUSTING
RING IN THIS DIRECTION TURNING THE ADJUSTING
REDUCES THE DROP ARM RING IN THIS DIRECTION
TRAVEL (INCREASES GAP REDUCES THE DROP ARM
BETWEEN AXLE AND AXLE TRAVEL (INCREASES GAP
STOP BETWEEN AXLE AND
AXLE STOP
ADJUSTING RING PLUG
A
ADJUSTING RING FOR
LH WHEEL TURN
STEERING GEAR
3G
A
ADJUSTING RING FOR
RH WHEEL TURN
DETAIL A -A
AIR BLEED
60
OIL DRAIN
DROP ARM
86
INSTALL DROP ARM AT 90°

TO THE STEERING GEAR
Steering Adjustments
2-4-9
WHEELS AND TYRES
DESCRIPTION
Sizes of tyres available; 16.00 R25 and optional 20.50 sures prior deflection which, in turn, ensures proper
R25. traction, flotation, support of load, and prevents exces-
sive flexing of the tyre. Over inflation increases rim
CAUTION stresses, which results in lowered rim life.
DO NOT MIX TYRES AND RIMS OF DIF- CAUTION

FERENT MANUFACTURERS.
FOR EXTENDED TRAVEL CHECK THE
Each wheel assembly (tyre and rim) including spare
COLD TYRE PRESSURE PRIOR TO
wheel stowage brackets weighs approximately 403 to
START, (REFER TO TYRE INFLATION
453kg (888 to 909 pounds) depending on the tyre size
DECAL ON THE CRANE). THE TYRE
and is mounted on the planetary hub with 10 M22 lug
LOAD RATING IS BASED UPON
nuts.
TRAVEL NOT EXCEEDING 45 MILES
NOTE (72 KM) IN ANY ONE HOUR PERIOD. AT
DESTINATION, THE TYRES MUST BE
The tyre diameters, widths, and
weights may vary slightly depending
on the tyre manufacturer.
3G ALLOWED TO COOL TO AMBIENT
TEMPERATURE BEFORE CRANE LIFT-
ING ON RUBBER.
Off-highway tyres are designed to operate with a certain Refer to and adhere to the inflation pressures on the
sidewall deflection of bulge. Correct air pressure en- Tyre Inflation decal on the crane.
60
MAINTENANCE
WARNING 1. Position the wheel assembly on the mounting

studs. Install the lug nuts and washer and tighten them
until they are just snug, rotating the wheel so the nut be-
86
DO NOT ATTEMPT TO DEMOUNT OR

MOUNT TYRES WITHOUT PROPER ing tightened is in the top position.
TRAINING. THE HIGH PRESSURES IN-
2. Ensure the wheel assembly is positioned properly
VOLVED CAN CAUSE TYRE AND RIM
on the hub.
PARTS AND TOOLS TO FLY WITH EX-
PLOSIVE FORCE, IF PROPER PROCE- 3. Torque the lug nuts to 440 pounds-foot (59 kgm) in
DURES ARE NOT USED, CAUSING SE- the sequence shown in the Lug Nut Torquing Sequence
VERE INJURY OR DEATH TO PERSON- figure.
NEL AND DAMAGE TO THE CRANE
AND SURROUNDING AREA. WHEEL STUDS/NUTS
MOUNTING WHEEL ASSEMBLIES Correct tightening of wheel nuts at regular intervals is an

essential requirement if expensive repairs are to be
avoided.
NOTE
Problems will invariably occur if wheel nuts are tight-
Do not lubricate the wheel studs or lug ened to a torque significantly above or below the recom-
nuts. mended figure.
2-4-10
Undertightening wheel nuts inevitably results in a fairly wheel disc(s) are checked for signs of damage. If notice-
rapid loosening with damage to studs, nuts and wheel able deformation is present it is unlikely that the wheel
disc locations. Ultimately the wheel studs may shear can be adequately secured even when tightened to the
and the wheel(s) become detached. correct torque.
Overtightening can be equally in as much as the device

When tightening wheel nuts, the progressive pattern il-
incorporated to prevent rotation of the stud i.e. serra-
lustrated should be adopted. Never full tighten one nut
tions or dowels, may be destroyed.
whilst others are fully loosened. Checks should be made
Subsequent loosening of the stud retaining nut may re- during the tightening process to ensure that the nuts are
sult particularly on axles where the left hand side hubs fitting snugly in their locations in the wheel disc. This is
are fitted with left hand thread wheel nuts and right hand particularly important with twin wheels where the loca-
thread locknuts. tion of the innermost wheel must also be checked.
Overstressing of the studs is also an obvious danger

NOTE
where nuts have been overtightened.
Once wheel nuts have been found loose it is recom- Wheel stud and nut threads should be
mended that the studs and the location areas of the clean and dry.
3G
1 1 1
5 7
5 8
5 3
60
10 3
3 4
4 9
4 6
7 6
86
8 6
2 2 2
Lug Nut Tightening Sequence
2-4-11
BRAKE SYSTEM
DESCRIPTION
The brake system is pneumatically controlled and can relay valves (one for each axle), park brake relay valve,
be operated from either cab. The components which spring brake control valve, brake chambers, and service
make up the brake system include the brake valves and brakes.
park brake valves (one in each cab), the service brake
THEORY OF OPERATION
Each wheel end on the 3rd, 4th and 5th axles have a erates from the footpedal and applies the road brakes.
spring powered brake chamber. The rear of the cham-
ber contains a high powered spring, held off by air pres- The service brakes are applied by air pressure. De-
sure. The spring brakes are released by the parking pressing the foot brake pedal on the cab floor causes
brake push-pull knob in the cab. Pushing down on the pressurized air to enter the service brake chamber on
parking brake causes air pressure to enter the spring each wheel, applying the brakes. In the event of a loss of
brake chamber on each wheel and compress the spring, supply pressure to the service brakes, the spring brake
3G
releasing the brake. At least 40 psi (275.8 kPa/2.75 bar)
is required to keep the parking brake valve engaged. If
supply pressure to the valve drops below 40 psi (275.8
kPa/2.75 bar) the valve will release, applying the
valve will allow the operator to release or bleed off the air
pressure in the spring brake chamber by depressing the
foot brake pedal to apply the brakes.
brakes. A second brake chamber which is a single diaphragm

tyre is fitted to each end of the 1st , 2nd and 3rd axles for
The front of the actuator is a single diaphragm which op- service braking of the duplex brakes.
60
86
2-4-12
SERVICE BRAKES
DESCRIPTION
The service brakes are the drum and shoe type. The plungers that ensure the brakes are properly adjusted to
brakes on the 3rd, 4th and 5th axles are single wedge compensate for brake lining wear.
actuated and the brakes on the 1st and 2nd axles are
dual wedge actuated. Each wedge is actuated by an air NOTE
brake chamber (power unit) mounted on the brake back-
ing plate. The brakes have automatically adjusting The 3rd axle is available as an option.
MAINTENANCE
GENERAL BRAKE ASSEMBLY
A schedule for the periodic adjustment, cleaning inspec- Initial Adjustment

tion, and lubrication of brake equipment should be es-
tablished by the operator on the basis of past experi- The brake actuator (expander unit) is adjusted at the
3G
ence and severity of operation. Linings and drums are
parts particularly subject to wear depreciation. To com-
pensate for this wear, brakes should be adjusted as fre-
quently as required to maintain satisfactory operation
minimum dimension by the manufacturer. This dimen-
sion changes with respect to the brake diameter. When
changing linings (after turning down the lining), adjust
the adjusting screw to obtain the value of 174 + 0.5mm.
and maximum safety. Adjustments should provide uni- Do not block the screw. Check the sealing of the boots,
form lining clearance, correct travel of levers and proper
Operational Check
equalization.
60
Slowly operate the brake system using the pedal oper-
Brakes should be cleaned, inspected, lubricated, and ated valve. Lock through the holes to see that the shoes
adjusted each time the hubs are removed. move against the drum. After releasing the pedal, the
brake shoes should return instantly to the original posi-
During a major overhaul, the following parts should be
tion.
86
carefully checked and replaced with genuine replace-

ment parts as required. Brake Linings
1. Check the backing plates for distortion, looseness, In the event of wear or oil impregnation, always change
and sheared rivets. the linings on both sides of the axle. Never replace the
linings on one side only.
2. Check the anchor pins for wear or misalignment.
Brake Drum
3. Check the brake shoes for wear at the anchor pin
holes. Admissible machining of the brake drum is 74% of the
nominal diameter.
4. Shoe return springs should be replaced at the time
of overhaul. Brake Chamber Installation
5. Check the brake linings for grease saturation wear, Screw the counter nut onto the brake chamber a mini-
and loose rivets or bolts. mum of 22mm. Coat the threads with Teroson-Atmosit.
Screw in the brake chamber until tight then back off as
6. Check the drums for cracks, scoring or other dam- necessary. Torque the counter nut to 116 + 14.5 pounds-
age. foot (16.0 + 2.0 kgm).
2-4-13
Brake Actuator (Expander Unit) Cleaning and Inspection
The brake actuator (expander unit) must be disassem- 1. Clean all parts with a non-residue type cleaning
bled every two years and if necessary rebuilt using the solvent.
applicable repair kit. Before installation, coat all moving
parts with Shell Grease 16 or ThermaxTex EP71. 2. Inspect all parts for wear, scoring, cracks, or other
damage.
The brakes will adjust themselves automatically during
operation to a certain diameter with respect to operating 3. Before assembly, grease all moving parts with
condition. Shell 16 grease.
Disassembly
Assembly
1. Remove the push rod assembly by removing the
1. Install the spring washer, spacer adjusting ring,
snap ring. Remove the cup, springs, cage, and balls.
and piston into the housing.
2. Remove the clip, spring clip, and brake shoe loca-
tor. 2. Install the brake shoe locator, spring clip, and clip.
3. Remove the adjuster, adjusting ring, and spacer 3. Install the cage, balls, cup, and springs. Install the
from the piston. Remove the spring washer. snap ring and the push rod assembly.
4. Remove the plugs, pins, and springs.

3G
9
4. Install the plugs, pins, and spring.
2
60
10
86
6
7
8
4
5
3
1 Wedge Set
2 Adjustment Set
3 Seal Set
4 Spring
5 Disk
6 Screw
1 7 Pressure Plate
8 Spring
9 Pressure Plate
10 Screw
Brake Actuator
2-4-14
AIR VALVES
DESCRIPTION
The air valves used in the brake system are the brake NOTE
valves, park brake valves, service brake relay valves,
park brake relay valve, and the spring brake control For more detailed information concern-
valve. These valves control the application and release ing the air valves used in the crane’s
of the service brakes and parking brakes and are all a brake system refer to Section 7 - AIR
part of the cranes air system. SYSTEM.
3G
60
86
2-4-15
86
60
3G
SECTION 5
STEERING SYSTEM
TABLE OF CONTENTS
Page
STEERING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
Front Axle Steering from the Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
Front Axle Steering from the Turntable Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
Rear Axle Steering from the Turntable or Carrier Cabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
Front Axle Steering from the Carrier Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
Rear Axle Steering from the Turntable or Carrier Cabs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-5
Front Axle Steering from the Turntable Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
3G
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-6
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-7
Relay Shaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-8
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-9
60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-9
Centring the Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-11
DUAL STEERING BEVEL GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-12
DUAL STEERING BEVEL GEARBOX (Fitted with Drive/Steer Controls from the Turntable Cab) . . . 2-5-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-14
ORBITROL STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-18
STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-19
2-5-1
Page
EMERGENCY STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-20
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-20
STEER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-21
ORBITROL STEERING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-22
FLOW INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-23
FLOW CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3G 2-5-24
HYDRAULIC RESERVOIR - STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-25
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-25
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-25
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-25
60
86
2-5-2
LIST OF FIGURES
Title Page
Relay Shaft Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-8
Steering Gear Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-10
Bevel Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-13
Bevel Gear Installation (Fitted with Drive/Steer Controls fron the Turntable Cab) . . . . . . . . . . . . . . . . . . 2-5-15
Orbitrol Steering Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-18
Hydraulic Reservoir - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5-27
3G
60
86
2-5-3
Page
2-5-17
WARNING
ENSURE THE ENGINE IS SHUT DOWN

BEFORE PROCEEDING.
2-5-18
WARNING
THE HYDRAULIC LINES MUST BE

PROPERLY CONNECTED AS TAGGED
DURING REMOVAL.
2-5-25
WARNING
3G
ENSURE THE CARRIER ENGINE IS
SHUTDOWN BEFORE PROCEEDING.
60
86
2-5-4
STEERING SYSTEMS
DESCRIPTION
The crane is equipped with three steering systems, one directly to the carrier bevel gearbox. This system is used
for steering the front axles from the carrier cab, one for for site travel and is operated by a steering wheel.
steering the front axles from the turntable cab and one
for steering the rear axle from the turntable or carrier REAR AXLE STEERING FROM THE TURNTABLE
cabs. OR CARRIER CABS
FRONT AXLE STEERING FROM THE CARRIER The system for steering the rear axle from the turntable
CAB cab (optional) or carrier cab consists of the steer pump,
an air piloted solenoid operated directional control
The system for steering the front axle from the carrier valve, a single solenoid operating directional control
cab consists of the steering pump, ground driven emer- valve, a double solenoid operated control valve, steer
gency steering pump, flow control valve, flow indicator, reversing switch, rear steer control switch and the rear
bevel gearbox, front steering gear, and front steer cylin- steer cylinders. This system provides the operator with
ders. This system is primarily used for roading the crane independent rear wheel steering, four wheel co-ordi-
and is operated by the steering wheel in the carrier cab. nated or crab steering. It is used for job site travel and
The steering pumps are mounted on and driven by the
engine. The ground driven emergency steering pump is
mounted on and driven by the transmission.
3G limited roading and is operated by a switch in either cab.
The steer reversing switch is located on the electrical

swivel. The purpose of this switch is to reverse the direc-
FRONT AXLE STEERING FROM THE TURNTABLE tion of the hydraulic flow to the steer cylinders in accor-
CAB dance with the position of the turntable. This means that
the crane will turn in the direction the steering wheel is
60
Steering from the turntable cab is via an orbitrol steering turned whether the turntable is facing the front or rear of
valve which operates a hydraulic motor which is coupled the carrier.
THEORY OF OPERATION
86
FRONT AXLE STEERING FROM THE CARRIER gear to the applicable ends of the front steer cylinders as
CAB determined by the positioning of the steering wheel in
the cab.
Hydraulic flow for steering is provided by the steering
pumps and the ground driven emergency steering REAR AXLE STEERING FROM THE TURNTABLE
pump. The steering pumps supply the flow for the dual OR CARRIER CABS
line steer system. Two pumps are used so that in the For rear axle steering from the turntable or carrier cabs
event of a failure in one pump, the other pump can pro- the steering lock in the carrier cab must be unlocked and
vide adequate steering until repairs are made. Flow the P.T.O. in the carrier cab engaged.
from the steering pumps is routed through the flow con-
trol valve to the front steering gear. Flow from the ground Hydraulic flow is provided by the outrigger/pilot section
driven emergency steering pump is routed directly to the of the hydraulic pump. Flow from the pump is routed to
front steering gear. As the steering wheel is turned, the the air piloted solenoid operated directional control
bevel gear transmits the mechanical force at a 90 de- valve and rear steer solenoid valve. As the control
gree angle to the front steering gear. The mechanical in- switch in the cab is positioned to the left or right, the ap-
put to the steering gear shifts the internal valving within plicable solenoid on the rear steer valve and the retract
the gear which routes hydraulic flow from the steering on the air piloted solenoid operated directional control
2-5-5
valve selected and hydraulic oil is routed to the appropri- and turning the steering wheel to the left will turn the
ate ends of the rear axle steering cylinders. wheels to the right. This allows the crane to turn in the
direction the steering wheel is turned whether the turnta-
FRONT AXLE STEERING FROM THE TURNTABLE ble is facing the front or the rear of the carrier.
CAB
The steer selector valve is actuated by the steer revers- When the power to the turntable switch is engaged, the
ing switch. With the turntable over the rear of the crane electrical supply operates a solenoid valve which re-
carrier the valve is de-energized. Turning the steering leases air to the bevel gearbox clutch cylinder. This en-
wheel to the right will turn the wheels to the right and gages the integral dog clutch which allows the steering
turning the wheels to the left will turn the wheels to the to be driven from the turntable cab.
left. This causes the crane to turn in the direction the
steering wheel is turned. Rotating the turntable over the The orbitrol steering valve is activated by turning the
front of the carrier actuates the steer reversing switch, steering wheel. The volume of oil flow to the cylinder de-
which in turn energizes the solenoid in the steer control pends upon how far the steering wheel is turned. The oil
valve and shifts the valve spool. This reverses the flow of passes through a solenoid operated directional flow
oil to the steer cylinders on the rear axle thus turning the control valve through the swivel coupling to the carrier
steering wheel to the right will turn the wheels to the left steering motor which drives the bevel gearbox.
MAINTENANCE
TROUBLESHOOTING
3G
SYMPTON PROBABLE CAUSE SOLUTION
1. Hard to steer left and right a. Hydraulic oil low. a. Refill hydraulic
reservoir.
60
b. Clogged or loose b. Clean or tighten
hydraulic lines or lines or fittings.
fittings.
c. Insufficient lubricant c. Lubricate steer
on steer cylinders. cylinders.
d. Defective pressure d. Repair or replace
86
relief valve. valve.

e. Defective steering e. Repair or replace
control valve. valve.
f. Defective steering f. Repair or replace
pump. pump.
g. Defective solenoid g. Check electrical
valve. supply and
solenoid valves.
2. Hard to steer either a. Clogged or loose a. Clean or tighten

left or right. hydraulic lines or lines or fittings.
fittings.
b. Insufficient lubricant b. Lubricate
on steer cylinder. cylinder.
c. Defective steer c. Repair or replace
cylinder. cylinder.
2-5-6
3. Steering is erratic left a. Hydraulic oil low. a. Refill hydraulic

and right. reservoir.
b. Clogged or loose b. Clean or tighten

hydraulic lines or lines or fittings.
fittings.
c. Defective pressure c. Repair or replace

relief valve. valve.
d. Defective steering d. Repair or replace

control valve. valve.
e. Defective steering e. Repair or replace

pump. pump.
f. Insufficient lubricant f. Lubricate steer

on steer cylinders. cylinders.
4. Noisy steering pump a. Hydraulic oil low. a. Refill hydraulic

caused by cavitation.
b.
3G
Suction line plugged
or too small.
b.
reservoir.
Clean line and

check for size.
5. Steering pump shaft a. Worn shaft seal. a. Replace shaft

seal leakage. seal.
60
NOTE
If replacing the shaft seal does not stop

leakage, the pump should be disassem-
bled and checked for the following.
86
b. Broken diaphragm b. Replace seal or

seal or backup gasket.
gasket.
c. Bearing out of c. Replace bearing.

position.
d. Excessive internal d. Replace pump.

wear.
FUNCTIONAL CHECK 1. Check all fittings for leakage. An accumulation of

moist, black dirt is a good indication of leakage.
A normal periodic functional check of the entire power
steering system will generally be adequate to ensure 2. With the engine running at idle and a full throttle
satisfactory service. and with the crane standing still and moving actuate the
2-5-7
control lever and turn the steering wheels through their Never hold the system at relief pressure for more than a
full range of travel. few seconds at a time. The pressure gauge readings
should be as follows: 2500 psi (17237 kPa/172 bar) for
3. Ensure the system has adequate power. If there is the steering pump,, 3500 psi (24132 kPa/241 bar) for
an indication of ”hard steering”, this can be caused by the steering portion of the pilot solenoid operated direc-
either a reduced oil flow to the control valve or a reduced tional control valve, and 2029 psi (1400 kPa/140 bar) for
system relief pressure. Adequate oil flow under all con- the front steering gear.
ditions can best be checked by timing the full travel of the
RELAY SHAFT ALIGNMENT
cylinder with the steered axle unloaded and loaded. If
there is a great difference at low engine speed and slight NOTE
difference at high engine speeds this may indicate a de-
fective pump drive. Adequate oil pressure can only be For proper alignment, the axle must be
determine by connecting a pressure gauge (5000 psi in the straight ahead position.
[34,475 kPa/344.75 bar] full scale recommended) at the
pump outlet port or at the IN port of the steering control There are two relay shafts used in the steering system,
valve. With the engine running at a medium speed, turn between the bevel box and steering gear and between
the steering wheel to one end of the travel and hold the the steering gear and steering linkage. Ensure the uni-
cylinders at the travel limit briefly, just long enough to versal joints on the relay shafts are properly aligned as
read the pressure gauge. shown on the figure titled Relay Shaft Alignment.
3G
60
Steering Gear
Steering Gear Relay Shaft
Relay Shaft
86
Bevel Box
Steering Gear
Relay Shaft Alignment
2-5-8
STEERING GEAR
DESCRIPTION
The Z.F. Steering Gear is a semi-integral power steering thrust by means of two anti-friction bearings. The control
unit that directs the steering fluid to the steer cylinders in valve is installed across in the piston. The valve is com-
response to the movement of the steering wheel. The posed of a valve spool and two fixed reaction pistons.
steering housing contains two control valves, a com- One finger of the steering nut fits snugly into the bore of
plete mechanical steering gear, and it is at the same time the valve spool. The piston and the sector shaft are posi-
the operating cylinder of the piston. The worm and the tively connected by a gearing. Due to a special tooth
steering nut are connected by an endless chain or balls. shape on the sector shaft, their axial adjustment is pos-
The balls are returned via a recirculating tube. The sible. This ensures clearance free operation in the
steering nut is maintained clearance free against axial straight ahead travel range.
THEORY OF OPERATION
In the neutral position of the valve, the oil pressure in the only one of the two cylinder chambers. The piston as-
right and the left cylinder chambers are balanced. By
sure difference is produced between the left and the

3G
moving the valve spool from the neutral position, a pres-
right cylinder chambers. The piston will receive more oil

sists the worm rotation. A compression spring arranged
in the steering nut causes the return of the steering nut
and also of the valve spools to neutral position. This op-
eration is assisted by the hydraulic reaction pistons.
pressure on one side, and the hydraulic power assis- They are floatingly mounted in bores of the valve spool,
tance is operative. The valve is actuated by a rotation of and secured against axial movement by locking plates.
the steering wheel or by the forces which coming from The outside faces of the two reaction pistons are perma-
60
the road wheels, act through the sector shaft and piston nently pressurized in the operating position of the valve.
on the steering nut and worm. Any rotation of the worm Likewise only one of the two faces in the bores of the
means an axial movement of the piston and a radial valve spool are pressurized with oil. This causes a force
movement of the output shaft. This operation causes the trying to return the valve spool to neutral position. This
valve spools to be moved by the finger on the steering process is called hydraulic reaction.
86
nut. Consequently the pressure oil is now supplied to
MAINTENANCE
NOTE

REMOVAL 4. Remove the bolts and washers mounting the steer-
ing gear to the mounting bracket on the carrier frame.
1. Tag and disconnect the hydraulic lines to the steer- Remove the steering gear.
ing gear. Cap or plug all lines and openings.
INSTALLATION
2. Disconnect the drop arm from the steering gear.
3. Remove the nut, bolt, and washer securing the re- 1. Position the steering gear to the mounting bracket
lay shaft to the steering gear. on the carrier frame and secure in place with the mount-
2-5-9
ing bolts and washers. Torque the bolts to 144 pounds-
foot (20 kgm).
Turning the adjusting ring in

this direction reduces the drop
arm travel (increases gap be-
tween axle and axle stop)
Turning the adjusting ring in

this direction reduces the drop
arm travel (increases gap be-
tween axle and axle stop)
Adjusting ring for

L/H wheel turn
Adjusting ring for

R/H wheel turn DETAIL E -E
E
E
3G Port #1
Pressure port from pump
Port #2
Cylinder Port #4
Return
Pressurized for right wheel turn
to tank
60
Cylinder Port #3
Air Bleed
Pressurized for left wheel turn
oil drain
Torque to 295 ft-lbs then back off

86
to nearest cotter pin hole
Cylinder Port #3
Port #1 Pressurized for right wheel turn
Pressure port Cylinder Port #4
from pump Pressurized for left wheel turn
Port #2
Return
to tank
Steering Gear Service Information
2-5-10
2. Centre the steering gear. Refer to CENTRING THE 3. Divide the number of turns in half and turn the input
STEERING GEAR. stub that number of turns back to centre the steering
gear.
3. Connect the drop arm to the steering gear and se-
cure in place with the castle nut. Torque the nut to 295 4. Refer to the figure titled Steering Gear Service In-
pounds-foot (40.8 kgm) then back the nut off to the near- formation and check for proper positioning of the index
est cotter pin hole and install the cotter pin. Refer to the mark.
figure titled Steering Gear Service Information.
NOTE
4. Connect the relay shaft to the steering gear with the
For procedure concerning centring the
bolt, nut, and washer. Refer to RELAY SHAFT ALIGN-
front wheels, refer to HYDRAULIC
MENT. Torque the bolt to 35 pounds-foot (4.8 kgm).
POWER BLEEDING AND ADJUST-
CENTRING THE STEERING GEAR MENT in Section 4 - AXLE AND BRAKE
SYSTEM.
NOTE
CAUTION
For proper alignment, the axle must be
DO NOT OPERATE FRONT AXLE
in the straight ahead position.
STEERING FROM THE TURNTABLE
The following procedure is to be used to centre the CAB UNLESS THE FRONT AXLE
steering gear after installation.
1. Turn the input stub until it bottoms out.

3G STOPS ARE CORRECTLY SET. DAM-
AGE TO THE STEERING GEAR WILL
RESULT. REFER TO HYDRAULIC
POWER BLEEDING AND ADJUST-
2. Turn the input stub in the opposite direction and MENT IN SECTION 4 - AXLE AND
count the number of turns until it bottoms out. BRAKE SYSTEM.
60
86
2-5-11
DUAL STEERING BEVEL GEARBOX
DESCRIPTION
The bevel gearbox is located at the front of the carrier. It steering column at a 90 degrees angle to the steering
is connected to the carrier steering column and the gear. The bevel gear is necessary because the distance
steering gear by relay shafts. The bevel gear is used to and angles between the steering column and the steer-
transmit mechanical turning power from the carrier cab ing gear make a direct link impossible.
MAINTENANCE
NOTE 3. Remove the bolt (6), and nuts (7) securing the
gearbox to the mounting bracket (9) and remove the
The bevel box is not serviceable and if gearbox.
defective should be replaced.
INSTALLATION
REMOVAL
1. Position the gearbox on the mounting bracket and
1. Remove the bolt (3) nut (4) and coupling (2) secur-3G secure in place with the bolts (6), and nuts (7). Torque
ing the steering column relay shaft (1) to the gearbox (8) the bolts to 163 pounds-foot (22.6 kgm).
and disconnect the shaft.
2. Connect the relay shafts to the gearbox and secure
2. Remove the bolt (3), nut (4) and coupling (2) secur- in place with the bolts (3), nuts (4) and couplings (2). Re-
ing the steering gear relay shaft (5) to the gearbox (8) fer to RELAY SHAFT ALIGNMENT. Torque the bolts to
and disconnect the shaft. 35 pounds-foot (4.8 kgm).
60
86
2-5-12
1
9
4
3
5 4 2
3G
3
2
60
8
86
Bevel Gear Installation
2-5-13
DUAL STEERING BEVEL GEARBOX
(Fitted with Drive/Steer Controls from the Turntable Cab)
DESCRIPTION
The bevel gearbox is located at the front of the carrier. It and angles between the steering column and the steer-
is connected to the carrier steering column and the ing gear make a direct link impossible. Integral spur
steering gear by relay shafts. The bevel gear is used to gearing driven by a hydraulic motor and controlled by an
transmit mechanical turning power from the carrier cab air operated dog clutch, provides for steering from the
steering column at a 90 degrees angle to the steering turntable cab.
gear. The bevel gear is necessary because the distance
MAINTENANCE
NOTE 3. Remove the bolt (6), nuts (8), and washers (7) se-
curing the gearbox to the mounting bracket and remove
For more detailed information refer to the gearbox.
REMOVAL
1. Remove the bolt (3) nut (4) and coupling (2) secur-
3G INSTALLATION
1. Position the gearbox on the mounting bracket and

secure in place with the bolts (6), nuts (8) and washers
ing the steering column relay shaft (1) to the gearbox (9) (7). Torque the bolts to 75 pounds-foot (10.4 kgm).
and disconnect the shaft.
2. Connect the relay shafts to the gearbox and secure
60
2. Remove the bolt (3), nut (4) and coupling (2) secur- in place with the bolts (3), nuts (4) and couplings (2). Re-
ing the steering gear relay shaft (5) to the gearbox (9) fer to RELAY SHAFT ALIGNMENT. Torque the bolts to
and disconnect the shaft. 35 pounds-foot (4.8 kgm).
86
2-5-14
4
9 3G 6
8
60
86
2 3
Bevel Gear Installation

(Fitted with Drive/ Steer Controls from the Turntable Cab)
2-5-15
ORBITROL STEERING VALVE
DESCRIPTION
The orbitrol steering valve is located in the turntable cab, spool being directly connected to the steering wheel, a
on the steering column. Some of the major components drive shaft mechanically linked to the rotor gear and the
are; a metering and emergency manual pump unit con- outer sleeve, thus providing feedback, and a check
sisting of a fixed outer ring with integral teeth and an in- valve between the return and pressure inlet ports. The
ner rotor with external teeth, a four-way rotary servo orbitrol unit is a hydrostatic valve operated by turning the
valve consisting of an outer valve sleeve and inner valve steering wheel.
THEORY OF OPERATION
When the steering wheel is stationary and the rotary valve sleeve so that the ports of the rotary servo valves
valve is in the neutral position, the valve ports are open are closed when the angular movement of the rotary
allowing free flow through the unit to the reservoir. Turn- gear coincides with that of the steering wheel.
ing the steering wheel in either direction results in the
valves being rotated relative to each other. The chan-
tion of about 1.5 degrees. These channels are com-

pletely open at about 6 degrees. After about 4 degrees
of rotation the neutral ports close.
3G
nels to the steering motor ports gradually open at a rota- In the event of supply pump failure, the orbitrol steering
control reverts automatically to manual emergency
steering. Turning the turntable cab steering wheel re-
sults in rotation of the inner spool so that when it has
been rotated through 8 degrees, a cross pin drives the
The flow through the metering unit results in; a rotation outer sleeve, which through the drive, rotates the rotor
of the motor gear, the feeding of a volume of fluid, which gear. The metering pump thus acts as a hand operated
60
is directly proportional to the angular movement of the pump, directing oil to the steering cylinders. The check
steering wheel, to the front steering cylinders to produce valve between the return and inlet ports of the orbitrol
angular movement of the front wheels, and an internal unit then opens and admits return oil from the cylinders
mechanical feedback from the rotor gear to the outer to the suction line.
86
MAINTENANCE
NOTE

TROUBLESHOOTING
1. Steering wheel does a. Broken centring springs. a. Replace springs.

not centre. No response
when steering wheel is
turned . b. Dirt in system. b. Drain, flush and
refill with clean
oil.
2. Slow or hard steering a. Dirt in system a. Drain, flush and

refill with clean oil
b. Wear on Orbitrol valve b. Replace.

2-5-16 sleeve and spool.
c. Wear on Orbit gear. c. Replace.

1. Steering wheel does d. Oil level low . d. Fill to proper level

not centre. No response
when steering wheel is e. Defective pump e. Check and
turned(cont’d) . correct.
f. Defective cylinders. f. Check and

correct.
g. Trouble in lines g. Check and

or filter. correct.
3. Wrong response to a. Lines connected to a. Connect lines

steering wheel. wrong ports. correctly.
4. Continuous steering a. Dirty fluid. a. Replace

wheel rotation.
b. Broken centring b.Replace

springs.
c. Input linkage is c. Realign.
d.
3G
binding.
Burr on sleeve
or spool.
d. Repair.
5. No response a. Sleeve and spool a. Repair or

locked. replace
60
defective parts.
b. Pump failure. b. Check and

correct.
c. Hose or filter c. Check and

clogged. correct.
86
d. Relief valve stuck. d. Drain, flush

and refill.
e. Air in system. e. Bleed system.
WARNING 2. Tag and remove all hydraulic lines that connect to

the orbitrol steering valve.
ENSURE THE ENGINE IS SHUT DOWN
BEFORE PROCEEDING. 3. Remove the bolts, nuts and spring washers secur-
ing the steering column to the column support.
REMOVAL
4. Remove the column support.
1. Loosen and remove the nut that secures the steer-
ing wheel to the steering column. Remove the steering 5. Remove the bolts and washers securing the col-
wheel. umn to the valve.
2-5-17
6. Remove orbitrol steering valve to a clean work WARNING
area.
THE HYDRAULIC LINES MUST BE
INSTALLATION PROPERLY CONNECTED AS TAGGED
DURING REMOVAL.
1. Secure orbitrol steering valve and steering column 3. Install the hydraulic lines to the orbitrol valve as
in position using the bolts and spring washers. tagged during removal.
2. Secure the steering column onto the support with 4. Install the steering wheel to the steering column us-
bolts, washers and nuts. ing the nut.
6 8
3G 7
12
14
60
15
13 1. Adjustable Steering Column

2. Steering Column
3. Steering Valve
5 1 9 4. Support
86
5. Handwheel
17 6. Steering Wheel
7. Turning handle
8. Cap
2 9. Carriage Bolt
10. Bolt
11. Washer Spring
10 12. Screw
13. Nut
3 14. Washer
11 15. Washer Spring
Orbitrol Steering Valve Installation
2-5-18
STEERING PUMP
DESCRIPTION
The steering pump is mounted on and driven by the en- more detailed information, refer to Section 8 - HYDRAU-
gine. The pump is a gear type pump and provides a pri- LIC SYSTEM.
ority flow of approximately 2 x 22.4 gpm (60 lpm). For
3G
60
86
2-5-19
EMERGENCY STEERING PUMP
DESCRIPTION
The emergency steering pump is used to provide an al- pendent on ground speed, 38 gpm (144 lpm) @ 70 kph.
ternate source of hydraulic flow in the event of steering For more detailed information refer to section 8 - HY-
pump failure. It is mounted on and driven by the trans- DRAULIC SYSTEM.
mission. The pump is a gear-type pump, supply is de-
3G
60
86
2-5-20
STEER CYLINDERS
DESCRIPTION
Eight steer cylinders are utilized on the crane, two on end of one cylinder is connected to the barrel end of the
each steer axle. One steer cylinder has a 2.76 inch other thus providing dual cylinder action for steering the
(70mm) cylinder bore with an extended length of 24.4 axle in either direction.
inches (620 mm) and a retracted length of 16.5 inches
(420mm). The steer cylinders weigh approximately 20.00 pounds
(10.0 kg).
The cylinders are connected hydraulically so the rod Maximum working pressure 2616 psi (180 bar).
MAINTENANCE
NOTE
REMOVAL
3G
2. Remove the cotter pins and castle nuts securing
the steer cylinders to the axles. Remove the cylinders.
1. Tag and disconnect the hydraulic hoses from the INSTALLATION

steer cylinder ports. Cap or plug all openings.
1. Position the steer cylinder onto the axle and secure
60
in place with the cotter pins and castle nuts.
NOTE
2. Connect the hydraulic hoses to the cylinders as
Wheel and axle alignment will be easier
if the tie rod ends are not unscrewed 3. Function the cylinders and check for proper opera-
86
from the steer cylinder. tion and any leakage,
2-5-21
ORBITROL STEERING MOTOR
DESCRIPTION
The orbitrol steering motor is mounted on the carrier mechanical connection between the motor drive to the
bevel gearbox. It is operated from the turntable cab or- gearbox output shaft. This provides dual emergency
bitrol steering valve. An air operated clutch controls the steering from the turntable cab.
THEORY OF OPERATION
When the turntable cab steering wheel is turned in either motor which drives the steering gearbox.
direction oil flows from the orbitrol valve to the orbitrol
MAINTENANCE
NOTE
REMOVAL
3G
INSTALLATION
1. Enter motor drive shaft into gearbox driving bush.

1. Remove two bolts securing the motor to bevel
gearbox. 2. Locate motor flange holes with holes in gearbox
60
casing and install two M8 x 20 long screws.
2. Carefully withdraw motor. 3. Torque the screws to 18 lbs ft (2.5 kgm).

86
2-5-22
FLOW INDICATOR
DESCRIPTION
The flow indicator consists of a spring loaded ball piston The flow indicator is fitted, in the Engine driven pump cir-
and a set of electrical contacts. The switch indicates to cuit, and is mounted on the steering valve plate.
the operator a flow of oil in the steering system by means
of a warning light in the operators cab.
MAINTENANCE
NOTE

3G
60
86
2-5-23
FLOW CONTROL VALVE
DESCRIPTION
The flow control valves are mounted on the steering arrows on the valve body.
valve plate assembly. They are fitted in the steering cir-
cuit between the engine driven pump and the steering A further flow control valve is fitted in the emergency
wormbox. Flow rate is preset and direction indicator by steer circuit.
MAINTENANCE
NOTE

applicable SM package.
3G
60
86
2-5-24
HYDRAULIC RESERVOIR STEERING
DESCRIPTION
The hydraulic reservoir, attached to the right side of the allow for filling the reservoir with clean hydraulic oil and
carrier, has a total capacity of 43.3 U.S. gallons (164 also allows air to enter or exhaust from the reservoir. A
litres). The all steel reservoir has an internally marked large access cover on top of the reservoir, provides ac-
baffle, that helps cool and prevent oil from foaming. cess for cleaning.
A sight gauge is provided on the side of the reservoir to

indicate the oil level. A fill cap, that also incorporates a Three internal filters are installed in the reservoir, to en-
breather (vent) is located on the top of the reservoir, to sure no contaminents enter the system.
MAINTENANCE
REMOVAL AND DISASSEMBLY 8. Remove bolts (6) and spring washers (7) and re-
move mounting plate assemblies (8, 25).
WARNING
9. Remove oil filters (5).
ENSURE THE CARRIER ENGINE IS
SHUTDOWN BEFORE PROCEEDING.
3G 10. Remove the drain bolts (18) drain plugs (17) and
seals (15,16).
NOTE 11. Remove seals (19), adaptors (20) and elbows (23).
The capacity of the hydraulic tank is CLEANING AND INSPECTION

60
43.3 US Gallons (164 Litres).
1. It is recommended that all gaskets, seals and O-
1. Completely drain the oil from the hydraulic steering rings be replaced if a new tank is to be installed.
tank into a container of suitable capacity.
2. Inspect the reservoir for any internal or external
damage.
86
2. Tag and remove all hydraulic lines from the tank.

Cap all hoses and plug all ports to prevent contamina- 3. If the reservoir is to be reused, flush with clean sol-
tion. vent, and dry filtered compressed air.
3. Remove nuts, bolts and washers securing the tank 4. If during inspection the access cover plate gasket
(1 ,2 and 3). (13) was found to be damaged, replace gasket (13).
4. Using a suitable lifting device lift the tank clear of 5. After flushing the tank, plug all openings until the
the carrier. tank is to be installed.
5. Locate the hydraulic tank in a clean area for disas- 6. Clean all plugs with clean solvent and place them in
sembly. a plastic bag until they are needed for assembly.
ASSEMBLY AND INSTALLATION

6. Remove the sight gauge (14) from the face of the
tank. 1. Install adaptors (20) and elbows (23) with new
seals (19).
7. Remove spring washers and nuts (10, 11) and re-
move the access cover (26) with its gasket (13). 2. Install new filters (5).
2-5-25
3. Install mounting plate assemblies (8, 25). Secure in 8. Using a suitable lifting device lift the hydraulic tank
position using bolts (6) and spring washers (7). on to its mounting and the decking, and secure in posi-
tion using screws, spring washers and nuts (1, 2, 3)
4. Install drain bolts (18) drain plugs (17) and new
seals (15,16).
9. Install all hydraulic lines as tagged prior to removal.
5. Install sight gauge (14).
6. Replace if necessary gasket (13) and install it and 10. Fill the reservoir with clean, filtered hydraulic oil to
access cover (26) with spring washers and screws (10, the top of the sight gauge.
11).
7. Install adaptors (20) and elbows (23) with new 11. Start the engine and operate all functions. Recheck
seals (19). the level of the hydraulic oil and refill as necessary.
3G
60
86
2-5-26
11 24
10
12
26
13
14
19
20
23
4
3G 1
2
25 3
8
60
5
16
6 9 22 21 17
86
7 25 15
18
1. Screw 10. Washer Spring 19. Seal

2. Washer Spring 11. Nut 20. Adaptor
3. Nut 12. Breather Filler Cap 21. Seal
4. Tank 13. Gasket 22. Adaptor
5. Oil Filter 14. Gauge Level 23. Elbow
6. Screw 15. Seal 24. Adaptor
7. Washer Spring 16. Seal 25. Mounting Plate Assembly
8. Mounting Plate Assembly 17. Plug Drain 26. Access Cover
9. Gasket 18. Bolt Drain
Hydraulic Reservoir Steering
2-5-27
86
60
3G
SECTION 6
SUSPENSION SYSTEM
TABLE OF CONTENTS
Page
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-3
SUSPENSION CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
Bleeding the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-4
3G
Setting the Ride Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Setting and Checking Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3RD Axle Five Axle Machines Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the 3RD Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6-4
2-6-5
2-6-5
2-6-5
Pressure Reducing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
Counterbalance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-6
60
LIST OF FIGURES
Proximity Sensors Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-5

86
Suspension Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-7

Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-8
Suspension System - 5 Axle Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6-9
2-6-1, 2-6-2
86
60
3G
SUSPENSION
DESCRIPTION
The suspension system is hydrogas with hydraulic lock- stopped making the axles rigid. This is required for ‘on
out and an automatic levelling system, operated from rubber’ and ‘outrigger’ duties. When returning to road
the carrier cab. travel, simple cab mounted switches will return the oil
flow and if required automatically level the unit.
Each crane axle is supported by two hydraulic oil cylin-
ders. When used for road travel oil moves freely from the
cylinders into carrier mounted accumulators, these ac- A lock valve is mounted on the side of the cylinders.
cumulators contain nitrogen gas which cushion the oil These lock valves are used to lock the suspension and
movement giving the axle its suspension and its name are operated via a switch in the carrier cab. A warning
Hydrogas. This oil flow movement can be automatically light indicates when the locks are engaged.
THEORY OF OPERATION
Oil from pump through filter (10 micron) to air pilot con- The module control valves will be switched off automati-
trol valve returns to tank when valve is in neutral.3G cally by the proximity switches (located at each corner of
the machine) when the correct suspension height is
When auto level is selected oil from port ‘B’ of air pilot achieved.
control valve flows to port ‘B’ of the four solenoid valve
modules. The valves will also have been energised into Axle Raise (On Outriggers Only)
the open position. Oil can now flow to the eight lock
valves (pneumatic piloted) which are also in the open Air pilot control valve energised to give oil flow from port
60
position. Pneumatic blocking valves will also be in the ‘A’ to solenoid valve which is also energised to the open
open position. position from this valve oil will flow to the four check
valves through the check valves direct to the annular
Oil will now pressurise the piston side of the suspension side of suspension cylinders.
cylinders lifting the machine, oil dispelled from the rod
side of suspension cylinders is connected to the oil sup- Displaced oil from the piston side exits through the air
86
ply to the piston side via the four blocking valves. This piloted lock valves, through the valve modules ‘A’ to ‘C;
controls the speed of rise of the suspension. and direct to tank.
2-6-3
SUSPENSION CYLINDERS
DESCRIPTION
Each axle is suspended by a cylinder at either end. The length of 19.6 inches (498mm). Each cylinder is also fit-
cylinder bore is 3.9 inches (100mm) with a retracted ted with an integral lock valve for suspension lockout.
MAINTENANCE
NOTE

REMOVAL 2. Partially close the T.U.V. relief valves to generate
approx. 20 bar (290 psi). With an assistant holding the
1. Lower the crane onto its bump stops. auto ride height selector bleed each of the front and rear
suspension cylinder full sides using the bleed nipple fit-
2. Open T.U.V. relief valves, allowing the system to 3G ted, until clear oil runs freely.
discharge.
3. Using the same procedure as above bleed as
3. Disconnect all hydraulic and air connections tag- much air as possible from the annular sides of the cylin-
ging them as you do so. ders using the annular bleed nipple.
4. Remove bolts, washers, nuts and pin securing the 4. Close the T.U.V. relief valves fully to the seated lock
nut position. Raise the machine to the maximum height
60
cylinder to the axle and carrier frame.
using the individual height control switches, and again
5. Lift the cylinder clear to a clean work area. bleed the annular sides of all suspension cylinders until
clear oil runs freely.
INSTALLATION
NOTE
86
1. Relocate the cylinder in its original position and se-

Exercise extreme caution when carry-
cure to to the carrier frame and the axles using the bolts,
ing out this operation. The machine will
washers, nuts and pins. Torque the nuts to 317 lb/ft.
tend to lower slightly on the opposite
side as oil is released.
2. Reconnect all hydraulic and air lines as tagged
prior to removal. 5. Return the machine to normal ride height using the
auto-level facility, engage the axle locks and block the
3. Bleed the system . (Refer to the Section ‘Bleeding
machine on outriggers. The axles should remain locked
the System’)
in the ride height position and lift the wheels clear of the
ground. If there is any significant drop on any of the ax-
Bleeding the System
les, carry out the bleeding procedure again until all air is
expelled.
1. With the machine on rubber and the suspension at
its lowest position (resting on the axle stops) with the Setting the Ride Height
T.U.V. relief valves fully open, engage the PTO and start
the engine. Select auto ride height and hold for 2-3 min- The ride height is controlled by proximity switches trig-
utes allowing oil to circulate through the T.U.V. relief gered by a height control rod on the front and rear sus-
valves and flush part of the system. pension. The height control rod is adjustable and should
2-6-4
be set on assembly no further adjustment being nor- imity switches. Move the control rod into the point where
mally required. the upper switch which is normally open just closes and
mark the position of the rod.
1. Proximity Switch Setting
Now move the rod out to the point where the lower
Remove the bottom nut from the height control rod and switch, which is normally closed, just closes and again
push the rod fully in. Screw the proximity switches in until mark the position of the rod.
they just touch the control rod and then back off one
complete turn. This will give the correct operating clear-
ance of 1.0mm. The distance between the two marks should be approx.
12mm. The rod should then be set using the two nuts to
2. With the machine on firm level ground raise the ma- mid way between the two marks.
chine high enough to insert 65mm front and 57mm rear
suspension setting blocks between the front and rear After having set all four corners raise the machine and
axle stops. remove the setting blocks. Readjust the ride height us-
ing the autoride height facility and check that the front
Lower the machine onto the setting blocks using proxim- and rear bump clearances are within ± 6mm of the set-
ity switch testers connected to the upper and lower prox- ting block heights.
Proximity Sensors
3G
60
Height Control Rod

86
Proximity Sensors Location
Valve Setting And Checking Procedure 2. With the T.U.V. relief valves fully open select 3rd
axle lower for 2-3 minutes allowing oil to circulate
3rd Axle Five Axle Machines Only through the valves and flush the system.
3. Partially close the T.U.V. relief valves to generate

The third axle can be independantly raised and lowered
approx 20 bar (290 psi) and bleed the full bore side of the
from the carrier cab. To ensure correct operation the fol-
suspension cylinders until clear oil runs freely.
lowing pressure must be checked and set where neces-
sary.
4. Close the T.U.V. bar relief valves to their set locknut
position. (preset to 211 bar (3080 psi).
Bleeding The 3rd Axle
5. Block the machine on outriggers and lower the 3rd
1. Raise the 3rd axle to its highest position. axle to its lowest position.
2-6-5
6. Open the annular bleed nipples and select 3rd axle NOTE
raise until clear oil runs from the bleed nipples, (Note - do
not allow the axle to raise). Axle loading should be finally checked
and trimmed if necessary using a
Pressure Reducing Valve weighbridge.
1. Fit a 280 bar (4000 psi) pressure gauge to the test Pressure Switches
point located between the pressure reducing valve and
third axle accumulator. Two pressure switches are fitted adjacent to their re-
spective pressure reducing valves, located in the centre
2. On the control panel in the cab select the heavy ax-
of rotation. The switch on the RHS of the carrier oper-
le configuration.
ates when the heavy travel mode is selected. This valve
3. With the axle locks engaged and the carrier engine should be set at 82 bar (1190 psi).
running with the P.T.O. engaged select 3rd axle lower
The valve on the LHS operates when light travel mode is
and check the pressure. The correct pressure for 15.3
selected. This valve should be set at 67 bar (971 psi).
tonne axle load is 82 bar (1190 psi).
4. If adjustment is necessary,the pressure reducing These switches are used to illuminate the indicator light
valve is located below the centre of rotation on the RHS on the third axle switch to show that the axle takes the
of the carrier. To adjust slacken the lock nut on the pres- required load.
sure reducing valve and turn the adjusting screw clock-
wise to increase pressure, anti-clockwise to decrease
3G
pressure. Finally, tighten the locknut, raise the axle and
re-lower to check the pressure is correct.
Counterbalance Valve
1. The counterbalance valve is pre-set to 145 bar

(2102 psi) and should not require further adjustment.
NOTE
To check its operation fit a 280 bar (4000 psi) pressure
60
Axle loading should be finally checked gauge to test point as previous.
and trimmed if necessary using a
weighbridge. 2. Observe the pressure as the third axle is lowered,
due to the area ratio of the cylinder and the weight of the
5. Still with axles locked select light axle configura- axle this should be in the region of 46 - 55 bar (667 - 798
tion, raise the lower centre axle to re-set pressure in sys- psi) depending on friction before the axle touches the
86
tem. Check pressure, the correct pressure for a 12 ground.

tonne axle load is 67 bar (971.5 psi).
3. If the pressure to lower the axle is too high a false
6. If adjustment is necessary, the pressure reducing indication of the axle set light will be given and the pres-
valve is located below the centre of rotation on the LHS sure on the counterbalance valve should be reduced.
of the carrier. To adjust slacken the locknut on the pres-
sure reducing valve and turn the adjusting screw clock- 4. If the wheels drop uncontrolled the pressure is too
wise to increase pressure, anti-clockwise to decrease low or air is present in the cylinders. Bleed the annular
pressure. Finally tighten the locknut, raise the axle and side of the cylinders or increase the counterbalance
re-lower to check pressure is correct. valve pressure.
2-6-6
66
76
68
75
69
70
3G 67
71
60
72
73
74
86
66. 3rd Axle Raise / Lower Switch 72. Rear Left Height Switch
67. Suspension Lock Switch 73. Rear Right Height Switch
68. Power Control Switch 74. Ride Height Set Light
69. Auto Ride Height Switch 75. 3rd Axle Load Condition Switch
70. Front Left Height Switch 76. Axles Raise Switch
71. Front Right Height Switch
Suspension Control Panel
2-6-7
3G
60
86
Suspension System
2-6-8
Suspension Cylinder
Accumulator
4 litre
Relief Valve Pressure Switch

Test Point
211 bar 82 bar
Pressure
Switch 67 bar
Solenoid Valve
Check Valve
3G
Pressure Reducing
60
Valve 82 bar
Pressure Reducing
Valve 67 bar
86
Counterbalance
Valve 145 bar
Solenoid Valve
From Air Pilot Solenoid
Operated Control Valve
Solenoid Valve
with special sublate
Tank Return
Suspension System - 5 Axle Option
2-6-9
86
60
3G
SECTION 7
AIR SYSTEM
TABLE OF CONTENTS
Page
AIR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-5
Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-6
Brake Functional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-6
Checking The Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-6
Air System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-7
RELAY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-10
3G
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-10
FOOT THROTTLE VALVE CARRIER ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-11
DOUBLE CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Operating and Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-12
QUICK RELEASE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-13
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-13
SUPPLY DUMP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-14
TYRE INFLATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
2-7-1
Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-15
AIR DRYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-16
Preventive Maintenance and Checking Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-16
GOVERNOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-18
DIFFERENTIAL PROTECTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-20
3G
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7-20
2-7-20
2-7-20
2-7-20
RESERVOIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-21
LOW PRESSURE INDICATING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-22
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-22
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-22
86
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-22
Operating and Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-22
SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-23
MULTI CIRCUIT PROTECTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-24
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-24
AIR CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-25
2-7-2
Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-25
DUAL BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Operating Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-26
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-27
PARK BRAKE CONTROL VALVE TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-28
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-28
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-28
Operating and Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-28
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3G 2-7-28
HAND BRAKE CONTROL VALVE CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-29
NON RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-29
60
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-30
86
LIST OF FIGURES
Title Page
Air Component Location (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-8
Air Component Location (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7-9
2-7-3
Page
2-7-6
WARNING
BEFORE REMOVING OR DISCON-

NECTING ANY COMPONENT OR LINE
OF THE AIR SYSTEM, ENSURE THAT
ALL AIR PRESSURE IN BOTH SYS-
TEMS HAS BEEN DEPLETED.
2-7-6
WARNING
BEFORE ATTEMPTING TO REMOVE

ANY COMPONENTS FOR LEAK RE-
PAIR ENSURE THAT ALL AIR PRES-
SURE IN BOTH AIR SYSTEMS HAS
3G
BEEN DEPLETED.
60
86
2-7-4
AIR SYSTEM
DESCRIPTION
The crane is fitted with a dual circuit brake system using actuator brakes is also fitted with a differential protection
compressed air as the operating mechanism. All axles valve to prevent compounding of the brakes.
are fitted with wedge expanding drum brakes, those on
axles 1, 2 and 3 have two actuators per hub (Duplex) On cranes with drive from the turntable cab, a treadle
whilst those on axles 4 and 5 are fitted with one actuator brake a parking brake and throttle control for the carrier
per hub (Simplex). The service brake utilises all the ac- engine are fitted to provide the same brake controls as
tuators and is split into two separate circuits. The pri- the carrier cab. This is for off highway use only.
mary circuit operates on the leading actuator on axles
No. 1, 2 and 3 and both actuators on axle No. 4. The sec- The schematic diagram of the air braking system identi-
ondary circuit operates on the trailing actuator on axles fies the components. Complete air schematic diagrams
No. 1, 2 and 3 and both actuators on axle No. 5 in the are supplied with this manual, and should be referred to
event of a total on partial failure of one circuit the other when undertaking any servicing.
circuit will provide braking in excess of the minimum
standard required. Air Piping Main Schematic PN 6294992235 (4 Axle CT)
3G 6294992213 (5 Axle CT)
The parking brake operates on the spring brake actua- 6294992214 (5 Axle AT)
tors on axles No. 3, 4 and 5. This is controlled by a hand Air Piping Aux Schematic PN 6294992221 (10x6 CT)
operated valve mounted in the cab adjacent to the 6294992222 (10x8 CT)
driver. This valve releases air from the spring hold off 6294992223 (10x6 AT)
chamber, allowing the stored energy in the spring to ap- 6294992224 (10x8 AT)
ply the brakes. 6294992225 (8x6 USA)
60
6294992226 (8x8 CT)
Compressed air is supplied from an engine driven com-
pressor and fed through an air drier to reduce moisture, Air pressure switches operate a warning light in the cab
the air then enters a multi circuit protection valve (which when the air pressure in the reservoirs is low.
in the event of failure in one circuit will not allow the air
pressure in the other circuit to drop below a set level). Pressure gauges in the cab monitor the pressure in the
86
From here the air is distributed to the four pneumatic cir- reservoirs.
cuits on the crane via Primary Braking, Secondary Brak-
ing, Parking Brake and Auxiliary systems. Air pressure switches in the signal lines from the brake
foot valve operate the brake stop lights.
The primary and secondary reservoirs are connected
separately to the treadle valves in the driving compart- A trailer coupling allows the air system to be charged
ment. Application of the brakes via the treadle valve from a towing vehicle in the event of a breakdown.
passes air along the signal pipes to the relevant relay
valves. Air from the reservoirs is passed through the re- A rachet spanner is provided, stowed in the cab in close
lay valves at the same pressure as the signal from the proximity to the driver, for the purpose of manually re-
treadle valve. That part of the circuit incorporating spring leasing the spring brakes in an emergency.
MAINTENANCE
All connecting lines of the air system are either tubing or

flexible hoses. All tubing used in the system, except that
from the compressor to the air dryer, is nylon.
2-7-5
CAUTION b) Wheels on axles 2 and 5 are locked.
DO NOT ALLOW THE NYLON TUBING c) Wheels on axles 1, 3 and 4 are unlocked.
TO BE EXPOSED TO FLAMES OR EX-
CESSIVE HEAT. IF ANY WHITE SHOWS Close front reservoir drain cock and refill the system.
THROUGH THE OUTSIDE COVERING, 2. Switch off the engine and completely drain the rear
THAT SECTION OF THE LINE SHOULD air reservoirs for axles 2 and 5. Position the handbrakes
BE REPLACED, AND ACTION TAKEN to off position. Operate the footbrakes from both carrier
TO ELIMINATE THE CAUSE OF THE and turntable cabs and verify that in each case:
CHAFING OR OTHER DAMAGE.
a) Low air pressure warning light is illuminated.
WARNING
b) Wheels on axles 1, 3 and 4 are locked.
BEFORE REMOVING OR DISCON-
NECTING ANY COMPONENT OR LINE c) Wheels on axles 2 and 5 are unlocked.
OF THE AIR SYSTEM, ENSURE THAT
Close rear reservoir drain cock and refill the system.
ALL AIR PRESSURE IN BOTH SYS-
TEMS HAS BEEN DEPLETED. 3. Switch off the engine and position handbrakes to
off position. Verify all wheels are unlocked.
LEAK DETECTION
3G
If a leak is suspected in the air system, shut down the en-
gine and record the pressure readings by fitting a gauge
at the test points. A loss of 6 psi (41.37 kPa/.413 bar) or
Completely exhaust the parking (36 litre) reservoir and
verify that all wheels are now locked.
Close parking reservoir drain cock and refill system.

less within a 30 minute time interval is usually consid-
ered acceptable. CHECKING THE BRAKE SYSTEM
60
If a leak is detected and is not obvious or cannot be To make a full check of the air brake system first place
heard, the leaking valve, fitting, or reservoir may be iso- suitable chocks against each wheel to prevent the crane
lated by wetting the suspected area with a concentrated rolling away. Exhaust all reservoirs, check all control
liquid soap solution and observing for bubbles. valves are off (on position in the case of the spring brake
type valves) and reservoir cocks are shut. Turn on igni-
WARNING tion switch. The low pressure warning light should oper-
86
ate immediately. Fit pressure gauges at the test points.

BEFORE ATTEMPTING TO REMOVE Start the engine and run up to charge the air reservoirs,
ANY COMPONENTS FOR LEAK RE- steady build up should be recorded on each pressure
PAIR ENSURE THAT ALL AIR PRES- gauge.
SURE IN BOTH AIR SYSTEMS HAS
BEEN DEPLETED. The low pressure warning light should extinguish when
the pressure reaches approximately 68 psi. With the
BRAKE FUNCTIONAL CHECKS compressor running at maximum speed air pressure
should build up in the system from zero to the normal
(FROM FULL SYSTEM WITH CRANE UP ON OUT- setting of low pressure in not more than 3 minutes.
RIGGERS)
Build up pressure to the governor valve cut-out pres-
1. Switch off the engine and completely drain the air sure, 8.6 bar (130 psi) and stop engine. The needles of
reservoir for axles 1, 3 and 4. Position the handbrakes to the pressure gauges should remain steady. Any drop of
off position. Operate the footbrake from both carrier and pressure should not be greater than 0.07 bar (1 psi) per
turntable cabs, and verify that in each case: minute. There should be no leakage from pipework or fit-
tings. Apply the foot brake to the full application with the
a) Low air pressure warning light is illuminated. crane stationary. Check that a drop in reservoir pressure
2-7-6
occured on application and that after equalization does gine. Move the hand control valve slowly to ”off” position
not exceed 0.14 bar (2 psi) per minute. Release the foot this will release the parking brakes. The air pressure
brake and check that the existing reservoir pressure is should fall as the handle is moved to the off and then re-
maintained. main steady.
To check the spring brake parking system build up the Check stop lights work both in service and secondary
reservoir pressure to the cut out pressure and stop, en- brake application checks.
AIR SYSTEM COMPONENTS
ITEM
DESCRIPTION
NUMBER
1. Footbrake Valve
2. Throttle Valve
3. Air Coupling Valve
4.
5.
6.
Handbrake Control Valve
Compressor - Air Fittings
Relay Valve - Service 1
3G
7. Tyre Inflator Valve
6294992235 (4 Axle CT)
8. Supply Dump Valve Air Piping Main
6294992213 (5 Axle CT)
9. Air Dryer Schematic
60
6294992214 (5 Axle AT)
10. Reservoir - Service 1
11. Reservoir - Service 2
12. Reservoir - Auxiliary 6294992221 (10x6 CT)
6294992222 (10x8 CT)
13. Quick Release Valve - Axle 3
Air Piping Aux 6294992223 (10x6 AT)
86
14. Relay Valve - Parking Circuit

Schematic 6294992224 (10x8 AT)
15. Relay Valve - Service 1A 6294992225 (8x6 USA)
16. Relay Valve - Service 1B 6294992226 (8x8 CT)
18. Relay Valve - Service 2A
19. Differential Protection Valve - Circuit 1
20. Reservoir - Parking Circuit
21. Relay Valve - Service 2B
23. Differential Protection Valve - Circuit 2
24. Reservoir - Service 1A
25. Reservoir - Service 2A
2-7-7
3G
60
86
Air Component Location (Sheet 1 of 2)
2-7-8
3G
60
86
Air Component Location (Sheet 2 of 2)
2-7-9
RELAY VALVE
DESCRIPTION
A relay valve is used in a compressed air system, where and immediately. One of its uses is to speed the applica-
it supplies the air to operate an item of equipment when tion and release of the rear brakes on a long wheelbase
signalled by a control valve, to which it reacts precisely vehicle.
MAINTENANCE
NOTE

REMOVAL 6. Remove valve.
1. Chock the wheels.

INSTALLATION
2. Deplete the pressure in the air system. 3G
3. Tag and label all hoses and connectors before dis-
connecting them from the valve.
1. Position valve on mounting and secure with the
hardware retained on removal.
4. Disconnect hoses and remove connectors from 2. Connect hoses and connectors as tagged prior to
valve. removal.
60
5. Remove any hardware fastening the valve to its
mounting and retain them for installation. 3. Check for any leaks.
86
2-7-10
FOOT THROTTLE VALVE CARRIER ENGINE
DESCRIPTION
The foot throttle valve is mounted to the carrier cab floor. foot pedal.
The valve is actuated by pressure being applied to the
MAINTENANCE
REMOVAL INSTALLATION
1. Deplete the pressure in the air system. 1. Re-position valve and pedal assembly in cab floor.
2. Disconnect the inlet pipe from the port in the inlet

2. Secure the assembly in position using the four
housing (top port).
bolts.
3. Disconnect the supply pipe from the centre port.
3. Re-connect supply pipe to the centre port.
4. Undo the four bolts holding the plate to the cab
floor. 3G
5. Lift out the foot throttle valve complete with pedal
assembly.
4. Re-connect inlet pipe to the top port in the inlet
housing.
5. Check for leaks.

60
86
2-7-11
DOUBLE CHECK VALVE
DESCRIPTION
When two separate means of charging any pipe line are die-cast aluminium body, and a rubber shuttle with an
available a double check valve is fitted to isolate which- aluminium sleeve.
ever means is not in use. The valve simply consists of a
MAINTENANCE
NOTE

REMOVAL 2. Apply and release air to one inlet port and note the
gauge registers application and release.
3. Repeat by applying and releasing air to the other
2. Deplete the pressure in both air systems.
3. Disconnect and tag the air lines from the double

check valve.
3G inlet port.
4. The leakage check should be performed at the inlet

ports of the valve in the following madder.
4. Remove the bolt and washer and remove the a. Disconnect the line from the inlet port.
valve.
60
b. Apply air to the other inlet port and coat the oppo-
site inlet port with a soap solution. Permissible leakage
INSTALLATION
is a one-inch bubble in five seconds.
1. Install the fittings and air lines to the double check c. Repeat step b applying air to the other inlet port
valve as tagged during removal. while checking the opposite inlet port for leakage.
86
If the double check valve does not function as described

2. Reposition the valve and secure it in place with the
or if a leakage is excessive, it is recommended that the
bolt and washer.
valve be replaced.
Operating and Leakage Checks Preventive Maintenance
If the double check valve is to be bench tested or tested Every 3600 operating hours, 100,000 miles (160,900
on the vehicle, two separately controlled air supplies km), or yearly.
must be connected to the inlet ports.
1. Remove, disassemble, clean, and inspect the
1. Install an accurate test gauge in the outlet port or in valve. Replace the valve if any parts show signs of wear
a line from the outlet port. or deterioration.
2-7-12
QUICK RELEASE VALVE
DESCRIPTION
The quick release valve is fitted into the air brake system close to the brake chambers the brakes are set more
to release the air out of the brake chambers after brake rapidly than if the air had to be piped and exhausted from
actuation. Because the quick release valve is located the brake control valve in the carrier cab.
MAINTENANCE
NOTE

Every 3 months, or 10,000 miles, check quick release REMOVAL
valves as follows:
1. Apply vehicle brakes and ensure that when they

are released the air pressure is quickly exhausted
through the valve exhaust ports.
3G 2.
3.
Deplete the pressure in the air system.
Tag all hoses.
4. Disconnect hoses from valve.

2. With brakes applied, use soapy water to detect any
5. Note which way round the valve is fitted and re-
air leaks from the valve body or exhaust port. Any leak-
60
move mounting bolts to free the unit.
age at the exhaust port must not exceed a 25mm dia. (1
in) soap bubble in 1 second. No other leakage is al- INSTALLATION
lowed.
1. Position valve on mounting and fasten in position
using mounting bolts.
86
3. if any Quick Release Valve is found to be faulty in

operation, or is leaking, it is to be removed and service 2. Re-connect hoses as tagged during removal.
by renewing all the parts which are included in the serv-
ice k. 3. Check for leaks as specified in the service check.
2-7-13
SUPPLY DUMP VALVE
DESCRIPTION
The tyre inflator is fitted to the carrier to enable it to be an air line and a tyre pressure gauge. The use of the sup-
independent of other sources of compressed air when ply dump valve enables an air pressure greater than the
the tyres require inflating. The installation consists of a carrier system to be obtained.
supply dump valve, a safety valve, an operating valve,
MAINTENANCE
The supply dump valve is virtually maintenance free, 4. Disconnect hoses from valve.
however, it should be checked during normal servicing
for any leaks or chaffed air lines. 5. Remove mounting bolts to free the valve.
INSTALLATION
REMOVAL
1. Position valve on mounting and fasten in position
using mounting bolts.
2.
3.
Deplete the pressure in the air system.
Tag all hoses.

3G 2.
3.
Re-connect hoses as tagged during removal
Check for leaks.

60
86
2-7-14
TYRE INFLATOR
DESCRIPTION
The tyre inflator is incorporated in the air brake system mounted on the carrier frame in a convenient position
to provide a ready and simple method of inflating and if where it can be readily operated and observed during
necessary, deflating the vehicle tyres. The tyre inflator is operation, preferably equidistant from all wheels.
MAINTENANCE
Periodically check that the tyre inflator mounting and air REMOVAL
line connections are secure. Examine the pressure
regulator for damage. 1. Chock the wheels.
No period can be given for overhaul, this depends on the 2. Deplete pressure in the air system.
amount of usage of the valve and also whether the valve
3. Tag all hoses.
is defective or the rubber components are deteriorating.
At the overhaul period all parts contained in the repair kit 4. Disconnect hoses from valve.
must be replaced and the remaining parts checked for
wear.
Service Check
3G 5. Remove nuts, washers and any other hardware
mounting the valve to the bracket including any spacers
used.
The air pressure gauge should be tested after a period in 6. Remove the valve.
service against a master gauge, which may be simply in-
60
serted in the hose connection. Leakage tests can be INSTALLATION
carried out with the air system fully charged by applying
1. Position valve on mounting and secure using nuts,
soap solution to inlet connection and associated air
washers and any hardware required, at the same time
pipework including the gauge. Remove the valve cap
replacing any spacers removed on removal.
and coat the hose connector outlet with soap solution.
86
No leakage is permissible. Press the inflate button and 2. Re-connect hoses as tagged.
apply soap solution to the exhaust check valve, which
tests the condition of the deflate valve. 3. Check for any leaks.
2-7-15
AIR DRYER
DESCRIPTION
The air dryer is used to remove water, oil, carbon and dirt air reservoirs.
from compressed air, before it enters the braking system
MAINTENANCE
NOTE

REMOVAL 4. Connect the air lines to the dryer as tagged during
removal.
5. Test the air dryer as outlined under Preventive
2.
3.
Deplete the pressure in both air systems. 3G
Ensure the ignition switch is in the Off position.
Maintenance and Checking Serviceability.
Preventive Maintenance and Checking Service-

ability
4. Tag and disconnect the air lines from the dryer.
Every 900 Operating Hours/23,000 Miles (37,000 km/
Three Months)
5. Disconnect the electrical lead from the bottom of
60
the dryer. 1. Check for moisture in the air system by opening the
reservoir’s drain cock or automatic drain valve. In areas
6. Remove the four bolts, lockwashers, and nuts at-
where more than approximately a 30 degree range of
taching the dryer to the carrier frame and remove the
temperature is common, small amounts of water can ac-
dryer.
cumulate in the air system due to condensation. The
86
presence of small amounts of water due to condensa-

7. If the dryer is to be replaced with a new one, re-
tion is normal and should not be considered as an indi-
move the fittings from the dryer ports.
cation that the dryer is not performing properly.
NOTE The desiccant cartridge should be replaced or rebuilt

when it has been determined the desiccant is contami-
The dryer does not have to be removed nated and does not have adequate water absorption ca-
to disassemble it. pacity. However, the following checks should be made
before replacing the desiccant cartridge to ensure the
INSTALLATION water accumulation is not related to the items listed be-
low.
1. Install the fittings in the dryer ports.
a. An outside air source has been used to charge the
2. Position the air dryer on the mounting bracket and system. This air did not pass through the drying bed.
secure it with the four bolts, lockwashers, and nuts.
b. Air usage is exceptionally high and not normal for a
3. Connect the electrical lead to the connection on the highway vehicle. This may be due to accessory air de-
bottom of the dryer. mands or some unusual air requirement that does not
2-7-16
allow the compressor to load and unload (compressing 5. Check for excessive leakage at the purge valve by
and non-compressing cycle) in a normal fashion. Check coating the exhaust with a soap solution while the com-
for high air system leakage. pressor is loaded (compressing air).
c. The air dryer has been installed in a system that 6. Check the operation of the safety valve by pulling
has been previously used without an air dryer. This type the exposed stem while the compressor is loaded (com-
system will be saturated with moisture and several pressing air). There must be an exhaust of air while the
weeks of operation may be required to dry it out. stem is held and the valve should reseat when the stem
is released.
d. Location of the air dryer is too close (less than 8 feet
{1.83m}) to the air compressor. 7. Check all lines and fittings leading to and from the
air dryer for leakage and integrity.
3. Check the mounting bolts for tightness. Check the
electrical connection to the dryer.
8. Check the operation of the heater and thermostat
4. Check the operation of the integral single check during cold weather operation. This can be done by al-
valve. Build the air system to governor cut-out and ob- lowing the end cover assembly to cool below 50 degrees
serve the test air gauge installed in the No. 1 reservoir. A f (10 degrees C) and feeling the end cover when the igni-
rapid loss of pressure could indicate a failed check tion is turned on. The end cover should be warm to the
valve. This can be confirmed by checking at the purge touch within a few moments. Warming should cease at
valve exhaust. about 85 degrees F (29.4 degrees C).
NOTE
The purge valve will be open when the

3G The desiccant change interval may vary; however, it is
generally recommended the desiccant be replaced
every 12 months (yearly). If experience shows that ex-
governor cut-out pressure is reached. tended shortened life is the result of a particular installa-
Allow two minutes for the purge cycle tion, the yearly interval can be increased or reduced ac-
before testing the check valve. cordingly.
60
86
2-7-17
GOVERNOR VALVE
DESCRIPTION
The governor valve automatically controls the integral lowing the compressor to run light whilst a sufficient
unloader mechanism fitted to certain compressors, al- pressure level is maintained in the reservoirs.
MAINTENANCE
NOTE

REMOVAL a. Unscrew the cover at the top of the governor.
1. Chock the wheels. b. Loosen the adjusting screw locknut.
3G c. Turn the adjusting screw counterclockwise to raise

2. Deplete all pressure in both systems.
the pressure settings and clockwise to lower the pres-
3. Tag and disconnect the air lines from the governor. sure setting.
d. Tighten the adjusting screw locknut to lock the ad-

4. Remove the governor mounting bolts and remove
justment.
the governor.
3. Repeat Step 2 as necessary.
60
INSTALLATION
4. Leakage checks on the governor are made at its
1. Position the governor and secure it with the mount- exhaust port in both the cut-in and cut-out positions. In
ing bolts. the cut-in position, check the exhaust port for inlet valve
leakage by applying a soap solution at the port. Leakage
2. Connect the air lines to the governor ports, as could also be through the bottom piston grommet. In the
86
tagged prior to removal. cut-out position, check the exhaust port to determine
leakage at the exhaust valve seat or stem grommet, In
Service Checks
this position, leakage could also be through the upper
piston grommet.
1. Start the vehicle engine and build up air pressure in
the system. Check the pressure registered by the dash 5. If the governor does not function as described, or if
gauge or a test gauge at the time the governor cuts-out. leakage is excessive, it is recommended that it be re-
stopping the compression of air by the compressor. paired or replaced. Refer to the applicable Grove Parts
Manual.
2. With the engine still running, perform a series of
brake applications to reduce the air pressure and ob- Preventive Maintenance
serve the pressure the governor cuts-in the compressor.
The cut-in pressure is 110 psi (754.9 kPa/7.58 bar). Every 500 operating hours or after 15,000 miles
Never adjusts the governor pressure settings unless (24,135km)
they are checked with a gauge that is known to be accu- 1. Clean or replace the governor filters.
rate. If it has been determine that the pressure settings
of the governor must be changed, the procedure is as 2. If cleaning, us a cleaning solvent which is known to
follows. have no detrimental effect on metal or rubber material.
2-7-18
3. If the filters are removed, they should be replaced (160,900km), disassemble the governor and clean all
with new filters. parts.
Every 3,000 operating hours or after 100,000 miles
3G
60
86
2-7-19
DIFFERENTIAL PROTECTION VALVE
DESCRIPTION
The differential protection valve is designed to prevent applications of the service brake while the secondary
overloading of the spring brake actuator push rod, slack brake is applied, or vice versa. The valve thus prevents
adjuster and the foundation brake, caused by severe compounding of the full spring and diaphragm forces.
MAINTENANCE
NOTE

1. Prior to installing the valve on the crane, all con-

necting air lines should be inspected for kinks, cuts,

3G chafing, and deterioration. Lines displaying any of these
deficiencies should be replaced.
2. Position the valve on the mounting and secure it

3. Identify, mark, and disconnect all air lines from the
with the bolts, lockwashers, and nuts provided.
differential protection valve.
3. Connect the air lines to the proper port on the valve
60
4. Remove the bolt, lockwashers, and nuts that se- in accordance with identification marks made during re-
cure the valve and remove the valve. moval.
86
2-7-20
RESERVOIRS
DESCRIPTION
Reservoirs are storage tanks that function to provide a brakes and auxiliary devices.
volume of compressed air, for the operation of the
MAINTENANCE
NOTE

REMOVAL 6. If a new reservoir is to be installed, remove the
brackets, fittings, and components from the reservoir.
INSTALLATION
2. Deplete all pressure in both air systems. 3G 1. If a new reservoir is being installed, install the
brackets and all fitting sand components on the reser-
3. Disconnect and tag all air lines from the reservoir to
voir.
be removed.
2. Position the reservoir on the supporting framework
4. Remove the bolts, lockwashers, and nuts attaching and secure the brackets to the frame with the bolts, lock-
the reservoir bracket to supporting framework. washers and nuts.
60
5. Remove the reservoir with the brackets from the 3. Connect all air lines to the reservoir as tagged dur-
framework. ing removal.
86
2-7-21
LOW PRESSURE INDICATING SWITCH
DESCRIPTION
The low pressure indicator switch, gives an automatic air brake system fall below the safe minimum advisable
warning signal to the driver. Should the pressure in the for normal vehicle operation.
MAINTENANCE
NOTE

REMOVAL Operating and Leakage Checks
1. With the engine shut down and the ignition switch

1. Chock the vehicle wheels.
on, slowly reduce pressure in the system.
2. Deplete all pressure in both air systems.

3G
3. Disconnect the electrical lead from the indicator
2. The switch should actuate at approximately 75 psi
(517 kPa/5.17 bar) as indicated by sounding of the
buzzer and illumination of the LOW AIR indicator. This
pressure may be read on the dual pressure gauge in the
switch.
cab.
4. Unscrew the indicator switch from the fitting. 3. With air pressure present at the port, coat the indi-
60
cator switch with a soap solution. No leakage is permit-
ted.
INSTALLATION
Preventive Maintenance
1. Screw the indicator switch into the appropriate
Every 10,000 Miles (16,090 Km), or monthly.
86
valve fitting.
Perform the procedures under Operating and Leakage
2. Connect the electrical lead to the switch. Checks.
2-7-22
SAFETY VALVE
DESCRIPTION
The safety valve is incorporated in an air system to pre- does occur the valve allows the access pressure to ex-
vent excessive pressure build-up. However if a build up haust into the atmosphere.
MAINTENANCE
NOTE

REMOVAL 3. Using the wrench flat, unscrew the valve from the
fitting on the reservoir.
1. Chock the vehicle wheels. INSTALLATION

3G 1. Using the wrench flat closest to the threaded end,
screw the valve into the fitting.
60
86
2-7-23
MULTI-CIRCUIT PROTECTION VALVE
DESCRIPTION
The multi-circuit protection valve is designed so that ensure at least the specified braking efficiency.
should one part of the vehicle air braking system fail, the
rest of the system will remain capable of stopping the ve- Feedback type valve elements remain open above the
hicle with at least the efficiency specified for secondary closing pressure in normal service, when the air reser-
braking. voirs are fully charged, these valve elements allow
equalization of the reservoir pressures with the air sup-
ply pressure. The fitting of the feedback type valve ele-
A failure in a circuit downstream of the valve element ments in the Service Brake reservoir supply lines also al-
automatically causes the element to isolate the effected lows the compressor unloader valve governor to moni-
circuit from the air supply line and to keep the air pres- tor all the reservoir pressures without the use of an extra
sure in the remaining circuits at a level high enough to sensing tank.
MAINTENANCE
3G NOTE

1. Prior to installing the valve on the crane, all con-

60
1. Chock the wheels. necting air lines should be inspected for kinks, cuts,
chafing, and deterioration. Lines displaying any of these
deficiencies should be replaced.
2. Deplete all pressure in both air systems.
2. Position the valve on the mounting and secure it
86
with the bolts, lockwashers, and nuts provided.

3. Identify, mark, and disconnect all air lines from the
valve. 3. Connect the air lines to the proper port on the valve
in accordance with identification marks during removal.
4. Remove the bolts, lockwashers, and nuts that se- 4. Perform the procedures under Operating and
cure the valve and remove the valve. Leakage Checks.
2-7-24
AIR CYLINDER
DESCRIPTION
There are two airshift cylinders, both having a bore of pump disconnect assembly and the front wheel drive
.98 inches (25mm) and a stroke of 1.96 inches (50mm). disconnect.
The cylinders are for the operation of the main hydraulic
MAINTENANCE
NOTE

1. Tag and disconnect all air lines from the cylinder. 1. Relocate cylinder on mounting bracket and secure
in position using bolts, washers and nuts.
2. Remove bolts, washers and nuts securing the cyl-
inder to its bracket.
3. Remove the cylinder to a clean work area.

3G 2.
3.
Reconnect all air lines as tagged on removal.
Check for leaks.

60
86
2-7-25
DUAL BRAKE VALVE
MAINTENANCE
NOTE

REMOVAL Service Checks
Operating Test
1. Chock the wheels. CAUTION
A CHANGE IN VEHICLE BRAKING

CHARACTERISTICS OR A LOW PRES-
2. Deplete all pressure in both air systems. SURE WARNING MAY INDICATE A
MALFUNCTION IN ONE OR THE
OTHER BRAKE CIRCUIT, AND AL-
3. Identify, mark, and disconnect all air lines from the THOUGH THE VEHICLE AIR BRAKE
brake valve.
3G SYSTEM MAY CONTINUE TO FUNC-
TION THE VEHICLE SHOULD NOT BE
OPERATED UNTIL THE NECESSARY
4. Remove the three bolts, lockwasher, and nuts se- REPAIRS HAVE BEEN MADE AND
curing the brake valve and treadle assembly to the cab BOTH BRAKING CIRCUITS, INCLUD-
floor. Remove the brake valve and treadle assembly as ING THE PNEUMATIC AND MECHANI-
60
a unit. CAL DEVICES ARE OPERATING NOR-
MALLY. ALWAYS CHECK THE VEHICLE
BRAKES AFTER PERFORMING
NOTE BRAKE WORK AND BEFORE RETURN-
ING THE VEHICLE TO SERVICE.
86
1. Check the delivery pressure of both No. 1 and No. 2

The basic brake valve alone can be re- circuits using a test gauge known to be accurate. De-
moved by removing the three press the treadle to several positions between the fully
capscrews on the inner bolt circle. released and fully applied positions, and check the de-
livered pressure on the test gauges to see that it varies
equally and proportionally with the movement of the
INSTALLATION brake pedal.
2. After a full application is released, the reading on

the test gauges should fall off to zero promptly. It should
1. Position the brake valve and treadle assembly in be noted that the No. 1 circuit delivery pressure will be
the cab floor opening and secure it with the three bolts, about 2 psi (13.8 kPa/0.14 bar) greater than the No. 2
lockwashers, and nuts. circuit delivery pressure with both supply reservoirs at
the same pressure. This is normal for this valve.
Leakage Test
2. Connect the air lines to the proper ports on the
valve is accordance with the identification marks made 1. Make and hold a high pressure (80 psi {551.86
during removal. kPa/55.1 bar}) application.
2-7-26
2. Coat the exhaust port and body of the brake valve 4. Lubricate the plunger using a barium base lubri-
with a soap solution. cant.
3. Leakage of a one-inch (2.54cm) bubble in three

seconds is permitted. Every 3600 operating hours, 100,000 miles (160,900
km), or yearly.
Every 300 operating hours, 20,000 miles, (32,180 km), It is recommended that the inlet and exhaust valves, ex-
or three months. haust diaphragm, I]rings, and rubber graduating spring
be replaced if they show signs of wear or deterioration.
1. Clean any accumulated dirt, gravel, or foreign ma-
terial away from the heel of the treadle, plunger boot,
Every 7200 operating hours, 200,000 miles (321,800
and mounting plate.
km), or two years.
2. Lubricate the treadle roller, roller pin, and hinge pin
using a barium base lubricant such as Bendix piece 1. Disassemble the brake valve, clean, and inspect all
number 240176. parts.
3. Check the rubber plunger boot for crack, holes, or
deterioration, and replace it if necessary. Also check the 2. Install new parts where they are found to be worn or
mounting plate and treadle for integrity. 3G damaged.
60
86
2-7-27
PARK BRAKE CONTROL VALVE TURNTABLE
DESCRIPTION
The park brake control valve is fitted to cranes with drive/ The button will pop out when the air pressure falls below
steer controls from the turntable cab and is basically an 420 psi (275 kPa/2.75 bar) exhausting the delivery line,
on-off, push-pull control valve. When the air pressure and engaging the park brakes. The button needs 50 psi
reaches 50 psi (344 kPa/3.44 bar) and the button is (344 kPa/3.44 bar) to remain in.
pushed in air is provided to disengage the park brakes.
MAINTENANCE
REMOVAL Operating and Leakage Check
NOTE
If the park brake control valve does not
operate as described or leakage is ex-
2. Deplete all pressure in both air systems. cessive, it is recommended that a re-
3. Tag and disconnect the two air lines from the park
control valve.
3G placement obtained from Customer
Services, Grove Manufacturing Com-
pany.
1. Chock the wheels and fully charge the air system.

4. Drive out the roll pin securing the knob to the valve 2. With the park brake valve plunger pulled out (ex-
60
stem. haust position), coat the exhaust port and plunger stem
with a soap solution. A one-inch (2.54cm) bubble in five
5. Loosen and remove the valve mounting nut and re- seconds is permitted. There should be no leakage be-
move the valve. tween the upper and lower body.
86
3. Push the park brake valve plunger in (applied posi-

INSTALLATION tion). A one-inch (2.54cm ) bubble in three seconds is
permitted.
1. Position the valve through the hole in the console 4. Reduce the air pressure and observe the park
and secure it with the valve mounting nut. brake valve plunger. It should pop out when the air pres-
sure drops to approximately 40 psi (275 kPa/2/75 bar)
exhausting the delivery line and engaging the park
2. Position the knob on the valve stem and drive in the brakes.
roll pin.
3. Connect the two air lines to the park control valve Every 10,000 miles (18,530 Km) or 3 months. Perform
as tagged prior to removal. the procedures under Operating and Leakage Check.
2-7-28
HAND BRAKE CONTROL VALVE CARRIER
DESCRIPTION
NOTE

GENERAL ruple protection valve through the hand brake control
The hand brake control valve works in conjunction with a valve to the relay valve, causing the relay valve to actu-
relay valve and this prevents any brake lag during appli- ate the spring brake chambers. The handle of the hand
cation or releasing. The hand brake control valve brake control valve is spring biased towards the brake
senses air from the quadruple protection valve. When off position in the gate to prevent an accidental full appli-
the control valve is operated, air is routed from the quad- cation of the brake.
MAINTENANCE
REMOVAL

3G INSTALLATION
1. Install the valve on its mounting.
2. Install the fittings and air lines to the valve as

2. Deplete the pressure in both air systems. tagged during removal.
3. Disconnect and tag the air lines from the valve and 3. Allow the system pressure to reach operating pres-
60
remove the valve. sure, and check all air lines and connectors for leaks.
86
2-7-29
NON RETURN VALVE
DESCRIPTION
A non return valve is normally fitted in an air pressure pressed air to pass in one direction only.
braking system, when it is necessary to allow com-
MAINTENANCE
NOTE

1. Position valve in the air line.

1. Tag and disconnect all air lines, at the non return
valve.
2. Reconnect air lines as tagged prior to removal.
2. Remove non return valve.

3G 3. Check connections for any leaks.
60
86
2-7-30
SECTION 8
HYDRAULIC SYSTEM
TABLE OF CONTENTS
Page
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-10
Hydraulic Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-10
Draining and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-10
Removing Air from the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-11
Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-12
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-12
3G
Valve Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
Binding Spools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-13
SUPPLY PRESSURE AND RETURN CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Pump Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
60
Pump 1 (Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Pump 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Pump 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Pump 4 (Emergency Steer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-15
86
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-15
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-16
VALVE SETTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-17
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-17
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-21
HYDRAULIC PUMPS - CARRIER, OUTRIGGER, SUSPENSION & REAR STEERING . . . . . . . . . . . . . . 2-8-23
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-23
HYDRAULIC PUMPS - TURNTABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-24
2-8-1
Page
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-24
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-24
HYDRAULIC PUMP DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-25
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-25
STEERING PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-27
EMERGENCY STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-28
3G
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8-28
2-8-28
2-8-28
2-8-28
CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-29
60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-29
HYDRAULIC REMOTE CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
86
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Joystick Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Telescope Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-31
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-31
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-32
AUXILIARY HOIST CONTROL VALVE (HO-30B HOIST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-33
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-33
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-33
2-8-2
Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-33
SOLENOID OPERATED CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-34
HOLDING VALVES - TELESCOPE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-35
COUNTERBALANCE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-36
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-36
3G
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VALVE BLOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8-36
2-8-37
2-8-37
2-8-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-37
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-38
60
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-38
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-38
CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
86
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-39
CYLINDER COUNTERWEIGHT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-40
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-40
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-40
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-41
Leakage Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-42
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-42
HYDRAULIC OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
2-8-3
Page
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
Temperature Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-43
LIST OF FIGURES
Title Page
ANSI Graphical Symbols (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-8
ANSI Graphical Symbols (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-9
Hydraulic Reservoir Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-22
Hydraulic Pump Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-26
Hydraulic Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8-44
3G
60
86
2-8-4
Page
2-8-10
WARNING
THE HYDRAULIC SYSTEM ON THIS

MACHINE SHOULD NOT BE TAM-
PERED WITH BY PERSONS WHO
HAVE NOT BEEN TRAINED IN THE
FUNCTIONS OF THE VARIOUS
VALVES ASSOCIATED WITH THE CIR-
CUIT
EVEN WITH THE ENGINE STOPPED,

BECAUSE OF THE USE OF COUNTER-
BALANCE AND LOCK VALVES, MANY
COMPONENTS OF THE CIRCUIT MAY
3G
STILL BE IN A LOADED CONDITION.
UNDER NO CIRCUMSTANCES
SHOULD THE CIRCUIT BE BROKEN
WITH AN ELEVATED BOOM OR WITH A
LOAD SUSPENDED FROM THE HOOK.
60
2-8-10
WARNING
IT IS MANDATORY THAT ALL HY-

DRAULIC HOSES AND FITTINGS BE
86
CORRECTLY TAGGED AN IDENTIFIED

BEFORE THEY ARE DISCONNECTED
TO EFFECT REPAIRS OR SERVICE.
FAILURE TO CORRECTLY TAG AND
IDENTIFY HOSES AND FITTINGS CAN
CAUSE WRONG CONNECTION,
WHICH CAN RESULT IN DEATH OR IN-
JURY TO PERSONNEL.
2-8-12
WARNING
EXTREME CARE MUST BE USED

WHEN REMOVING ANY PLUGS OR
RESTRICTIONS FROM A HYDRAULIC
SYSTEM SUSPECTED TO HAVE EN-
TRAPPED AIR THAT MAY BE PRES-
SURIZED.
2-8-5
Page
2-8-12
WARNING
DO NOT ATTEMPT TO LOOSEN FIT-

TINGS IN PRESSURIZED LINES OR
WHILE THE HYDRAULIC PUMPS ARE
IN OPERATION.
2-8-15
WARNING
ENSURE THAT ALL HYDRAULIC SYS-

TEMS ARE SHUT DOWN AND THE
PRESSURE IS RELIEVED.
2-8-16
3GWARNING

2-8-21
60
WARNING
ENSURE THE TURNTABLE ENGINE IS

SHUT DOWN BEFORE PROCEEDING.
2-8-42
86
WARNING
ENSURE PRESSURE IS APPLIED TO

THE PISTON SIDE OF THE CYLINDER
ONLY AND THE RETRACT HOSE IS
CAPPED.
2-8-42
WARNING
ENSURE PRESSURE IS APPLIED TO

THE RETRACT (ROD) SIDE OF THE
CYLINDER ONLY AND THAT THE EX-
TEND HOSE IS CAPPED.
2-8-6
HYDRAULIC SYSTEM
DESCRIPTION
This section describes the supply pressure and return A complete hydraulic system schematic showing all op-
hydraulic circuit, pumps and disconnect, all hydraulic tions is enclosed with this manual and an A.N.S.I.
valves, and all hydraulic cylinders. Description and op- graphical symbols chart is provided in this section.
eration of individual hydraulic circuits are discussed in
their individual Sections.
3G
60
86
2-8-7
LINES AND LINE FUNCTIONS
CYLINDER SINGLE
ACTING
LINE, WORKING
LINE, PILOT CYLINDER DOUBLE

ACTING
DIFFERENTIAL
LINE, DRAIN
NON DIFFERENTIAL
CONNECTOR
VALVES
LINE, FLEXIBLE
CHECK
LINES JOINING
LINES PASSING
ON OFF (MANUAL
SHUT OFF)
DIRECTION OF FLOW
LINE TO RESERVOIR PRESSURE RELIEF

ABOVE FLUID LEVEL
BELOW FLUID LEVEL
LINE TO VENTED
3G PRESSURE REDUCING
FLOW CONTROL
MANIFOLD ADJUSTABLE
NON COMPENSATED
PLUG OR PLUGGED FLOW CONTROL

CONNECTION ADJUSTABLE
60
(TEMPERATURE
AND PRESSURE
RESTRICTION, FIXED COMPENSATED)
RESTRICTION, VARIABLE TWO POSITION

TWO CONNECTION
86
PUMPS
TWO POSITION
SINGLE, FIXED THREE CONNECTION
DISPLACEMENT
TWO POSITION
SINGLE, VARIABLE FOUR CONNECTION
DISPLACEMENT
ACTUATORS THREE POSITION

FOUR CONNECTION
MOTOR, FIXED
DISPLACEMENT TWO POSITION
REVERSIBLE IN TRANSITION
MOTOR, FIXED
DISPLACEMENT
NON REVERSIBLE VALVES CAPABLE OF
INFINITE POSITIONING
(HORIZONTAL BARS
MOTOR, VARIABLE INDICATE INFINITE
DISPLACEMENT, POSITIONING ABILITY
REVERSIBLE
1951 1
A.N.S.I. Graphical Symbols (Sheet 1 of 2)
2-8-8
METHOD OF OPERATION MISCELLANEOUS
ROTATING SHAFT
SPRING
MANUAL
ENCLOSURE
PUSH BUTTON RESERVOIR

VENTED
PUSH PULL LEVER PRESSURIZED
PEDAL OR TREADLE PRESSURE GAUGE
MECHANICAL
3G ELECTRIC MOTOR
60
DETENT ACCUMULATOR,
SPRING LOADED
PRESSURE ACCUMULATOR,
COMPENSATED GAS CHARGED
86
SOLENOID, SINGLE
WINDING HEATER
COOLER
REVERSING MOTOR
PILOT PRESSURE
REMOTE SUPPLY TEMPERATURE
CONTROLLER
INTERNAL SUPPLY FILTER, STRAINER
1951 2
A.N.S.I. Graphical Symbols (Sheet 2 of 2)
2-8-9
MAINTENANCE
WARNING 6. For swing components, ensure the crane jib is po-

sitioned over the front of the carrier with the swing lock
THE HYDRAULIC SYSTEM ON THIS pin engaged.
MACHINE SHOULD NOT BE TAM-
7. For outrigger components ensure that the turntable
PERED WITH BY PERSONS WHO HAVE
is in line with the carrier, swing lock pin engaged and that
NOT BEEN TRAINED IN THE FUNC-
the outrigger stabilizers are not supporting the weight of
TIONS OF THE VARIOUS VALVES AS-
the crane.
SOCIATED WITH THE CIRCUIT
8. Allow time for the hydraulic oil to cool, if the crane
EVEN WITH THE ENGINE STOPPED, has been operating.
BECAUSE OF THE USE OF COUNTER-
BALANCE AND LOCK VALVES, MANY 9. Where possible keep your hands, body and face
COMPONENTS OF THE CIRCUIT MAY out of the direct line of the connection you are releasing
STILL BE IN A LOADED CONDITION. in case of residual pressure in the system.
CAUTION
UNDER NO CIRCUMSTANCES
SHOULD THE CIRCUIT BE BROKEN A DIFFERENT GRADE OF HYDRAULIC
WITH AN ELEVATED BOOM OR WITH A
LOAD SUSPENDED FROM THE HOOK.
Trained mechanics should be aware of the following

3G OIL IS TO BE USED IN ARTIC CONDI-
TIONS, THEREFORE REFERENCE
SHOULD BE MADE TO THE LUBRICA-
TION SCHEDULE, FOR THE OPERAT-
general rules for safety. ING TEMPERATURE LIMITS AND REC-
OMMENDED OIL GRADE.
60
1. If the crane hydraulic tank is fitted with a pr-
essurised filler cap, this should be removed before dis- WARNING
connecting or removing any hydraulic component or
IT IS MANDATORY THAT ALL HYDRAU-
pipes.
LIC HOSES AND FITTINGS BE COR-
RECTLY TAGGED AN IDENTIFIED BE-
2. Switch off the engine/s before breaking into the hy-
86
FORE THEY ARE DISCONNECTED TO

draulic circuit.
EFFECT REPAIRS OR SERVICE. FAIL-
URE TO CORRECTLY TAG AND IDEN-
3. For components in telescoping circuit ensure jib is TIFY HOSES AND FITTINGS CAN
horizontal and where possible fully retracted thereby CAUSE WRONG CONNECTION,
eliminating the possibility of self retraction under the ef- WHICH CAN RESULT IN DEATH OR IN-
fect of gravity. JURY TO PERSONNEL.
4. For components in the derricking circuit ensure jib HYDRAULIC OIL RECOMMENDATIONS
is approximately horizontal where possible and is sup-
ported from either above or below by either a second For the hydraulic oil specifications refer to Section 15 -
crane, suitable trestle or the jib rest if fitted. This will en- Lubrication.
sure that as jib is supported hydraulically it cannot self DRAINING AND FLUSHING
derrick under the effect of gravity where circuit is broken.
If a component has been changed because of a failure
5. For components in the hoisting circuit ensure that that might allow metal or abrasive particles to enter the
the snatchblock is resting on the ground and the hoist system, all systems must be thoroughly checked,
rope completely relieved of load. drained, and flushed.
2-8-10
1. Remove the reservoir drain plug. Allow approxi- 10. Disconnect the return lines from a pair of outrigger
mately three minutes, after oil stops flowing from the stabilizer cylinders and activate the cylinders to their
drain port, for the side walls to drain. maximum down position.
2. Clean and install the reservoir plug and fill the res- 11. Connect the return lines and raise the stabilizer cyl-
ervoir with a 50 - 50 mixture of fuel oil and clean hydrau- inders to the stowed position. Replenish the oil level as
lic oil. necessary.
12. Repeat Steps 10 and 11 for the remaining two out-

3. Cycle the crane through all functions several times;
rigger stabilizer cylinders.
then return the crane to its stowed position and turn the
front and rear wheels to the extreme left. Shut down the 13. Disconnect the return line from the telescope cylin-
engine. der and fully extend the boom.
4. Remove the reservoir drain plug and drain the res- 14. Connect the return line and retract the boom. Re-
ervoir. Clean and install the drain plug and fill the reser- plenish the reservoir oil level as necessary.
voir with clean oil. 15. Disconnect the return lines from both front steer
cylinders and turn the front wheels to the extreme right.
CAUTION
16. Connect the return lines and turn the front wheels
OIL SUPPLY LINES MUST BE CON- to the extreme left and then back the centre. Replenish
NECTED TO THE CYLINDERS WHEN
FLUSHING THE SYSTEM.
NOTE
3G the reservoir oil level and necessary.
17. Repeat Steps 15 and 16 for the other steering cylin-

ders.
CAUTION
Draining the various components will
be facilitated by connecting a drain line WHEN OILS ARE CHANGED OR
60
in place of the disconnected return line. ADDED, ENSURE THAT OILS OF DIF-
FERENT MANUFACTURERS ARE OF
5. Disconnect the return line from the lift cylinder and THE SAME SPECIFICATIONS. HOW-
raise the boom to maximum elevation. EVER, DISCOLORATION (MILKINESS)
MAY OCCUR.
6. Connect the cylinder return line and lower the
86
boom to its stowed position. Replenish the reservoir oil When hydraulic oils are changed, recheck the reservoir
level as required. oil level after brief system operation and add oil as re-
quired.
7. Disconnect the return line from an outrigger exten-
sion cylinder and fully extend the outrigger. The steering reservoir capacity is 43.5 U.S. gallons (164
litres). The turntable hydraulic tank capacity is 300 U.S.
8. Connect the outrigger return line and retract the gallons (1136 litres).
outrigger. Replenish the reservoir oil level as necessary.
Ensure the crane is in the travel mode of operation when
the oil system is being filled. The system must be filled
9. Repeat Steps 7 and 8 for the remaining outriggers.
with all cylinders retracted and the boom at rest. Fill the
CAUTION reservoir to the full mark on the reservoir sight gauge.
After the reservoir is filled, operate all circuits and re-
WHEN DRAINING THE STABILIZER check the reservoir sight gauge. Add oil as required.
CYLINDERS, ALWAYS OPERATE
REMOVING AIR FROM THE HYDRAULIC SYSTEM
EITHER BOTH FRONT OR BOTH REAR
CYLINDERS TOGETHER TO PREVENT Due to the manner in which the hydraulic system is de-
TWISTING THE CRANE. signed, air entering the hydraulic oil will normally be re-
2-8-11
moved automatically by passage of the oil over the baf- is first telescoped In (not OUT) in the morning. Telescop-
fles in the hydraulic reservoir. However, if a component ing OUT may cause air to be forced back into a cylinder.
has been replaced, the reservoir level is too low, or a
leak develops in the suction lines to the pumps, air can WARNING
enter the system. If air becomes entrapped in the hy-
draulic oil, it may be detectable in pumps and motor op-
WHEN REMOVING ANY PLUGS OR RE-
erated components such as the swing mechanism and
STRICTIONS FROM A HYDRAULIC
hoist(s), because it can cause these units to become
noisy during operation. Should noisy operation occur,
first check the level of the hydraulic reservoir and replen-
SURIZED.
ish as necessary. Then inspect for leaks in the suction
lines leading to the pumps. Entrapped air may be removed from cylinders having
wet rods by cycling. On certain cylinders, a plugged port
Minute leaks may be difficult to locate. Should you en- is provided on the rod end to bleed-off entrapped air.
counter a leak that is not readily detectable, the follow-
ing method may be used when checking for such leaks. WARNING
Seal all normal openings in the hydraulic system and the
reservoir. Using a positive means to control the pressure DO NOT ATTEMPT TO LOOSEN FIT-
(i.e. a regulator), pressurize the hydraulic system to 2 to TINGS IN PRESSURIZED LINES OR
4 psi (13.79 to 27.6 kPa/0.1379 to 0.276 bar) and in- WHILE THE HYDRAULIC PUMPS ARE
helpful in detecting minute leaks while the system is

pressurized. Remove the pressure, repair any leaks
3G
spect all joints and fittings for evidence of leaks. A soap
solution applied to the fittings and joints may also prove
IN OPERATION.
In the event that air entrapment should persist, bleeding

of air by loosening various clamp and screw type fittings
may become necessary.
found, and reopen any openings (vents, etc) closed for
inspection. Refill the reservoir after completing any re- if the above procedures fail to eliminate air entrapment,
pairs or service. Operate all hydraulic circuits several
60
contact Grove Customer Services.
times in both directions. This action should return any
entrapped air to the reservoir where it can be removed PARTS REPLACEMENT
from the oil by the baffle system provided.
Parts found damaged or out of tolerance when mainte-
CAUTION nance is being performed should be replaced. Refer to
86
the Grove Parts Manual for proper replacement parts.

LOCATE THE CRANE ON A FIRM SUP-
PORTING SURFACE AND POSITION CONTROL VALVES
THE BOOM IN THE MOST STABLE PO- The module control valves that control the crane func-
SITION WHEN EXTENDING THE BOOM tions are installed on the turntable. The valves are con-
AT LOW ANGLES. trolled hydraulically through pilot pressure signals from
the hydraulic remote control valves in the cab.
However, if the air is not readily removed, lower the
boom to below horizontal, extend the telescope cylin- Inspection
ders as far as practicable, and allow the boom to remain
in this position overnight. This should allow entrapped Inspect the module control valves for visible damage,
air to find its way to the holding valve where telescoping binding spools, and evidence of leakage. If excessive in-
the boom IN the next morning should force the air back ternal leakage is suspected during operation with a
to the reservoir. spool in its centre position, it is possible that the area be-
tween the spool and working section bore of the valve
While allowing the boom to remain in an extended and body is worn beyond serviceable limits. If this condition
lowered position overnight is helpful in removing en- exists, the spool and body must be replaced as an as-
trapped air from the hydraulic cylinder, ensure the boom sembly.
2-8-12
Valve Leakage Check valves in the control valves are designed to per-
mit a flow of oil in one direction only. If a piece of dirt or
Dripping oil indicates some type of external leakage. rust has worked its way into the check valve and lodges
The machine should be removed from service for imme- between the poppet and seat, it will keep the valve open
diate repairs. External leaks sometimes develop at fit- and allow a return flow of oil. The remedy is to clean the
tings and seals. Spool seals are susceptible since they valve, but it is also a good idea to follow through and en-
are subject to wear. Seals may be damaged by tempera- sure the hydraulic system filters are still serviceable.
ture that are too high, or by dirt or paint accumulation on
the spool. Damaged seals must be replaced. Binding Spools
Some of the most common causes for stiff spool move-

A component functioning at reduced efficiency may indi-
ment or jammed spool action are; system overheating,
cate that the control valve for that component is leaking
excessive pressure, contaminated or deteriorated oil, or
internally. Assuming preliminary check-out reveals that
warped mountings. When scorched or deteriorated oil
adequate volume is being supplied to the affected valve
or contamination is the cause, flushing the system and
bank, relief valves are properly adjusted, and the com-
replenishing with clean oil may solve the problem. If the
ponent is not at fault, check the valve for scored or worn
spool bores are badly scored or galled, the valve must
parts. Scoring is a sign of the number one problem in hy-
be removed for servicing.
draulics - contamination; external contamination by dust
or internal contamination by debris from deteriorating Warping occurs when mounting plates are not level or
components or oxidized oil. Scored or severely worn they become distorted from machine damage. As men-
valve components must be replaced.
Warped mounting surfaces can distort the assembly

3G tioned previously, the valve can be shimmed level.
Also, check the valve for rust. Rust or dirt collecting on

and cause leakage and binding. To check for valve dis- the linkages can prevent free movement of the spool,
tortion, loosen the mounting bolts slightly. If the leakage and keep it from the true centre position. Excessive sys-
stops when the bolts have been backed off slightly, dis- tem pressure can create both internal and external leaks
60
tortion was the problem. To correct this condition shim in valves that are otherwise sound. Therefore, it is ex-
the valve assembly to level and retighten the mounting tremely important that relief valves be adjusted only by
bolts. qualified personnel using the proper equipment.
86
2-8-13
SUPPLY PRESSURE AND RETURN CIRCUIT
DESCRIPTION
The supply pressure and return circuit is made up of PUMP DISTRIBUTION

separate circuits which route oil from the hydraulic
pumps for the individual operating circuits. The supply PUMP 1 (STEERING)
pressure and return circuit consists of the reservoir, four
hydraulic pumps , oil cooler, oil filters, and a hydraulic The pump is a two section pump. Both sections can de-
swivel. Refer to Section 13 SWIVELS for Description liver 22.4 gpm (60 lpm). Both sections of the pump sup-
and Maintenance of the hydraulic swivel. ply hydraulic oil to the power steering system.
HYDRAULIC RESERVOIR PUMP 2
The reservoir, attached to the decking to the right of the The pump is a four section pump driven by the turntable
carrier frame, has a total capacity of approximately 43.6 engine. Section one supplies hydraulic oil to the boom
gallons (164 litres) the reservoir attached to the turnta- lift and telescope circuits. Section two supplies the main
ble has a capacity of 300 gallons (1136 litres). The all- hoist and fast auxiliary hoist circuits. Section three sup-
steel reservoir has integral baffles that help cool the oil plies the auxiliary hoist, fast main hoist and fast lift cir-
and prevent oil foaming. 3G
Oil flows through suction lines from the reservoir to each
hydraulic pump. The return flow to the side of the reser-
cuits. Pump sections 1, 2 and 3 all have a delivery rate of
46.2 gpm (175 lpm).
Section four supplies the swing and counterweight re-

voir, but on this opposite side of a baffle plate which acts
moval circuits. Pump section 4 has a delivery rate of
to separate return and supply oil.
21.9 gpm (83 lpm).
60
A sight gauge is located on the front of the reservoir to
indicate oil level. A breather/filler cap (vent) is located on PUMP 3
the top of the reservoir to allow air to enter the exhaust
from the reservoir. It is most important that the breather The pump is a single section pump. The pump delivers
be kept clean to prevent damage to the reservoir. A large oil to the outrigger, rear steering and suspension sys-
access cover on the top centre of the reservoir provides tems and has a delivery of 35 gpm (132 lpm) @ 2300
86
access for cleaning. This opening may also be used to rpm.

fill the reservoir after it has been completely drained.
PUMP 4 (EMERGENCY STEER)
OIL COOLER
This is a single section ground driven pump which sup-
An air-cooled hydraulic oil cooler is mounted on the rear plies oil to the steer system in the event of the main
of the turntable. An electric motor driven fan pulls cool air pump failing. The supply rate of the pump is dependent
through the cooling fins on the cooler. Return oil from the on the ground speed, but is limited to 6 gpm (24 lpm) by a
telescope, lift, swing, and hoist circuits is routed through flow control valve. Emergency steer however does not
the oil cooler before returning to the tank. work in reverse direction, only in a forward direction.
2-8-14
MAINTENANCE
TROUBLESHOOTING
1. No oil flows in a. Low oil level a. Fill reservoir

systems.
b. Pump coupling or b. Properly engage the PTO.

shaft sheared or If drive shaft or coupling
disengaged. is damaged or sheared,
remove and repair as
necessary.
c. Reservoir-to-pump c. Clean, repair, or replace

supply line broken line as necessary. Check
or restricted. Air all lines for security,
entering at suction suction lines for cracks,
lines. Pump not priming. and proper attachment.
Tighten, repair, or replace
components as
necessary.
d. Internal contamination. d. Repair or replace pump.

3G Drain, flush, and refill
system with
recommended oil.
2. Excessive a. System relief valve a. Use adequate pressure

pressure build up. set too high. gauge and adjust system
relief valve as necessary.
60
b. Restricted pump-to- b. Clean, repair or replace
control valve supply lines as necessary.
line.
3. Pump noise. a. Air entering at a. Check all lines for

Accompanied by suction lines. Low security and proper
oil foaming in oil level. attachment. Tighten,
86
reservoir. repair, or replace

components as
necessary. Ensure that oil
level in reservoir is
adequate. Fill to HIGH
mark on sight gauge.
b. Excessive engine b. Regulate engine speed.

rpm.
HYDRAULIC FILTER WARNING

Removal
2. Tag and remove the hydraulic lines that connect to

1. Shut down the engine. the filter. Cap or plug all open lines.
2-8-15
3. Loosen and remove the bolts and washers which WARNING
secure the filter to the bracket. Remove the filter.
4. If new filters are to be installed, remove the fittings, TEMS ARE SHUT DOWN AND THE
seals, and differential pressure switch from the applica- PRESSURE IS RELIEVED.
ble old filter and install them on the new filter.
2. Remove the drain plug on the bottom of the filter
Installation and drain the oil.
1. Install the filter to the mounting bracket using bolts
3. Unscrew the filter bowl from the filter using an oil fil-
and washers.
ter strap wrench.
2. Install the hydraulic and electrical lines to the ap-
4. Remove the oil element and the seal.
propriate port as tagged during removal.
3. Start the engine and check for leaks. 5. Install a new element and seal to the filter.
Filter Element Replacement 6. Install the filter bowl.
1. Shut down the engine. 7. Start the engine and check for leakage.
3G
60
86
2-8-16
VALVE SETTING PROCEDURE
DESCRIPTION
REFER TO HYDRAULIC CIRCUIT DIAGRAM Remove the domed protective nut and slacken the lock
6294992132 nut, turn the adjustment screw clockwise to increase the
pressure and anti-clockwise to reduce the pressure. Re-
The following instructions gives the valve setting proce- tighten the locknut and replace the domed protective
dure for the turntable hydraulic system. nut. Check the pressure to confirm the process has not
altered the required pressure.
GENERAL
2. Pilot Supply Pressure
Unless otherwise stated all pressure measurements
and settings shall be made with the engine running at
Fit a 40 bar (600 psi) pressure gauge to the ‘Pilot Sup-
medium engine speed (1500 rpm).
ply’. With the engine running at ‘idle speed’ the pressure
All pilot lines shall be bled to eliminate air and to ensure should be 31 bar (450 psi).
correct response from the pilot controllers.
If adjustment is required the pilot supply pressure reduc-
A bank of test points is provided adjacent to the ‘Main ing sequence valve (shown overleaf) should be ad-
Hydraulic Valve Plate Assembly’ located behind the
turntable operators cab. These are for use with the
Grove standard test kit.
3G justed in the sequence described below. This valve is lo-
cated above the main hydraulic valve plate assembly.
a. Pilot Sequence Cartridge

The following motions are provided with sequential con-
trol of two valve spools i.e. (main hoist raise/lower, aux. Initially back off the locknut on the relief valve cartridge
hoist raise/lower, tele-out and derrick-in). The second and screw the adjuster fully in. Fit a 70 bar (1000 psi)
60
spool starts to move at approx half the pilot control lever pressure gauge to the sequence valve test point on the
movement. It is therefore important that the pressures of test point panel and with the engine running at “idle
both the relevant valve banks are checked. speed” adjust the pilot sequence cartridge to give 41 bar
(600psi) and lock in position.
PRESSURES
86
b. Relief Valve Cartridge

All pressures are pre-set but should be checked using
the following procedure and corrected where neces-
With the pressure gauge still connected to the sequence
sary.
valve test point and the engine at idle, back off the relief
1. Orbitrol Steering valve cartridge adjuster to give a reading of 35 bar (500
bar) and lock in position.
Fit a 280 bar (4000 psi) pressure gauge into the steering
pressure test point. With the engine running at ‘idle c. Pressure Reducing Cartridge (Pilot pressure)
speed’ the pressure should be 50 bar (725 psi).
Fit a 70 bar (1000 psi) pressure gauge to the “pilots” test
If adjustment is required the relief valve located above point and with the engine running at “idle speed” adjust
the pressure filters at the back of the engine should be the pressure reducing cartridge P2 to give a reading of
adjusted. 31 bar (450 psi) and lock in position.
2-8-17
Remove the adjustment screws protective nut, slacken
Pressure Pressure the locknut and adjust the adjusting screw. Clockwise to
Sequence Reducing Reducing increase pressure and anti-clockwise to reduce pres-
Assembly Cartridge P1 Cartridge P2
sure. Re-tighten the locknut, replace protective nut and
check pressure by selecting ‘tele-in’.
Relief
Cartridge
If this adjustment does not achieve the required pres-
sure, check the adjustment on the independent relief
valve fitted on the retract port connections, again adjust
the adjusting screw clockwise to increase pressure and
anti-clockwise to decrease pressure. Re-tighten the
locknut and check pressure by selecting “tele-in”.
Pilot Sequence
Cartridge The ‘tele-out’ motion is protected by independant fac-
tory pre-set relief valve.
Pressure Reducing Sequence Valve To check the ‘tele-out’ setting, derrick the boom to a safe
angle and telescope the main boom fully out. With the
3. Swing and Ballast Removal tele-out control partially selected check that the pres-
sure is 207 bar (3000 psi). Fully select the tele-out con-
Fit a 280 bar (4000 psi) pressure gauge to the ‘Swing
Pressure’ test point. With the swing lock pin engaged
and the swing motion fully selected the pressure should
be 207 bar (3000 psi) in both directions.
3G trol and increase the engine speed to prevent stalling
and check the pressure remains at 207 bar (3000 psi).
5. Main Hoist
If adjustment is required the swing/ballast valve should The main hoist/fast aux hoist control valve is located in
be adjusted. This valve is located on the rear left hand the front left hand area of the control valve assembly
60
corner of the main hydraulic valve plate assembly, look- plate. With the main hoist reeved on single fall and an-
ing towards the boom head. Slacken the locknut and chored to a load in excess of 9.8 tonnes fit a 280 bar
turn the adjustment screw clockwise to increase the (4000 psi) pressure gauge to the main hoist test point.
pressure and anti-clockwise to decrease the pressure. ‘Partially’ select hoist raise, the gauge reading should be
Re-tighten the locknut and finally check the pressure. 250 bar (3625 psi).
86
The ballast ‘lower’ operation has a built in port relief If adjustment is found necessary the main hoist/fast aux
valve which is factory pre-set and should not normally hoist relief valve should be adjusted. Remove the pro-
require adjustment. To check the ‘ballast lower’ pres- tective nut and slacken the locknut and adjust the ad-
sure setting select ballast lower and with the cylinder justment screw. Clockwise to increase pressure, anti-
fully extended the gauge reading should be 30 bar (435 clockwise to reduce pressure. Re-tighten the locknut re-
psi). place the protective nut and re-check the pressure set-
ting.
4. Telescope and Derrick
If the pressure is correct ‘fully’ select hoist raise, the
Fit a 280 bar (4000 psi) pressure gauge into the ‘Tele/ gauge reading should remain the same. If the gauge
Derrick’ pressure test point. reading changes significantly check the fast main hoist
control valve, see 6 below.
With the boom retracted select ‘tele-in’, the gauge
should read 241 bar (3500 psi). 6. Fast Main Hoist
If adjustment is required the tele/derrick control valve The fast main hoist aux hoist control valve is located in
should be adjusted. This valve is located on the front left the front right hand area of the control valve plate as-
hand side of the main hydraulic valve plate assembly. sembly.
2-8-18
If when checking the main hoist pressure and when the open. All other valves should be checked using the fol-
main hoist is fully selected there is a significant change lowing procedure and corrected where necessary.
in pressure that fast main hoist/aux hoist control valve
requires adjustment. 1. Outrigger Relief Valves
Remove the protective nut and slacken the locknut Fit a 280 bar (4000 psi) pressure gauge to the test point
back, adjust the adjustment screw, clockwise to in- on the inlet port P of the outrigger selector valve.
crease pressure and anti-clockwise to reduce pressure.
Re-tighten the locknut and replace protective nut and re- Select stabilizer retract on the outrigger controls with the
check pressure setting. stabilizer fully retracted. The maximum pressure should
be 172 bar (2500 psi) main relief valve.
Boost Main Hoist Pressure Switch
Select stabilizer extend with the stabilizer fully ex-
The boost hoist pressure switch is used to cut the boost tended. The maximum pressure should be 140 bar
hoist ‘lower’ facility if attempting to lower too heavy a (2030 psi) service port A relief valve.
load with the boost hoist selected thus preventing dam-
age to the motors and control valves. Both valves are pre-set and are not adjustable.
The pressure switch is located in the hoist motor 2. Hydra-Gas Suspension

pipework next to the counterbalance valve on the main
A. Pre-Charging Accumulator Bag for the First
hoist unit. 3G Time/Replacement
With the hoist reeved on single fall the maximum per-
missible load hoisting with boost hoist selected MUST 1. Before installing accumulator or replacement of
NOT exceed 4.9 tonnes. separator bag, pour a little oil into accumulator to form
an oil cushion. To prevent bag from being damaged, un-
To adjust the setting, remove the protective cap, slacken screw valve cap.
the locknut and adjust the rotary adjuster. The normal
60
setting for 3.9 tonnes is approx 250 bar (3625 psi). 2. Force check valve of accumulator open so that any
nitrogen in the bag can escape, thus, opening poppet
After checking that the machine can not lift in excess of valve. Oil can now flow off.
4.9 tonnes on single fall with boost hoist selected,
tighten the locknut and replace protective cap. 3. Raise the oil port slightly and pour a little oil (ap-
prox. 1/10 of capacity) into it, and rotate accumulator
86
7. Auxiliary Hoist about its axis.
The aux hoist relief valves are automatically set to 250 B. Charging Accumulators with Nitrogen
bar (3625 psi) when adjusting for the main hoist and no
further adjustment is necessary. As the maximum pres- Bosch Accumulators
sure required to lift the maximum line pull of 6.8 tonne is
1. Ensure all accumulators have been pre-charged
250 bar (3625 psi).
(see section A) before starting and system pressure is
REFER TO HYDRAULIC CIRCUIT DIAGRAM zero (i.e. with machine fully raised on outriggers with ax-
6294992132 les ‘UNLOCKED’ and TUV relief valves fully open.
The following instructions gives the valve setting proce- 2. Obtain a nitrogen charging kit. Bosch part number
dure for the carrier hydraulic system. 0.538.103.001 and adaptors UK 1.533.291.994 or Ger-
man 1533.373.001.
PRESSURES
3. Remove accumulator with valve cap, attach the
All pressures are pre-set with the exception of the four gauge into accumulator. Firstly with large nut, then hand
accumulator TUV relief valves which are supplied fully tighten the knurled sealing ring.
2-8-19
4. Attach hose assembly from nitrogen bottle to 6. The accumulator pre-charge pressure is 60 bar
gauge. (870 psi) for front and rear axle pairs and 38 bar (551 psi)
for 3rd axle. (5 axle machines only).
5. Open the gas bottle and allow nitrogen to flow into
the accumulator, exhaust nitrogen from hose through
knurled thumbscrew on the gauge. Press button on the
end of the gauge to take a pressure reading of charged C. Bleeding the System - (See SECTION 6 in this
accumulator. manual).
3G
60
86
2-8-20
HYDRAULIC RESERVOIR
DESCRIPTION
The hydraulic reservoir is attached to the left hand side level. A fill cap, that also incorporates a breather (vent),
of the turntable, it has a total capacity of 300 U.S. gallons is located on the top of the reservoir, to allow for filling the
(1136 litres). The all steel reservoir has an internally reservoir, with clear hydraulic oil, and also allows air to
mounted integral baffle that helps cool and prevent oil enter an exhaust from the reservoir. A large round ac-
from foaming. cess cover on top of the reservoir provides access for
cleaning. A drain plug is provided at the bottom of the
A sight gauge is provided on the reservoir to indicate oil reservoir, for draining the oil.
MAINTENANCE
REMOVAL AND DISASSEMBLY 9. Remove the magnetic plug (4) and magnet assem-
bly (5).
WARNING
10. Remove thermometer (6).
ENSURE THE TURNTABLE ENGINE IS 3G
SHUT DOWN BEFORE PROCEEDING. 11. Remove any other fittings not previously moni-
tored.
NOTE
CLEANING AND INSPECTION
The capacity of the hydraulic tank is
1. It is recommended that all gaskets, seals, and O-
300 U.S. gallons (1136 litres).
rings be replaced if a new tank is to be installed.
60
1. Drain the hydraulic oil from the hydraulic tank into a
2. Inspect the reservoir for any internal or external
container of suitable capacity. Allow a few minutes from
damage.
the tank to completely drain.
3. If the reservoir is to be reused, flush with clean sol-
2. Tag and disconnect all hydraulic lines from the hy- vent, and dry with filtered. compressed air.
86
draulic tank. Cap all hoses and plug all open ports to pre-
vent contamination. 4. After flushing the reservoir, plug all openings until
the reservoir is to be installed.
3. Support the weight of the tank with a suitable lifting
device. 5. Clean all plugs with clean solvent and place them in
a clean plastic bag until they are needed for assembly.
4. Having ensured all lines to the tank have been
tagged and disconnected, remove the nuts, bolts and ASSEMBLY AND INSTALLATION
washers securing the tank to its mounting.
1. Install thermometer (6).
5. Using the lifting device to lift the tank clear of the 2. Install magnetic plug (4) and magnet assembly (5).
turntable.
3. Install all adaptors, plugs and any other fittings re-
6. Locate the hydraulic tank in a clean area for disas- moved on disassembly, with new seals.
sembly.
4. Install sight gauge (3).
7. Remove the sight gauge (3) from the tank.
5. Using a suitable lifting device lift the hydraulic tank
8. Remove all adaptors and seals from the tank. back onto its mounting brackets on the crane.
2-8-21
6. Secure tank in position using the nuts bolts and 8. Fill the reservoir with clean, filtered hydraulic oil, to
washers removed during removal. the top of the sight gauge.
9. Start the engine and operate all functions. Recheck

7. Install all hydraulic lines as tagged prior to removal. the level of the hydraulic oil and refill as necessary.
3G 2
7
1
60
86
8
1. Hydraulic Reservoir
2. Breather Cap
3. Level Indicator
4. Magnetic Pipe Plug
5. Magnet Assembly
6 6. Thermometer Assembly
4
7. Pipe Plug
8. Plug
Hydraulic Reservoir
2-8-22
HYDRAULIC PUMPS - CARRIER, OUTRIGGER,
SUSPENSION AND REAR STEERING
DESCRIPTION
The hydraulic pumps are mounted on the torque con- The hydraulic pumps are a positive displacement; gear-
verter. The purpose of the pumps is to convert the me- type pumps . For information relating to pump deliveries
chanical energy of the torque converter into fluid energy refer to the specification list at the front of this manual.
for the operation of the crane’s hydraulic components.
MAINTENANCE
NOTE

REMOVAL 6. Remove and discard the gasket between the drive
3G pad and the pump.
1. Remove the pump cover plate.
INSTALLATION
2. Tag and disconnect the supply lines from the pump.
Cap all the lines and openings. NOTE
3. Tag and disconnect the pump distribution lines During assembly, assure that a new
from the pump. Cap all the lines and openings. gasket is used between the drive pad,
60
and pump.
CAUTION
1. Install pump to torque convertor. Assure that the
KEEP THE PUMP AS LEVEL AS POSSI- distribution and supply lines are properly connected as
BLE TO AVOID DAMAGING THE tagged during removal.
86
SPLINES.
2. Operate the pump for at least two minutes at zero
4. Remove the four nuts and washers attaching the pressure and moderate speed (not over 1500 rpm). If
pump to the torque convertor drive pad. Remove the the pump appears to be operating satisfactorily, in-
pump. crease the rpm intermittently, until the governed rpm has
been attained. Continue this procedure for approxi-
5. Cover the pump mount opening to prevent dirt from mately five minutes while checking for proper operation
entering the drive unit. and leakage.
2-8-23
HYDRAULIC PUMPS - TURNTABLE
DESCRIPTION
The hydraulic pumps are mounted on the turntable en- The hydraulic pumps are a positive displacement; gear-
gine. The purpose of the pump is to convert the me- type pumps . For information relating to pump deliveries
chanical energy of the turntable engine into fluid energy refer to the specification list at the front of this manual.
for the operation of the crane’s hydraulic components.
MAINTENANCE
NOTE

REMOVAL 6. Remove and discard the gasket between the drive
pad and the pump.
1. Remove the pump cover plate.
3G
2. Tag and disconnect the supply lines from the pump.
Cap all the lines and openings.
INSTALLATION
NOTE
3. Tag and disconnect the pump distribution lines During assembly, assure that a new
from the pump. Cap all the lines and openings. gasket is used between the drive pad,
and pump.
60
CAUTION
1. Install pump to torque convertor. Assure that the
KEEP THE PUMP AS LEVEL AS POSSI- distribution and supply lines are properly connected as
BLE TO AVOID DAMAGING THE tagged during removal.
SPLINES.
2. Operate the pump for at least two minutes at zero
86
4. Remove the four nuts and washers attaching the pressure and moderate speed (not over 1500 rpm). If
pump to the torque convertor drive pad. Remove the the pump appears to be operating satisfactorily, in-
pump. crease the rpm intermittently, until the governed rpm has
been attained. Continue this procedure for approxi-
5. Cover the pump mount opening to prevent dirt from mately five minutes while checking for proper operation
entering the drive unit. and leakage.
2-8-24
HYDRAULIC PUMP DISCONNECT
DESCRIPTION
The hydraulic pump disconnect is mounted on the drive the load of turning the pump during engine cranking.
pad on the transmission. It is operated from the carrier The disconnect assembly basically consists of two
cab by the pump disconnect control. pneumatic airshift cylinders, lever assemblies and
mounting brackets.
The disconnect aids cold weather starting by eliminating
MAINTENANCE
1. Disconnect and tag all air lines to the airshift cylin-

1. Relocate bracket complete with airshift cylinder
der. Cap all hoses and plug all ports.
and linkage and secure in position using screws and
2. Remove clevis pin (14), and cotter pin (13) from spring washers.
clevis (11) releasing the linkage from the transmission
pump disconnect rod.
3. Remove screws and spring washers securing

bracket (1) to pump flange.
3G 2. Relocate clevis (11) on the linkage and pin it to the
transmission disconnect rod using clevis pin (14) and
cotter pin (13)
4. Lift bracket (7) clear with airshift cylinder and link- 3. Reconnect all air lines to the airshift cylinder as
age. tagged prior to removal.
60
86
2-8-25
12
4
5
2
5
6 15
3
7
10
9
10
1
3G 8
13
6
5
14
60
5
4 13
14 11
86
13
1. Bracket Pump Disconnect 9. Lever Weld Assembly

2. Pneumatic Airshift Cylinder 10. Bush Oilite
3. Cylinder Stop 11. Yoke
4. Bolt 12. Switch
5. Washer 13. Cotter Pin
6. Locknut 14. Clevis Pin
7. Clevis 15. Nut Locking
8. Clevis Pin
Hydraulic Pump Disconnect
2-8-26
STEERING PUMPS
DESCRIPTION
The steering pumps are mounted on a drive pad of the pumps are gear type pumps and provides a controlled
torque converter, the pumps provide the hydraulic flow flow of 22.4 gpm (60 lpm) via two flow control valves.
necessary to power the steer cylinders on the axles. The
MAINTENANCE
NOTE

NOTE 5. Remove the nut, lockwasher, and drive gear from
the pumps.
Pump maintenance is limited to re-
placement of the seals. INSTALLATION
REMOVAL
1. Thoroughly clean the area around the steering

3G 1. Install the drive gear, lockwasher, and nut onto the
pumps.
pump.
2. Place the pump and drive gear onto the mounting
2. Tag and disconnect hoses from the pump. Cap the pad. Secure the pump in place with the nuts and wash-
60
hoses and pump connections. ers.
3. Remove the nuts and lockwashers securing the 3. Connect the hydraulic lines to the pump as tagged
pumps. during REMOVAL.
4. Remove the pumps and drive gear. Cover the 4. Function test the pump and check for proper opera-
86
mounting pad. tion and any leakage.
2-8-27
EMERGENCY STEERING PUMP
DESCRIPTION
The emergency steering pump is used to provide an al- The emergency steering pump is mounted on the trans-
ternate source of hydraulic flow in the event of steering mission and ground driven.
pump failure. Two pumps are used, a main pump and an
emergency pump so that in the event of a failure in one
pump, the other pump can provide adequate steering
until repairs are made.
MAINTENANCE
NOTE

REMOVAL 1. Before breaking a circuit connection, hose off or
CAUTION
3G otherwise clean the outside of the unit thoroughly to pre-
vent entry of dirt into the system.
2. Tag and disconnect the hydraulic hoses from the

BEFORE BREAKING A CIRCUIT CON- pump. Cap or plug all openings.
NECTION, ENSURE THAT POWER IS
3. Remove the nuts and bolts and washers securing
60
OFF AND SYSTEM PRESSURE HAS
BEEN RELEASED. the pump to the transmission mounting and remove the
pump.
CAUTION INSTALLATION
1. Position the pump to the mounting on the transmis-

86
ABSOLUTE CLEANLINESS IS ESSEN-

sion and secure in place with the bolts and nuts and
TIAL WHEN WORKING ON THE HY-
washers. Torque the bolts to 32 pounds-foot (4.4 kgm).
DRAULIC SYSTEM. ALWAYS WORK IN
A CLEAN AREA. THE PRESENCE OF 2. Connect the hydraulic lines to the pump as tagged
DIRT AND FOREIGN MATERIALS IN during removal.
THE SYSTEM CAN RESULT IN SERI-
OUS DAMAGE OR INADEQUATE OP- 3. Function test the pump and check for proper opera-
ERATION. tion and any leakage.
2-8-28
CONTROL VALVES
DESCRIPTION
The control valves are mounted on a valve plate, acces- solenoid valve. The valves control all craning functions
sible via the door in the cover behind the operators cab i.e. TELE, DERRICK, MAIN AND AUX HOIST, SWING.
on the turntable. The valve plate consists of a control These valves are pilot controlled, via the joystick con-
valve, pressure reducing valve, non-return valve and trollers in the turntable cab.
MAINTENANCE
NOTE

REMOVAL 4. If a new valve is to be fitted remove all fittings, clean
them and retain them for fitting to the new valve.
1. Clean the valve to be removed prior to commenc- 3G
ing, to prevent the ingress of dirt, into the valve which
may damage the valve.
INSTALLATION
1. Position the valve on its mounting and secure in po-

sition using nuts, bolts and washers.,
2. Tag and disconnect all hydraulic lines to the valve
to be removed. Cap or plug all openings. 2. Connect hydraulic lines to valve as tagged prior to
removal.
60
3. Remove nuts, bolts and washers, securing the
valve to the valve plate, and remove the valve to a clean 3. Function test the valve, checking for proper opera-
work area. tion and any leakage.
86
2-8-29
HYDRAULIC REMOTE CONTROL VALVE
DESCRIPTION
There are two hydraulic remote control valves utilized in telescope function. Pushing the control lever to either
the turntable cab. These hydraulic remote control valves side operates swing. Positioning the lever diagonally
are dual function joystick type valves. One valve is lo- operates both functions simultaneously.
cated in each armrest. The valve in the right armrest
controls the main hoist and boom lift. Moving the control If the crane is equipped with an optional auxiliary hoist,
lever straight forward or back operates the main hoist the auxiliary hoist function replaces the telescope func-
function. Pushing the control lever to either side oper- tion on the control lever on the left armrest and the tele-
ates boom lift. Positioning the lever in a diagonal direc- scope function is controlled by a pedal operated single
tion operates both functions simultaneously. The valve function control valve. The pedal is located on the left
in the left armrest controls swing and telescope. Push- side of the cab floor, the control valve is mounted be-
ing the control lever straight forward or back controls the neath the cab and is connected to the pedal by linkage.
THEORY OF OPERATION
3G
These valves provide proportional pilot pressure signals
to the main directional valve spools of the module. The
control principle is based on the pressure reducing valve
concept and will from a fixed input pressure create con-
trol pressures that vary proportionally with the lever
stroke.
MAINTENANCE
60
NOTE 2. Raise the armrest. Connect the hydraulic lines to
the valve as tagged during Removal.
the applicable SM package. Functional Check
86
JOYSTICK CONTROL VALVES With the engine running at governed rpm, operate both
functions controlled by the control valve. Check for
Removal proper operation and check the valve for any leakage.
1. Gain access to the base of the control valve by rais- TELESCOPE CONTROL VALVE (When Auxiliary
ing the armrest. Hoist is Fitted)
2. Tag and disconnect the hydraulic tubing going into Removal

the control valve. Cap or plug all openings.
1. Disconnect the pedal linkage from the control
3. Lower the armrest and remove the bolts securing valve.
the control valve to the armrest. Remove the control
valve. 2. Tag and disconnect the hydraulic lines from the
control valve.
Installation
3. Remove the bolts, nuts, and washers securing the
1. Position the valve to the armrest and secure in control valve to the mounting bracket and remove the
place with the attaching bolts. valve.
2-8-30
Installation 3. Connect the pedal linkage to the control valve.
Functional Check
1. Position the valve onto the mounting bracket and
secure in place with the bolts, nuts and lockwashers. With the engine running at governed rpm, telescope the
boom the whole way out and then the whole way back in.
2. Connect the hydraulic lines to the valve as tagged Check for proper operation and check the valve for any
during Removal. leakage.
3G
60
86
2-8-31
MASTER CYLINDER
DESCRIPTION
The master cylinder is located beneath the turntable cab pose of the cylinder is to reapply the swing brake during
floor and is attached to the swing brake pedal. The pur- free swing operation.
MAINTENANCE
NOTE

1. Disconnect the clevis on the master cylinder from 1. Position the cylinder on its mounting and secure it
the swing brake valve. in position, using nuts, bolts and washers.
all openings.
3G
2. Tag and disconnect all hydraulic lines. Cap or plug
2. Reconnect the clevis on the master cylinder to the
swing brake valve.
3. Connect the hydraulic lines as tagged prior to re-

3. Remove nuts, bolts and washers securing the cyl- moval.
inder to the bracket.
4. Bleed the cylinder (refer to the SM package on the
60
4. Remove the cylinder to a clean work area. master cylinder).
86
2-8-32
AUXILIARY HOIST CONTROL VALVE (HO-30B HOIST)
DESCRIPTION
The auxiliary hoist control valve is designed to provide its seat. This allows flow to the return reservoir through
an even flow of oil to the hoist motor in both directions. the directional control valve.
To drive the hoist motor in the raise direction, hydraulic

An orifice plug is installed in the pilot pressure port to re-
oil flows through the in port and pushes the free flow
strict back flow when the directional control valve is
poppet off its seat. The oil then flows to the out port and
closed. The restriction prevents the pilot operated pop-
on to the hoist drive motor.
pet from chattering on its seat.
When driving the hoist motor in the lower direction, oil
from the directional control valve enters the out port. The A vent is provided that vents the area between the pilot
pilot operated poppet is held shut by the adjustment piston seal and the free flow poppet and pilot operated
spring until pressure of sufficient force is sensed at the poppet seals to prevent a hydraulic lock should
pilot pressure port to move the pilot operated poppet off weepage around the seals occur.
MAINTENANCE
3G NOTE

60
1. Position the valve and secure in place with the bolts
and washers.
1. Tag and disconnect the hydraulic lines running to
the valve. Cap or plug all openings. 2. Connect the hydraulic lines to the valve as tagged
during removal.
86
3. Operate the control lever(s) of the affected cir-

2. Remove the bolts and washers securing the valve cuit(s). Check for smooth operation of cylinders and mo-
and remove the valve. tors. Check the valve bank(s) and lines for leakage.
2-8-33
SOLENOID OPERATED CONTROL VALVES
DESCRIPTION
The valve is held in its normally closed position by a lower circuit, dump system, axle raise, suspension
spring. When the solenoid is energized, the plunger as- blocking and three valves mounted on the module for
sembly forces the spool to shift, causing the valve to control of the crane functions. A further eight valves are
open. De-energizing the solenoid causes spring pres- used for the operation of the outrigger cylinders and sta-
sure to shift the spool to its normally closed position. A bilizers. Four port double operated solenoid valves are
four port single operated solenoid valve is used in the used in the rear axle steering from the turntable circuit.
turntable cab steering control system, the auxiliary hoist
MAINTENANCE
NOTE

REMOVAL
1. Tag and disconnect the hydraulic lines running to

the selector valve. Cap or plug all openings.
3G INSTALLATION
1. Position the valve and secure in place with the

bolts, nuts, and washers.
2. Remove the bolts, nuts, and washers securing the 2. Connect the hydraulic lines to the valve as tagged
valve and remove the valve. during removal.
60
86
2-8-34
HOLDING VALVES - TELESCOPIC CYLINDERS
DESCRIPTION
Holding valves are utilized on the crane, one in each block of their respective cylinder.
telescope cylinder. Both valves are installed in the port
MAINTENANCE
NOTE

REMOVAL CAUTION
DO NOT DAMAGE THE O-RINGS DUR-

1. To remove the holding valve, unscrew it from the ING INSTALLATION OF THE HOLDING
port block. VALVE. IF THE HOLDING VALVE
INSTALLATION
3G TURNS FREELY THEN GETS HARD TO
TURN, THEN EASY TO TURN; REMOVE
THE HOLDING VALVE AND CHECK
THE O-RINGS. THEY HAVE PROBABLY
BEEN DAMAGED BY A SHARP EDGE
1. Check the inside of the port block for any sharp OF A PORT.
edges or burrs and remove as necessary with emery
60
cloth. NOTE
The holding valve should turn by hand

2. Install new O-rings onto the holding valve. until compression of the O-rings be-
gins.
86
3. Lubricate the holding valve and O-rings with clean 4 Carefully install the holding valve into the port block
hydraulic oil. until fully seated.
2-8-35
COUNTERBALANCE VALVE
DESCRIPTION
The counterbalance valve is fitted to the hoist unit. The the hoist motor, in both directions.
purpose of the valve is to provide and even flow of oil to
MAINTENANCE
NOTE

1. Tag and disconnect all lines to the counterbalance 1. Relocate the flange adaptors on the counterbal-
valve. Cap or plug all ports and openings. ance valve complete with new O-rings.
2. Remove the counterbalance valve mounting

screws.
3. Remove the counterbalance valve to a clean work

3G 2. Secure the flange adaptors with their mounting
screws.
area. 3. Position the counterbalance valve on its mounting

and secure it with mounting screws.
4. Remove the flange adaptor mounting screws, and
60
remove the flanges adaptors complete with their O- 4. Install all lines to the valve as tagged prior to re-
rings. moval.
86
2-8-36
VALVE BLOCKING
DESCRIPTION
The valve is mounted to the steering valve plate assem- from the main pump to the emergency steer pump, to
bly, located beneath the carrier cab. Should one of the ensure the flow of hydraulic oil to the steering system.
main steer pumps fail, the valve automatically changes
MAINTENANCE
NOTE

1. Clean the surfaces of the valve. 1. Locate the valve on its mounting and secure in po-
3G sition using nuts, bolts and washers.
all ports and openings.
2. Connect all hydraulic lines as tagged prior to re-
3. Remove the nuts, bolts and washers securing the moval.
valve to the steering valve plate.
3. Check for any leaks and that the valve and steering
4. Remove the valve to a clean work area. is functioning correctly.
60
86
2-8-37
RELIEF VALVE
DESCRIPTION
The relief valve is fitted on the accumulator assembly in divert excess hydraulic pressure back to the hydraulic
the hydraulic system. The purpose of the relief valve is to tank.
MAINTENANCE
NOTE

1. Tag and disconnect all lines to the valve. Plug or 1. Position the valve on its mounting, and secure it in
cap all ports and openings. position using the appropriate hardware.
2. Remove any hardware securing the valve to its

mounting.
3. Remove the valve to a clean work area.

3G 2. Install all lines to the valve as tagged prior to re-
moval.
3. Check all connections for leaks.

60
86
2-8-38
CHECK VALVE
DESCRIPTION
The pilot operated check valve, is located in the port normally closed and is opening by pilot pressure.
block on the outrigger stabilizer cylinder. The valve is
MAINTENANCE
NOTE

REMOVAL CAUTION
DO NOT DAMAGE THE O-RINGS DUR-

1. To remove the check valve unscrew it from the port ING INSTALLATION OF THE CHECK
block on the cylinder. VALVE. IF THE CHECK VALVE TURNS
INSTALLATION
3G FREELY THEN GETS HARD TO TURN,
THEN EASY TO TURN; REMOVE THE
CHECK VALVE AND CHECK THE O-
RINGS. THEY HAVE PROBABLY BEEN
DAMAGED BY A SHARP EDGE OF A
1. Check the inside of the port for any sharp edges or PORT.
60
burrs. Remove as necessary with emery cloth.
NOTE
The check valve should turn by hand

2. Install new O-rings on the check valve. until compression of the O-rings be-
gins.
86
3. Lubricate the check valve and O-rings with clean 4. Carefully install the check valve into the port block
hydraulic oil. until fully sealed.
2-8-39
CYLINDER COUNTERWEIGHT REMOVAL
DESCRIPTION
The counterweight removal cylinders are of the double The cylinders have a bore of 4 inches (101mm). The re-
acting type and are mounted to the counterweight pan- tracted length of the cylinders from the barrel end to the
niers. The cylinders are used for lifting and removing ad- centre of the eye is 41.75 inches (1060mm) and has a
ditional ballast into position when required. stroke of 31.5 inches (800mm).
MAINTENANCE
NOTE

REMOVAL 3. Remove the cylinder to a clean work area.
INSTALLATION
1. Remove the counterweight. For detailed informa- 3G
tion concerning the removal and installation of the coun-
terweights refer to Section VII in the Superstructure Op-
erator’s and Safety Handbook.
1. Position the cylinder on it’s mounting.
2. Secure the cylinder in position using the bolts and

spring washers.
1. Tag and disconnect all hydraulic lines to the cylin-
3. Connect all hydraulic lines to the cylinder as tagged
60
der. Cap or plug all ports and hose ends.
prior to the removal.
2. Remove bolts and spring washers securing the cyl- 4. Check for correct operation of counterweight re-
inder to the pannier. moval system and any possible leaks.
86
2-8-40
CYLINDERS
DESCRIPTION
This sub assembly provides descriptive information for For information on how the cylinder functions in the indi-
all the hydraulic cylinders used on this crane. The de- vidual circuits, refer to the Description and Operation of
scription of the cylinder given here is for the cylinder it- that circuit.
self.
MAINTENANCE
GENERAL nents. The resulting value is the number of degrees

each wear ring gap is to be located with respect to each
There must be a gap between the ends of each wear ring other.
when it is installed onto the piston or head. In addition,
each wear ring gap is to be located as follows. Divide
360 degrees by the number of wear rings on the compo- The approximate wear ring gaps are as follows.
PISTON WEAR RING GAP
Piston Size
3G Wear Ring Gap
Inch mm Inch mm
60
1 to 4.75 25.4 to 120.65 0.125 3.175
5.5 to 10.0 139.70 to 254.00 0.187 4.750
greater than 10.0 greater than 254.00 0.250 6.350

86
HEAD WEAR RING GAP
Head Size Wear Ring Gap
Inch mm Inch mm
1 to 4.75 25.4 to 120.65 0.125 3.175
5.0 to 10.0 127.00 to 254.00 0.187 4.750
greater than 10.0 greater than 254.00 0.250 6.350
2-8-41
LEAKAGE CHECK 4. Apply hydraulic pressure to the retract (rod) side of
the cylinder and observe the open cylinder port for leak-
A hydraulic cylinder should not be disassembled unless age. If leakage is observed, the seals in the cylinder
it is essential. The following checks will provide a means must be replaced.
of determining if a cylinder has a faulty or leaking piston
seal.
5. Reconnect all cylinder ports.
1. Extend the rod to its maximum stroke. Disconnect
the retract hose from the cylinder. Cap the retract hose. NOTE
WARNING
Piston seal trouble may be due to either
ENSURE PRESSURE IS APPLIED TO worn or damaged seals or to a scored
THE PISTON SIDE OF THE CYLINDER cylinder. A scored cylinder is usually
ONLY AND THE RETRACT HOSE IS caused by abrasive contaminates in
CAPPED. the hydraulic oil and is likely to reoccur
unless the system is drained, thor-
2. Apply hydraulic pressure to the piston side of the
oughly cleaned, and filled with clean,
cylinder and observe the open cylinder port for leakage.
filtered hydraulic oil.
If leakage is observed, the seals in the cylinder must be
replaced.
3. Fully retract the cylinder rod. Disconnect the EX-

TEND hose from the cylinder. Cap the extend hose.
3G TEMPERATURE EFFECTS ON HYDRAULIC CYLIN-
DERS
WARNING The following chart has been compiled to assist you in

determining the approximate amount of retraction that
ENSURE PRESSURE IS APPLIED TO may be expected from an hydraulic cylinder as a result
60
THE RETRACT (ROD) SIDE OF THE of change in temperature of hydraulic oil. The chart is for
CYLINDER ONLY AND THAT THE EX- dry rod cylinders. Where the cylinder rod is filled with oil
TEND HOSE IS CAPPED. the contraction rate is somewhat grater.
INCH MM INCH MM
(3OFT STROKE) 9.15M

46 18 46 18
86
38 15 38 15
(2OFT STROKE) 6.1M

30 12 30 12
APPROXIMATE CYLINDER
CONTRACTION - INCHES/MM
(ANY DIAMETER CYLINDER)
23 9 23 9
(1OFT STROKE) 3.05M

15 6 15 6
(5FT STROKE) 1.52M

8 3 8 3
0 0
0° 10° 20° 30° 40° 50° 60° 70° 80° 90° 100° °F
-18 -12 -7 -1 8 10 15.6 21 27 32 38 °C
2-8-42
HYDRAULIC OIL COOLER
DESCRIPTION
An air cooled hydraulic oil cooler is mounted on the right A temperature switch installed in the return manifold
side of the turntable. The oil cooler consists of a hydrau- control the operation of the fan motor.
lic radiator and a fan. The fan directs cool air through the
cooling fins on the cooler.
THEORY OF OPERATION
If the hydraulic oil reaches a temperature of 50° C, the the fan motor. The fan remains operational until the oil
temperature switch fitted in the return manifold activates cools to safe operating temperature.
MAINTENANCE

all openings.
3G 1. Position the oil cooler on it’s mounting.
2. Secure the oil cooler using the nuts, bolts and

washers (items 4, 5, 6 7 and 8).
2. Remove nuts, bolts and washers, (items4, 5, 6, 7
and 8).
3. Install the hydraulic lines as tagged prior to the re-
moval.
60
3. Remove the oil cooler to a clean work area.
TEMPERATURE SWITCH
NOTE
When replacing a temperature switch in the return mani-
If a new oil cooler is to be fitted remove fold, it is important the correct maximum torque of 2.5
all fittings and clean them thoroughly kgm (18lbs/ft) is not exceeded. Over tightening will frac-
86
before installing them in the new oil ture the body, therefore the use of a suitable torque
cool. Ensure new seals are used. wrench is recommended.
2-8-43
1
4
6
2 3
7
8
6
3G 9
10, 11, 12
60
1. Cooler Complete
2. Seal Dowty
3. Adaptor
86
4. Screw
5. Screw Hexagonal Head
6. Washer Plain
7. Washer Spring
8. Nut
9. Adaptor
10. Shim 1mm
11. Shim 3mm
12. Shim 6mm
Hydraulic Oil Cooler Installation
2-8-44
SECTION 9
SWING SYSTEM
TABLE OF CONTENTS
Page
SWING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-5

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-6
SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
3G
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-9
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-10
SWING GEARBOX AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
60
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-11
86
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-12
Swing Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-12
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-12
SWING BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-14
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-14
Torquing Turntable Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-14
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-15
Inner Race Torquing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-16
Outer Race Torquing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-17
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-18
2-9-1
LIST OF FIGURES
Title Page
Setting Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-17
Outer Ring Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-19
Inner Ring Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-20
Special Turntable Bolt Torquing Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9-21
Page
2-9-9
WARNING
MINOR CONCENTRATIONS OF ACE-

TIC ACID VAPOR MAY BE PRODUCED
DURING APPLICATION. ADEQUATE
VENTILATION SHOULD BE PROVIDED
CONFINED AREAS.
3G
WHEN SILICONE RTV IS APPLIED IN
2-9-9
WARNING
EYE CONTACT WITH THESE SILI-

CONE RTV MATERIALS MAY CAUSE
60
IRRITATION. IF EYE CONTACT TAKES
PLACE, FLUSH THE EYES WITH
WATER FOR 15 MINUTES AND HAVE
THE EYES EXAMINED BY A DOCTOR.
2-9-11
86
WARNING
MINOR CONCENTRATIONS OF ACE-

DURING APPLICATION. ADEQUATE
CONFINED AREAS.
2-9-12
WARNING
EYE CONTACT WITH THESE SILI-

CONE RTV MATERIALS MAY CAUSE
IRRITATION. IF EYE CONTACT TAKES
PLACE, FLUSH THE EYES WITH
WATER FOR 15 MINUTES AND HAVE
THE EYES EXAMINED BY A DOCTOR.
2-9-2
Page
2-9-14
WARNING
FAILURE TO MAINTAIN PROPER

TORQUE OF THE TURNTABLE BEAR-
ING ATTACHING BOLTS WILL RESULT
IN DAMAGE TO THE CRANE AND POS-
SIBLE INJURY TO PERSONNEL.
2-9-15
WARNING
IT IS MANDATORY THAT BEARING AT-

TACHING BOLTS BE INSPECTED FOR
LACK OF TORQUE AND RETORQUED,
AS REQUIRED, AFTER THE FIRST 300
HOURS OF CRANE OPERATION. THE
3G
BOLTS MAY LOOSEN IN SERVICE DUE
TO VIBRATION, SHOCK-LOADS, AND
TEMPERATURE CHANGES. THERE-
FORE, PERIODIC INSPECTION
SHOULD BE ACCOMPLISHED EVERY
500 HOURS THEREAFTER, ENSURING
THE BOLTS ARE PROPERLY
60
TORQUED.
2-9-16
WARNING
ENSURE THE LIFTING DEVICE IS CA-

86
PABLE OF FULLY SUPPORTING THE

WEIGHT OF THE TURNTABLE. EN-
SURE THE TURNTABLE WILL NOT
TILT OR SLIDE DURING LIFTING AND
MOVING. FAILURE TO DO SO MAY RE-
SULT IN DEATH OR INJURY TO PER-
SONNEL AND DAMAGE TO EQUIP-
MENT.
2-9-16
WARNING
ENSURE THE TURNTABLE IS FULLY

SUPPORTED BEFORE PROCEEDING.
Page
2-9-3
2-9-17
WARNING
ENSURE THAT ANY BLOCKING MATE-

RIAL USED IS CAPABLE OF FULLY
SUPPORTING THE WEIGHT OF THE
TURNTABLE AND WILL NOT ALLOW
IT TO TILT OR SHIFT. FAILURE TO DO
SO MAY RESULT IN DEATH OR INJURY
TO PERSONNEL.
2-9-17
WARNING
ANYTIME A TURNTABLE BOLT HAS

BEEN REMOVED, IT MUST BE RE-
PLACED WITH A NEW SAME GRADE
BOLT AND NUT.
3G
60
86
2-9-4
SWING SYSTEM
DESCRIPTION
The turntable has full 360 degree rotation in both direc- gaged from the cab. A brake pedal and swing brake con-
tions and is equipped with free swing. A pin type swing trol are used to stop rotation.
lock is fitted to lock the turntable in position. The pin type The swing system consists of the hydraulic remote pilot
swing lock consists of a round pin and a retainer weld- control valve, control valve, pressure reducing valve,
ment which locks the turntable with the boom straight brake pedal two position selector valve, swing drive, and
over the front or rear. The lock is engaged and disen- swing brake assembly.
THEORY OF OPERATION
The system is supplied by the rear section of a four sec- Pilot pressure signals from the hydraulic remote control
tion pump at the rate of 21.9 U.S. gpm (83 lpm). The valve in the turntable cab, causes the spool in the selec-
pump supplies oil to the ballast removal system as well tor valve to move. The movement of the remote control
as the swing system selector control valve. valve is proportional to the movement of the swing. If the
3G
Pilot pressure for the swing system is supplied by a dedi- swing brake control switch is in the disengage position,
cated pilot supply pump mounted on the turntable en- the turntable will rotate in the direction selected by the
gine. The oil pressure is reduced from 50 bar to 31 bar by hydraulic remote control. The swing brake is operated
a pressure reducing valve, before feeding the pilot con- via a brake pedal connected to a master cylinder, the oil
trols. supply being drawn from the drain line.
60
86
2-9-5
MAINTENANCE
TROUBLESHOOTING
SYMPTOM PROBABLE CAUSE SOLUTION

1. Boom swing a. Damaged relief valve. a. Replace relief valve.
operation erratic
in either direction.
b. Swing brake dragging b. Readjust and/or replace
(not releasing properly) necessary parts.
c. Low engine rpm c. Increase engine rpm
to obtain smooth
swing operation.
d. Low hydraulic oil. d. Replenish hydraulic oil
to proper level.
e. Improper movement e. Feather controls to
of control lever to neutral to maintain smooth
neutral. stopping action.
f.
g.
3G
Insufficient lubricant
on swing bearing.
Crane not level.

f.
g.
Lubricate bearing properly
(Refer to Section 15 -
LUBRICATION).
Level crane using
outriggers.
h. Damaged swing h. Repair or replaced swing
motor. motor.
60
i. Excessive overload. i. Reduce load (Refer to
load capacity chart)
j. Restricted or partly j. Replace hose of fittings.
clogged hydraulic hose
or fittings.
k. Pump cavitation in k. Retighten suction hose or
swing section. replace any damaged
86
fitting.
l. Improperly torqued l. Torque turntable bolts
turntable bolts. evenly.
m. Excessive preload on m. Adjust as necessary.
upper and lower
pinion shaft bearing.
n. Improperly torqued n. Torque swing motor
swing motor attachment attachment bolts.
bolts.
o. Malfunction of the o. Remove swing box and
swing box. make necessary repairs.
p. Worn or damaged p. Repair or replace
pump section. damaged section.
q. Damaged pressure q. Repair or replace valve.
reducing valve.
2-9-6
2. Boom swing a. Crane not level. a. Level crane using

operation erratic outriggers.
in one direction
only.
b. Turntable bearing b. Rotate machine 360
binding due degrees in both directions
continuous limited several times and
swing (Example: lubricate turntable bearing.
concrete pourer).
c. Restricted hose or b. Replace hose or fitting.
fitting.
d. Damaged swing d. Replace pinion.
pinion.
3. Boom will not a. Damaged relief a. Remove, clean, and

swing in either valve. repair or replace relief
direction. valve.
b. Damaged swing b. Repair or replace swing
motor. motor.
c. Swing brake not c. Repair as necessary.
d.
3G
releasing properly.
Completely inoperative
pressure reducing
valve.
d. Replace pressure
reducing valve.
e. Internal damage to e. Remove swing box and

swing box. repair.
f. Worn or damaged f. Replace pump section.
60
hydraulic pump
section.
4. Swing operation a. Damaged relief a. Adjust, repair or replace

slow in either valve. valve.
direction
86
b. Improperly adjusted b. Readjust.

swing brake.
c. Improperly adjusted c. Adjust valve. (Refer to
pressure reducing VALVES in Section 8).
valve.
d. Improperly lubricated d. Lubricate bearing per
swing bearing. recommendations.
e. Improper size hose e. Refer to manufacturer’s
and/or fittings installed. specifications.
f. Clogged or restricted f. Clean or replace
hydraulic hoses or damaged parts.
fittings.
g. Worn or damaged g. Replace bearings.
output shaft bearings.
h. Worn or damaged h. Repair or replace motor.
swing motor.
i. Worn or damaged i. Repair or replace pump
hydraulic pump section. section.
2-9-7
5. Swing operation a. Crane not level. a. Level crane.

slow in one
direction only.
b. Clogged or restricted b. Replace hose or fitting.
hose.
c. Improperly torqued c. Retorque turntable
turntable bearing. bearing.
6. Swing brake a. Improper brake a. Adjust brake.

operation erratic. adjustment.
b. Brake pedal not b. Check brake pedal.
fully retracted.
c. Dirty of glazed brake c. Clean or replace linings.
pad linings.
d. Kinked or bent lines d. Straighten or replace as
and/or hoses and required.
fittings.
7. Swing brake a. Internal damage to a. Repair or replace
8.
system will not
operate.
Boom swings
slowly.
a.
3G
the swing brake
assembly.
Insufficient hydraulic
volume.
a.
affected parts.
Check delivery of
hydraulic pump. Ensure
sufficient fluid is available
to pump. Check pump
drive speed.
60
b. Damaged pressure b. Adjust, repair or replace
reducing valve. valve.
c. Damaged swing motor. c. Repair or replace motor
.
9. Swing motor a. Control valve spool a. Repair or replace valve.
continues to sticking or valve
86
operate when swing otherwise damaged.

control is in neutral
position.
10. Swing motor a. Improper port a. Reverse port

turning in wrong connections. connections.
direction.
11. Swing motor a. Air in system. a. Refer to Section 8 -

noisy. HYDRAULICS for removal
or air from the system.
b. Motor binding. b. Repair or replace motor.
2-9-8
SWING MOTOR
DESCRIPTION
The swing motor is mounted on top of the swing gearbox After the brake releases the motor drives the gearbox
which is located to the right hand side of the turntable. through the brake.
NOTE

MAINTENANCE
REMOVAL WARNING
EYE CONTACT WITH THESE SILICONE

1. Ensure the swing brake is engaged.
RTV MATERIALS MAY CAUSE IRRITA-
3G
2. Clean the port area around the motor. Tag and dis-
connect the hydraulic hoses from the motor assembly.
Cap or plug all openings.
TION. IF EYE CONTACT TAKES PLACE,
FLUSH THE EYES WITH WATER FOR 15
MINUTES AND HAVE THE EYES EXAM-
INED BY A DOCTOR.
a. Remove dirt, grease, or moisture from the surfaces

CAUTION
to be sealed.
60
PULL STRAIGHT UP ON THE MOTOR b. Dry the surfaces.
ASSEMBLY TO AVOID DAMAGING THE
SPLINED SHAFT. c. Apply a thin bead, maximum 0.125 inch (3.175mm)
diameter, completely around one mating surface and all
fasteners holes to ensure complete sealing and prevent
86
3. Remove the bolts and washers securing the motor

leakage.
and lift the swing motor free.
d. Assemble the components immediately to permit
INSTALLATION silicone RTV gasket material to spread evenly.
CAUTION
1. Apply a thin film of silicone RTV sealant between
the motor and swing gearbox. USE CARE WHEN ENGAGING THE
SWING MOTOR DRIVE GEAR WITH
WARNING THE SWING GEARBOX DO NOT
FORCE THE SHAFT TO ENGAGE.
MINOR CONCENTRATIONS OF ACE- 2. Install the swing motor on the swing gearbox with
TIC ACID VAPOR MAY BE PRODUCED the nuts and washers. Torque the nuts to 83 pounds-foot
DURING APPLICATION. ADEQUATE (12 kgm).
WHEN SILICONE RTV IS APPLIED IN 3. Connect the hydraulic hoses to the swing motor, as
CONFINED AREAS. tagged prior to removal.
2-9-9
TEST 2. Inspect for hydraulic leaks and repair as neces-
1. Test swing of turntable in each direction. Stop and sary.
start swing several times.
3G
60
86
2-9-10
SWING GEARBOX AND BRAKE
DESCRIPTION
The swing gearbox and brake, used in conjunction with SWING GEARBOX
the swing motor, provides the rotating force for turntable
rotation and the means of stopping the turntable rotation The swing gearbox is bolted to the turntable base plate,
to prevent swing. and its pinion gear meshes with the ring gear of the turn-
table bearing to rotate the turntable. The swing brake is
installed on the side of the gearbox and the swing motor
SWING BRAKE
is mounted on top of the gearbox.. The swing motor
drives the gearbox. The swing gearbox utilizes double
The multi-disc swing brake assembly is mounted in the reduction planetary gearing which results in a compo-
side of the swing gearbox. The brake mechanism is a nent circular unit of high strength and efficiency. The
disc pack that is hydraulically released and spring ap- round gear case with horizontal rotating gears ensures
plied. The brake has one hydraulic port, and a drain lubricant circulation.
MAINTENANCE
3G NOTE

60
NOTE 6. Cover the brake port and the swing motor opening
to ensure that no dirt, dust, etc., gets into the gearbox.
The swing brake can be removed and
disassembled independently of the
Installation
swing gearbox.
86
SWING BRAKE 1. Lightly coat of the brake and the shaft splines with
NEVER-SEEZE compound.
Removal
2. Remove dirt, grease, or moisture from the surface
1. Ensure that the turntable lock pin is installed.
to be sealed.
Scribe a line along the sides of the brake, and gearbox to
aid in correct alignment at assembly.
3. Dry the surfaces
2. Disconnect and tag all hydraulic lines to the brake.
Cap or plug all openings. WARNING
3. Remove the motor. Refer to SWING MOTOR RE-

MOVAL in this section. MINOR CONCENTRATIONS OF ACE-
4. Remove the nuts and washers securing the brake DURING APPLICATION. ADEQUATE
to the gear housing. Remove the brake. VENTILATION SHOULD BE PROVIDED
5. Carefully remove the brake assembly. CONFINED AREAS.
2-9-11
WARNING NOTE
EYE CONTACT WITH THESE SILICONE The three sections that make up the
RTV MATERIALS MAY CAUSE IRRITA- swing gearbox assembly are held to-
TION. IF EYE CONTACT TAKES PLACE, gether by flanges and bolts. Prior to
FLUSH THE EYES WITH WATER FOR 15 separation, fine scribe lines should be
MINUTES AND HAVE THE EYES EXAM- made at each joint to serve as an align-
INED BY A DOCTOR. ment guide on assembly. Proceed with
removal of bolts. If sections resist
4. Apply a thin bead, maximum 0.125 (3.175mm) di- separation, tap on sides with fibre or
ameter, completely around one mating surface and all rubber mallet. DO NOT use a pry bar to
fasteners holes to ensure complete sealing and prevent force separation.
leakage.
3. Refer to SWING MOTOR - REMOVAL in this sec-
5. Assemble the components immediately to permit tion and remove the swing motor.
the silicone RTV gasket to spread evenly.
4. Refer to SWING BRAKE - Removal in this section
NOTE and remove the swing brake.
5. Remove the sixteen bolts securing the swing gear-

Do not use force when assembling the
box assembly to the mounting plate on the turntable
units as it may result in damage to the
units.
6. Secure in position using nuts and washers, and

3G base plate.
6. Use a suitable lifting device and remove the swing

gearbox from the turntable.
torque to 32 lb/ft (4.5 kgm).
Installation
7. Connect all hydraulic lines as tagged prior to re-
60
moval. 1. Refer to SWING BRAKE - INSTALLATION in this
section and install the swing brake.
Test
2. Refer to SWING MOTOR - INSTALLATION in this
1. Test brake to ensure it is functioning correctly. section and install the swing motor.
86
2. Inspect for hydraulic leaks and repair as neces- 3. Using an adequate lifting device, lift and position
sary. the assembly onto the turntable.
4. Install the sixteen bolts securing the swing gearbox

SWING GEARBOX
to the mounting plate on the turntable base plate. Torque
Removal the bolts to 128 lbs/ft (18 kgm) lubricated with 80W/90.
5. Connect the hydraulic lines to the swing motor and

1. Ensure the turntable lock pin is installed.
brake as tagged during removal.
2. Disconnect and tag the hydraulic lines from the Servicing
swing motor and swing brake.
Normal maintenance should only consist of proper lubri-
NOTE cation and a periodic check of mounting bolt torque val-
ues, refer to SM package.
The swing motor and swing brake may
or may not be removed at this time. If Lubrication consists of lubrication of the pinion gear
not removing at this time, proceed to shaft bearings, and maintaining the gearbox oil level. Oil
step 6. in a new gearbox should be drained and flushed out af-
2-9-12
ter one month of use and subsequent oil change should NOTE
be scheduled after approximately 1000 hours of opera- Cleaning of the gearbox with a solvent
tion on each year, whichever occurs first. Operation in is recommended to prevent an accu-
high humidity or polluted air areas will require more fre- mulation of grit and grime. Avoid steam
quent changes to minimize moisture or contaminate ac- cleaning where moisture and dirt might
cumulation. be driven into the vent of the swing box.
3G
60
86
2-9-13
SWING BEARING
DESCRIPTION
The swing bearing is designed to transmit axial and ra- After machining, the races are induction hardened then
dial loads as single unit during 360 degrees of rotation. polished, before the polishing commences the visible
areas of discolour where heating commenced and fin-
The rings are made from rolled and profiled sections of ished are stamped ”SZ”, this is referred to as the ”soft
high quality medium carbon steel heat roller to a circle zone” and should be positioned in a staggered formation
and flash butt welded while the larger rings are seam- so that no two zones can overlap when loaded over the
less forged. side or rear of the machine.
MAINTENANCE
NOTE

GENERAL
3G
The swing bearing is the most critical maintenance point
Maintaining proper torque value for bolts is extremely
important for structural strength, performance, and reli-
ability of the crane. Variations in torque can cause distor-
of the crane. It is here, at the centreline of rotation, that tion, binding, or complete separation of the turntable
stresses of loads are concentrated. In addition, the from the carrier.
bearing provides the only attachment between the turn-
CAUTION
60
table and carrier. Therefore, proper care of the bearing
and periodic maintenance of the turntable-to-bearing at- REPEATED RETORQUING MAY CAUSE
tach bolts - IS A MUST - to ensure safe and efficient op- BOLTS TO STRETCH. IF BOLTS KEEP
eration. WORKING LOOSE, THEY MUST BE RE-
PLACED WITH NEW BOLTS OF THE
86
TORQUING TURNTABLE BOLTS PROPER GRADE AND SIZE.
Proper identification of bolt grade is important. When

General
marked as a high strength bolt, the serviceman must be
aware of bolt classifications and that he is installing a
WARNING high strength heat-treated tempered component and
the bolt must be installed according to specifications.
FAILURE TO MAINTAIN PROPER Special attention should be given to the existence of lu-
TORQUE OF THE TURNTABLE BEAR- bricant and plating that will cause variation from dry
ING ATTACHING BOLTS WILL RESULT torque values. When a high strength bolt is removed, or
IN DAMAGE TO THE CRANE AND POS- untorqued, the bolt must be replaced with a new bolt of
SIBLE INJURY TO PERSONNEL. the same classification.
2-9-14
WARNING torque wrench any erratic or jerking motion can result in
the application of excessive or improper torque. AL-
IT IS MANDATORY THAT BEARING AT- WAYS use a slow, even movement and STOP when the
TACHING BOLTS BE INSPECTED FOR predetermined value has been reached.
LACK OF TORQUE AND RETORQUED,
AS REQUIRED, AFTER THE FIRST 300 If if is reported by the crane operator or suspected that
HOURS OF CRANE OPERATION. THE the crane has been overloaded beyond the capacities
BOLTS MAY LOOSEN IN SERVICE DUE specified above the bolt line on the cranes’ capacity
TO VIBRATION, SHOCK-LOADS, AND chart, then all turntable bolts must be inspected for
TEMPERATURE CHANGES. THERE- looseness and retorqued to specifications.
FORE, PERIODIC INSPECTION Turntable bolts should be torqued diametrically op-
SHOULD BE ACCOMPLISHED EVERY posed, working in sequence from one side of the circle to
500 HOURS THEREAFTER, ENSURING the opposite side rather than tightening adjacent bolts
THE BOLTS ARE PROPERLY successively. torque first to 50% then to the final torque
TORQUED. value.
All bolts should be checked at the annual inspection us- When using step wrenches, calculated wrench settings
ing torque measuring equipment to ensure that they are are valid only when the following conditions are met.
tightened to the correct degree of pre stress. If one or
1. Torque wrenches must be those specified and
more bolts are found to be tightened to less than 80% of
3G forces must be applied at the handle grip. The use of
the prescribed pre stress, the loose bolt or bolts should
handle extensions will change applied torque to the bolt.
be replaced, as should the two adjacent bolts. If 20% of
the total number of bolts in a single ring are found to be 2. All handles must be parallel to the step wrench dur-
tightened to less than 80% of the prescribed pre stress, ing final tightening. Multiplier reaction bars may be
all bolts should be replaced. Replacement bolts should misaligned no more than 30 degrees without causing
always be tightened progressively in the sequence indi- serious error in torque.
cated under the headings inner and outer race torquing
60
3. Multiplier bar handles must be propped or sup-
procedures.
ported within the outer 1/4 of the handle length, or seri-
KNOW YOUR TORQUE WRENCH! Flexible beam type ous under or over tightening will occur.
wrenches, even though they might have a pre-set fea- The inner face of the bearing is secured to the carrier by
ture, must be pulled at right angle and the force must be 40 1.25 UNC Grade 8 bolts. The outer race of the bear-
86
applied at the centre of the handle. Force value readings ing is secured to the turntable by 36 1.25 UNC Grade 8
must be made while the tool is in motion.Rigid handle bolts.
type, with toque limiting devices that can be pre-set to
required values, eliminate dial readings and provide Torque Values
more reliable less variable readings.
Torque all turntable bolts to 1810 pounds-foot (250.24
kgm).
NOTE
Using the 4 to 1 multipliers and no step wrenches, set
If multipliers and/or special tools are the torque wrench for 255 pounds-foot (35.25 kgm).
used to reach hard to get at areas, en-
sure torque readings are accurate. Inner Race Torquing Procedure
1. Torque all bolts to a preliminary torque valve of 900

Torque wrenches are precision instruments and must be
pounds-foot (12.5 kgm) torque the bolts in the order as
handled with care. To ensure accuracy, calibrations
shown in the illustration inner ring torque sequence 1.
must be made on a scheduled basis. Whenever there is
a possibility that a torque wrench may have been either 2. Torque all bolts to a final torque valve of 1810
overstressed or damaged, it should immediately be re- pounds-foot (250 kgs) torque the bolts in the sequence
moved from service until recalibrated. When using a as shown in the illustration inner ring torque sequence 2.
2-9-15
Outer Race Torquing Procedure 11. Tag and disconnect all air and hydraulic lines be-
tween the turntable and swivel coupling. Cap or plug all
1. Torque all bolts to a preliminary valve of 900 ports and openings.
pounds-foot (124.5 kgm) torque the bolts in the order as
shown in the illustration outer ring torque sequence 1. WARNING
2. Torque all bolts to a final valve of 1810 pounds-foot

ENSURE THE LIFTING DEVICE IS CA-
(250 kgm) torque the bolts in the sequence as shown in
PABLE OF FULLY SUPPORTING THE
the illustration outer ring torque sequence 2.
WEIGHT OF THE TURNTABLE, EN-
SURE THE TURNTABLE WILL NOT TILT
REMOVAL OR SLIDE DURING LIFTING AND MOV-
ING, FAILURE TO DO SO MAY RESULT
1. Fully extend and set the outriggers enough to take IN DEATH OR INJURY TO PERSONNEL
up the slack in the pads, locking the outrigger jacks in AND DAMAGE TO EQUIPMENT.
position.
CAUTION
NOTE
Do not raise the machine on the outrig- USE SPARE PIVOT SHAFTS OR OTHER
gers, 3G MATERIAL CAPABLE OF SUPPORT-
ING THE WEIGHT OF THE TURNTABLE.
DO NOT DAMAGE THE PIVOT SHAFT
2. Ensure the boom slightly and shut down the en-
BUSHINGS.
gine.
3. Elevate the boom slightly and shut down the en- NOTE
gine.
60
If a lifting device capable of lifting the
4. Tag and disconnect the battery cables from the bat- entire turntable is not available, turnta-
teries. ble weight may be reduced by remov-
ing various components such as the
5. Remove the boom and lift cylinder following the hoist(s) and counterweight.
86
procedure outlined in section 10, boom.

12. Install spare pivot shafts or other suitable material
6. Disengage the swing lock. through the lower lift cylinder pivot bushings and
through the boom pivot bushings.
7. Tag and disconnect all plugs and sockets on the
main turntable electrical harness. 13. Attach a suitable lifting device to the spare pivot
shafts and take in cable or chain to remove slack. Do not
8. Unclip the main turntable electrical harness and pull up on the turntable.
pull it clear of the turntable tracing its path back to the
electrical swivel coupling.
WARNING
9. Tie back the main turntable harness clear of the
turntable. ENSURE THE TURNTABLE IS FULLY
SUPPORTED BEFORE PROCEEDING.
10. Disconnect any further linkage between the electri-
cal swivel coupling and turntable which may inhibit the 14. Remove the bolts and washers securing the turnta-
removal of the turntable from the carrier frame. ble bearing to the carrier frame.
2-9-16
WARNING Installation
WARNING
ENSURE THAT ANY BLOCKING MATE-
RIAL USED IN CAPABLE OF FULLY ANYTIME A TURNTABLE BOLT HAS
SUPPORTING THE WEIGHT OF THE BEEN REMOVED, IT MUST BE RE-
TURNTABLE AND WILL NOT ALLOW IT PLACED WITH A NEW SAME GRADE
TO TILT OR SHIFT. FAILURE TO DO SO BOLT AND NUT.
MAY RESULT IN DEATH OR INJURY TO NOTE
PERSONNEL.
If the same bearing is to be used again,
align the marked teeth on the pinion
15. Carefully lift the turntable, and set it on blocking that
shaft and the marked teeth on the bear-
will not allow the turntable to tilt or shift, ensure the block-
ing.
ing provides access to the bearing from underneath.
Leave the lifting device attached. NOTE
If a new bearing is being installed, a

NOTE new pinion gear must also be used.
Align the high point ( maximum eccen-
Depending upon the manufacturer, the tricity) on the bearing with the new pin-
bearing weight between 780 and 837
pounds (354 and 380kg). Ensure the
bearing lifting device is capable of sup-
porting the weight.
3G ion gear high point.
SHIM
NOTE
60
If the same bearing is to be used again,

mark the pinion and bearing where the
teeth mesh (point of maximum eccen-
MAXIMUM
tricity). This will facilitate installation
86
ECCENTRICITY
when checking the gear backlash. TOOTH
PINION
16. Place a lifting device under the bearing.
17. Remove the bolts and washers securing the turnta- Setting Backlash
ble bearing to the turntable.
1. Using an appropriate lifting device, lift the turntable
bearing up to the turntable, aligning the marked high
18. Using the lifting device, remove the turntable bear- points. Use a 0.005 inch (0.127mm) thick shim to set the
ing from the turntable. backlash.
2. Install the bolts and washers securing the bearing

Inspection to the turntable. Torque the bolts in accordance with
TORQUING TURNTABLE BOLTS.
Check the bearing teeth for chipping or cracking. If any
CAUTION
evidence of these is found, replace the bearing. Ensure
the bolt holes are free of dirt, oil, or foreign material. REMOVE THE BACKLASH SHIM.
2-9-17
3. Using an appropriate lifting device, align the turnta- 8. Install the boom following the procedures outlined
ble over the carrier in the travel position and carefully in the boom group.
lower the turntable onto the carrier frame. Install the
bolts and washers and torque the bolts in accordance 9. Reconnect the batteries.
with TORQUING TURNTABLE BOLTS.
4. Connect any linkage removed on disassembly Testing

which inhibited the removal of the turntable.
Activate the crane and check for proper function.
5. Connect all air and oil lines to the swivel.
NOTE
6. Re-route the main turntable harness and clip in po-
sition.
If the turntable does not turn freely after
7. Reconnect all plugs and sockets all tagged prior to bearing and pinion replacement, con-
removal. tact Customer Services.
3G
60
86
2-9-18
Start
OUTER RING 36 1 2
TORQUE SEQUENCE 1 35 3
34 4
33 5
32 6
31 7
30 8
29 9
Front of the Carrier
28 19
18 20
17 21
16 22
3G
15
14
13
12 26
25
24
23
11 10 27
Start
60
OUTER RING 36 1 2
34 4
33 17
32 18
86
16 19
15 20
14 21
Front of the Carrier
13 9
26 10
25 11
24 12
23 27
22 28
8 29
7 30
6 5 31
2-9-19
INNER RING 10 21 22
8 24
7 25
6 26
5 27
4 28
3 29
2 30
Start 1 11
40 12
Front of the Turntable
39 13
38 14
37 15
3G 36
35
34
33 19
18
17
16
32 31 20
60
25 11 12
24 13
INNER RING 23 14
21 31
5 32
86
4 33
3 34
2 35
Start 1 6
40 7
39 8
38 9
Front of the Turntable
37 10
36 26
20 27
19 28
18 29
17 16 30
2-9-20
7
2
3G 6
5
60
Description Williams Tool No. Grove Part No. Quantity Required
1. 1 1/2” Socket 3/4” Drive 6-648 9-999-100143 1

2. Backlash Adapter ST-50ABR 9-999-100141 1
86
3. 4 to 1 Multiplier TM-750LW 9-999-100134 1

4. 1/2” Drive Torque Wrench STW-3RCF 9-999-100136 1
5. 13” Extension 3/4” Drive 6-113 9-999-100137 2
6. 10” Extension 3/4” Drive 6-110 9-999-100138 1
7. Tool Box (Optional) TB-11 9-999-100146 1
Orders for special tools shall be referred to:-
Grove Worldwide
Grove Europe
Crown Works
Sunderland SR4 6TT
Special Turntable Bolt Torquing Tools
2-9-21
86
60
3G
SECTION 10
BOOM
TABLE OF CONTENTS
Page
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-7
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-7
Fly Section Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-7
Fly Section Retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-11
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
3G
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
Boom Alignment and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-18
Boom Nose Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-20
60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-21
BOOM EXTENSION AND RETRACTION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-23
Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-23
86
TELESCOPE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-25

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-25
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-25
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-28
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-28
TELESCOPE CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-29
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-29
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-29
Venting Telescopic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-29
LIFT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-31
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-31
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-31
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-34
2-10-1
Page
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-35
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-36
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-36
HOSE REEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-37
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-37
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-37
SWINGAWAY BOOM EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-38
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-38
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-39
AUXILIARY BOOM NOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-41
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3G 2-10-41
LIST OF FIGURES
Title Page
Boom Assembly (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-9
60
Boom Assembly (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-10
Boom Assembly (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-11
Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-12
Shim and Spacer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-13
Front Lower and Side Wear Pad Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-13
Boom Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-19
86
Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-20

Boom Nose Sheave Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-22
Boom Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-24
Swingaway Boom Extension Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-40
Auxiliary Boom Nose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10-41
2-10-2
Page
2-10-8
WARNING
WEAR GLOVES WHEN HANDLING

WIRE ROPE.
2-10-8
WARNING
ENSURE ANY BLOCKING AND LIFT-

ING DEVICES ARE CAPABLE OF SUP-
PORTING THE BOOM ASSEMBLY AND
COMPONENTS.
2-10-8
WARNING
3G
ENSURE THE BOOM LIFT CYLINDER
IS PROPERLY SUPPORTED BEFORE
DISCONNECTING IT FROM THE
BOOM.
2-10-12
WARNING
60
WHEN EXTENDING/PULLING OUT
THE BOOM SECTIONS, ENSURE THAT
SUPPORTING AND LIFTING EQUIP-
MENT IS ADJUSTED TO EVENLY DIS-
86
TRIBUTE THE WEIGHT OF THE BOOM.

AT NO TIME MUST THE CENTRE OF
GRAVITY OF THE BOOM BE AL-
LOWED TO BE OUTSIDE THE LIFTING
POINTS OF THE LIFTING EQUIPMENT
OR OUTSIDE THE LIMITS OF THE SUP-
PORTING BLOCKS.
2-10-14
WARNING
NEVER HANDLE WIRE ROPE WITH

BARE HANDS.
2-10-15
WARNING

BARE HANDS.
2-10-3
Page
2-10-16
WARNING

BARE HANDS.
2-10-17
WARNING

BARE HANDS.
2-10-17
WARNING

BARE HANDS.
3GWARNING

2-10-17
BARE HANDS.
2-10-18
60
WARNING
IF YOU MUST ENTER OR WORK WITH

ANY PART OF YOUR BODY WITHIN
THE BOOM ALL POWER MUST BE
SHUT OFF AND THE BOOM SECTIONS
86
MUST BE ADEQUATELY BLOCKED TO

PREVENT ANY EXTENSION, RETRAC-
TION OR OTHER MOVEMENTS.
2-10-23
WARNING

BARE HANDS.
2-10-29
WARNING

WHEN REMOVING ANY PLUGS OR
RESTRICTIONS FROM A HYDRAULIC
SURIZED.
2-10-4
Page
2-10-30
WARNING
DO NOT ATTEMPT TO LOOSEN FIT-

WHILE THE HYDRAULIC PUMPS ARE
IN OPERATION.
2-10-37
WARNING
BEFORE DISCONNECTING THE

HOSES FROM THE OUTER - MID TELE-
SCOPING CYLINDERS SECURE THE
HOSES FROM ROTATING BY USING
THE HOSE REEL RETAINING BOLT.
3GWARNING
2-10-37
ENSURE THE RETAINING BOLT RE-

MAINS INSTALLED UNTIL THE HOSES
ARE ATTACHED TO THE TELESCOPE
60
CYLINDERS.
2-10-38
WARNING
BEFORE ERECTING OR STOWING

86
THE SWINGAWAY, READ AND AD-

HERE TO THE WARNING DECALS IN-
STALLED ON THE SWINGAWAY AND/
OR SUPPORT BRACKETS.
2-10-38
WARNING
WHEN ERECTING THE SWINGAWAY,

ENSURE THAT ALL PERSONNEL AND
EQUIPMENT ARE KEPT CLEAR OF
THE SWING PATH.
2-10-39
WARNING
DO NOT MODIFY THE ATTACH POINTS

TO PERMIT THE INSTALLATION OF
THE ATTACH PINS.
2-10-5
Page
2-10-39
WARNING
DO NOT PLACE BLOCKING UNDER

THE SWINGAWAY SHEAVE WHEEL.
2-10-39
WARNING
WHEN STOWING THE SWINGAWAY,

THE SWING PATH.
2-10-39
WARNING
3G
ALL STOWAGE PINS AND SAFETY
CLIPS MUST BE IN PLACE BEFORE
PERFORMING ANY CRANE OPERA-
TIONS.
2-10-40
60
WARNING
FAILURE TO MAINTAIN THE PROPER

CLEARANCE BETWEEN THE SWIN-
GAWAY ANCHOR FITTINGS AND THE
BOOM NOSE ATTACH FITTINGS
86
COULD CAUSE THESE FITTINGS TO

CONTACT EACH OTHER DURING OP-
ERATION OF THE BOOM.
2-10-6
BOOM
DESCRIPTION
The boom is a 12.96m to 48.72m (42¢-6² to 160¢-0²) as- Multi-Section Fixed Offset Lattice Jib
sembly consisting of five section, fully powered.
A fixed extension jib 7.01m (23¢) plus 22.55m (74¢) to
35.35m (116¢) offsettable at 10°, 17° or 30°.
The boom assembly is trapezoidal in design and uses a
two-stage and a single stage cylinder for extension and Non-Telescopic Offsettable Swingaway Boom
retraction, plus cable synchronisation for extension of
the fourth and fifth section. A non-telescopic swingaway 10m (32¢-10²) lattice ex-
tension offsettable at 2 degrees, 15 degrees or 30 de-
Boom assembly lift is provided by one 16² (406mm) di- grees, stows alongside the base section when not in
ameter bore lift cylinder boom elevation is from -3 de- use.
grees below horizontal to + 80 degrees.
Optional Telescopic Offsettable Swingaway Boom
Rooster Sheave A 10.0m to 14.6m or 17.70m (32¢-10² to 48¢ or 58¢) swin-

3G gaway boom extension with a rectangular roller
An optional auxiliary boom nose (rooster sheave) is mounted section which extends/retracts from within the
available to simplify single part cable usage. The rooster 10.0m (32¢-10²) lattice extension. Offsettable at 2 de-
sheave is installed on the main boom and is secured by grees, 15 degrees or 30 degrees, stows alongside the
pins. boom base section when not in use.
THEORY OF OPERATION
60
The inner-mid and mid boom sections are telescoped cables are routed around four sheaves on the front of
using a double stage cylinder, these can be operated in- the lower telescope cylinder and back to the cable an-
dependently which provides for a four section boom chor (sled). As the telescope cylinders extend, the lower
mode or a fine section boom mode. cylinder pushes forward on the extension cables and
86
thereby pulls forward on the cable anchor (sled), which

A single stage cylinder telescopes the outer mid section, is pinned to the fly section. This causes the fly section to
with cables telescoping the fly section. The outer mid be pulled forward (extended) with the cable anchor at
and fly section are synchronised. the same speed and rate as the outer mid section is ex-
tending.
All sections telescope to set percentages 37%, 66% etc,
the alternate modes allow the best configuration to be FLY SECTION RETRACTION.
used.
Fly section retraction is provided by the two boom re-
The load moment indicator constantly monitors the tele- traction cables. The retraction cables are fastened at
scoping of the boom and will prevent further telescoping one end to the front of the boom inner mid section,
if an error occurs. routed around a sheave at the rear of the outer mid sec-
tion and fastened to the cable anchor (sled). As the
FLY SECTION EXTENSION. lower telescope cylinder retracts the outer mid section,
the retraction sheaves at the rear of the section pulls on
Fly section extension is provided by the four boom ex- the retractions cables and thereby pulls back on the ca-
tension cables. The cable end anchors one end of the ble anchor (sled), which is pinned to the fly section. This
cables to the upper telescope cylinder section. These causes the fly section to be pulled back (retracted) with
2-10-7
the cable anchor at the same speed and rate as the For operation of the boom refer to the Superstructure
outer mid section is being retracted. Operators and Safety Handbook Section III.
MAINTENANCE
NOTE
The boom assembly weighs approxi-

mately 35368 pounds (16040 kg). Re-
moval of the swingaway boom exten-
sion will simplify removal, therefore,
the above weight is for the boom with-
out the swingaway boom extension at-
tached.
REMOVAL
1. Extend and set the outriggers and fully retract the

boom.
2. Remove the swingaway boom extension accord-

ing to the removal procedure in this section.
3G
WARNING
8. Place an adequate supporting device at the end of
60
WEAR GLOVES WHEN HANDLING the lift cylinder at the nearest point where it is pinned to
WIRE ROPE. the boom as shown.
3. Remove the hook block or headache ball and wind WARNING

the remaining hoist rope onto the hoist drum.
ENSURE THE BOOM LIFT CYLINDER IS
86
4. Position the boom to horizontal and ensure the PROPERLY SUPPORTED BEFORE DIS-
boom lock pins are disengaged. CONNECTING IT FROM THE BOOM.
WARNING
ENSURE ANY BLOCKING AND LIFT-

ING DEVICES USED ARE CAPABLE OF
SUPPORTING THE BOOM ASSEMBLY
AND COMPONENTS.
RETAINER PLATE
5. Attach an adequate lifting device to provide equal
distribution of the weight of the boom. PIVOT SHAFT
6. Tag and disconnect the hydraulic lines to the cylin-

ders. plug all open ports and hose connections.
9. Remove the bolts, washers, and retainer plate se-
7. Tag and disconnect any other wiring or hoses to the curing the upper lift cylinder pivot shaft and remove the
boom. shaft.
2-10-8
23
16
5
9
13
11 6
17
3G
60
20
12
86
1
2
24 24
24 10
15
4 3
1. Base Section 7. Retraction Sheave

2. Inner Mid 8. Roller Assembly
3. Outer Mid 9. Extension Sheave
4. Fly Section 10. Retraction Cable
5. Upper Telescope Cylinder 11. Adjusting Bolt
6. Lower Telescope Cylinder 12. Guide Plate
Boom Assembly (Sheet 1 of 3)
2-10-9
6
21
5
15
3
3G 21
19
4
60
22
86
18
22
13
14
7
10 22
13. Extension Cable 19. Limit Switch

14. Cable Anchor 20. Cylinder Sheave Mount
15. Mid Section 21. Trunnion Plate
16. Cylinder Support 22. Side Wear Pad
17. Cable End 23. Roller Guide
18. Actuator Arm 24. Adjustable Wear Pad
2-10-10
13 10 2 1
8
3 4
12 14
11 5
1.
2.
3.
Wear Pad
3G
Cylinder Support
Extension Cable
8.
9.
10.
Safety Wire
Wear Pad
Cable End
4. Upper Telescope Cylinder 11. Wear Pad
5. Lower Telescope Cylinder 12. Cable Adjuster
6. Cylinder Sheave 13. Wear Pad
7. Cylinder Sheave Mount 14. Bolt
60
11. Lift the boom vertically until clear of the crane. re-
BOLT PIN
move to a clean area and place on suitable supports.
86
DISASSEMBLY
EYE BOLT
NOTE
The boom may be disassembled with

BOOM PIVOT PIN
the base section remaining on the
crane if repair of the base section is not
required.
NOTE
If the base section is not being removed

from the crane for disassembly, start
with step 3.
1. Remove the boom in accordance with the removal

procedures outlined in this section.
10. Remove the bolts, eye bolts, and pins securing the
boom pivot pin and remove the boom pivot pin. 2. Place the boom in a horizontal position.
2-10-11
WEAR PAD
RETAINER
PLATE
BOLT
BOLT
SETSCREW
ROLLER ASSEMBLY
ROLLER ASSEMBLY
6. Loosen the adjustable side wear pads.
7. Remove the bolts and washers securing the upper

telescope cylinder to the rear of the base section.
3G NOTE
An adequate supply of hydraulic pres-

WASHER
sure will facilitate boom disassembly. If
a source of hydraulic pressure is not
BELLEVILLE
WASHER available, the boom sections can be re-
BOLT moved by an adequate lifting device us-
60
ing a lifting/dragging motion.
Roller Assembly
WARNING
WHEN EXTENDING/PULLING OUT THE

3. Remove the bolts and washers securing the side
86
BOOM SECTIONS, ENSURE THAT SUP-

roller assemblies to the base section and withdraw the PORTING AND LIFTING EQUIPMENT IS
roller assemblies from both sides of the base section. ADJUSTED TO EVENLY DISTRIBUTE
THE WEIGHT OF THE BOOM. AT NO
NOTE TIME MUST THE CENTRE OF GRAVITY
OF THE BOOM BE ALLOWED TO BE
Note the location and quantity of the OUTSIDE THE LIFTING POINTS OF THE
shims removed to ensure the same LIFTING EQUIPMENT OR OUTSIDE
amount is installed during assembly. THE LIMITS OF THE SUPPORTING
BLOCKS.
4. Remove the bolts securing the shims and spacers
to the top of the base section and pull out the shims and 8. Connect a supply of hydraulic oil to the top tele-
spacers. scope cylinder. Telescope the cylinder until the rear of
the inner mid section is in the centre of the access hole in
5. Remove the bolts and washers from the side wear the side of the base section and access can be obtained
pad keepers and screws from the brass side pads at the to the rear of the inner mid section. If hydraulic pressure
front of the base section. Remove the wear pads and is not available, obtain extension by pulling the section
keepers. out with available lifting equipment.
2-10-12
BOLT AND
SHIMS GUIDE BLOCK SPACER
WASHER
Shim and Spacer Installation
3G
1. Wear Pad
2. Socket
Plate
60
3. Swivel Plate
4. Wear Pad
5. Setscrew
6. Bolt
7. Washer
8. Keeper 8
86
4 6
7
8
4 1
5
1
2
3
2
3
Front Lower and Side Wear Pad Installation
2-10-13
CAUTION 18. Remove the nuts from the retraction cables at the
end of the inner mid section.
DO NOT LET THE TELESCOPE CYLIN-
DER FALL. 19. Remove the bolts and washers securing the retrac-
tion cable guide plates and remove the guide plates.
9. Place adequate blocking between the two tele-
scope cylinders so that the top cylinder is held steady
and will not fall.
10. Retract the cylinder. As the cylinder retracts, it will

be withdrawn from the mounting fixture at the rear of the
base section.
11. Lift the inner mid, mid, outer mid and fly section as-
sembly enough to allow access to the lower wear pads
at the front of the base section and remove the wear
pads. WARNING
12. Remove the inner mid, mid, outer mid and fly sec- NEVER HANDLE WIRE ROPE WITH
tions from the base section as an assembly and place BARE HANDS.
them on suitable supports to evenly distribute the
weight.
13. If necessary, remove the side adjustable wear

3G 20. Pull the retraction cables free from the bracket and
back inside the boom section. Feed the cables between
the inner mid and outer mid sections and keeping the ca-
pads from the base section. bles as tight as possible, tie the cables to the upper
boom nose sheave pin with suitable ropes.
14. Remove the upper telescope cylinder trunnion CAUTION
60
bolts and blocks.
FAILURE TO KEEP THE RETRACTION
15. Disconnect the oil supply from the top cylinder and CABLES AS TIGHT AS POSSIBLE (SO
plug the exposed port. THEY ARE SUSPENDED CLEAR OF
THE BOTTOM OF THE SECTIONS)
16. Connect the oil supply to the bottom telescope cyl- COULD RESULT IN DAMAGE TO THE
86
inder. If available use approximately 30 feet of extra CABLES OR JAMMING OF THE SEC-
hose to each post. TIONS.
17. Extend the bottom cylinder or lift and drag the 21. Remove the bolts and washers securing the side
boom sections approximately 3 feet. roller assemblies to the front of the inner mid section and
remove the side roller assemblies.
GUIDE PLATE NOTE
Note the location and quantity of the

ADJUSTMENT NUT shims removed to ensure the same
amount is installed during assembly.
22. Remove the bolts securing the spacers to the top of

JAM NUT
the inner mid sections and pull out the spacers.
23. Remove the bolts and washers from the side wear
pad keepers and screws from the brass side pads at the
front of the inner mid section. Remove the wear pads.
2-10-14
24. Loosen the adjustable side wear pads.
25. Remove the bolts and washers securing the lower

telescope cylinder to the rear of the inner mid section. RETRACTION
SHEAVE
THRUST
SPACER
26. Extend the lower telescope cylinder to push out the MOUNTING RETRACTION
PLATE CABLE
rear of the outer mid and fly sections to the centre of the
access hole in the inner mid section.
27. Retract the cylinder if hydraulic pressure was util- CABLE

ized to extend the sections. This will withdraw the cylin- GUIDE
der from its mounting fixture at the rear of the inner mid
section.
28. Lift the outer mid and fly section assembly enough PIN
to allow access to the lower wear pads at the front of the

inner mid section and remove the wear pads. 33. Remove the cable guides from both sides of the re-
29. Lower the boom sections to a central position

3G
within the inner mid section and, ensuring the weight of
traction sheaves.
34. Pull the cables back through the sections until they
are in line with their anchor points on the cable anchor
the load is kept evenly distributed, withdraw the outer
(sled).
mid and fly sections as an assembly from the inner mid
section or otherwise extend the telescope cylinder to 35. Remove the bolts and washers securing the side
60
push out the sections adjusting the centre of gravity con- roller assemblies to the outer mid section and withdraw
tinuously until the sections are fully out. the roller assemblies from both sides of the outer mid
section.
NOTE
pads from the inner mid section.
86
Note the location and quantity of the

shims removed to ensure the same
31. Retract the telescope cylinder. Disconnect the
amount is installed during assembly.
hoses and plug all open ports.
36. Remove the bolts securing the spacers to the top of
WARNING the inner mid section and pull out the spacers.
37. Remove the bolts and washers from the side wear
NEVER HANDLE WIRE ROPE WITH pad keepers and screws from the brass side pads at the
BARE HANDS. front of the outer mid section. Remove the wear pads
and keepers.
32. Release the retraction cables from the boom head. 38. Loosen the adjustable side wear pads.
2-10-15
39. Place suitable supports under the bottom cylinder 47. Push the cable anchor (sled) back towards the rear
in front of the retraction sheaves. of the boom. Lift the cable anchor up and tie the cable
anchor to the bottom telescope cylinder.
40. Remove the bottom telescope cylinder trunnion
bolts and blocks. 48. Withdraw the top cylinder from the fly section, con-
tinuously adjusting the lifting equipment to evenly dis-
41. Raise the fly section enough to allow access to the tribute the weight of the cylinder.
front bottom wear pads in the outer mid section and re-
move the wear pads. 49. Withdraw the bottom telescope cylinder, continu-
ally adjusting the lifting equipment to evenly distribute
42. Withdraw the fly section from the outer mid section the weight of the cylinder.
ensuring the weight of the load is kept evenly distrib-
uted. CLEANING AND INSPECTION
1. Clean all metal parts with a suitable solvent and dry

thoroughly.
pads from the outer mid section.
NOTE
44. Remove the lock wire and bolts securing the me-
chanical actuators to the boom and remove the actua- It is a good practice to replace all wear
tors. pads at disassembly.
3G
45. Remove the nuts and large bolts which will release
the cable end bracket. Tie the bracket and extension ca-
ble ends securely to the top of the bottom telescope cyl-
2. Check the cylinder mounts for damage, elongation
of holes. cracks or other damage. Replace or repair as
required.
inder.
3. Check the cylinder saddle and support foot for
WARNING wear or other damage. Replace as required.
60
NEVER HANDLE WIRE ROPE WITH ASSEMBLY
BARE HANDS.
NOTE
During assembly, lubricate all moving

86
parts with Never-Seez Paste Type lubri-

ROLL PIN
cant. All bolts should be torqued in ac-
cordance with the specifications out-
lined in Chapter 1, Section 2 - GEN-
ERAL MAINTENANCE.
RETRACTION
CABLE
NOTE
The rear, upper, and side wear pads

ROLL PIN must be installed during assembly of
the boom. The capscrews securing the
rear upper wear pads must be treated
with Loctite Primer Grade T and Loctite
Adhesive Sealant Grade 242.
46. Push the cable anchor (sled) forward just enough
to gain sufficient access to the roll pins securing the re- 1. Lubricate the lower telescope cylinder wear pads
traction cables. Remove the roll pins and pull the retrac- and secure the extension. cables to the cylinder in the
tion cables from the rear of the boom. same manner as during disassembly.
2-10-16
2. Using adequate lifting equipment, carefully install CAUTION
the cylinder in the fly section. Place a wedge under the
rear of the cylinder until it is parallel to the base of the THE CABLES MUST BE KEPT TIGHT
section and centred within the section horizontally. AND CLEAR OF THE BOTTOM OF THE
SECTION OTHERWISE THE CABLES
COULD BE DAMAGED OR THE SEC-
WARNING TIONS JAMMED DURING ASSEMBLY.
WARNING
BARE HANDS. NEVER HANDLE WIRE ROPE WITH
BARE HANDS.
3. Attach the retraction cables to the rear of the cable 11. Route the retraction cables around their pulleys
anchor (sled). Push the cable anchor far enough For- and install the cable guides. Route the ends of the ca-
ward so that the bolts and nuts securing the cable end bles along the outside of the outer mid section and tie the
can be installed when the top telescope cylinder is in- cable ends to the upper boom nose sheave pin as was
stalled. done during Disassembly.
12. If removed, install the side adjustable wear pads

4. Slide the top cylinder into position and block the into the inner mid section.
rear of the cylinder so that it is parallel to the base of the
3G
section and centred horizontally within the section. 13. Lubricate the upper rear wear pads and inside of
the inner mid section. Insert the outer mid and fly sec-
tions as an assembly into the inner mid section except
5. Secure the cable end to the upper telescope cylin-
for approximately 3 feet. Insert the bottom wear pads.
der using the bolts and nuts.
WARNING
60
6. Install the mechanical actuators and secure in NEVER HANDLE WIRE ROPE WITH
place with the bolts and lock wire. BARE HANDS.
14. Remove the retraction cables from the boom nose

7. Adjust the rear upper wear pads on the fly section
and pass them back between the inner and outer mid
to make contact with the outer mid section on insertion.
86
sections and back out through the guide channels. In-

Apply Never-Seez lubricant to the pads. Lubricate the
stall the nuts and locknuts securing the retraction cables
full length of the inside of the outer mid section where the
to the front of the inner mid section.
fly section wear pads will make contact. Install the lower
telescope cylinder trunnion blocks. 15. Install the sections fully into the inner mid section
ensuring the bottom telescope cylinder aligns with the
8. If removed, install the side adjustable wear pads mounting fixture at the rear of the inner mid section. Ap-
into the outer mid section. ply medium strength thread locking adhesive/sealant
and primer to the mounting bolts and secure the lower
telescope cylinder to the inner mid section with the
9. Partially insert the fly section into the outer mid sec- mounting bolts and cylinder plates. Torque the bolts to
tion and install the bottom wear pads. 370 pounds-foot (51 kgm).
16. Lubricate the rear wear pads of the inner mid sec-
10. Fully insert the fly section into the outer mid section. tion and the length of the base section where the pads
Ensure the retraction cables are pulled back through the will contact.
outer mid section as the fly section is being installed. In-
stall the top wear pads, side rollers, and telescope cylin- 17. If removed, install the side adjustable wear pads
der trunnion block screws. into the base section.
2-10-17
18. Insert the inner mid, outer mid, and fly sections as a INSPECTION
unit into the base section. Install the bottom wear pads
after the boom sections are more than half way into the Visually inspect the telescoping sections for adequate
base section. lubrication of bottom plates. Observe extended sections
for evidence of cracks, warping, or other damage. Peri-
odically check security of boom wear pads. Check the
19. Slide the sections the remainder of the way into the
boom nose sheaves for security and freedom of move-
base section ensuring the upper telescope cylinder
ment.
aligns with the mounting fixture at the rear of the base
section. Apply medium strength thread locking adhe- BOOM ALIGNMENT AND SERVICING
sive/sealant and primer to the mounting bolts and se-
cure the upper telescope cylinder to the base section Lubrication of the boom is limited to the sides and bot-
with the mounting bolts and cylinder plates. Torque the tom of the bottom plates of the telescoping sections. Re-
bolts to 370 pounds-foot (51 kgm). fer to Section 15 - LUBRICATION for the proper lubri-
cant.
INSTALLATION
The telescoping sequence required to give access to
the boom internals for service are shown on the diagram
1. Place the boom in position on the crane. Install the
following. Before attempting to extend the boom for in-
lift cylinder pivot pin and secure in place with the retainer
spection the outriggers must be fully extended and sta-
plate, bolts, and washers.
bility of the crane for the required boom length must be
2. Connect all hoses and electrical wiring as tagged

during REMOVAL.
3G verified.
WARNING
3. Adjust the cables (extension and retraction). Refer IF YOU MUST ENTER OR WORK WITH
to CABLE ADJUSTMENT in this section. ANY PART OF YOUR BODY WITHIN
THE BOOM ALL POWER MUST BE
60
SHUT OFF AND THE BOOM SECTIONS
FUNCTIONAL CHECK
MUST BE ADEQUATELY BLOCKED TO
PREVENT ANY EXTENSION, RETRAC-
1. Activate the hydraulic system.
TION OR OTHER MOVEMENTS.
86
2. Elevate the boom and hold in the extended posi- Boom alignment is achieved by adjustment of the wear
tion. The boom should stay in position until retracted by pads located at various points in the boom assembly.
the operator. Adjustment of the wear pads is as follows:
3. Extend and retract the boom several times at vari- 1. Extend the boom horizontally to positions shown.
ous elevations. Check for smooth operation of the tele-
2. Lubricate the boom bottom plates (sides and bot-
scope cylinders.
tom).
4. Check operation of all electrical/electronic compo- 3. Adjust the side wear pads snug against the boom
nents affected by boom removal. section, then back them off 1/4 turn.
2-10-18
For access to second stage cylinder hoses telescope the inner
mid section out until manifold block is visible through access
hole keeping the fly, outer mid and mid sections retracted.
Access for rear pads

on inner mid section.
18.60M BOOM
T1(I/MID) 63%
T2(MID) 0%
T3(O/MID) 0%
18.60 metres
T3(FLY) 0%
Access for extension
cable adjustment.
21.90M BOOM
T1(I/MID) 0%
T2(MID) 100%
3G 21.90 metres T3(O/MID) 0%
T3(FLY) 0%
Access for rear pads Access for rear pads

on fly section. on outer mid section.
28.40M BOOM
T1(I/MID) 0%
60
T2(MID) 100%
T3(O/MID) 37%
28.40 metres
T3(FLY) 37%
86
Access to change over valve, single stage

cylinder holding valve and rear pads on
mid section.
30.84M BOOM
T1(I/MID) 100%
T2(MID) 100%
T3(O/MID) 0%
30.84 metres T3(FLY) 0%
Access to second stage of 2 stage

cylinder holding valve.
35.92M BOOM
T1(I/MID) 0%
T2(MID) 100%
T3(FLY) 78%
Boom Servicing
2-10-19
NOTE: DEFLECTION EXAGGERATED
FOR ILLUSTRATION PURPOSES.
Boom Alignment
CAUTION BOOM NOSE SHEAVES
REMOVAL
WHEN EXTENDING AND RETRACTING
THE BOOM DURING ALIGNMENT,
MOVEMENT SHOULD BE STOPPED IF
A RESTRICTION IS ENCOUNTERED,
3G 1. Remove the hitch pins from the cable retainer and
cable retainer pins, remove the cable retainer and cable
retainer pins from the upper and lower part of the boom
AND WEAR PADS RE-ADJUSTED AS nose respectively.
NECESSARY TO PROVIDE FREE
TRAVEL OF THE AFFECTED BOOM 2. Remove the hardware securing the upper boom
60
SECTION(S). nose sheave shaft.
NOTE
4. Retract and extend the boom; check for the high
point where the boom has brushed the wear pads at the The upper boom nose sheave shaft
widest point. weighs approximately 148 pounds (67
86
kg). The boom nose sheaves weigh ap-

proximately 34 pounds (15.5 kg)
5. Retract the boom sections to align the high point on apiece.
the boom section with the adjacent wear pads.
3. Carefully pull the upper boom nose sheave shaft
6. Turn the adjusting screws snug against the boom from the boom nose, removing the washers and boom
section then adjust them out 1/8 turn. nose sheaves as required.
4. Remove the locknut, tongued lockwasher, and

7. Attach a weight and extend the boom full length. keyed washer on one end and the bolts, washers, and
Check for side deflection. end cap from the opposite end of lower sheave shaft.
NOTE
Example: If the boom deflects to the left, the forward left
adjustable wear pad would be adjusted in and the rear The lower boom nose sheave shaft
left adjustable wear pad would be adjusted out, away weighs approximately 73 pounds (33
from the internal boom section in a similar manner. The kg). The boom nose sheaves weigh ap-
forward right adjustable wear pad will be adjusted out proximately 34 pounds (15.5 kg)
and the right adjustable pad adjusted in. apiece.
2-10-20
5. Carefully pull the lower boom nose sheave shaft 3. Install the keyed washer.
from the boom nose, removing the spacers and boom
nose sheaves as required. NOTE
INSTALLATION
The lockwasher can be used more than
CAUTION once but must be replaced if not in
good condition.
DO NOT INSTALL THE LOWER BOOM
NOSE SHEAVES OVER THE 4. Install the tongued lockwasher with the tabs out.
THREADED END OF THE LOWER
BOOM NOSE SHEAVE SHAFT. 5. Install the outer locknut with the chamfer side in.
Tighten the locknut until play is within 0.03 inches (0.8
CAUTION
mm) total. Bend one lockwasher tab into the slot on the
locknut.
DO NOT INSTALL THE SHEAVES OVER
THE THREADED END OF THE SHEAVE
SHAFT. NOTE
NOTE The upper boom nose sheave shaft

weighs approximately 148 pounds (67
The lower boom nose sheave shaft
weighs approximately 73 pounds (33
kg). The boom nose sheaves weigh ap-
3G kg). The boom nose sheaves weigh ap-
apiece.
apiece.
6. Carefully install the upper boom nose sheave shaft
1. Carefully install the lower boom nose sheave shaft into the boom nose, installing the washers and boom
60
into the boom nose, installing the spacers and lower nose sheaves as required. Ensure the sheaves are in-
boom nose sheaves as possible. Ensure the sheaves stalled so the grease fittings are accessible. Secure the
are installed so the grease fittings are accessible. shaft in place with the mounting hardware.
2. Install the end cap onto the lower boom nose 7. Install the cable retainer pin into the lower part of
sheave shaft and secure in place with the bolts and the boom nose and the cable retainer into the upper part
86
washers. of the boom nose and secure in place with the hitch pins.
2-10-21
10 12 10 12
6 6
8 9
3G
2
3,4,5
60
6
1
11
10
86
10
1. End Cap 7. Spacer

2. Shaft 8. Spacer
3. Keyed Washer 9. Spacer
4. Tongued Washer 10. Sheave
5. Locknut 11. Lower Shaft
6. Cable Retainer Pin 12. Cable Retainer
Boom Nose Sheave Installation
2-10-22
BOOM EXTENSION AND RETRACTION CABLE
MAINTENANCE
NOTE 0.094-inch (2.38 mm) for diameters 1.25 to 1.5 inches

(32 to 38 mm) inclusive.
For more detailed information concern-
ing maintenance of the extension and 5. In standing ropes, more than two broken wires in
retraction cables, refer to WIRE ROPE one lay in sections beyond end connections or more
in Chapter 1 Section 2 - GENERAL than one broken wire at an end connection.
MAINTENANCE.
ADJUSTMENT
INSPECTION
1. Fully retract the boom and tighten retract cables
WARNING evenly to 20 lbs.ft (2.75 kg.m) at each side of the boom
by adjusting nut (1) and jam nut (2).
BARE HANDS. 2. Fully extend boom to gain access to the four exten-
The following information is taken from a National Con-

sensus standard as referenced by Federal Government
Agencies.
3G sion cables anchor, and alter cable tension if necessary
by adjusting nut (4), and swivel nut (5) at either side of
the cable anchor bracket.
3. Fully retract the boom and readjust retraction ca-

All wire rope will eventually deteriorate to a point where it
bles evenly to approximately 20 lbs.ft (2.75 kg.m) so that
is no longer usable. Wire rope shall betaken out of serv-
60
the fly section stop bottoms out at B, 3 to 6mm (0.125 to
ice when any of the following conditions exist.
0.25 inches) before the stop block on the outer-mid sec-
tion bottoms out. Check this dimension at A.
1. In running ropes, six randomly distributed broken
wires in one lay or three broken wires in one strand in
4. Finally lock nuts (1) with jam nuts (2).
one lay.
86
2. Wear of one-third the original diameter of outside NOTE

individual wires. Kinking, crushing, bird caging,or any
other damage resulting in distortion of the rope struc- Although this should not be necessary
ture. under normal operating circum-
stances, it is possible to adjust the ex-
3. Evidence of any heat damage from any cause. tension cables individually by the fol-
lowing procedure.
4. Reductions from nominal diameter of more than:
Fully adjust boom to gain access to the
0.016-inch (0.4 mm) for diameters up to and including four extension cables anchor, and ad-
0.3125-inch (8 mm) just cable to tension required by adjust-
0.031-inch (0.79 mm) for diameters 0.375 and 0.5-inch ing the bushes (3) using the special
(10 and 13 mm) inclusive. tools shown.
0.047-inch (1.19 mm) for diameters 0.5625 to 0.75-inch
(14 to 19 mm) inclusive. When the cables are satisfactorily ad-
0.063-inch (1.59 mm) for diameters 0.875 to 1.125 justed lockwire the bushes together us-
inches (22 to 29 mm) inclusive. ing safety wire.
2-10-23
1 2
B 3G
60
A
86
4 5 3
Special Tools
Boom Cable Adjustment
2-10-24
TELESCOPE CIRCUIT
DESCRIPTION
The boom telescope circuit consists of two telescope A holding valve is threaded into the rod end of each tele-
cylinders, directional control valves, hose reel, holding scope cylinder. The holding valve functions during the
valves, relief valve and telescope control module. The retraction, extension, or holding operation. During ex-
holding valves are mounted in the port blocks on the rod tension, oil unseats the poppet (check) valve in the hold-
end of each cylinder. ing valve when pressure is 6 ± 4 psi (41.37 ± 27.58
kPa/0.414 ± 0.276 bar). This oil is routed to the piston
Movement of a telescope control valve lever forward side of the cylinder which forces the rod out of the cylin-
(OUT) or rearward (IN) from centre (neutral) shifts a der, causing the boom sections to extend.
spool within the telescope control valve which aligns ap-
propriate passages in the control valve to route oil to the
holding valve. The holding valve passes oil to and from During retraction, oil enters the retract port and flows to
the telescope cylinder. the rod side of the cylinder. When pilot pressure reaches
a pre-determined value, the main poppet unseats, and
The telescope cylinder valves are closed spool type. oil flows from the piston side of the cylinder to the reser-
voir, causing the section to retract.
3G
Oil from the telescope control valve is routed to the cylin-
der by external lines. Foreign material is prevented from
entering the cylinder by a wiper seal during rod retrac-
tion. O-ring seals prevent internal and external leakage.
When holding a boom section at a given length, oil is
trapped in the cylinder by the holding valve.
MAINTENANCE
60
TROUBLESHOOTING
1. Erratic operation of extending a. Low hydraulic oil level. a. Replenish hydraulic oil to
telescoping cylinder. proper level.
86
b. Damaged relief valves. b. Repair or replace relief valves.
c. Air in telescope cylinder. c. Bleed by lowering telescope

cylinder below horizontal.
d. Low engine rpm. d. Increase engine rpm to recom-

mended setting.
e. Lack of lubrication on boom e. Properly lubricate all boom sec-

sections. tions.
f. Extremely tight boom nose f. Inspect and properly lubricate

sheaves. boom nose sheaves.
g. Improper boom alignment g. Reduce and properly hoist

caused from side loading. load.
h. Worn boom wear pads. h. Replace wear pads and prop-

erly lubricate.
i. Distorted boom section. i. Replace distorted section.

2-10-25
1. Erratic operation of extending j. Damaged telescope cylinder. j. Repair or replace cylinder.

telescoping cylinder (continued).
k. Clogged, broken, or loose hy- k. Clean, tighten, or replace
draulic lines or fittings. lines or fittings.
l. Damaged control valve. l. Repair or replace control

valve.
2. Erratic operation of retracting a. Low hydraulic oil level. a. Replenish hydraulic oil to
telescoping cylinder. proper level.
b. Damaged relief valve. b. Repair or replace relief

valve.
c. Air in cylinder. c. Bleed by lowering telescop-

ing cylinders below horizontal
and cycle telescope cylinder.
3G
d. Low engine rpm.
e. Lack of lubrication.
d. Increase engine rpm to rec-
ommended setting.
e. Properly lubricate all boom

sections.
f. Check valve malfunctioning. f. Repair or replace check

60
valve.
g. Improper boom alignment g. Reduce and properly hoist

caused from side loading. load.
h. Extremely tight boom nose h. Inspect and properly lubri-

86
sheaves. cate.
i. Distorted boom section. i. Replace distorted section.
j. Worn boom wear pads. j. Replace wear pads and prop-

erly lubricate.
k. Bent cylinder rod. k. Replace cylinder rod and all

cylinder seals.
l. Scored cylinder barrel. l. Repair or replace cylinder

barrel.
m. Damaged piston seals. m. Replace all cylinder seals.
n. Loose or damaged piston. n. Replace all seals and

retorque or replace piston.
2-10-26
3. Telescope cylinder will not ex- a. Low hydraulic oil level. a. Replenish oil to proper level.
tend.
b. Relief valve malfunctioning. b. Repair or replace relief
valve.
c. Excessive load. c. Reduce load.
d. Clogged hose and fittings. d. Replace hose or fittings.

(Refer to Parts Manual).
e. Broken valve linkage. e. Repair or replace linkage.
f. Broken valve spool. f. Replace valve.
g. Damaged piston seals. g. Replace all cylinder seals.
h. Damaged piston. h. Replace piston and all cylin-

der seals.
.
3G
i. Bent boom section
j. Broken hydraulic pump coupling.

i. Replace
section.
damaged
j. Replace broken hydraulic

boom
pump coupling.
k. Worn or damaged hydraulic k. Repair or replace pump sec-

60
pump section. tion.
4. Telescope cylinder will not re- a. Low hydraulic oil level. a. Replenish oil to proper
tract. level.retract.
86
b. Relief valve damaged. b. Repair or replace relief valve.
c. Excessive load. c. Reduce load. (Refer to load

chart).
d. Inoperative check valve. d. Replace check valve.
e. Clogged hose and fittings. e. Replace hose or fittings. (Re-

fer to Parts Manual).
f. Broken valve linkage. f. Replace or repair linkage.
g. Broken valve spool. g. Replace valve section.
h. Broken piston. h. Replace piston and all cylin-

der seals.
i. Damaged piston seals. i. Replace all cylinder seals.
2-10-27
4. Telescope cylinder will not re- j. Bent boom section. j. Replace damaged boom sec-
tract (continued). tion.
k. Broken hydraulic pump cou- k. Replace broken hydraulic

pling. .pump coupling.
l. Worn or damaged hydraulic l. Repair or replace pump.

pump.
m. Broken hydraulic pump shaft. m. Replace pump shaft.
REMOVAL AND INSTALLATION DISASSEMBLY AND ASSEMBLY
Removal and installation of the telescope cylinder from NOTE

the boom is described under disassembly and assembly
of the boom. Refer to BOOM MAINTENANCE in this For more detailed information refer to
Section. 3G the applicable SM package.
60
86
2-10-28
TELESCOPE CYLINDERS
DESCRIPTION
The boom has two telescope cylinders one cylinder hav- (1060cms). The cylinder has a stroke of 29 ft 73/4 inches
ing a bore of 7.5 inches (19.05 cm), the other cylinder is (903.6 cms).
a two-stage 9.25 inch (22.86cm). The cylinders are in-
ternally ported. Foreign material is prevented from en- The cylinder weighs approximately 916 kg (2021 lbs)
tering the cylinders during rod retraction by a wiper seal dry.
in the head. O-ring seals prevent internal and external
The retracted length of the two-stage cylinder from end
leakage.
to end of the ram is 36 ft 11/4 inches (1100 cms).
The cylinder has a stroke of 29ft 5 inches (896 cms).

The retracted length of the first cylinder from centre of
the block to the end of of the ram is 34ft 91/2 inches The cylinder weighs approximately 1964 kg (4330 lbs).
MAINTENANCE
3G NOTE

REMOVAL ders as far as practicable, and allow the boom to remain
60
in this position overnight. This should allow entrapped
Removal and installation of the telescope cylinder from air to find its way to the holding valve where telescoping
the boom is described under disassembly and assembly the boom IN the next morning should force the air back
of the boom. Refer to BOOM MAINTENANCE in this to the reservoir.
Section.
While allowing the boom to remain in an extended and
86
VENTING TELESCOPIC CYLINDERS lowered position overnight is helpful in removing en-

trapped air from the hydraulic cylinder, ensure the boom
Extend and set outriggers and telescope the boom over is first telescoped IN (not OUT) in the morning. Tele-
the rear of the carrier. scoping OUT may cause air to be forced back into a cyl-
inder.
CAUTION
WARNING
LOCATE THE CRANE ON A FIRM SUP-
PORTING SURFACE AND POSITION EXTREME CARE MUST BE USED
THE BOOM IN THE MOST STABLE PO- WHEN REMOVING ANY PLUGS OR RE-
SITION WHEN EXTENDING THE BOOM STRICTIONS FROM A HYDRAULIC
Lowering the boom to below horizontal and fully tele- TRAPPED AIR THAT MAY BE PRES-
scoping the boom in and out several times should re- SURIZED.
move entrapped air from the cylinders.
Entrapped air may be removed from cylinders having
However, if the air is not readily removed, lower the wet rods by cycling. On certain cylinders, a plugged port
boom to below horizontal, extend the telescope cylin- is provided on the rod end to bleed off entrapped air.
2-10-29
WARNING In the event that air entrapment should persist bleeding
of air by loosening various clamp and screw type fittings
DO NOT ATTEMPT TO LOOSEN FIT- may become necessary.
WHILE THE HYDRAULIC PUMPS ARE If the above procedures fail to eliminate air entrapment,
IN OPERATION. contact Grove Customer Services.
3G
60
86
2-10-30
LIFT CIRCUIT
DESCRIPTION
The boom lift circuit consists of the lift cylinder, the hold- horizontal. The lift control valve is the closed spool type
ing valves, and the control valves. The lift cylinder is and is described under VALVES in Section 8.
mounted with the cylinder end attached to the turntable
and the rod end attached to the boom. A holding valve is
mounted in a port block on the lift cylinder. The lift and lift The lift cylinder is the double acting type with a cylinder
boost control valves are located in the valve compart- bore of 16 inches (40.6cm). The lift cylinder weighs ap-
ment behind the superstructure cab. proximately 3589 pounds (1631 kg). Refer to CYLIN-
DERS in this section for the description and mainte-
Boom elevation is from -3 degrees to +80 degrees from nance of the lift cylinder.
THEORY OF OPERATION
The directional control valve bank housing the lift control When booming down, oil enters the retract port of the
valve is supplied by flow from the 46.2 gpm (175 lpm) port block and flows to the cylinder rod side. When pilot
section of the hydraulic pump. Flow from the pump trav-
els to the lift directional control valve.
When booming up, oil unseats the poppet (check) valve

3G pressure reaches a pre-determined value, the main
poppet unseats and oil flows from the piston side of the
cylinder to the reservoir.
in the holding valve, letting oil flow to the piston side of

the cylinder. Pressure is applied to the piston, forcing the All return flow from the control valve goes to the reser-
rod to extend, raising the boom. voir.
60
MAINTENANCE
TROUBLESHOOTING
86
1. Boom raises erratically. a. Low hydraulic oil. a. Replenish hydraulic oil to

proper level.
b. Low engine rpm. b. Increase engine rpm to recom-

mended setting.
c. Main relief valve damaged. c. Replace relief valve.
d. Air in cylinder rods. d. Bleed cylinder rods.
e. Bent boom pivot shaft. e. Replace pivot shaft.
2-10-31
2. Boom lowers erratically . a. Low hydraulic oil. a. Replenish hydraulic oil to

proper oil level.
b. Low engine rpm. b. Increase engine rpm to rec-

ommended level.
c. Circuit and/or relief valve inop- c. Repair or replace relief valve.

erative.
d. Air in hydraulic cylinders. d. Bleed air from cylinders.
e. Control valve linkage out of ad- e. Adjust linkage to obtain full

justment. spool travel.
f. Damaged hydraulic pump sec- f. Repair or replace pump sec-

tion. tion.
3. Boom raises slowly. a. Low hydraulic oil level. a. Replenish hydraulic oil to
3G
b. Low engine rpm.
proper level.
b. Increase and maintain engine

rpm.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Extremely cold hydraulic oil. d. Operate unit to bring oil to op-

60
erating temperature.
e. Improper hose or fittings, in- e. Replace hose or fittings. (Re-

stalled. fer to Parts Manual).
86
f. Control valve linkage out of ad- f. Adjust linkage to obtain full

justment. spool travel.
g. Operating two functions with in g. Feather controls to obtain de-

the same control valve bank assem- sired speed of both functions.
bly.
h. Restriction in return hose. h. Replace return hose.
i. Cylinder piston seals leaking. i. Replace all cylinder seals.
j. Scored cylinder barrels. j. Hone or replace barrel.
k. Worn hydraulic pump section. k. Repair or replace pump sec-

tion.
2-10-32
4. Boom lowers slowly. a. Low hydraulic oil level. a. Replenish hydraulic oil to
proper level.
b. Low engine rpm. b. Increase rpm to recom-

mended level.
c. Damaged relief valve. c. Repair or replace relief valve.
d. Operating two functions within d. Feather controls to obtain de-

the same control valve bank assem- sired speed of both functions.
bly.
e. Extremely cold hydraulic oil. e. Operate unit to bring oil to op-

erating temperature.
f. Improper hose or fittings in- f. Replace hose or fittings. (Re-

stalled. fer to Parts Manual).
g. Control valve linkage out of g. Adjust linkage to obtain full ad-

3G
spool travel.
h. Restriction in return hose.

justment.
h. Replace return hose.
i. Cylinder piston seals worn. i. Replace all cylinder seals.
j. Scored cylinder barrels. j. Hone or replace barrel.

60
k. Worn hydraulic pump section. k. Repair or replace pump sec-
tion.
l. Piston rod broken (loose from l. Replace piston rod and all cyl-
piston). inder seals.
86
5. Boom will not raise. a. Low hydraulic oil. a. Replenish hydraulic oil to
proper level.
b. Main relief valve or circuit relief b. Repair or replace relief valve.

valve damaged.
c. Excessive load. c. Reduce load as required.
d. Improperly adjusted control d. Adjust linkage to obtain full

valve linkage. spool travel.
e. Worn or damaged hydraulic e. Repair or replace pump sec-

pump section. tion.
f. Broken pump shaft. f. Replace pump shaft and

seals.
g. Broken pump drive coupling. g. Replace drive coupling.
h. Broken control valve spool. h. Replace control valve.
2-10-33
6. Boom will not lower. a. Low hydraulic oil. a. Replenish hydraulic oil to
proper level.
b. Main relief valve or circuit relief b. Repair or replace relief valve.

valve damaged.
c. Worn or damaged hydraulic c. Repair or replace pump sec-

pump section. tion.
d. Broken pump shaft. d. Replace pump shaft and

seals.
e. Broken pump drive coupling. e. Replace drive coupling.
f. Broken control valve spool. f. Replace control valve.
REMOVAL
NOTE
3G 8. Raise the boom until the cylinder rod end can be re-
moved from the boom lift cylinder attach fittings. Lower
the cylinder to the safety blocking. Do not disconnect the
cylinder lifting device.
The following procedure is used to re-
move the lift cylinder, use a lifting de- 9. Lower the boom to the blocking or holding device.
vice capable of supporting the weight
60
of the boom. Lift the boom enough so 10. Remove the bolts, spring washers, washers and
the lift cylinder rod end can be removed keep plate from the lower lift cylinder pivot shaft.
from the attach fittings, then lower the
11. Remove the lower pivot shaft.
boom onto cribbing strong enough to
support the boom weight. 12. Remove the lift cylinder.
86
1. Extend and set the outriggers. INSTALLATION
2. Ensure the boom is fully supported. 1. Using an attachment that will not score the lift cylin-
der rod or bushing, attach an adequate lifting device to
3. Remove the bolts, spring washers, washers and the lift cylinder. Position the lift cylinder, and install the
keep plates from the lift cylinders upper pin. lower pivot shaft. Install the bolts, washers, spring wash-
ers and keep plates.
4. Place safety blocking under the cylinder to be re-
moved. 2. Raise the boom and raise the rod end of the cylin-
der. Position it so as the boom is lowered, it will slide into
5. Attach an adequate lifting device to the cylinder so the boom lift cylinder attach fitting.
it can not slide or fall.
3. Lower the boom and the lift cylinder until they are
6. Remove the upper pivot shaft from the rod end of aligned to install the upper pivot shaft. Install the upper
the cylinder. pivot shaft.
7. Tag, disconnect, and cap with high pressure fittings 4. Install the bolts, washers, spring washers and keep
the hydraulic lines to the lift cylinder to be removed. plate to the upper pivot shaft.
2-10-34
5. Connect all hydraulic lines to the cylinder as tagged DISASSEMBLY AND ASSEMBLY
prior to removal.
NOTE
6. Raise and lower the boom, checking the leaks and For further information refer to the ap-
proper operation. plicable SM package.
3G
60
86
2-10-35
LIFT CYLINDER
DESCRIPTION
The lift cylinder is the double acting type with a cylinder protect the O-ring from damage and prevent movement
bore of 40.6cm (16 inches). Foreign matter is prevented of the O-ring seal during rod retraction and extension.
from entering the cylinder by a wiper seal. An O-ring seal The O-ring seal between the rod side and the piston pre-
prevents oil leakage from the cylinder. The backup rings vents internal leakage.
MAINTENANCE
NOTE

Removal and installation of the lift cylinder from the the lift circuit. Refer to LIFT CIRCUIT MAINTENANCE in
boom is described under disassembly and assembly of this Section.
3G
60
86
2-10-36
HOSE REEL
DESCRIPTION
The quadruple plus one hydraulic hose reel supplies the vides drag on the hoses so that no slack develops when
manifold for the outer mid telescope cylinder. The hose the telescope cylinders are being extended or the boom
reel is mounted in the turntable centre section, under the is being lowered, and retrieves the hoses as the tele-
boom. scope cylinders are being retracted or when the boom is
raised.
The hose reel is spring return. The spring return pro-
MAINTENANCE
NOTE

Lubricate the hose reel spring with engine oil through INSTALLATION
the drain access holes located around the circumfer-3G
ence of the spring cover. Lubricate every 50 operating
hours.
NOTE
The drum must have a minimum of

With the boom fully retracted, spray motor oil, under seven pre tension turns.
pressure, into the hose reel spring housing. The spring
1. Position the hose reel assembly on the turntable
should be saturated with oil. If air pressure lubricating
60
and secure with the washer and bolts.
equipment is not available, use a pump oil can, but en-
sure the spring is completely saturated with oil. 2. Connect the hydraulic supply hoses to the reel.
REMOVAL NOTE
86
WARNING Ensure there is enough hose unwound

BEFORE DISCONNECTING THE from the hose reel to attach the hoses
HOSES FROM THE OUTER - MID TELE- to the telescope cylinders.
SCOPING CYLINDERS SECURE THE
WARNING
HOSES FROM ROTATING BY USING
THE HOSE REEL RETAINING BOLT. ENSURE THE RETAINING BOLT RE-
MAINS INSTALLED UNTIL THE HOSES
1. Secure the rotation of the hose reel by using the re- ARE ATTACHED TO THE TELESCOPE
taining bolt. CYLINDERS.
2. Tag and disconnect the hydraulic hoses from the 3. Connect the hydraulic hoses to the telescope cylin-
hose reel; cap hoses and openings. ders.
3. Tag and disconnect the hydraulic hoses from the 4. Remove the retaining bolt from the hose reel to al-
telescope cylinders, cap all hoses and openings. low tension to be applied to the hoses.
4. Remove the bolts and washers securing the hose 5. Secure the retaining bolt to the hose reel so the
reel to the turntable, remove the hose reel. hose reel is allowed to rotate.
2-10-37
SWINGAWAY BOOM EXTENSION
DESCRIPTION
The telescopic swingaway boom extension may be swingaway to be rotated and stowed on the right side of
used to obtain additional boom reach of 10m (32ft 10 in) the base section of the boom.
to 14.6 m (48ft) or 17.7m (58ft), to a maximum tip height
of 60m (196ft 10in). The swingaway is offsettable at 2°, The telescoping swingaway boom extension weighs ap-
15° or 30°. proximately 1597 kg (3514 lbs).
An option of a 10m (32ft 10 in) non-telescopic swin-

The boom extension mounts directly to the boom nose, gaway boom extension offsettable at 2°, 15° or 30° is
utilizing a four point attachment. In addition, the swin- also available.
gaway can be stowed on the right side of the base sec-
tion of the boom. Removing the attach pins from the at- The non-telescopic swingaway boom extension weighs
tach points on the left side of the boom nose allows the approximately 1098 kg (2416 lbs).
MAINTENANCE
3G
WARNING 6. Remove rear stowage pin (3) and swing boom ex-
tension (4) to engage with boom nose (5).
BEFORE ERECTING OR STOWING THE
SWINGAWAY, READ AND ADHERE TO 7. Remove the retainer clips (6) from the attach pins
60
THE WARNING DECALS INSTALLED (7) stowed in the base of the swingaway and insert the
ON THE SWINGAWAY AND/OR SUP- attach pins (7) through the anchor fittings (8) on the right
PORT BRACKETS. hand side of the boom nose. Install the retainer clips (6)
in the attach pins (7).
REMOVAL
86
8. Remove front stowage pin (9).

1. Extend and set the outriggers.
9. Slowly extend the boom approximately 500mm (20
2. Elevate the boom and swing to over the rear.
inches) until the extension (4) disengages with ramps,
front and rear. Control the movement of the boom exten-
3. If extended, fully retract all the boom sections and
sion with a rope during this operation.
lower to horizontal position to permit ease of installation
of pins and access to the boom nose.
WARNING
NOTE
WHEN ERECTING THE SWINGAWAY,
The auxiliary boom nose (rooster ENSURE ALL PERSONNEL AND
sheave) does not have to be removed. EQUIPMENT ARE KEPT CLEAR OF
THE SWING PATH.
4. Remove the boom nose idler sheave safety clips
(2) and the attach pins (1). 10 . Using the rope attached to the tip of the swingaway,
swing the swingaway into place ahead of the boom
5. Lay the cable off to the left side of the boom while nose, engaging the anchor fittings (10) with the attach
erecting the swingaway. pins (6) and clips (7) on the left side of the boom nose.
2-10-38
NOTE 4. Attach a length of rope to the swingaway tip.
Steps 11 and 12 apply only if there is dif- 5. Ensure clips and pins (3) and (9) are removed from
ficulty in aligning the upper swingaway stowage brackets.
extension attach point to the boom
nose. 6. Remove the retainer clips (6) and pins (7) from the
attach fittings (10) on the left side of the boom nose and
WARNING stow them in the base of the swingaway.
DO NOT MODIFY THE ATTACH POINTS

WARNING
TO PERMIT THE INSTALLATION OF
THE ATTACH PINS.
WHEN STOWING THE SWINGAWAY,
WARNING
THE SWING PATH.
DO NOT PLACE BLOCKING UNDER
THE SWINGAWAY SHEAVE WHEEL.
CAUTION
11. Place blocking under the tip of the swingaway base
section (4) and relieve the weight of the swingaway by a DO NOT ALLOW THE SWINGAWAY TO
slight lowering of the boom.
3G
12. Install the attach pin (6) and safety clip (7) into the
SLAM INTO THE STOWAGE BRACKET
WHEN SWINGING INTO THE STOWED
POSITION.
upper anchor (10) on the left side of the boom nose. Re-
move the rope from the tip of the swingaway. 7. Using the rope attached to the tip of the swingaway,
swing the swingaway to the side of the boom until the
60
13. Extend and lower the boom until the blocking can ramp guide comes in contact with the rear support.
be placed under the swingaway.
8. While holding the extension against the rear sup-
14. Lower the swingaway onto the cribbing. Discon- port, fully retract the boom, ensuring the guide finger
nect and stow the pins securing the swingaway to the (21) located on the roller support is engaged with the an-
boom nose.
86
gle (22) located on the rear support.
15. Retract the boom, freeing the swingaway from the 9. Install the front stowage pin (9) and safety clip.
boom nose.
10. Remove the attach retaining clips (6) and attach

INSTALLATION
pins (7) from the right side of the boom and stow them in
the base of the swingaway.
1. Position the crane so the swingaway lies in front of
the crane with the swingaway base facing the crane.
Fully extend and set the outriggers. 11. Swing the cable over the main boom nose idler
sheave and install the attach pin (1) and safety clip (2).
2. Extend and lower the boom to engage the anchor
(10) and anchor fittings (8) on the swingaway. WARNING
3. Install the attach pins (6) and safety clips (7) to se- ALL STOWAGE PINS AND SAFETY
cure the swingaway to the boom nose. Raise the boom CLIPS MUST BE IN PLACE BEFORE
lifting the swingaway from the cribbing on which it was PERFORMING ANY CRANE OPERA-
resting. TIONS.
2-10-39
WARNING
FAILURE TO MAINTAIN THE PROPER

CLEARANCE BETWEEN THE SWIN-
GAWAY ANCHOR FITTINGS AND THE
BOOM NOSE ATTACH FITTINGS
COULD CAUSE THESE FITTINGS TO
CONTACT EACH OTHER DURING OP-
ERATION OF THE BOOM.
20 25
16,17 6 26,27
10
14 7 23
12,13
3G 10
6
18,19
7
15
26,27
60
24 2 1
4
21 7
23
86
8
6
22
3
7
18 8
5
9
19
11
Swingaway Boom Extension Removal
2-10-40
AUXILIARY BOOM NOSE
DESCRIPTION
An optional auxiliary boom nose (rooster sheave) is nose and is secured by pins that pass through the
available for the boom to simplify single part cable us- rooster sheave and the main boom nose.
age. The rooster sheave is installed on the main boom
1. Hitch Pin
2. Hitch Pin Clip
3. Aux Boom Nose Assembly 5
4. End Cap 9
5. Sheave Wheel 8
6. Shaft 10
7. Locknut
8. Tongued Lockwasher 7
9. Keyed Washer
10. Grease Fitting
4 6
3G
3
60
86
1
3
1 1
4
4 3
2 2 2
5
5
Auxiliary Boom Nose Installation
2-10-41
86
60
3G
SECTION 11
HOISTS
TABLE OF CONTENTS
Page
HOISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Hoist Installation and Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-3
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
Adjustment of the Motor Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-4
3G
PISTON TYPE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-5
AUXILIARY HOIST (HO30B GROVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-6
60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-6
Hoist Installation and Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-6
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
86
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
Adjustment of the Motor Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-7
VANE TYPE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-8
HOIST TO BOOM ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-9
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-11
2-11-1
LIST OF FIGURES
Title Page
Hoist to Boom Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11-10
3G
60
86
2-11-2
HOISTS
DESCRIPTION
The main hoist is mounted on the turntable to the rear of reduction unit within the hoist drum. An overrunning
the boom. clutch will allow the hoist to be raised without releasing
the brake, while holding the load, until there is sufficient
The hoist uses a bent axis axial piston motor, to drive the pressure to release the brake when hoisting down.
THEORY OF OPERATION
The hydraulic pump supplies oil to the hoist directional mote control lever is placed in a working position, it
control valve. Movement of the directional control valve sends a pilot pressure signal to shift the valve spool in
spool is controlled by pilot pressure signals received the directional control valve, thus routing pressure and
from the remote control levers in the cab. When the re- flow to drive the hoist.
MAINTENANCE
3G NOTE

60
REMOVAL 3. Check the hoist to boom alignment according to the
HOIST TO BOOM ALIGNMENT procedure in this Sec-
1. Remove the cable, the cable follower, the idler tion.
roller, and the hoist rotation indicator, as applicable.
4. Place a level between the turntable pivot shaft
86
2. Attach a suitable lifting sling to the hoist. bushings.
3. Tag and disconnect the hydraulic supply lines to 5. Place a level across the top of the hoist drum and
the hoist; cap or plug all lines and openings. determine if the hoist is sitting in the same place in rela-
tion to the level positioned between the turntable pivot
4. Remove the nuts, bolts, and washers securing the
shaft bushings.
hoist and remove the unit from the mounting pad.
5. Mark for reuse any shims that may be present on 6. With the hoist level, check to determine if all the
the mounting pad. hoist mounting pads are in contact with the mounting
plate by rocking the hoist.
HOIST INSTALLATION AND ALIGNMENT
7. Keeping the hoist level, use a feeler gauge to deter-
1. Ensure the mounting plate and hoist pads are mine the amount of gap between the pads and mounting
clean and free from debris and the hoist has not been plate.
damaged during handling.
8. Add shims as required to make the hoist level and
2. With the hoist supported in a suitable lifting sling, provide a solid, secure mount. Altering the shim thick-
position the hoist on the mount. ness to fit a tapering gap is acceptable.
2-11-3
9. With shims installed to satisfy any gap, install the 3. Ensure the hydraulic connections are secure and
fastener hardware. Torque to 479 pounds-foot (66 kgm, free from leaks.
dry.).
SERVICING
10. Connect the hydraulic hoses and lines as tagged
1. Remove the cable from the hoist (if applicable).
prior to removal.
2. Rotate the hoist drum until one drain plug is at the
11. Remove the lifting sling from the hoist.
highest point.
12. Install the cable follower, and the hoist rotation indi- 3. Remove the drain plugs.
cator, as applicable on the hoist.
4. Fill the drum with EPGL gear lubricant until oil be-
13. Service the hoist. Refer to SERVICING in this Sec- gins to flow from the horizontally positioned opening.
tion.
5. Install the pipe plugs.
14. Install the cable, following procedures outlined un-
der INSTALLING CABLE ON THE HOIST, in the Opera- NOTE
tor’s and Safety Handbook.
Drum lubricant capacity is approxi-
mately 6 litres.
FUNCTIONAL CHECK
3G
1. Attach a test weight to the hook and raise and lower
the load several times.
6. Check every 250 hours.
ADJUSTMENT OF THE MOTOR CONTROL VALVE
2. Check the hoist for smooth operation of the hoist If adjustment of the motor control valve is necessary
motor and brake system. contact Grove Customer Service.
60
86
2-11-4
PISTON TYPE MOTOR
DESCRIPTION
The motor is a bent axis axial piston type motor, and is the drive shaft. Cylinder movement is cardan-free, direct
used to drive the reduction unit within the main hoist. via the tapered pistons.
Due to the bent axis drive, the torque is created direct at
MAINTENANCE
NOTE

1. Reposition the motor on the drum and secure in po-

1. Drain the oil from the drum by removing the plugs.
3G sition using bolts and spring washers.
2. Tag and disconnect all hydraulic lines to the motor. 2. Secure the motor to the hoist drum bracket using
Cap or plug all lines and openings. bolts and washers.
3. Reconnect all hydraulic lines as tagged prior to re-

3. Remove the bolts and spring washers securing the
moval.
motor to the drum support bracket and the hoist drum.
60
4. Fill the hoist drum with oil. Refer to section 15 - LU-
4. Remove the motor to a clean work area. BRICATION in this manual.
86
2-11-5
AUXILIARY HOIST (HO-30B GROVE)
DESCRIPTION
The auxiliary hoist is mounted on the turntable. When within the hoist. An overrunning clutch will allow the hoist
the optional auxiliary hoist is provided, it is mounted to to be raised without releasing the brake while holding
the rear of the main hoist. the load until there is sufficient pressure to release the
brake when hoisting down.
The hoist uses a vane motor to drive the reduction unit
THEORY OF OPERATION
The hydraulic pump supplies oil to the hoist directional mote control lever is placed in a working position, it
control valve. Movement of the directional control valve sends a pilot pressure signal to shift the valve spool in
spool is controlled by pilot pressure signals received the directional control valve, thus routing pressure and
from the remote control levers in the cab. When the re- flow to drive the hoist.
3G
MAINTENANCE
NOTE

60
REMOVAL 3. Check the hoist to boom alignment according to the
HOIST TO BOOM ALIGNMENT procedure in this Sec-
1. Remove the cable, the cable follower, the idler tion.
roller, and the hoist rotation indicator, as applicable.
4. Place a level between the turntable pivot shaft
86
2. Attach a suitable lifting sling to the hoist. bushings.
3. Tag and disconnect the hydraulic supply lines to 5. Place a level across the top of the hoist drum and
the hoist; cap or plug all lines and openings. determine if the hoist is sitting in the same place in rela-
tion to the level positioned between the turntable pivot
4. Remove the nuts, bolts, and washers securing the
shaft bushings.
hoist and remove the unit from the mounting pad.
5. Mark for reuse any shims that may be present on 6. With the hoist level, check to determine if all the
the mounting pad. hoist mounting pads are in contact with the mounting
plate by rocking the hoist.
HOIST INSTALLATION AND ALIGNMENT
7. Keeping the hoist level, use a feeler gauge to deter-
1. Ensure the mounting plate and hoist pads are mine the amount of gap between the pads and mounting
clean and free from debris and the hoist has not been plate.
damaged during handling.
8. Add shims as required to make the hoist level and
2. With the hoist supported in a suitable lifting sling, provide a solid, secure mount. Altering the shim thick-
position the hoist on the mount. ness to fit a tapering gap is acceptable.
2-11-6
9. With shims installed to satisfy any gap, install the 3. Ensure the hydraulic connections are secure and
fastener hardware. Torque to 479 pounds-foot (66 kgm, free from leaks.
dry.).
SERVICING
10. Connect the hydraulic hoses and lines as tagged
1. Remove the cable from the hoist (if applicable).
prior to removal.
2. Rotate the hoist drum until one drain plug is at the
11. Remove the lifting sling from the hoist.
highest point.
12. Install the cable follower, and the hoist rotation indi- 3. Remove the drain plugs.
cator, as applicable on the hoist.
4. Fill the drum with EPGL gear lubricant until oil be-
13. Service the hoist. Refer to SERVICING in this Sec- gins to flow from the horizontally positioned opening.
tion.
5. Install the pipe plugs.
14. Install the cable, following procedures outlined un-
der INSTALLING CABLE ON THE HOIST, in the Opera- NOTE
tor’s and Safety Handbook.
Drum lubricant capacity is approxi-
mately 6 litres.
FUNCTIONAL CHECK
3G
1. Attach a test weight to the hook and raise and lower
the load several times.
6. Check every 250 hours.
ADJUSTMENT OF THE MOTOR CONTROL VALVE
2. Check the hoist for smooth operation of the hoist If adjustment of the motor control valve is necessary
motor and brake system. contact Grove Customer Service.
60
86
2-11-7
VANE TYPE MOTOR
DESCRIPTION
The vane motor is a fixed displacement, rotary balanced consisting of the port plate with a built-in check valve, a
motor that converts hydraulic oil flow into rotary me- cam ring assembly containing the rotor, vanes, vane
chanical motion. The motor consists of four basic sub springs and cam ring, and the end cap assembly con-
assemblies, a body or housing and shaft with a perma- sisting of the end cap and needle bearing.
nently lubricated bearing, a front port plate assembly
MAINTENANCE
NOTE

1.
2. Tag and disconnect the hydraulic lines from the

3G
Drain the oil from the drum by removing the plugs.
motor and the hoist motor control valve. Cap or plug all
1. Using a new gasket, position the motor and gasket
to the left end cover. Secure the motor and gasket in
place with the bolts and washers.
lines and openings. 2. Connect the hydraulic line as tagged during re-
moval.
3. Remove the hex head bolts and washers securing
60
the motor to the left end cover; remove the motor; dis- 3. Fill the drum with oil. Refer to Section 15 - LUBRI-
card the motor gasket. CATION in this manual.
86
2-11-8
HOIST TO BOOM ALIGNMENT
PROCEDURE a. String a chalkline from point A, (outer boom

centreline) across the base section centreline and the
1. Lower the boom to the level position. hoist drum midpoint.
2. Find a line on top of the hoist drum which is parallel b. Pull the line taut, aligning it directly over the top of
to the drum axis as follows. point B.
a. Use a Miracle Point Gauge and find a zero degree c. With a protractor, measure the angle between the
dial point next to each flange on top of the drum. chalkline and the cross line drawn on the hoist. If the
measurement of the angle exceeds 90 degrees _ 1/2
NOTE degrees, realignment will be necessary.
If this special equipment is not avail- CAUTION

able, sufficient accuracy in locating a
centreline may be obtained by using a DO NOT ALTER HOLES OR STOP
steel square against the machines in- BLOCKS ON THE CRANE MOUNTING
ner surfaces of both flanges. It is advis- PLATE, AS VERY SMALL ADJUST-
able to avoid using any cast surfaces in MENTS RESULT IN LARGE ANGULAR
this procedure unless a check from
both flanges indicates that the resul-
tant line is straight.
3G CHANGES, EXTREME CARE SHOULD
BE TAKEN TO AVOID OVERCORREC-
TION.
b. Draw a line between the hoist drum flanges, pass- 5. If realignment is necessary, remove the hoist
ing through both points as located above and determine mounting bolts and shift the hoist as necessary to
the midpoint. achieve the minimum angular tolerance. Trial and error
60
location may be necessary for proper line-up of the bolt
3. Find the midpoint of the lines drawn across the top holes and stop blocks. If all bolts cannot be inserted or
of the base boom section, perpendicular to its length, at the stop blocks interfere with line-up, a slight elongation
both ends of the boom section. (Figure points A and B). of the hoist bolt holes and/or shimming of the mounting
lugs might be necessary.
4. Check as follows to see if the hoist is aligned per-
86
pendicularly to the boom.
2-11-9
BOOM
CENTERLINE
POINT TAUT
A CHALK
LINE
LOCATING CENTERLINE
WITH SQUARE
BOOM
CENTERLINE PROTRACTOR
3G POINT
B
Hoist to Boom Alignment

60
86
2-11-10
COUNTERWEIGHT
DESCRIPTION
The crane is equipped with two removeable counter- On cranes not fitted with an auxiliary hoist, a 1420kg
weights, one weighing 3800kg (8375lbs) and the other (3130lbs) counterweight is fixed to the turntable to ac-
weighing 7800kg (17200lbs). The counterweights are count for the weight of the auxiliary hoist.
removed or installed by hydraulic cylinders attached to
the turntable.
MAINTENANCE
COUNTERWEIGHT REMOVAL AND INSTALLATION CYLINDER COUNTERWEIGHT REMOVAL
NOTE
NOTE
For detailed information concerning
For detailed information concerning the removal, installation, assembly and
the removal and installation of the disassembly of the cylinder refer to
counterweights refer to Section VII in
the Superstructure Operator’s and
Safety Handbook.
3G CYLINDER COUNTERWEIGHT RE-
MOVAL Section 8 HYDRAULIC SYS-
TEM.
60
86
2-11-11
86
60
3G
SECTION 12
OUTRIGGERS
TABLE OF CONTENTS
Page
OUTRIGGERS CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-4
OUTRIGGER BEAM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
3G
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-8
EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Internal Leak Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-11
STABILIZER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
86
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-12
LIST OF FIGURES
Title Page
Outrigger Beam Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12-9
2-12-1
Page
2-12-8
WARNING
ENSURE ANY BLOCKING MATERIAL

USED IS CAPABLE OF SUPPORTING
THE WEIGHT OF THE OUTRIGGER
BEAM ASEMBLY. DO NOT ALLOW IT
TO TILT OR SLIDE.
3G
60
86
2-12-2
OUTRIGGER CIRCUIT
DESCRIPTION
Hydraulic power for the outrigger systems is provided by for extending and retracting on each side of the carrier
the carrier hydraulic system. The outrigger system com- and a optional switch control panel located in the turnta-
prises four two stage telescopic beams fitted with ble cab. Bubble level indicators are mounted adjacent to
double-acting cylinders for extension and retraction the control systems.
functions and at the extremity of each beam, a double-
acting stabilizer for levelling functions. The outrigger controls are used to bring the crane to ON
OUTRIGGERS condition with beams fully extended for
RATED lifting duties. For rated FREE ON WHEELS du-
Each stabilizer incorporates a lock valve which hydrauli-
ties, the tyres must be inflated to correct pressure and
cally locks the stabilizer in a selected position thus pre-
axle suspension locks engaged.
venting retraction of the stabilizer in the event of a mal-
function occuring in the equipment or hose failure. Each
With the beams FULLY RETRACTED the crane may be
stabilizer can be individually adjusted to accurately level
jacked up for wheel changing or under carrier servicing.
the crane.
In this condition the turntable MUST NOT be swung.
Duplicate operating controls are provided. These com- 3G The crane must be LEVELLED and remain LEVEL dur-
prise beam and stabilizer independent switch controls, ing operation.
THEORY OF OPERATION
The appropriate OUTRIGGER SELECTOR switch must When the extension/retraction switch is in the RE-
be positioned before the extension/retraction switch is TRACT position, the flow through the selector valve is
60
positioned. Flow from the 132 lpm (35 gpm) pump sec- directed to the rod side of the cylinder. The oil in the pis-
tion supplies the outrigger circuit. Depressing one of the ton side flows through the open solenoid back to the in-
outrigger selector switches causes that solenoid valve tegrated outrigger valve. If a stabilizer cylinder is to be
to open. As the extension/retraction switch is moved, retracted, then pilot pressure from the pressurized re-
the integral outrigger flow control valve shifts allowing tract line unseats the cylinder check valve allowing oil to
86
flow to either the extend or retract line as applicable. If flow from the piston side through the open solenoid
the extension/retraction switch is in the EXTEND posi- valve to the outrigger valve. The outrigger valve directs
tion, the flow continues through the open solenoid valve the flow to the reservoir.
to the piston side of the cylinder. If the stabilizer(s) is/are
to be extended, the flow first unseats the cylinder check
valve then extends the cylinder. The oil from the rod end The outrigger valve has two internal relief valves. A 140
flows through the outrigger valve, and then to the reser- bar (2030 psi) port relief is in the retract circuit and a 175
voir. bar (2537 psi) relief protects the extend circuit.
2-12-3
MAINTENANCE
TROUBLESHOOTING

1. Slow or erratic operation of outrig- a. Damaged relief valves. a. Remove relief valve; clean or re-
ger extension cylinders. place.
b. Low hydraulic oil. b. Replenish oil to proper level.
c. Sticking solenoid valve spool. c. Repair or replace valve spool.
d. Improper ground to base of sole- d. Ground properly.

noid.
e. Damaged O-rings and swivel. e. Remove swivel and replace O-

rings.
f. Directional selector switch sticking. f. Clean or replace switch.
g. Collector ring dirty or glazed. g. Clean and deglaze collector ring.
h.
3G
Damaged wiring to solenoid switch.
i. Weak brush springs on collector

h.
i.
Replace wiring.
Replace brush springs.

switch.
j. Damaged extension cylinder (inter- j. Remove extension cylinder and

60
nal parts). repair as necessary.
k. Bent cylinder rods. k. Replace piston rods and seals.
l. Excessive material on outrigger l. Clean outrigger beams.

beams.
86
m. Binding outrigger beam. m. Repair or replace outrigger

beam.
n. Damaged outrigger valve. n. Repair or replace valve.
o. Damaged valve coil. o. Replace coil.
p. Main hydraulic pump cavitation. p. Replace or tighten hose or fit-

tings.
q. Partially shifted hydraulic selector q. Disassemble, clean, and polish

spool. spool and valve housing with very fine
emery cloth (water paper.)
r. Insufficient voltage for operation of r. Solenoids require a minimum of

solenoid valve. 9.5 volts to energize. Check outrigger
wiring and electrical swivel coupling
collector rings.
2-12-4
1. Slow or erratic operation of outrig- s. Damaged piston seals. s. Replace all cylinder seals.
ger extension cylinders (continued).
t. Worn or damaged hydraulic pump t. Repair or replace pump section.
section.
u. Scored cylinder barrel. u. Repair or replace extension.
v. Cracked or damaged piston. v. Replace piston and all cylinder

seals.
w. Piston loose on piston rod. w. Replace all cylinder seals and

torque piston lockout.
2. Sticking spool. a. Dirt in system. a. Change oil and flush system.
b. Distortion caused by tie bolts being b. Retorque tie bolts.

overtorqued.
c. Flow in excess of valve rating. c. Limit flow through valve to that

recommended. Check pump output
d.
3G
Pressure in excess of valve rating.
and cylinder ratio.
d. Check relief valve setting or pump

compensation with that recom-
mended.
e. Electrical failure. e. Check wiring and solenoids.

60
3. External leakage. a. Damaged O-rings or quad rings. a. Check for chipped packings and
replace.
b. Loose tie bolts. b. Retorque tie bolts.
c. Damaged solenoid. c. Replace damaged parts.

86
4. Solenoid failure. a. No current. a. Check power source of at least

85% of coil rating.
b. Damaged solenoid assembly. b. Replace solenoid.
c. Short in solenoid. c. Replace coil.
d. Loss of solenoid force. d. Decrease time of solenoid ener-

gization, decrease cycle rate.
5. Outrigger vertical jack cylinder a. Low in hydraulic oil. a. Replenish oil to proper level.
slow or erratic.
b. Damaged main relief valve. b. Repair or replace valve.
c. Damaged holding valve seals. c. Replace holding valve seals.
d. Bent cylinder rod. d. Replace cylinder rod and seals.
2-12-5
5. Outrigger vertical jack cylinder e. Bent outrigger housing. e. Repair or replace outrigger hous-
slow or erratic (continued). ing.
f. Damaged O-rings in swivel. f. Replace O-rings.
g. Excessive material on beams. g. Clean outrigger beams.
h. Sticking solenoid valve spool. h. Repair or replace valve spool.
i. Damaged wiring to solenoid. i. Repair or replace wiring.
j. Weak brush springs. j. Replace brush springs.
k. Collector ring dirty or glazed. k. Clean or deglaze collector ring.
l. Directional selector switch sticking. l. Clean or replace switch.
m. Main hydraulic pump cavitation. m. Replace or tighten hose and fit-

tings.
n. Worn or damaged hydraulic pump
section. n. Repair or replace pump section.
6. Jack cylinder retracts under load. a.

3G
Damaged piston seals. a. Replace all cylinder seals.
b. Damaged holding valve seals. b. Replace seals.
c. Damaged holding valve. c. Replace valve assembly.

60
d. Scored cylinder barrel. d. Repair or replace cylinder.
e. Cracked or damaged piston. e. Replace piston and all cylinder

seals.
7. Jack cylinder extends while ma- a. Damaged piston seals. a. Replace all cylinder seals.
86
chine is traveling.
b. Scored cylinder barrel. b. Replace jack cylinder.
c. Cracked or damaged piston. c. Replace piston and seals.
d. Piston loose on cylinder rod. d. Replace seal and retorque.
8. Outrigger system will not activate a. Hydraulic oil low. a. Replenish system.
(from stowed or extended and down
position). b. Loose or broken wire on switch. b. Repair or replace wiring.
c. Clogged, broken, or loose lines or fit- c. Clean, tighten, or replace lines or

tings. fittings.
d. Damaged relief valve or damaged d. Repair or replace valve.

control valve.
2-12-6
9. Outrigger system activates, but a. Clogged, broken, or loose hydraulic a. Clean, tighten, or replace lines or
selected outrigger will not stow or ex- lines or fittings. fittings.
tend and lower as desired.
b. Loose or broken wire on control b. Repair or replace wiring.
switch or solenoid valve.
c. Damaged solenoid valve. c. Repair or replace valve.
d. Damaged control switch. d. Replace switch.
e. Damaged hydraulic cylinder. e. Repair or replace cylinder.
10. Outriggers will not set. a. Improper sequence of activation. a. Activate individual control
switch; then activate system control
switch.
11. Two outriggers activate from sin- a. Damaged solenoid valves. a. Repair or replace.
gle control switch.
12. One/two outriggers will not stow.
13. Individual outrigger will not set or

stow.
a.
a.
b.
3G
Hydraulic lock.
Damaged piston seals.
Damaged check valve.

a.
a.
b.
Recycle individual outrigger(s).
Replace seals.
Repair or replace valve.
c. Loosen or broken wire on control c. Repair or replace wiring.

switch or solenoid valve.
60
d. Damaged solenoid valve. d. Repair or replace valve.
86
2-12-7
OUTRIGGER BEAM ASSEMBLY
DESCRIPTION
The outrigger beam assembly consists of an outrigger and the required hoses and mounting hardware.
beam, a stabilizer cylinder, a twin extension cylinder,
THEORY OF OPERATION
When the outrigger extension is activated, it extends or jack cylinder applies force to the outrigger beam verti-
retracts the outrigger beam within the outrigger box. The cally. This sequence of events provides for lifting and
jack cylinders are mounted to the end of the beam. The stabilizing the crane for operation.
MAINTENANCE
REMOVAL NOTE
1. Extend the outrigger slightly to facilitate attaching a The outrigger beam assembly weighs
lifting device to the outrigger beam.
2. Tag and disconnect the hydraulic hoses at (A, B,

and C), cap or plug all lines and openings.
3G approximately 2392 kg (5272 lbs) front
and 2960 kg (6524 lbs) rear.
6. Position the outrigger beam on the blocking mate-

rial.
NOTE
INSPECTION
60
Do not allow the end of the outrigger ex- Inspect the outrigger inner and outer beam for bends,
tension cylinder to fall when the cylin- evidence of cracks, or other damage. Check the outrig-
der mounting shaft is removed. Use an ger beam internally for hydraulic fluid, which may indi-
adequate soft support to cushion any cate a leaking cylinder, loose connection, or damaged
distance the rod will drop. hydraulic line.
86
3. Remove the pin (10) and clip (15) anchoring the ex- INSTALLATION
tension cylinder to the anchor bracket (35).
1. Attach a suitable lifting device to the outrigger
4. Attach a suitable lifting device to the outrigger beam assembly.
beam assembly. 2. Slide the beam into the outrigger housing and align
the cylinder anchor with the anchor bracket.
5. Pull the outrigger beam assembly out of the outrig-
ger box, re-adjusting the lifting attachment to prevent 3. Secure the cylinder anchor to the anchor bracket
the beam assembly from falling to the ground, when the using pin (10) and clip (15).
outrigger beam assembly clears the outrigger box.
4. Connect hydraulic lines as tagged prior to removal.
WARNING When replacing rolling hoses (22) and (25) it may be
necessary to include a slight twist when refitting, thus
ENSURE ANY BLOCKING MATERIAL
eliminating any possibility of a foil occuring. Always
USED IN CAPABLE OF SUPPORTING
check the operation several times after replacing rolling
THE WEIGHT OF THE OUTRIGGER
hoses.
BEAM ASSEMBLY, DO NOT ALLOW IT
TO TILT OR SLIDE. 5. Check for oil leakage after initial operation.
2-12-8
3G
60
1. Outrigger Beam Inner 22. Pipe

2. Outrigger Beam Outer 23. Bracket
3. Nut 24. Clip
86
4. Adaptor 25. Hose

5. Hose 26. Screw
6. Hose 27. Adaptor
7. Stabilizer Cylinder 28. Hose Tray
8. Elbow 29. Bulkhead Adaptor
9. Pin 30. Pipe
10. Pin 31. Washer Plain
11. Washer Spring 32. Washer Spring
12. Nut 33. Nut
13. Bolt 34. Bolt
14. Extension Cylinder 35. Anchor bracket
15. Locking Clip 36. Pivot Pin
16. Screw 37. Cotter Pin
17. Screw 38. Plug
18. Washer Plain 39. Plastic Bearing
19. Washer Spring 40. Adaptor
20. Nut 41. Ring
21. Adaptor
Outrigger Beam Assembly
2-12-9
EXTENSION CYLINDER
DESCRIPTION
Twin piggy back type outrigger extension cylinder is util- length of the cylinders measured between the centres of
ized within each outrigger box assembly. The extension each of the rod bushings is 4800mm (189²). It is at-
cylinder provides the force for the outrigger beam’s hori- tached to the outrigger box by means of a pin through a
zontal movement. The cylinders have a 70mm (2.75²) clevis on the barrel end of the cylinder. Attachment of the
diameter bore and are the double acting type. Each cyl- rod end t the outrigger beams is by means of a pin
inder has a retracted length of 2280mm (91²) between through a bushing. The cylinder weighs approximately
the centres of each of the rod bushings. The extended 90kg (197lbs).
MAINTENANCE
NOTE
Refer to SM package for disassembly
INTERNAL LEAK PROCEDURE

3G
and assembly of the cylinders.
REMOVAL
NOTE
1. Extend the rod until it reaches the end of its stroke,
then stop engine. Cylinder can be removed with beam
partially extended to expose the work-
60
2. Disconnect and cap the retract hose. ing area aperture.
1. Tag and disconnect hose couplings (A, B and C) lo-

3. Start engine and operate cylinder extend control. cated at the rear of the beam assembly.
86
4. Observe the open cylinder port of leakage. 2. Tag and disconnect hose couplings (F) and (G) lo-
cate through the beam side wall aperture near the stabi-
lizer cylinder.
5. Leakage will indicate the piston seals require re-
newal. 3. Cap and label all loose hoses for cleanliness and
for refitting identification.
NOTE
4. Remove clips (13) and pins (12).
Reverse this procedure to determine 5. Remove split pins (9) and pin (8).
leakage at the retraction stage, usually
one test is sufficient to determine a flow 6. Withdraw the cylinder with hoses attached gently
path exists across a piston seal. from the rear of the beam assembly, lifting it initially over
the saddle in which the anchor was resting.
Score marks in the cylinder walls will NOTE

give a similar effect, in such events
drain and clean the hydraulic system of The extension cylinder weights ap-
abrasive before fitting a new cylinder. proximately 90kg (197lbs).
2-12-10
INSTALLATION FUNCTIONAL CHECK
1. Use suitable slings to lift the cylinder

2. Tilt the cylinder and guide it with hoses into the
beam. 2. Extend and retract the outrigger.
3. Install pin (8) and split pins (9). 3. Observe the operation of the outrigger beam.
4. Install pins (12) and clips (13).
4. Check all hydraulic connections for evidence of
5. Reconnect all hoses as tagged prior to removal. leakage.
3G
60
86
2-12-11
STABILIZER CYLINDER
DESCRIPTION
Four stabilizer cylinders are used on the crane, one at and are the double acting type.Each cylinder has a re-
the end of each outrigger beam. The stabilizer cylinders tracted length of1222mm (48²) measured from the end
provide the force for the outrigger beam’s vertical move- of the cylinder to the end of the cylinder rod. The ex-
ment. The rear outrigger cylinders have a 177 mm (7²) tended length of the cylinder from the end of the cylinder
diameter bore and are the double acting type. The front to the end of the cylinder rod is 1854mm (73²). The stabi-
outrigger cylinders have a 152mm (6²) diameter bore lizer cylinder weighs approximately 152kg (334lbs).
MAINTENANCE
NOTE
Refer to SM package for Disassembly

and Assembly of the cylinders.
REMOVAL
NOTE
Due to the length of the cylinder assem-

3G 5. With a suitable sling positioned at the rod ball end
lift out the cylinder assembly from beam fabrication.
INSTALLATION
bly it is advisable to first remove the 1. Reassembly is a direct reversal of the removal pro-
beam assembly complete. cedure.
60
1. After the beam assembly removal procedure has
FUNCTIONAL CHECK
been completed turn the unit completely over and place
upside down onto suitable packing.
2. Remove the cylinder holding bolts and washers
2. Extend and retract the stabilizer cylinder.
86
from the stabilizer cylinder base plate.
3. Disconnect hose couplings. 3. Check for smooth operation of the cylinder.
4. Cap and label loose hoses and ports for cleanli- 4. Check all hydraulic connections and hoses for evi-
ness and refit identification. dence of leakage.
2-12-12
SECTION 13
SWIVELS
TABLE OF CONTENTS
Page
SWIVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-3
9 PORT AIR/HYDRAULIC SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-4
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-5
ELECTRICAL SWIVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-7
3G
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-8
Removal . . . . . Alternatives
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-9
60
LIST OF FIGURES
Title Page
Air/Hydraulic and Electric Swivel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13-10
86
2-13-1
Page
2-13-4
WARNING
STOP THE ENGINE BEFORE CARRY-

ING OUT ANY REPAIRS TO THE HY-
DRAULIC SYSTEM.
2-13-7
WARNING
DISCONNECT THE BATTERIES BE-

FORE PERFORMING ANY MAINTE-
NANCE ON THE ELECTRICAL SYS-
TEM. SERIOUS BURNS MAY RESULT
FROM ACCIDENTAL SHORTING OR
GROUNDING OF LIVE CIRCUITS.
3G WARNING
2-13-8

60
FROM ACCIDENTAL SHORTING OR
GROUNDING OF LIVE CIRCUITS.
86
2-13-2
SWIVELS
DESCRIPTION
Depending on the machine specification there are two and is mounted to the carrier frame by nuts, bolts and
types of swivel fitted, air/ hydraulic and electrical. Solid washers. If required an electrical swivel is mounted on
connections can not be used to transfer oil, or electricity top of the air/hydraulic swivel and attached to the drive
between the carrier and the turntable, due to the con- post, this allows the collector ring to remain stationary
tinuous 360° swing. The use of swivels efficiently ac- with the carrier. The outer portion (brush assembly) is on
complishes this function.
a mounting plate which is bolted to the barrel, this allows
The air/hydraulic swivel when fitted is a nine port swivel the brush assembly to rotate with the turntable.
3G
60
86
2-13-3
9 PORT AIR/HYDRAULIC SWIVEL
DESCRIPTION
Each port on the air/hydraulic swivel swivel is stamped scribed below.

with the port number. The function of each port is de-
Port Port
Function Function
Number Number
1 Steer - Hydraulic 6 Service Brakes - Air
2 Steer - Hydraulic 7 Parking Brakes - Air
3 Service Brakes - Air 8 Parking Brakes - Air
4 Service Brakes - Air 9 Throttle - Air
5 Service Brakes - Air
3G
THEORY OF OPERATION
The air/hydraulic swivel allows oil to flow from the main sponds with a mating port on the barrel of the swivel.
pumps and steer pump, to various crane functions on Each channel is separated by a series of seals that pre-
the turntable. All oil and air is routed into the spool por- vents transfer of air and oil pressure. Return oil flow from
tion of the swivel where through a series of internally the crane functions is accomplished in the same manner
60
drilled passages oil and air is transferred to a circumfer- through another set of ports.
ential channel on the spool exterior. This channel corre-
MAINTENANCE
86
NOTE

WARNING
STOP THE ENGINE BEFORE CARRY-

ING OUT ANY REPAIRS TO THE HY-
DRAULIC SYSTEM.
REMOVAL 2. Derrick the boom out to its optimum position.
Refer to the figure Air/Hydraulic and Electrical Swivel

3. Using suitable blocking material block the boom
Assembly.
near its base.
1. Extend and set the outriggers. Ensure the crane is
level. 4. Drain the hydraulic tank.
2-13-4
5. Remove the electrical swivel (Refer to Electrical INSTALLATION
Swivel - Removal in this section).
1. Position the air/hydraulic swivel complete below
6. Tag and disconnect all hydraulic lines. Cap or plug the mounting.
all ports and hose ends.
2. Attach a suitable rope or sling to the swivel and us-
7. Tag and disconnect all air lines. Cap or plug all
ing the auxiliary lifting device lift the assembly up to its
ports and hose ends.
mounting.
NOTE
3. Secure the swivels in position with the four nuts,
The air/hydraulic swivel complete bolts and washers (1, 2 and 3).
weighs approximately 30.5 kg (67 lbs).
4. Reconnect all hydraulic lines to the swivel as
8. Using a suitable auxiliary lifting device attach a tagged prior to removal.
rope or sling capable of holding the weight of the air/hy-
draulic swivel and allow it to take the weight of the as-
5. Reconnect all air lines as tagged prior to removal.
sembly.
9. Remove any driveshafts obstructing the removal of 6. Remove the rope or sling from the swivel.
the swivel (Refer to Drive Lines - Removal in Section 2 of
this manual).
10. Remove the four nuts, bolts and washers (1, 2 and
3) securing the air/hydraulic swivel to the carrier.
3G 7. Install any driveshafts removed (Refer to Drive
Lines - Installation in Section 2 of this manual).
8. Install the electrical swivel (Refer to Electrical

Swivel - Installation in this section).
11. Using the auxiliary lifting device, lower the swivel to
the floor and remove it to a clean work area.
9. Fill the hydraulic tank with clean, filtered hydraulic
60
NOTE oil, to the top of the sight gauge. (Refer to Lubrication
Section in this manual).
If a new hydraulic/ air swivel is to be fit-
ted, the adaptors should be removed 10. Remove blocking from base of boom.
from the old swivel, one at a time and
86
placed into the compatible port on the 11. Start the engine and operate all functions. Recheck
new swivel, at the same angle as noted the level of the hydraulic oil, and refill as necessary.
on removal. This will facilitate in easier
reconnection of hoses on installation. 12. Check air/hydraulic swivel coupling for any leaks.
2-13-5
10
3G
1. Spring Washer 3
60
2. Nut
3. Bolt 1
4. Air/Hydraulic Swivel
5. Screw 2
6. Washer Plain
7. Washer Spring
86
8. Nut
9. Drive Post 8 9
10. Electrical Swivel
7
Air/Hydraulic and Electrical Swivel Assembly
2-13-6
ELECTRICAL SWIVEL
DESCRIPTION
The electrical swivel contains 2 x 15 amp and 45 x 10 the casing of the swivel. The collector ring leads are
amp rings in 5 sets of concentric ‘PANCAKE’ sections formed into connectors, which plug into receptacles
and 2 x 30 amp sliprings, there are also two micro from the carrier power supply.
switches for steer reverse and over rear duties, when re-
quired.
This crane has the option of additional outrigger controls
and steering from the turntable cab. This results in alter-
The collector ring leads are formed into one harness, native electrical swivel mountings which are described
which is routed downward and out through the side of below.
MAINTENANCE
3G NOTE

The following procedure is for machines with op- NOTE

tional additional outrigger controls from the turn-
60
table cab. The plugs and sockets are too large to
go through the centre of the air/hydrau-
REMOVAL lic swivel. They must be removed.
4. Tag each wire on its connector. Using pin removal

1. Extend and set the outriggers. Ensure the crane is
86
tools listed in Section 14 - Electrical System, remove the

level. pin with wires still attached, and mark each wire with the
pin socket number in the connector. Collect the wires
WARNING and secure them into a bundle. Mark the bundle with the
connector number.
FORE PERFORMING ANY MAINTE- 5. Repeat steps 3 for the rest of the connectors
TEM. SERIOUS BURNS MAY RESULT 6. Secure the connectors and wires from the connec-
FROM ACCIDENTAL SHORTING OR tors so the harness cam be withdrawn through the
GROUNDING OF LIVE CIRCUITS. centre of the drive post (10).
7. Remove nuts, bolts and washers (6, 7, 8 and 9) lift

2. Disconnect the batteries. (Refer to Section 14 - bracket (11) complete with electrical swivel clear of the
Electrical System). drive post (10).
3. Tag and disconnect the plugs which join the electri- 8. Remove nuts (15) and washers (14) and lift the
cal swivel harness to the carrier harnesses. electrical swivel from the bracket (11).
2-13-7
9. Remove screw (13) from drive disc (12), remove WARNING
the electrical swivel, withdrawing the harness carefully
through the centre of the drive post (10). DISCONNECT THE BATTERIES BE-
CAUTION NANCE ON THE ELECTRICAL SYS-
WHEN WITHDRAWING THE WIRING FROM ACCIDENTAL SHORTING OR
HARNESS THROUGH THE CENTRE OF GROUNDING OF LOVE CIRCUITS.
THE AIR/HYDRAULIC SWIVEL, EN-
SURE THE WIRES DO NOT GET 2. Disconnect the batteries. (Refer to Section 14 -
CAUGHT AND DAMAGED. Electrical System).
3. Tag and disconnect the plugs which join the electri-

10. Remove the swivel to a clean work area.
cal swivel harness to the carrier harnesses.
INSTALLATION NOTE
1. Carefully feed the wiring harness through the The plugs and sockets are too large to
centre of the drive post (10), ensuring the wires do not go through the centre of the air/hydrau-
get damaged. lic swivels. They must be removed.
2. Relocate the drive disc (12) on the electrical swivel 4. Tag each wire on its connector. Using pin removal
242 to retain the screw.

3G
shaft and secure in position using screw (13) use loctite
3. Reposition the electrical swivel on the bracket (11)

tools listed in Section 14 - Electrical System, remove the
pin with wires still attached, and mark each wire with the
pin socket number in the connector. Collect the wires
and secure them into a bundle. Mark the bundle with the
and secure in position using nuts (15) spring washers connector number.
(14).
5. Repeat steps 3 for the rest of the connectors.
60
4. Locate bracket (11) complete with electrical swivel
on its mounting brackets (5), secure in position using 6. Secure the connectors and wires from the connec-
nuts, bolts and washers (6, 7, 8 and 9). tors so that harness can be withdrawn through the
centre of the air/hydraulic swivel.
5. Install the individually tagged wires with their con-
7. Remove clips (11), washers (14) and pins (12) this
86
nectors into their relevant receptacles.

will now allow reaction arms (9) to be moved clear of the
6. Reconnect all plugs and sockets between the elec- bracket (1).
trical swivel and carrier harnesses as tagged prior to re-
8. Remove screws (2) and washers (3).
moval.
9. Remove setscrew (15) to free the electrical swivel
7. Connect the batteries. from the centre post.
8. Activate all systems, cycle all functions and ob- CAUTION

serve for proper operation.
WHEN WITHDRAWING THE WIRING
The following procedure is for machines with HARNESS THROUGH THE CENTRE OF
steering and outrigger operations from the turnta- THE AIR/HYDRAULIC SWIVEL, EN-
ble cab. SURE THE WIRES DO NOT GET
CAUGHT AND DAMAGED.
REMOVAL
10. Remove the swivel complete with mounting
1. Extend and set the outriggers. Ensure the crane is bracket (1) and withdraw harness carefully from the
level. crane.
2-13-8
11. Turn the electrical swivel upside down, for ease of 4. Fasten mounting bracket (1) to the air/hydraulic
access to bolts (5) and washers (4). Remove bolts (5) swivel, using screws (2) and washers (3).
and washers (4) to free the swivel from its mounting
bracket. 5. Locate the reaction arms as prior to removal and
pin in place using pins (12), washers (14) and clips (11).
INSTALLATION
6. Install the individually tagged wires with their con-
nectors into their relevant receptacles.
1. Secure bracket (1) to the base of the electrical
swivel using bolts (5) and washers (4).
7. Reconnect all plugs and sockets between the elec-
trical swivel and carrier harnesses, as tagged prior to re-
2. Feed the wiring harness through the centre of the
moval.
air/hydraulic swivel, taking great care not to damage it.
8. Connect the batteries.
3. Align the centre post coupling with the electrical
swivel coupling and secure position using setscrew (15) 9. Activate all systems, cycle all functions and ob-
use Loctite 242 to retain the screw. serve for proper operation.
3G
60
86
2-13-9
Electrical Swivel Mounting with optional
5
Outrigger Controls from the Turntable Cab
6 1. Screw
2. Washer
7 3. Spring Washer
4. Nut
12 8 5. Mounting Bracket
13 6. Screw
9
7. Washer
11
8. Washer Spring
1 14 9. Nut
15 10. Drive Post
2 11. Mounting Bracket
12. Drive Disc
3
13. Setscrew
14. Spring Washer
4 5
15. Nut
10
3G
60
Electrical Swivel Mounting with optional
Steering Controls from the Turntable Cab
1. Bracket
2. Screw
86
3. Washer
12 4. Screw
14 5. Washer Spring
6
6. Bracket
11 7. Washer Spring
14
8. Screw
10 5 9. Stud
11 4 1
8 10. Yoke
10 15 11. Pin Split
12. Pin
7 9
13. Locknut
2
14. Washer
3
13 15. Setscrew
12 14
11
14 11
2-13-10
SECTION 14
ELECTRICAL SYSTEM
TABLE OF CONTENTS
Page
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Relay Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-5
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-6
3G
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-7
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Cleaning the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
60
Battery Ground Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Adding Water to the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-16
Specific Gravity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
Activating Dry Charged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Electrical Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Windshield Wiper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Wiper Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
2-14-1
Page
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
Electrical Functional Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-20
LIST OF FIGURES
Title Page
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-6
Turntable Harness (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-9
Turntable Harness (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-10
Turntable Harness (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-11
Carrier Harness (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-12
Carrier Harness (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-13
Relay Panel Assembly - Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-14
Relay Panel Assembly - Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-15
3G
Checking Specific Gravity of Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-17
Instrument Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Electrical Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-18
Windshield Wiper Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14-19
60
86
2-14-2
Page
2-14-6
WARNING
WHEN MAINTENANCE WORK IS CAR-

RIED OUT ON THE CRANE SUCH AS
PAINTING, SPRAYING OR WELDING IT
IS ESSENTIAL THAT THE BATTERIES
ARE DISCONNECTED. IF THE BAT-
TERIES HAVE NOT BEEN DISCON-
NECTED AND AN ELECTRICAL FAULT
OCCURS THE CIRCUIT BREAKER
CUTS THE CIRCUIT AND AVOIDS
SOME DAMAGE TO THE SYSTEM.
HOWEVER, THE PROTECTION GIVEN
BY THIS DEVICE IS LIMITED AND
DOES NOT GIVE FULL PROTECTION
3G
WHICH DISCONNECTING THE BAT-
TERIES WOULD PROVIDE.
2-14-7
WARNING
IF IT SHOULD BECOME NECESSARY

60
TO PERFORM ELECTRICAL MAINTE-
NANCE ON LIVE OR HOT CIRCUITS,
REMOVE ALL RINGS, WATCHES, AND
OTHER JEWELRY BEFORE PER-
FORMING MAINTENANCE AS SERI-
86
OUS BURNS RESULT FROM ACCI-

DENTAL GROUNDING OR SHORTING
CIRCUITS.
2-14-7
WARNING
ENSURE THE BATTERIES ARE DIS-

CONNECTED BEFORE PERFORMING
ANY MAINTENANCE ON AN ELECTRI-
CAL CIRCUIT WHICH IS NOT FUSED.
2-14-7
WARNING
DO NOT DISCONNECT THE BATTERY,

OR BREAK THE CHARGING CIRCUIT
IN ANY OTHER WAY WHEN THE EN-
GINE IS RUNNING.
2-14-3
WARNING SAFETY SUMMARY(continued)
Page
2-14-16
WARNING
COVER ALL METAL AREAS OF THE

CLEANING BRUSH WITH INSULATING
TAPE PRIOR TO USE.
2-14-17
WARNING
BATTERY ELECTROLYTE MAY CAUSE

PAINFUL BURNS IF ALLOWED TO
CONTACT THE HANDS OR OTHER
PARTS OF THE BODY. TO AVOID SUCH
AN ACCIDENT, GOGGLES, RUBBER
GLOVES, AND A RUBBER APRON
3G
SHOULD BE WORN WHEN ADDING
ELECTROLYTE.
60
86
2-14-4
ELECTRICAL SYSTEM
DESCRIPTION
The electrical system is 24 volt operation with 24 volt CIRCUIT BREAKER

starting, consisting of an alternator, and two lead-acid
batteries, parallel connected on the carrier and two on In addition to the normal bank of fuses fitted to protect
the turntable. The system is the single wire ground re- the electrical circuits an additional safeguard in the form
turn type, utilizing the machine’s structure as ground. of a circuit breaker will break the circuit in the event of an
abnormally high current being drawn. The location of the
circuit breaker is in the Engine compartment adjacent to
Electrical power is transferred to and from the carrier
the starter motor
and tirntable through the electrical swivel. For more de-
tailed information on the electrical swivel, refer to Sec- BATTERIES
tion 13 - SWIVELS.
The batteries are the maintenance free type and are
completely sealed except for a small vent hole in the
All electrical circuits are protected by the fuses in the
side of the battery. The vent hole allows what small
fuse panels.
amount of gasses that are produced in the battery to es-
3G cape. A battery isolation switch is fitted in the carrier cab
Electrical schematics and wiring diagrams are supplied behind the drivers seat. This switch is used to isolate the
with this manual. batteries when required for maintenance work such as
paint spraying or welding.
ALTERNATORS
RELAY BOXES
Alternators are mounted on both the turntable and car- The carrier relay box is located in the carrier cab at the
60
rier engines and are belt driven. They are 55 ampere al- rear centre between the seats. It contains terminal
ternators with 24 volt output terminals. When the engine blocks, relays, and diodes for the carrier electrical cir-
is running, the 24 volt terminal supplies the machine cuits. The turntable relay box is located toward the front
electrical leads and the voltage to recharge the batteries RH corner of the turntable cab. It contains fuses relays
and maintain them at a full state of charge. and diodes for the turntable electrical circuits.
86
MAINTENANCE
GENERAL
Electrical system maintenance includes replacement of

damaged components. Standard wiring practices
should be observed when replacement is necessary.
2-14-5
CIRCUIT BREAKER This device will not operate under normal circum-
stances and in the event that the main feed is found to be
WARNING
disconnected by the ’breaker’ the wiring should be
WHEN MAINTENANCE WORK IS CAR- checked to ascertain whether or not a short circuit has
RIED OUT ON THE CRANE SUCH AS occured. Any fault should first be rectified before reset-
PAINTING, SPRAYING OR WELDING IT ting the switch by pressing in the button.
IS ESSENTIAL THAT THE BATTERIES
ARE DISCONNECTED. IF THE BATTER- The circuit breaker will be generally wired in as shown in
IES HAVE NOT BEEN DISCONNECTED the illustration and will be found in the vicinity of the
AND AN ELECTRICAL FAULT OCCURS starter motor.
THE CIRCUIT BREAKER CUTS THE
CIRCUIT AND AVOIDS SOME DAMAGE
TO THE SYSTEM. HOWEVER, THE
PROTECTION GIVEN BY THIS DEVICE
IS LIMITED AND DOES NOT GIVE FULL
PROTECTION WHICH DISCONNECT-
ING THE BATTERIES WOULD PRO-
VIDE.
3G
60
86
IDENTIFICATION
SYMBOL
Engine Harness
Starter
Alternator
Main Battery Lead (Black)
Circuit Breaker
2-14-6
WARNING TROUBLESHOOTING
IF IT SHOULD BECOME NECESSARY Most troubles associated with the electrical system can
TO PERFORM ELECTRICAL MAINTE- be traced to the electrical swivel. Troubles common to
NANCE ON LIVE OR HOT CIRCUITS, the swivel are:
REMOVE ALL RINGS, WATCHES, AND
1. Improper mounting.
OTHER JEWELRY BEFORE PERFORM-
ING MAINTENANCE AS SERIOUS 2. Foreign material between the brushes and slip
BURNS RESULT FROM ACCIDENTAL rings.
GROUNDING OR SHORTING CIR-
CUITS. 3. Incorrect wiring from the swivel to the components.
WARNING 4. Incorrect wire size.
5. Worn brushes.
ENSURE THE BATTERIES ARE DIS-
CONNECTED BEFORE PERFORMING 6. Improper spring tension on the brush assembly.
ANY MAINTENANCE ON AN ELECTRI-
CAL CIRCUIT WHICH IS NOT FUSED. 7. Loose setscrews on the collector ring assembly.
WARNING To isolate electrical troubles, a multimeter should be
DO NOT DISCONNECT THE BATTERY,

OR BREAK THE CHARGING CIRCUIT
IN ANY OTHER WAY WHEN THE EN-
3G
used. The multimeter, when used properly, can provide
readings necessary for service personnel to determine
the following.
GINE IS RUNNING. 1. Opens in the electrical system.
2. Resistance in the electrical system.

CAUTION
60
If troubles are not in the swivel, there may be a loose or
DO NOT USE A ’MEGGER’ WHEN TEST- corroded connection in the pin type connectors. Check
ING THE ELECTRICAL CIRCUITS. the connectors to ensure that the wire pins are properly
seated and engaged in the receptacle. If the male and
CAUTION female pins show any signs of corrosion, use a good
86
quality electrical contact cleaner or a fine sandpaper to

DISCONNECT THE ALTERNATOR BE- clean them. When the pins show signs of arcing or burn-
FORE CARRYING OUT ANY WELDING ing, it will probably be necessary to replace them.
ON THE CRANE BY SWITCHING OFF
THE BATTERY ISOLATION SWITCH. The following tables list the tools necessary for connec-
tor maintenance.
CAUTION
Because the pins are crimped to the wires, it is not possi-
THE NEGATIVE BATTERY TERMINAL ble to remove the pin. Using the proper extraction tool,
MUST BE EARTHED. TO REVERSE THE remove the pin(s) from the plug or receptacle. Cut the
CONNECTIONS WILL DAMAGE THE wire as close to the pin as possible. After cutting the pin
ALTERNATOR. off, the wire will most likely be too short. Using a wire that
is too short will allow pressure to be applied to the pin
CAUTION and wire where they are crimped when the pin is in-
serted in the plug or receptacle. Add a short length of the
NEVER REPLACE ORIGINAL WIRING same size wire to the short wire by crimp splice or solder.
WITH WIRING OF A SMALLER DIAME- Use heat shrinkable tubing or other suitable material to
TER. insulate the splice.
2-14-7
AMP Extraction Tool Table
Description AMP Part Number Grove Part Number
14 gauge wire (connectors) 305183 9-999-100176
12 to 8 gauge wire (connectors) 91019-3 9-999-100175
4 to 9 circuit (in-line connectors) 453300-1 N/A
15 circuit (in-line connectors) 458944-1 N/A
N/A means not available
AMP Crimping Tool Table
AMP Part Number Grove Part Number

Description
Tool Die Tool Die
14 to 12 gauge wire 69710-1 90145-1 9-999-100177 N/A
10 to 8 gauge wire 69710-1

3G 90140-1 9-999-100177 9-999-100178
4 to 9 circuit (in-line connectors) 69710-1 90306-1 9-999-100177 N/A
15 circuit (in-line connectors) 90299-1 - N/A -

60
Deutsch Extraction Tool Table
Description Deutsch Part Number Grove Part Number
12 gauge wire 114010 9-999-100194

86
16 gauge wire 0411-204-1605 9-999-100195
8 to 10 gauge wire 114008 7902-000012
4 to 6 gauge wire 114009 7902-000009
Deutsch Crimping Tool Table
Description Deutsch Part Number Grove Part Number

12 gauge wire HDT-12-00 9-999-100192
16 gauge wire HDT-16-00 9-999-100193
8 to 10 gauge wire CONSULT FACTORY
4 to 6 gauge wire CONSULT FACTORY
2-14-8
46
49 48 47
3G
KEY TO TURNTABLE HARNESS
1. SLI Central Unit 26. Engine Harness

2. Main Hoist Barrel Rotation Ind. Junction Box 27. Swing Brake Solenoid
60
3. Aux Hoist Barrel Rotation Ind. Junction Box 28. Relay Box Assembly (Optional)
4. Counterweight Rotate Solenoid (Optional) 29. Remote Control Cwt Removal (Optional)
5. Cwt Lock/Unlock Solenoids (Optional) 30. Tele-In Pressure Switch
6. Pilot Dump Solenoid 31. Counterweight Lower Solenoid
7. Oil Cooler Fan 32. Counterweight Raise Solenoid
8. Hydraulic Oil Temperature Switch 33. Motion Cut Solenoid
9. Boom Junction Box 34. Derrick-In Dump Solenoid
86
10. Main Hoist Pressure Switch 35. Over Lower Dump Solenoid
11. Main Hoist Boost Solenoid 36. Fuel Sender
12. Mid Section Solenoid 37. Main Hoist 3rd Wrap Indicator Switch
13. Inner Mid Section Solenoid 38. Cwt Lock Limit Switch Junction Box (Optional)
14. High/Low Pressure Solenoid 39. Auxiliary Hoist 3rd Wrap Indicator Switch
15. Automatic Counterweight Harness (Optional) 40. Cwt Lock RH Limit Switch (Optional)
16. Cwt Ram Retract Proximity Switches (Optional) 41. Marker Light
17. Cwt Raise Limit Switches (Optional) 42. Auxiliary Hoist Boost Solenoid
18. 50A Circuit Breaker (Mounted in side panel) 43. Cwt Lock LH Limit Switch (Optional)
19. Work Light (Mounted in front panel) 44. Marker Light
20. Collector Column Assembly 45. Cwt Removal Remote Control
21. Steer Reversal Solenoid 46. Boom Junction Box
22. Work Light 47. Boom Lights (Optional)
23. Floating Boom Pressure Switch (Optional) 48. Audible Alarm
24. Battery Assembly 49. Proximity Switch
25. Seat Switch
Turntable Harness (Sheet 1 of 3)
2-14-9
3G
60
86
2-14-10
3G
60
86
2-14-11
3G
60
86
Carrier Harness
2-14-12
KEY TO CARRIER HARNESS
1. Cross Differential Switch
2. Front RH Raise/Lower Solenoid
3. Air Drier
4. Handbrake Changeover Solenoid (AT Version Only)
5. Transmission Oil Pressure Sender
6. Tachograph Generator
7. Front Wheel Drive Switch
8. Turbine Speed Sensor (Other Side)
9. Stop Light Switches (AT Version Only)
10. Axles Raise Solenoid
11. Earth Point
12. Inter Axle Differential Switch (Other Side)
13. Rear Steer Solenoid
14. Third Axle Pressure Switch
15. Third Axle Raise/Lower Solenoid
16. Rear RH Raise/Lower Solenoid
17. Retarder Relay Box (Optional)
18. RH Indicator Light
19. RH Headlight and Sidelight
20. Air Solenoids
21. RH Side Indicator Light
22. Overhang Lights Connection
23. Horns
24. Stop Light Switches (CT Version Only)
25. LH Headlight and Sidelight
26. LH Indicator Light
27. LH Side Indicator Light
28.
29.
30.
31.
32.
3G
Carrier Harness Junctions to Relay Panel and Dash Harness
Transmission Steer Fail Switch
Engine Steer Fail Switch
Front RH Marker Light
Transmission Oil Cooler Solenoid
33. Front LH Marker Light
34. Fuel Sender
35. Engine Speed Sensor
36. Battery Assembly
37. Front RH Stabilizer Solenoid/Front RH Beam Solenoid
60
38. Front LH Ride Height Junction Box
39. Counterweight Lowered Limit Switch LH (Optional)
40. Front RH Ride Height Junction Box
41. Front LH Stabilizer Solenoid/Front LH Beam Solenoid
42. Counterweight Lowered Limit Switch RH (Optional)
43. Extend/Retract Solenoid
44. Rear Steer Junction Box
86
45. Collector Column Junction Box

46. Swing Pin Switch
47. Outrigger Control Box RH
48. Outrigger Control Box LH
49. Rear LH Ride Height Junction Box
50. Rear RH Ride Height Junction Box
51. Reverse Alarm
52. Rear RH Stabilizer Solenoid/Rear RH Beam Solenoid
53. Rear LH Stabilizer Solenoid/Rear LH Beam Solenoid
54. Rear RH Marker Light
55. Rear Lights RH
56. Trailer Socket Connection (Optional)
57. Rear Lights LH
58. Rear LH Marker Light
59. To 50 Amp Circuit Breaker (Mounted on Engine Cowl)
60. Engine Harness Junction
61. Auxiliary Starter Solenoid
62. Front LH Raise/Lower Solenoid
63. Lock Up Solenoid
64. Gear Shift Solenoids
65. Third Axle Suspension Load Solenoid
66. Third Axle Pressure Switch
67. Third Axle Lock Solenoid
68. Rear LH Raise/Lower Solenoid
69. Number Plate Lights
2-14-13
11 Way Green Socket
to Dashpanel Harness
11 Way Green Plug to

Dashpanel Harness Circuit
Breakers 15A 8A 20A 15A 15A 15A 8A 8A 8A 8A
11 Way Black Socket

to Turntable Harness
RL1 RL2 RL4 RL5 RL6
11 Way Black Plug to

Turntable Harness
3G RL7 RL8 RL9 RL10 RL11
6 Way Plug to
Engine Harness
Relays
60
3 Way Socket to Turn-
table Cab Harness
6 Way Socket
to Dash Carrier RL3
Controls Harness
86
8 Way Socket to Terminal

Collector Column Strip
8 Way Plug to
Turntable Harness RL1 Crank Relay
RL2 Start Relay
3 Way Plug to RL3 Hoist Boost Relay
Heater Harness RL4 Oil Cooler Relay
RL5 2nd Oil Cooler Relay - Optional
RL6 Hoist Low Relay
RL7 Suspension Lock 12v Relay
RL8 Bell Relay
RL9 Pressure Relief Relay
RL10 Motion Cut Relay
RL11 Rear Steer Relay
Relay Panel Assembly - Turntable
2-14-14
WIPE
Circuit UNIT
Beakers
15A 8A 20A20A 8A 8A 8A 8A 8A 8A 8A 8A 8A 8A 8A 8A 8A 8A
Relays
RL1 RL2 RL3 RL4 RL5 RL7 RL8 RL17 RL18
FLASH RL19 RL21

RL20 RL22 RL23 RL25 UNIT
RL1 Ignition On Relay

RL2 Ignition Key Removal Relay
RL3 Low Engine Oil Pressure Relay
RL4 Low Air Pressure (Tank 4) Relay
RL5 FWD Auto Disengage
RL6 Rear Steer Lock Relay
RL7 Rear Steer Unlock Relay
RL9 RL10 RL11 RL12 RL133G RL14 RL15 RL16
RL8
RL9
RL10
RL11
RL12
Rear Steer Inhibit Relay
Front RH Raise Relay
Front RH Lower Relay
Front LH Raise Relay
Front LH Lower Relay
DIM DIP RL13 Rear RH Raise Relay
UNIT
RL14 Rear RH Lower Relay
UK ONLY
RL15 Rear LH Raise Relay
RL6
RL16 Rear LH Lower Relay
60
RL17 Neutral Start Relay
RL18 Reverse Lights Relay
RL19 Gearshift Override Relay
RL20 FWD Auto Engage Relay
RL21 Gearshift Override Relay
RL22 Main Beam Relay
RL23 Engine Stop Relay
86
RL24
RL24 Suspension Locked Relay
RL25 Intermittent Wipe Relay
Connectors
Relay Panel Assembly - Carrier
2-14-15
ALTERNATOR WARNING
Removal COVER ALL METAL AREAS OF THE

CLEANING BRUSH WITH INSULATING
1. Open the engine compartment door. TAPE PRIOR TO USE.
2. Tag and disconnect the electrical leads from the 1. Tighten all vent caps and clean the top of the bat-
terminals on the alternator. tery and the terminals with a soft bristle brush dipped in
an alakaline solution (ammonia) or a solution of
3. Loosen the alternator attaching hardware and re- bicaronate of soda and water.
move the belt or belts from the alternator pulley.
2. After the foaming action of the cleaning solvent
stops, flush the top of the battery with clean water.
4. Remove the attaching hardware from the belt ten-
sion adjusting bracket. 3. Coat the terminals and the cable connectors with a
light coat of petroleum jelly, or equivalent.
5. Remove the nut, washers, and bolt attaching the
alternator to the mounting bracket and remove the alter- Battery Ground Check
nator.
A check of the battery ground connection can be made
Installation to ensure the negative battery cable has a solid ground
3G
1. Position the alternator on the mounting bracket and
secure with the bolt, washers, and nut. Do not tighten at
this time.
connection to the unit frame. Perform the check as fol-
lows.
1. Ensure the negative battery cable is securely at-

tached to the negative (-) battery terminal and the unit
2. Install the hardware attaching the alternator to the frame.
belt tension adjusting bracket.
60
2. Connect the positive lead of a dc voltmeter to the
negative (-) terminal on the battery.
3. Position the belt around the alternator pulley.
NOTE
4. Adjust the alternator until the proper belt tension is
obtained and tighten the attaching hardware. A dc voltmeter with a 20-volt scale
86
(minimum) should be used for this

5. Connect the electrical leads to the terminals as check.
3. Connect the negative lead of the voltmeter to the
BATTERIES frame.
Inspection 4. Motor the engine with the starter. The voltmeter

should indicate zero.
Check the battery and cables for cracks, corrosion, and
5. If a voltage reading is indicated on the voltmeter,
other visible damage. Check the electrolyte level and
clean and tighten the unit ground connection.
specific gravity of the battery to determine the state of
charge.
6. Disconnect the voltmeter leads from the battery
and the unit frame.
Cleaning the Batteries
Adding Water to the Battery
The top of the battery, as well as the battery terminals
and cable connectors, must be kept clean at all times. The water in the battery electrolyte solution evaporates
Clean the battery as follows. at high temperatures or with excessive charging rates;
2-14-16
therefore, it may sometimes be necessary to add water battery electrolyte in accordance with the following pro-
to the battery. Add only clean, distilled water, as neces- cedure.
sary, to bring the electrolyte to the proper level, avoid
overfilling the battery. WARNING
BATTERY ELECTROLYTE MAY CAUSE

Specific Gravity Test
PAINFUL BURNS IF ALLOWED TO
CONTACT THE HANDS OR OTHER
Specific gravity testing of the electrolyte determines the
PARTS OF THE BODY. TO AVOID SUCH
state of charge of each battery cell. Perform specific
AN ACCIDENT, GOGGLES, RUBBER
gravity check as follows.
GLOVES, AND A RUBBER APRON
1. Remove all vent caps from the battery. SHOULD BE WORN WHEN ADDING
ELECTROLYTE.
2. Using a hydrometer, check the specific gravity
NOTE
reading of each battery cell.
Proper electrolyte specific gravity for
NOTE filling new batteries (shipped with
plates dry charged) is 1.275.
A specific gravity reading, in any one
cell, of 1.250 or less, indicates the bat- Fill all battery cells with the prescribed electrolyte; do not
3.
tery requires a charging or replace-
ment.
Install the battery vent caps.

3G allow the electrolyte level to be more than 0.375 inch
(9.5mm) above the protector on top of the cell separa-
tors.
Removal
EXAMPLE READING SHOWS A 1. Unlock the padlock and remove it.

60
FULLY CHARGED CELL. DRAW
ONLY ENOUGH ELECTROLYTE 2. Lift hinged cover to gain access to batteries, and
TO OBTAIN PROPER READING
remove the nut and washer along with the battery
clamp, to free the batteries.
TAKE READING 3. Tag and disconnect all leads from the batteries’ ter-
86
AT EYE LEVEL minals starting with the negative terminals.

FLOAT MUST BE FREE
NOTE
Weight of the battery is 30 kg (66 lbs)

fully charged.
4. Remove each battery.
Installation
1. Install each battery.
Checking Specific Gravity of Batteries 2. Install the battery clamp, washer,, and nut used to
secure the batteries.
Activating Dry Charged Batteries 3. Connect all leads to the batteries’ terminals starting
with the positive terminals.
Under circumstances where shipping requirements
called for the batteries to the delivered dry charged, add 4. Close the battery cover.
2-14-17
5. Padlock the cover. Installation
INSTRUMENTS 1. Connect the electrical leads as marked prior to re-

moval.
GAUGES 2. Place the gauge into position on the panel and se-
cure it with the attaching hardware.
Removal
3. Position the front panel onto the console and se-
1. Remove the screws and washers securing the cure it in place with the screws and washers.
front panel to the console and pull the panel out enough
to gain access to the back of the gauge. Functional Check
Start the engine and observe for proper functioning of

2. Tag and disconnect the electrical leads to the the repaired indicator. (Refer to Operator’s and Safety
gauge; then tape the lead ends. Handbook). Troubleshoot further as necessary, any
system malfunction not corrected by repair or replace-
3. Remove the hardware securing the gauge to the in- ment of the indicator or associated wiring.
strument panel; then remove the gauge.
ELECTRICAL SWITCHES
3G Removal
1. Gain access to the back of the switch as described

under Instruments Gauges Removal.
2. Tag and disconnect the leads from the switch; then

tape the lead ends.
60
3. Remove switch by releasing spring catch and
pushing switch out of panel.
86
Instrument Removal and Installation
Inspection
1. Examine gauges for cracked and broken lenses.

Check gauge terminals and mounting studs for damage.
2. Check wiring for damaged insulation or damaged Electrical Switch Removal and Installation
terminals.
2-14-18
Inspection 5. Remove the locknuts securing the motor to the
cab.
1. Visually check the switch for evidence of cracks,
damaged connections, or other damage. 6. Remove the motor.
2. Check wiring for damaged insulation or damaged Wiper Blade

terminals.
1. To remove the wiper blade assembly from the arm
remove two screws.
3. Perform the following check to determine switch
serviceability. Inspection
a. Using an ohmmeter, check for continuity between Visually check the motor housing for evidence of cracks
the switch terminals with swing in ON or activated posi- or other damage. Check for excessive shaft end play in-
tion. dicating worn or damaged bearings. Inspect the wiper
blade for serviceability.
b. Position switch to OFF. Ohmmeter should register
zero (no continuity).
Installation
1. Position and press switch to the panel. 3G

2. Connect the electrical leads as marked prior to re-
moval.
3. Reinstall the front panel.

60
Functional Check
Operate the switch as described in the Operators’ and

Safety Handbook. Observe it for proper functioning in
the applicable circuit. Continue troubleshooting as nec-
essary any system or circuit malfunction not corrected
86
by repair or replacement of the switch or associated wir-

ing.
WINDSHIELD WIPER ASSEMBLY

Windshield Wiper Removal and Installation
Removal
1. Gain access to the wiper motor beneath the front Installation

console. in both turntable and carrier cabs.
1. Install the motor in the cab frame holes and secure
with locknuts either side of the cab frame.
2. Tag and disconnect the electrical leads from the
motor. 2. Install the serrated collar.
3. Lift plastic pivot to gain access and remove the nuts 3. Install the wiper arms and blades and secure them
and washers securing the wiper arms; then remove the to the motor drive with attaching washers and nuts.
wiper arms.
4. Connect the electrical leads to the motor as
4. Remove the serrated collar. marked prior to removal.
2-14-19
HEADLIGHTS 2. Turntable/Carrier Selector Switch (Fitted to
cranes with drive/steer controls from the turntable
The headlights are housed in the bumper bar. cab)
Located at the side of the carrier cab relay box. The sup-
Bulb Replacement ply to this switch is via the 50 amp circuit breaker.
CAUTION Switch turned to the left: Carrier selected
Switch turned to the right: turntable selected (carrier

TO PREVENT POSSIBLE BULB FAIL-
dashpanel)
URE DO NOT TOUCH HALOGEN
BULBS WITH BARE HANDS. With the selector switch in either, turntable or carrier and
the carrier ignition switch off:
1. Gain access via the rear of the bumper and discon-
nect the electrical harness from the rear of the light. The following checks may be made:
3. Flame Start System

2. Remove the protective cover allowing access to
the bulb. The flame start system is operational automatically
when the engine is started if coolant temperature is be-
will release the bulb.

3G
3. Hold down the two cups by the side of the bulb, this low 15°C. After a pre-glow phase of approximately 20
seconds the system is operational and receives a fuel
supply via the fuel pump.
4. Remove the bulb.
4. Tachograph Clock
Adjustment With the selector switch in either the turntable or

60
carrier mode and the carrier ignition switch off -
Adjustment of the headlamp is from the front via the ad- the following checks can be made.
justing screws.
4.1 Check the clock is set correctly and that it continues
to operate if the battery master switch is opened.
ELECTRICAL FUNCTIONAL CHECKS
86
Confirm operation by the rotating dial on the face of the

After any major electrical repairs the following functional instrument.
checks should be made:
4.2 Ensure the calibration switches are set correctly to
suit the specified tyres and the 2 speed axle facility.
Carrier
4.3 Adjust the setting for the overspeed lamp and
With the ignition switch off and on cranes with drive/ buzzer to operate at 80 kph.
steer controls from the turntable cab, the Turntable/Car-
rier select switch in the carrier position:- 4.4 Check the dial illumination lamp can be controlled
by the dimmer switch on the switch panel (after selecting
the crane side lamps).
1. Battery Isolator Switch
5. Cab Heater ’Webasto’ HL 18D
Located at the side of the carrier cab relay box. The
switch disconnects the negative side of the batteries, This ventilation and heating system has a 3- speed fan
and interrupts all power supplies except the tachograph and a 1.7 kw diesel heater that incorporates a selectable
clock. ’reduced heat’ and ’full heat’ mode.
2-14-20
Also contained within the unit are controls for air distri- In the event of a malfunction or incorrect operation this
bution, recirculation and temperature. switch will trip out, and will have to be manually reset be-
fore normal operation is possible.
Fresh Air Ventilation
6. Cab Heating and Ventilation System (Water
1. With the temperature slide control lever set in the Heater)
’cold’ position, the fan speed can be selected by a switch
on the unit. The unit below the front console consists of a hot water
matrix, a 3 speed fan motor and valves to control the hot
2. Set the air distribution lever to select the required water supply from the engine and air re-circulation.
option.
It includes slider controls to select air distribution, tem-
Heater (Reduced Heat Mode) perature and fan speed.
1. Setting the temperature slide control lever to a po- Check the operation.
sition about ’one-third’ towards hot, will activate an inter-
7. Cigar Lighter
nal micro switch to turn the heater unit on in the ’reduced
heat’ mode. Check operation.
After a brief delay the heater unit will start up at a re- 8. Horns
duced speed and pump frequency. 3G Check operation.
2. The fan speed can be adjusted to boost the air sup-
ply to the required level. 9. Cab Lamp
Heater (Full Heat Mode) Operate manually via switch on lamp and automatically
via the door switch.
60
1. Setting the temperature slide control lever to a po-
10. Hazard Warning Lamps
sition about two-thirds towards hot will activate an inter-
nal micro switch and select the ’full heat mode’. Switch located on switch panel in front dash.
This will cause the heater unit to run at an increased Check warning lamp in switch.
speed and pump frequency.
86
11. Side,Tail,Number Plate Lamps

Switching Off The Heater
Select 1st position of two position rocker switch at dash-
1. Return the temperature slide control lever to the panel.
’cold’ position. The heater unit will continue to run in a
’purging cycle’ for several minutes before shutting 12. Instrument Lamps
down.
Operate via side lamp switch.
NOTE
Check operation of dimmer switch located in switch
panel.
(i) The heater must be allowed to com-
plete this ’purging cycle’ before isolat- 13 Headlamps
ing the battery master switch.
Select 2nd position of two position rocker switch at dash-
(ii) The heater has a thermal cut-out panel.
trip-button located under a blank rub-
ber plug on the side of the motor cas- Select main or dip beam stalk on switch on steering col-
ing. umn.
2-14-21
Check main beam warning lamp on left hand dashpanel. 20. Dashpanel Warning Lamps
14. Headlamp ’flasher’ Assuming normal air pressure, the following warning
lamps should be on:
Operates via stalk switch on steering column. Engine steering pump failure
Transmission steering pump failure
15. Rear Fog Lamps Engine distress
Alternator
Selected by switch located on switch panel. Parking brake (with brake applied)
Functions only with headlamps dip beam selected. 21 Dashpanel Warning Lamps
The following warning lamps should be off:

Check warning lamp in switch.
Direction indicators
Carrier Ignition Switch: On Transmission lock-up
Main beam warning
16 Direction Indicators Turntable selected
Transmission temperature overspeed light
Select via switch on steering column. Suspension locked
3G Rear steering unlocked
Check warning lamps operated on dashpanel. Front wheel drive engaged
Low air 1.2.3.4
Remove one bulb to check bulb failure warning. P.T.O. engaged
Inter axle diff engaged
17. Reversing Lamps /Back Up Alarm Cross diff engaged
60
22. Wipers/Washers
Check the lamps and back up alarm function in all re-
verse gears. Motor is two speed, self park.
18. Stop Lamps The switch incorporates an intermittent delay wipe func-
tion.
86
Assuming sufficient air pressure, operate footbrake.

Check sweep angle and park position is correct.
19. Console Lamp Display Test Check screenwashers.
Select the switch on the console switch panel to self-test 23. Engine Distress System
and verify the operation of the audible warning buzzer
A warning lamp and buzzer on the dashpanel will oper-
and the following warning lamps:
ate in the event of:
Dir. indicator L/H Susp. locked a. Low engine oil pressure

Eng. Strg. failure Inter-axle b. High engine water temperature
Trans. strg. failure Cross diffs c. Engine coolant level
Lock-up P.T.O.
Main beam Rear strg. unlocked With the ignition on and the engine stationary, the lamp
Eng. distress F.W.D. and buzzer will be on.
Alternator Parking brake To Check Operation
Turntable selected Low air
Overspeed Dir. indicator R/H 1. Disconnect the No 542 cable at the engine oil pres-
Transmission temperature high switch sure switch located at the top front of the engine.
2-14-22
Disconnect the wire from the coolant level sender. Wait 30. Ignition Switch And Key Removal Interlock
until 10 seconds has elapsed and light and tone genera-
tor will both operate. (Sender fitted in header tank). The key operated switch has four positions:
OFF - ACC - ON - START

= distress lamp and buzzer off
1. The key cannot be removed unless:
2. Short-circuit the water temperature switch and the
lamp and tone generator will both operate. a. The switch is in the off position
24. Engine Oil Pressure Sender b. The engine is stopped
2. When the key is removed the steering lock will be

Remove cable #4 from sender and touch end to ground,
activated.
this will cause indicator needle to deflect.
31 Stopping The Engine
25. Transmission Oil Cooler
A separate engine stop switch is located on the central
To verify operation of the oil cooler fan, short out cables switch panel.
#146 and 530 at sender assembly (location: elbow on
top of torque converter). The fuel solenoid is energised to stop.
32. Air Warning Lamps And Gauges

26. Trans Temp. Gauge
Standard Engine
3G
This is a 12V dual scale Datcon gauge with a dropper re-
The specified gauges are now a mechanical type - dual
scale (English/metric).
A pressure switch is fitted in each air tank to operate the

sistance fitted at the gauge terminals (range 60/160°C) four low pressure warning lamps.
Disconnect or short-circuit the No 25 cable at the sender 1. Drain all air from the reservoirs - check all low air
60
to verify operation. lamps are illuminated.
27. Fuel Gauge And Sender Starting The Engine
2. Start the engine and build up air pressure - check

This is a 12V Datcon gauge with a dropper resistance
all lamps extinguish in relation to the appropriate pres-
86
fitted at the gauge terminals.

sure 68 psi.
1. Ensure the fuel sender unit is installed in the tank 3. With the engine running verify operation of the fol-
correctly. lowing:
2. Check the reading on the gauge corresponds to the a. Engine oil pressure gauge (Datcon 12V instru-
level of fuel in the tank. ment)
b. Transmission oil pressure gauge (V.D.O.)
28. Air Dryer c. Voltmeter (charge rate 26/28V)
d. Tachometer
With the ignition switched on, check the unit has a sup- e. Engine hourmeter
ply to it. f. Alternator lamp is extinguished
g. Distress lamp and buzzer are off
Check security of the earth connection.
h. Engine steering pump failure lamp is off
29. Neutral Start 33. P.T.O.
Check the engine will not start unless both the carrier Switch located on central switch panel. The P.T.O. can
and turntable cab gear selectors are in neutral. only be engaged or disengaged if:
2-14-23
a) The air pressure in system 4 is normal (above 110 Locking The Suspension
p.s.i.)
Before blocking up the machine on outriggers, or for free
b) The engine is stationary on rubber duties, engage the suspension lock switch.
This switch has an integral locking device to prevent in-
With the P.T.O. selected, check warning lamp on R/H advertent operation. Do not unlock the suspension
panel. when the machine is blocked up on outriggers.
Check warning lamp on dashpanel.
The P.T.O. can be selected either from the carrier or the
carrier control panel in the turntable cab. In addition to this, on 5 axle machines the 3rd axle must
be raised.
NOTE
To Raise The 3rd Axle
The warning lamp is activated by a
proximity switch only when positive Lock suspension, with the P.T.O. engaged and and en-
engagement is achieved. If the lamp gine running select 3rd axle ’raise’ switch until the
does not come on when the P.T.O. is se- wheels are fully raised.
lected, momentarily crank the engine
until the light comes on, then the en- To Lower The 3rd Axle
gine can be started normally.
Ensure all the other wheels are on the ground. With the
34. Suspension System
Before blocking up the crane on outriggers the suspen-

sion system should be set up.
3G P.T.O. engaged and engine running select 3rd axle
’lower’ switch and hold until the integral lamp in the
switch illuminates.
The lamp indicates the pressure loading on the axle is

A summary of operation is as follows: correct.
60
a) Set auto ride height 35. Outriggers
b) Lock suspension All four outrigger stabilizers can be operated from either
the LH or RH outrigger control box mid-way along the
c) Raise 3rd axle (5 axle machines only) carrier.
86
The suspension control panel is located at the rear of the However, as an added safety feature the LH/RH beams
central console. will only operate from their corresponding control box.
Refer to turntable for operating instructions on the inclu-
To Set Ride Height sion of the six position rotary control switch.
Engage P.T.O., start engine. Select power control Engage P.T.O., start engine.
switch, check integral lamp illuminates.
Block up machine, check all control switches function
Select auto ride height switch until the ride height set correctly.
lamp illuminates.
Automatic Hi-idle Feature
Independent Adjustment Of Ride Height
Whenever extend or retract is selected, a solenoid will
Four override switches are located on the control panel inject a measured amount of air into the throttle system
should it be necessary to raise or lower the individual and increase the engine idling speed to 1500 r.p.m.
corners of the crane. When adjusting the ride height
either automatically or individually the 3rd axle will auto- At the same time a lamp will come on in both control
matically adjust itself to the correct setting. housing for illumination purposes.
2-14-24
Ensure this hi-idle function does not operate when the Prior to installing a replacement APC 100 module to the
rear steer or suspension controls are selected. crane, the check-out kit must be used to ensure satisfac-
tory performance of the transmission electrical system.
36. Front Wheel Drive Failure to do so may result in internal damage to the
APC 100 module.
This function should only be selected with the wheels
stationary and the gear selector in neutral. Setting Up The Crane For An APC Check
Ensure the crane is set up as follows:

Start engine, release handbrake, check air pressure is
normal. 1. Suspension locked. Blocked up on outriggers.
Select front wheel drive switch. 2. P.T.O. disengaged.
Check warning lamp on right hand panel is illuminated, 3. Lock up enable switch selected.
this lamp is activated by a proximity switch. 4. Manual over-ride switch in automatic mode.
Engage 1st gear and check operation. 5. Install check-out kit. Switch on ignition
The front wheel drive cylinder should be retracted when Static Checks
selected. Carrier Gear Selector
37. Inter Axle Diff Lock
This function should only be selected when the wheels

are stationary, or turning very slowly.
3G 1. Verify the cab gearshift switch pattern is correct us-
ing the alphanumeric screen and the input/output
L.E.D.’s on the check out kit.
2. Verify the appropriate ancillary input L.E.D.’s func-

Start engine, release handbrake. tion correctly.
60
Select inter axle diff lock switch - on switch panel. Check a. Lock up enable switch - L.E.D. 25 on (selected)
warning lamp on right hand panel is illuminated. It may b. Throttle switch - L.E.D. 23 on (idle)
be necessary to engage 1st gear and turn the wheels to
achieve positive engagement. c. Ex. brake/retarder switch - L.E.D. 7 on (selected)
Dynamic Checks
38. Cross Diff. Lock
86
Manual Override Switch

are stationary or turning very slowly. Before driving the wheels in the protected automatic
mode, the manual over-ride switch should be selected
Start engine, release handbrake. and a check made that the transmission is shifting cor-
rectly in all gears.
Select foot switch at left hand side of steering column.
Check warning lamp on right hand panel is illuminated. The check-out kit functions and the lock-up will be inop-
erative in this situation.
It may be necessary to engage 1st gear and turn the
When the above check is found to be satisfactory the
wheels to achieve positive engagement.
manual over-ride can be switched out to activate the
39. APC 100 Transmission automatic control mode.
Lock-up Standard Driving Mode

Before undertaking the following series of checks, refer
to the detailed description of the transmission system, This function is automatically activated when the throttle
including the use of the Clark-Hurth APC check-out kit at is accelerated (normal driving). In this mode lock-up is
the end of the carrier instructions available from 3rd gear upwards.
2-14-25
1. Start engine. Release handbrake. Lock-up Ex. Brake/Retarder Mode
2. Select appropriate fwd. gear. The application of this function is to provide maximum
engine braking efficiency when the vehicle is travelling
3. Check the turbine speed input is displayed on the on long down gradients.
check-out kit screen. The yellow L.E.D. on the end panel
will also be extinguished. When the ex. brake/retarder foot-operated switch is se-
lected it will:
4. Increase r.p.m. until the lock-up lamp on the l/h
console illuminates, followed by a ’slight kick’ in the a. Activate an air valve in the engine exhaust system.
transmission. This should occur at a turbine speed of
b. Power a solenoid to inhibit the throttle function.
about 1630 r.p.m.
With the ex. brake/retarder switch selected a special set
5. The check-out kit screen display can be ’frozen’ by
of lock up limits is automatically applied by the APC 100.
using the hold button to verify the speed when L.E.D. 37
is illuminated. In this situation lock up can engage in any fwd. gear pro-
vided the turbine speed is above 1200 r.p.m.
6. Gradually reduce r.p.m. until the lockup lamp on
the console, and L.E.D. 37 are extinguished. Lock up will automatically disengage if the speed falls
below this level.
Lock-up Extended Range Mode
This should occur at a turbine speed of about 1000

3G
r.p.m. with foot off the throttle. This function is automati-
cally activated when the throttle pedal is not being accel-
The overall performance of this function can only be
properly checked with the vehicle on the road, in the ap-
propriate conditions.
erated (downhill driving). It will maintain lock up to a 1. Check the lock up lamp on the console and L.E.D.
lower disengagement point than the standard mode to 37 on the check out kit comes on immediately.
improve vehicle braking.
60
2. Check the air valve in the exhaust system is operat-
The throttle idle position is detected by a N/C air pres- ing. - This will cause a change in the engine note as the
sure switch located in the centre console. speed falls.
To Check Operation 3. Check the throttle function is disabled.

86
1. Temporarily short out the connections at the low air Change Of Direction Protection (Forward And Re-
pressure throttle switch. verse)
Direction change protections.

This will simulate the condition when the throttle pedal is
at idle. Forward to reverse of vice versa.
2. Repeat the lock up checks previously described for When the gear selector direction is reversed at a engine
the standard mode. or vehicle speed which is too high, the transmission is
put in neutral until the engine speed is below 1000 rpm
3. In this mode lock up is available from 2nd gear up-
and the vehicle speed is lower than 1 km/h. When the
wards.
new direction is engaged, 2nd gear is selected.
4. The lock engagement speed is about 1500 r.p.m. Neutral to Forward or Reverse.
and the disengagement should occur about 1000 r.p.m.
with foot off the throttle. Neither forward nor reverse can be selected when the
engine speed is too high (> 1000 rpm).
5. Remove temporary short-circuit from the throttle
switch. Forward, neutral, forward.
2-14-26
When driving in a certain direction and when putting the When lamp no. 5 is illuminated the system is opera-
gear selector in neutral and back in the same direction, tional. Check the unlocked lamp on the right hand dash-
neutral will be selected until the engine speed is low panel is illuminated.
enough (< 1000 rpm).
Engage P.T.O. and start engine.
40. Tachograph Check operation of tiller switch, right and left, assuming
forward movement of the carrier.
During the above check:
To Lock The Rear Wheels
Ensure the tachograph is operating.
Operate the tiller switch until lamp no. 2 illuminates. Turn
Ensure the tachograph calibration switches are ad- the right hand switch to the left to lock the wheels.
justed correctly or the specified correction box is fitted.
Lamp no. 3 should illuminate. Lamp no. 4 should extin-
guish together with the unlock lamp on the dashpanel.
Check the transmission steering pump failure warning
To facilitate pin engagement joggle the steering wheel
lamp is extinguished when the wheels are driven.
until lamp no. 3 illuminates.
41. Rear Steering (Option) Turn power control switch to the left, all lamps should go
off.
The tiller switch controls the steering operation on the
two rear most axles. 3G
The controls to lock and unlock the wheels are located
behind the drivers seat on the left hand side.
NOTE
With the power switch selected and the

turntable/carrier selector switch in the
carrier mode. Check the rear steer tiller
The left hand switch is the power control switch. control in the turntable cab is inopera-
tive.
60
The right hand switch is the lock/unlock switch.
42. Dim Dipped Lighting
The four lamps are: This is a legal requirement for all U.K. machines only,
which are capable of travelling at 25 m.p.h. or over. It
No. 1: Power on provides a level of lighting between the normal side
86
No. 2: Wheels aligned lights and normal dipped beam.

No. 3: Steering unlocked
No. 4: Steering not fully locked To check:
Switch on side lamps - side lamps on - headlamps off.

To Unlock The Rear Wheels
Switch on ignition - side lamps on and dipped beam
Turn the control switch to position 1 (to the right). Lamp headlamps on at a reduced level.
no. 1 should illuminate.
The dim dip function will be overridden when the vehicle
Lamps 2 and 3 will also be illuminated if the steering is lighting is selected normally.
aligned and locked.
Ensure control unit is fitted to a flat metal surface.
Turn the right hand switch to the right to unlock the Description Of The APC 100 Transmission
wheels.
The main feature of this transmission system provides
Lamp no. 3 should extinguish. Lamp no. 4 should illumi- for smoother and more-efficient gear changing, and in-
nate. If this does not happen joggle the steering wheel to cludes built-in protections against accidental or deliber-
free the lock pin. ate abuse.
2-14-27
The heart of the automatic powershift control system is If a downshift request is not granted the APC 100 will
the APC 100 computer module, which constantly moni- search for a gearshift position that is acceptable, then
tors the input signals from various switches (gearshift/ change to that position.
throttle) and speed sensor on the crane.
Change Of Direction
This data is evaluated by the model related programme
If the gearshift direction is reversed when the vehicle
in the APC 100 which will then allow the implementation
speed is too high (typically above 2 km/h) the APC 100
of a requested gearchange or direction change, only if
will select neutral until the vehicle speed is reduced, be-
the right conditions prevail. As well as providing the nec-
fore implementing the requested change.
essary output signals to power the transmission shift
control valves, it also controls engagement and dis-en- Convertor Lock-up
gagement of the convertor lock-up in relation to the
speed sensor input and the gearshift position. In this mode lock up is available is 3rd gear and higher.
Diagnostic L.E.D.’s NOTE
Three diagnostic L.E.D. indicators on the APC 100 pro- Whenever a gearshift is requested in
vide continuous information on the status of the system: lock-up drive, the lock up will automati-
cally disengage for 0.3 seconds before
RED L.E.D.: Lit when an internal fault in the APC 100 re-engaging after the change is imple-
prevents correct operation.
In this event all outputs are switched off.

3G mented.
Braking Mode (2) (Extended Range)
This mode is recognised when the engine is not being

GREEN L.E.D.: Lit when the throttle pedal is activated.
accelerated (i.e. going downhill). When the throttle is re-
YELLOW L.E.D.: Lit when there is no input from the tur- leased a new set of lock- limits is applied to improve
60
bine speed sensor. braking performance. The lock up clutch remains en-
gaged to a lower value than in the standard driving mode
Gearshift Warning Light (about 1000 r.p.m.) in this mode lock up can become ac-
tive in 2nd gear and higher.
This warning light is mounted on the dashpanel in the
cab and is used to indicate following abnormal situ- Exhaust Brake/Retarder Mode (3)
86
ations:-
This mode is recognised when the exhaust brake /retar-
der switch is selected. It would normally be used on long
Downshift is not granted due to too high speed.
down gradients, with the throttle pedal at idle.
Direction change is not granted due to too high speed.
Blinks fast when APC100 detects turbine speed failure. If lock up is not already engaged it will come in automati-
Blinks slow when APC100 detects the serial communi- cally when the braking switch is activated provided the
cation with the EGS is no longer possible. turbine speed is above 1200 r.p.m. This will provide
maximum braking in conjunction with the engine brake.
Upshifting
In this mode, lock up will automatically disengage at
A requested shift to a higher gear position is always about 1200 r.p.m. Lock up used in the ex. brake/retarder
granted. mode is available in all gears.
Downshifting NOTE
A requested shift to a lower gear position will only be When the ex. brake/retarder switch is
granted if it will not overspeed the transmission or create selected the throttle pedal function will
excessive shift shocks. be inhibited.
2-14-28
Manual Override Switch Function Switch On Ignition
In the event of a failure within the APC 100 resulting in It will then revert to information concerning internal
loss of drive, a manual over-ride rocker switch, incorpo- jumper connections within the check- out kit. This can be
rating a safety-lock device, is fitted on the centre con- ignored.
sole.
Simultaneously the 16 input L.E.D.’s and the 10 output
L.E.D.’s will illuminate briefly in a self test sequence.
This Feature Should Be Used In Emergency Situ- Press the hold button to display the turbine speed and
ations Only gearshift information on the screen.
When selected it will allow the vehicle to be driven with Hold Button
conventional use of the gearshift provided there are not
problems with the transmission control valves. Located on the bottom right-hand corner of the top cover
it has two main functions:
The various built-in protections of the APC 100 including
1. It can be used to ’freeze’ the information on the al-
the lock-up function are not available with the over-ride
phanumeric screen at any time (i.e. exact turbine speed
switch selected.
when the lock up is engaged or dis-engaged).
APC 100 Check-Out Kit 2. It will illuminate the L.E.D.’s indicating which inputs
3G and outputs are required for this installation.
The introduction of this transmission system allows the
use of the Clark APC 100 check-out kit to verify the elec- Diagnostic L.E.D.’s
trical installation.
The function of the three diagnostic L.E.D. indicators on
the front cover of the check-out kit is identical to the three
Description And Use
L.E.D.’s on the APC 100 computer module.
60
The check-out kit should be fitted to the vehicle, initially, RED L.E.D.: Lit when an internal fault in the check-out kit
in place of the APC 100 and used to eliminate any faults prevents correct operation.
in the crane wiring associated with the transmission.
Failure to do so may result in internal damage to the In this event all outputs are switched off.
APC 100 computer module.
GREEN L.E.D.: Lit when the throttle pedal is activated.
86
Ensure The Vehicle Is Set Up Correctly YELLOW L.E.D.: Lit when there is no input from the tur-
bine speed sensor.
1. Fully blocked up on outriggers.
This L.E.D. will extinguish when the wheels are driving,
2. P.T.O. disengaged. provided the speed sensor is functioning.
Carrier Gearshift Output Signals

3. Lock up enable switch selected.
1. Switch on ignition. Press hold button. Neutral se-
4. Manual over-ride switch in ’automatic’. lected.
5. Gear selector in neutral. The alphanumeric screen will display:
Position of gearshift : i.e. C : N5

Connect The APC Check-Out Kit
Actual gear selected : i.e. G : N5
The alphanumeric screen on the top cover will momen-
tarily display the type of transmission, followed by the The input L.E.D.’s used for the gearshift are: 1. 2. 3. 20.
crane model the check-out kit is programmed for. 21. 22
2-14-29
The output L.E.D’s used for the gearshift are: 12. 13. 14. Checking Ancillary Inputs And Outputs
15. 16. 19
FUNCTION INPUT OUTPUT

A typical correct sequence would be:
Lock up selected 25 - ON
Lock up not selected 25 - OFF
Lock up engaged 37 - ON
LEVER INPUT LED’S OUTPUT LED’S
DISPLAY
Lock up dis-engaged 37 - OFF
POSITION ‘ORANGE’ ‘GREEN’
Throttle pedal activated 23 - OFF
N.1 - - - - - - - - 14 15 16 - C N5 G N5
Throttle pedal at idle 23 - ON
N.2 - - 2 21 3 - - - 14 15 16 - C N1 G N1
Ex. brake/retarder selected 07 - ON
F1 Ex. brake/retarder
F.1 1 - 2 21 3 12 - 14 15 16 - C F1 G
07 - OFF
not selected
F.2 1 - 2 21 3 22 12 - 14 15 16 19 C F2 G F2
F.3 1 - - 21 3 - 12 - - 15 16 - C F3 G F3
Manual Override Switch
F.4 1 - - 21 3 22 12 - - 15 16 19 C F4 G F4
F.5
F.6
1
1
-
-
-
-
-
-
3
3
- 12
22 12
-
-
-
-
-
-
16
16 19
- C
C
3G
F5 G
F6 G
F5
F6
When the manual over-ride switch is selected the status
of the L.E.D.’s should be as follows:
Input L.E.D.’s = OFF (orange if selected)

F.7 1 - - - - - 12 - - - - - C F7 G F7
F.8 1 - - - - 22 12 - - - - 19 C F8 G F8
Output L.E.D.’s = Orange
60
Turbine Speed Sensor
R.1 - 20 2 21 3 - - 13 14 15 16 - C R1 G R1
The turbine speed sensor on this installation is a three
R.2 - 20 - 21 3 - - 13 - 15 16 - C R3 G R3 wire device that is powered from the APC 100 or the
check out kit. It is essential that the wiring for this sensor
R.3 - 20 - - 3 - - 13 - - 16 - C R5 G R5
is installed correctly, according to the electrical diagram.
86
R.4 - 20 - - - - - 13 - - - - C R7 G R7
NOTE
In order to register the turbine speed in-

put the standard Clark check-out kit.
The colour of the output L.E.D.’s will indicate any one of Part no. 12367 will require an internal
the following conditions: modification.
This modification will not prevent a

1. Correctly connected output off: L.E.D. off
Clark check-out kit from being used on
other current models with APC trans-
2. Correctly connected output on: L.E.D. green mission.
Dynamic Checks On Transmission

3. Load not connected or shorted to B +ve: L.E.D. or-
ange Before driving the wheels in the automatic mode the
manual over-ride switch should be selected and a check
made that the transmission is shifting correctly in all
4. Output shorted to ground: L.E.D. red gears.
2-14-30
Forward first can only be obtained when the vehicle is Alternator Front wheel drive
stationary, no attempt should be made to engage six Engine water temp. Trans oil o/heat
wheel drive unless the vehicle has been halted. The six P.T.O. Rear steering unlocked
wheel drive function can be obtained automatically via Inter-axle diff Suspension lock
the EGS 1st gear only or manually via the selector Lower oil pressure Low air
switch on the instrument dashpanel.
3. Ignition Switch Dashpanel Warning Lamps
This pre-check is very important because although the
Turn on the ignition switch.
check-out kit may indicate the outputs are electrically
correct the transmission may not be shifting correctly.
The Following Warning Lamps Will Be On:
Possible reasons are: 1. Engine low pressure

2. Alternator lamp
Wrong control valve connected 3. FWD this will automatically illuminate when the
Control valve mechanically damaged changeover switch is selected to turntable.
Control valve malfunction - hydraulic
The Following Warning Lamps Will Be Off:
Once the above check is found to be satisfactory the
manual over-ride should be switched out to activate the 1. Low air
electronic control system. 2. Transmission oil over-heat lamp
Turntable - Carrier Control Panel

3G 3.
4.
5.
6.
Rear steering unlocked lamp
Inter-axle differential locked lamp
P.T.O. engaged lamp
Suspension lock
NOTE
7. Engine temperature
This Control Panel Is Fitted Only To The
4. Neutral Start
60
Full ’All Terrain’ Version Of This Model
Check the engine will not start unless both the turntable
1. Turntable/Carrier Selector Switch (In Carrier and carrier cab gear selectors are in neutral.
Cab)
5. Neutral Lock Protection
Turning the switch to the right to select the turntable will
86
illuminate a lamp on the L/H dashpanel of the carrier In order to prevent accidental direction engagements
cab. from neutral (e.g. accidentally hitting the shift lever), the
following protection has been implemented.
The switch also supplies power to the ignition switch on
When the shift lever is placed in neutral for more than
the carrier control panel in the turntable cab.
three seconds, the protection becomes activated.
1. Check the turntable parking brake solenoid is now When the shift lever is placed in forward or reverse, once
energised. the protection is active, the transmission remains in neu-
tral.
2. Check the orbitrol steering solenoid is now ener-
gised. In order to deactivate the protection, follow next proce-
dure. After the shift lever is placed in forward or reverse,
2. Console Lamp Display Test make a short upshift with the shift lever. If the upshift re-
quest occurs within 1 second after the direction selec-
Select the push button switch on the turntable control tion, the protection is deactivated. If the upshift request
panel to verify the operation of the following warning occurs later than 1 second, no action is taken (transmis-
lamps and the audible warning buzzer: sion remains in neutral).
2-14-31
NOTE The P.T.O. can only be engaged or disengaged if:
If the shift lever is held in the upshift a) The air pressure in system 4 is above 110 p.s.i.
condition, then first the protection is
deactivated, followed by an upshift b) The engine is stationary
every 1.5 seconds. The protection is
Select the P.T.O. rocker switch.
shown by LED 8.
Check the warning lamp is illuminated.
6. Gear Selector
NOTE
Using a suitable test set check the signals from the gear
selector are correct to the matrix chart on the schematic The lamp is activated by a proximity
diagram. sensor only when positive engagement
is achieved.
NOTE
If the lamp does not illuminate when the
The Clark-Hurth APC check-out kit can- switch is selected momentarily crank
not be used to verify the operation of the engine until the lamp comes on. The
this gear selector. engine can then be started normally.
7. Eng. Distress Warning 3G

For details of functional checks on this circuit see carrier
instructions, item 23.
12. Outriggers
Before operating the outrigger controls ensure the ride-

height is set, and the suspension locked on the control
panel in the carrier cab.
8. Trans Oil Overheat Warning
Engage P.T.O. and start carrier engine.
60
Short-out the switch to check the lamp illuminates. The
switch is fitted on top of LAMP the torque convertor. Six Position Rotary Control Switch
9. Starting The Engine The switch is located on the main instrument console
and controls both the stabilizers and the beams.
1. Start the engine and build up air pressure.
86
The switching arrangement is such that it allows all four

2. Check the alternator lamp is extinguished. stabilizers to be deployed or retracted simultaneously
when the switch is selected to that position and the ex-
3. Check the engine oil pressure lamp is extin- tend/retract switch is operated.
guished.
Each beam is deployed or retracted individually when
10. Stopping The Engine the switch is selected to that position and will operate in
conjunction with the extend/retract switch when it is se-
A rocker type engine stop switch is located on the dash- lected.
panel. The fuel solenoid is energised to stop the engine.
Automatic Hi-idle Feature
11. Power Take-Off
Whenever extend or retract is selected, a solenoid will
P.T.O. selection from the turntable cab is a function of inject a measured amount of air into the throttle system,
the carrier engine. and increase the engine idling speed to 1500 r.p.m.
It is engaged to operate the following systems from the Ensure this hi-idle function does not operate when the
turntable, with the carrier engine running. rear steering function is selected.
2-14-32
13. Front Wheel Drive Sequence of Operation
With Ride-Heights Pre-Set:

are stationary, and the gear selector is in neutral. a. Select suspension ‘lock-up’ switch and then deploy
outriggers.
1. Start carrier engine. Release handbrake.
b. On completion of operations, the outriggers should
2. Select the front wheel drive switch on the panel. be retracted fully until crane is at rest on its tyres, only
then should the suspension be ‘un-locked’.
- check the warning lamp illuminates Sequence of Operation
3. Engage fwd 1st gear and check operation. Where Creepage has occured:
a. Engage P.T.o.
14. Inter-Axle Differential Lock
b. Select axle raise switch, this will cause the system
This function should only be selected when the wheels to be activated and the axle will be powered up against
are stationary, or turning very slowly. their bump stops.
1. Start carrier engine. Release handbrake. c. On completion of operations, lower the crane back
3G onto its tyres ensuring the axles are still blocked.
2. Select inter-axle diff foot switch. 16. Rear Wheel Steering
3. Check the warning lamp is illuminated. Before Checking This Function The Rear Wheels
Must Be Unlocked From The Carrier Cab Controls
NOTE
To Check Operation From The Turntable Cab
60
It may be necessary to engage fwd 1 1. Check the rear steering unlocked lamp is illumi-
gear and turn the wheels to obtain posi- nated.
tive engagement of the lock.
2. Engage P.T.O. and start carrier engine
15. Double Axle Retract Feature (Automatic
86
3. Check correct operation of tiller switch, assuming

Mode) the turntable is over the rear of the carrier.
This feature permits the crane operator to retract the 1st, 17. Orbitrol (Turntable Steering) Auto-reversal
2nd, 4th and 5th axles simultaneously against their re-
This system is automatically controlled by means of a
spective bump stops in the event of axle creepage after
switch and a cam in the collector column.
outrigger deployment.
To check operation:
IT SHOULD BE NOTED THAT ON MACHINES
WHERE A 3RD OR CENTRE AXLE HAS BEEN IN- 1. With the turntable over the front, operate the turnta-
CORPORATED THAT THIS AXLE IS INDEPEND- ble steering and check the wheels turn in the appropri-
ENTLY CONTROLLED AND NO ATTEMPTS ate direction.
SHOULD BE MADE TO RETRACT THIS AXLE
In this situation the steering reverse solenoid is de-ener-
WHILST RETRACTING THE OTHERS.
gised.
It is the responsibility of the operator to ensure that all 2. With the turntable over the rear (or trip the switch in
personnel and equipment are clear of the crane before the collector column) the steering operation should be
operation of outriggers or axles. reversed - and the solenoid will be energised.
2-14-33
3. Ensure the switch and cam are correctly adjusted. 4. As the temperature falls, the setting of the cab ther-
mostat will cause the heater to revert again to a ’full heat’
Turntable Control Panel mode. This cycle will be repeated until the heater is
switched off manually.
With The Ignition Switch Off - The Following
Checks Can Be Made To Switch Off The Heater
1. Cold Start Switch 1. Select the power switch to ’off’ on the cab thermo-
stat - the ’green’ L.E.D. should be off.
Select the spring-return switch on the panel, and hold,
check that the ether injection solenoid has energised. The heater will then continue to run in a ’purging cycle’
for several minutes.
2. Horn
NOTE
Select the horn push on the panel.
(i) The heater should always be al-
3. Cab Lamp lowed to shut down normally before
isolating the batteries via the master
The three position switch on the lamp should operate as switch.
follows:
(ii) In the event of a fault lock-out con-
Pos. 1 = lamp on direct dition causing the heater to shut down
Pos. 2 =
Centre pos =
lamp on via door switch
lamp off
3G prematurely, the ’green’ L.E.D. will re-
main illuminated.
(iii) In the event of high operating tem-

4. Cab Circulating Fan
peratures within the heater, an integral
This single speed fan is selected by a switch on the fan over-heat switch will trip out to protect
support bracket.
60
the heater. This switch is re-settable,
and is located under a blank rubber
5. Cab Heater ’Webasto HL 18D’ plug on the side of the heater.
This is a heater unit only and has no fresh air ventilation The Remainder Of The Checks Should Be Carried
facility. The maximum rated output is 1.7 kw which can Out With The Ignition Switch On
86
be adjusted for a ’reduced heat’ mode by a rotary th-

ermostatic cab control, i.e. turn c.w. to increase heat out- 6. Console Lamp Display Test
put.
Select the push button switch on the console panel to
A power ’on/off’ slide switch and L.E.D. are incorporated verify the operation of the two audible warning buzzers
with the cab thermostat control. and the following warning lamps:
To Switch On The Heater Swing brake release Engine distress

Suspension locked Alternator
1. Select the ’power on’ switch on the thermostat - the
7. Dashpanel Warning Lamps
’green’ L.E.D. should be illuminated.
Alternator
2. After a brief delay the dosing pump will switch on
Engine distress
and the heater will operate in the ’full heat’ mode.
Suspension locked - (provided the susp. locked switch
is selected)
3. When the temperature increases to a level deter-
mined by the setting of the cab thermostat, the dosing The Following Lamp Will Be Off:
pump frequency and the motor speed will decrease and
the heater will then operate in a ’reduced heat’ mode. Swing brake release
2-14-34
8. Frontscreen Wiper & Washer tion on and wait until 10 seconds has elapsed and light
and tone generator will both operate. (Sender fitted in
1. Select the 1st position of the rocker switch on the header tank).
panel to operate the single speed, self park motor.
= distress lamp and buzzer off
2. Select the spring-return 2nd position of the switch
to operate the screenwashers. 2. Switch the ignition off and disconnect wires. Switch
the ignition on and short out the water temperature
3. Check the washer jet is correctly adjusted. switch and the lamp tone generator will both operate.
4. Check the motor sweep angle and park position is 13. Swing Brake Release Lamp
correct. Select the swing brake release switch on the panel.
9. Roof Wiper Motor Check the lamp is illuminated.
1. Select the 1st position of the rocker switch on the Check the solenoid is energised.
panel to operate the single speed, self park motor.
14 Hyd. Oil Cooler
2. Select the spring-return 2nd position of the switch The temperature switch should power the fan motor
to operate the screenwashers. when the hyd. oil reaches a temperature of 50°C.
3. Check the washer jet is correctly adjusted.
4. Check the motor sweep angle and park position is

correct.
3G Ensure the correct switch is fitted by the ref. no. stamped
on the body i.e. XXX 2928.
To check operation:
10. Turntable Work Lamps Short circuit the switch to power the motor. Ensure the
fan rotation is correct. i.e. the fan should draw air
60
Select the 1st position of the rocker switch on the panel through the radiator matrix.
to operate the work lamps.
15. Hoist Rotation Indicator (Main & Aux)
11 Cab Roof Lamp & Boom Floodlamp
A transmitter fitted to the hoist barrel will power a tactile
Select the 2nd position of this switch to also operate the indicator (thumb thumper) in the top of the hoist control-
ler handle, whenever the barrel is turning.
86
cab roof lamp and/or boom floodlamps.

To check operation:
12. Engine Distress System
Manually spin the transmitter wheel at the barrel to con-
With the distress lamp and ignition on an audible warn- firm the indicator function.
ing buzzer will be activated in the event of:
NOTE
Low engine oil pressure
High engine water temperature The rate of pulses from the transmitter
Low water level will be proportional to barrel movement
up to a max speed of 50 mtrs/min. Be-
With the ignition on and engine stationary the lamp and yond this point the transmitter will
buzzer will be on. maintain a steady pulse rate, even
though the speed of the barrel is in-
To check operation; switch the ignition off then creased.
1. Disconnect the cable at the engine oil pressure Once the barrel speed drops below 50
switch located at the top front of engine. Disconnect the mtrs/min the rate of pulses will again be
wire from the coolant level sender. Then switch the igni- proportional.
2-14-35
16. Seat Tape Switches and Pilot Dump Solenoid The fuel solenoid is energised to stop the engine.
Two tape switches of the pressure pad type are located The ignition switch should be switched on before this
within the upholstery of the operators seat pack. The switch will function.
switches are connected in parallel, and will interrupt
power to the pilot dump solenoid valve unless the opera- 21. P.A.T. Load Moment Indicator D.S. 350 GW
tor is positioned normally on the seat.
Boom Assembly Proximity Sensors
The solenoid is located inside the turntable framework.
Ensure the boom is fully retracted, then adjust proximity
When de-energised, the solenoid will inhibit all craning sensors and secure same ensuring that there is an inter-
operations. space of between 4 and 5mm.
Check operations accordingly. Ensure both P.A.T. reeling drums are secure and that ca-
ble pays off and on neatly and evenly.
17. Fuel Gauge & Sender
It is extremely important that this operation is correct, if
These are 12V Datcon instruments with a dropper resis- however, this is not the case then the operator MUST
tance fitted at the gauge terminals. adjust the drums and roller guides accordingly.
L.M.I. Self-check
3G
1. Ensure the sender unit is installed in the tank cor-
rectly.
2. Check the reading on the gauge corresponds to the

When the ignition switch is turned on the L.M.I. will com-
plete an automatic self-check of the system, including
lamps and alarms etc.
level of fuel in the tank.
In the event of a malfunction, the console screen will dis-
18. Hoist Boost System
play an error code number.
60
To check the system:
If no fault is present the L.M.I. will go into a pre set-up
sequence.
1. Select the boost switch on the panel.
Pre Set-up Sequence
2. Check the boost solenoid is energised.
86
The console screen will now display a series of instruc-

3. Disconnect the din plug at the boost pressure
tions or information to the operator.
switch and check the solenoid is now de-energised.
The operator should respond by pushing the ’E’ button
19. Starting The Engine or the ’info’ button as indicated.
Start the engine - and check operation of: At the end of this sequence the operator has the option
of selecting:
Engine oil pressure gauge
Voltmeter - 26-28 volts with eng. running a. Full information run
Tachometer
Engine hour meter b. Programming procedure
Alternator lamp should be extinguished
Engine distress lamp should be extinguished Full Information Run
20. Stopping The Engine In this sequence the console screen will display detailed
identification of all the console features, lamps,
A rocker type engine stop switch is located on the panel. switches, symbols etc.
2-14-36
NOTE NOTE
Experienced Operators Can By-pass For More Detailed Information Refer To

This Sequence If Required, And Go Im- The L.M.I. Operators Handbook.
mediately Into The Programming Pro-
Battery-Powered Memory
cedure.
This feature of the L.M.I. system will retain programmed
Digital Input Signals
information for about 2 hours (i.e. with the ignition turned
off).
Turntable
When the ignition is turned on again within this period,
The following signal checks must be carried out after the the status of the console display should have remained
boom installation has been completed. unchanged.
1. Over the rear swing pin engaged - 24v on X1-40. If this does not happen the L.M.I. programming se-
2. Suspension locks engaged - 24v on X1-42 quences will have to be repeated.
3. Boom retracted - 24v on X1-76
4. Mid to inner-mid retracted - 24v on X1-67 ’Afnor’ Outrigger Interlock System (French Op-
5. Tele sequence ‘A’ selected - 24v on X1-78 tion)
6. Tele sequence ‘B’ selected - 24v on X1-80
7. Engine running, tele retract
selected
- 24v on X1-64
3G This installation consists of:
a. Display console (indicator lamps)
Programming Procedure b. Cant sensor
This procedure consists of: c. Red warning lamp on the L.M.I. reeling drum.
60
1. Programming the L.M.I. to the operating configura- d. Proximity sensors on each outrigger beam.
tion of the crane - by means of a four digit code number.
Display Console
This procedure is activated by selecting push button no.
The console is attached to the r/h side of the main L.M.I.
4.
86
console and includes warning lamps and a key-oper-

ated L.M.I. motion-cut over-ride switch.
2. Activating and programming the boom angle pre-
set limits (if desired). Blue lamp:
This procedure is activated by selecting push button no. Illuminates if the machine is 3° out of level.
16.
Red lamp:
3. For the purpose of checking the L.M.I. inputs on the
Will ’flash’ on if the L.M.I. is in over-ride - the lamp on the
assembly line - operating code number 0001 will nor-
reeling drum will also ’flash’.
mally suffice.
Orange lamp:
4. During the assembly audit routine a different code
number may be required depending on the crane con- This combined lamp and push button has several func-
figuration. tions:
5. If an incorrect code number is requested the con- 1. Lamp on - indicates ’on rubber’ duties selected.
sole screen will display ’E.O.4’ error. - pressing the lamp selects blocked duties.
2-14-37
2. Lamp ’flashing’ - indicates outriggers are not set NOTE
correctly.
- blocked duties selected. The external alarm will operate with the
motion-cut trip - but not the A2 block
3. Lamp off - indicates outriggers are set correctly. trip.
- blocked duties selected.
The external alarm is not fitted on
Key Override Switch cranes for the U.S.A. and Canada.
- This will ’latch in’ to override the L.M.I. motion-cut in the Motion Cut Trip
event of an overload condition.
In normal operation the L.M.I. will provide an output to
The red lamps on the console and reeling drum will power the motion cut relay and energise the motion cut
’flash’. solenoid.
X1/48 : 24V
Sequence Of Operation (Machine On Rubber)
An overload condition in the lift cylinders will cause this
1. With the axle locks engaged, the orange lamp will power supply to be interrupted.
be on, and on rubber duties selected.
The motion cut trip will prevent operation of the:
2. Extend outriggers to the correct working position. ’hoist raise’ - ’lift down’ - ’tele out’ functions.
The orange lamp will go out. At this point on rubber du-
ties are still selected.
3. To select blocked duties press the orange lamp.

3G NOTE
For checking purposes to simulate

Should any of the sensors move away from their target overload conditions, temporarily dis-
pads, the orange lamp will flash. connect the cable at X1/48 in the central
unit.
60
4. If the outrigger retract switch is selected - on rubber
duties will automatically be selected and the orange A2 Block Trip (Boom Limit Switches)
lamp will come on.
The attached block weight will keep the switch contacts
5. If the above sequence is started without the axle closed. Tripping the switch will interrupt power to the
motion cut solenoid , and prevents operation of the:
86
locks being engaged, the L.M.I. console screen will dis-

play an ’EO4’ error until the orange lamp is pressed to
’hoist raise’ - ’lift down’ - ’tele out’ functions.
select blocked duties.
It will activate the A2 block warning lamp (no. 8) and also
L.M.I. Power Supply
the console alarm (no. 23).
Ignition switch turned on
The main external alarm will not be activated.
X1/1 : 24V X1/3 : 0V
Key Override Switch (Central Unit)
L.M.I. Alarm Siren
This key switch when pushed in and turned to lock, will
The main external alarm is fitted on the end of the boom over-ride the motion cut trip and permanently energise
base section. the motion cut solenoid via the motion cut relay.
In normal operation the alarm is off. Warning lamp no. 11 on the console will ’flash’ to indicate
the L.M.I. has been over-ridden.
In this situation the L.M.I. will provide an output to power
the crane alarm relay and inhibit the alarm. Operation of the main external alarm will be inhibited.
X1/44 : 24V Operation of the A2 block trip will be unaffected.
2-14-38
NOTE Turn switch c.c.w. : over-rides the motion cut trip
and the external alarm
The over-ride switch should be wired
Turntable Over-Rear Pinned Signal
across X1/44 - 45.
With the turntable over the rear and the swing lock pin
On machines for Grove France, using engaged a switch on the swing boss will supply an input
this override switch will cause the main to the central unit.
2 amp fuse in the L.M.I. to blow. This will
take the L.M.I. out of operation, but will Switch activated = X1/40 : 24V
restore all crane functions.
Carrier Suspension ’Hard Signal’
Console Override Switch With the carrier suspension selected ’hard’, check the
input signal in the central unit. X1/42 : 24V
This spring-return to off 3 position switch has the follow-
Flat Boom Duty (U.S.A./Canada Only)
ing functions:
This option provides for a normally-closed proximity
Turn switch c.w. : over-rides A2 block trip only sensor to detect a boom angle of 16.5° or less.
3G
60
86
2-14-39
86
60
3G
SECTION 15
LUBRICATION
TABLE OF CONTENTS
Page
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-3
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-3
Hydraulic Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-5
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-5
Arctic Conditions (Below 0° F [-18° C]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Antiwear Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-6
Vapour Corrosion Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-9
3G
Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-11
LIST OF FIGURES
Title Page
Lubrication Diagram (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-12
60
Lubrication Diagram (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15-13
86
2-15-1, 2-15-2
86
60
3G
LUBRICATION
GENERAL
Following the designated lubrication procedures is im- where moderate temperature, humidity, and atmos-
portant in ensuring maximum crane lifetime and utiliza- pheric conditions prevail. In areas of extreme condi-
tion. The procedures and lubrication charts in this sections, the service periods and lubrication specifications
tion include information on the types of lubricants used, should be altered to meet existing conditions. For infor-
the location of the lubrication points, the frequency of lu- mation on extreme condition lubrication, contact your lo-
brication, and other information. cal service representative or Grove Customer Services.
The service intervals specified are for normal operation
LUBRICANTS
CAUTION grease may also be used. See EP-MPG for recom-

mended consistency grades
CHASSIS GREASE LUBRICANTS
MUST NOT BE APPLIED WITH AIR
PRESSURE DEVICES AS THIS LUBRI-
CANT IS USED ON SEALED FITTINGS.
3G EP-MPG Extreme Pressure Multipurpose Grease.
This is a lithium soap base grease with a high load carry-

ing capacity. The following properties are recom-
CAUTION mended.
THE MULTIPURPOSE GREASE IN- Timken OK Load 40 lb. Minimum

60
STALLED DURING MANUFACTURE IS Dropping Point 350°F (177°C)min.
OF A LITHIUM BASE. USE OF A NON- Oil Viscosity 75 SUS Minimum at 210°F(99°C)
COMPATIBLE GREASE COULD RE- Water Resistance Excellent
SULT IN DAMAGE TO EQUIPMENT.
Under normal operating conditions, the following con-
sistency grades are recommended
86
Specific recommendations of brand and grade of lubri-

cants are not made here due to regional availability,op- NLGI No. 0 or 00 for sub-zero Fahrenheit temperatures.
erating conditions, and the continual development of im- NLGI No. 1 or No. 2 for normal ambient temperatures.
proved products. Where questions arise, refer to the NLGI No. 2 or No. 3 for temperatures over 100°F
component manufacturer’s manual and a reliable sup- (38°C).
plier.
Unless otherwise specified, an EP-MPG containing mo-
SYMBOL DESCRIPTION lybdenum disulfide maybe used (see MPGM).
MPG Multipurpose Grease. MPGM Extreme Pressure Multipurpose Grease

Containing High Grade Molybdenum Disulfide
Lubricating grease of such composition, structure, and Filler.
consistency to meet the performance requirements for
chassis grease, wheel bearing grease, universal joint An extreme pressure multipurpose grease containing
grease, and other automotive uses of miscellaneous na- high grade molybdenum disulfide filler that imparts anti-
ture, such as fifth wheel service, should be inhibited to friction properties especially well suited for conditions of
prevent rusting and have excellent resistance to both heavy loading, particularly on slow oscillating or recipro-
heat and water.Higher quality EP-MPG multipurpose cating bearing surfaces.
2-15-3
WBG Wheel Bearing Grease. OGL Open Gear Lubricant.
This grease is of such composition, structure, and con- This is a special adhesive lubricant of heavy consis-
sistency that it is suitable for long time use in anti-friction tency for protection of wire rope and exposed gears
wheel bearings. It must have high resistance to the dete- where provision is not made for continuous lubricant re-
riorating effects of temperature and the separating ef- plenishment. Select the viscosity that gives best protec-
fects of centrifugal action.It shall not contain corrosive or tion and lubrication without peeling,scaling, or exces-
abrasive materials and shall inhibit corrosion in the pres- sive throw off.
ence of moisture. NLGI Grade No. 2 is recommended
EO Engine Oil.
where not otherwise specified.
Internal combustion engine lubricating oils are classified
RGL Regular Gear Lubricant. primarily by viscosity characteristics and on perform-
ance as determined by a series of tests called MS test
This is a straight-mineral gear oil of relatively high vis- sequences. Lubricants marketed for heavy duty service
cosity for the lubrication of spiral-bevel and worm gear consist of refined crude oil containing additives com-
rear axles and most manual transmissions operating pounded to meet the desired engine performance lev-
under low unit pressures and sliding velocities. API- els. Use only good quality oil provided by a reputable
GL-1 service classification. Unless otherwise specified, supplier in accordance with the service classification
the following viscosity characteristics are recom- and viscosIty requirements specified by the engine
mended.Viscosity Index 85 minimum Summer Opera- service manual.
tion SAE 90Winter Operation SAE 80
EPGL Extreme Pressure Multipurpose Gear Lubri-

3G ATF Automatic Transmission Fluid.
ATF shall meet the latest requirements for General Mo-

cant.
tors Dexron II specification.
This gear lubricant is compounded to achieve high load HTF Hydraulic Transmission Fluid.
60
carrying capacity and meet the requirements of either
API-GL-5 or MIL-L-2105C. Unless otherwise specified, A fluid qualified to Detroit Diesel Allison (Div.of GMC)
SAE 80W-90 viscosity may be used for year-round serv- specification for Type C-3 transmission fluid, SAE 10W
ice. Low temperature usage is restricted as follows. unless other-wise specified.
SBF Silicone Brake Fluid.

SAE Viscosity Number Minimum Ambient Temp
86
°F (°C) A silicone based hydraulic brake fluid, conforming to

MIL-B-46176, for use in hydraulic brake systems at am-
75W -40 ( -40) bient temperature ranging from minus 67 degrees to
80W -15 ( -26) plus 131 degrees F (-55 degrees to + 55 degrees C).It is
85W +10 ( -12) intended to be used in braking systems fitted with cups
90 +20 ( - 7) and seals made from natural rubber, buna 5,
140 +40 ( + 5) polychloroprene or ethylene proplene diene monomer.
250 +50 ( +10)
BF Brake Fluid.
EPGL(SCL) Extreme Pressure Gear Lubricant,Sul-
A glycol ether fluid for use in hydraulic brake systems.
pho Chloro-Lead.
Must meet or exceed SAE specification J1703.
This is a special gear lube formulated with EP additives THF Multipurpose Hydraulic/Transmission Oil.
of the sulfur chlorine-lead types. Usage is restricted to
those component parts for which the manufacturer A high quality multipurpose hydraulic/transmission oil
specifies a lubricant of this composition. (Refer Clark formulated to provide chatter - free performance of wet
MS-8-Specification.) brake and wet clutches in addition to good gear lubrica-
2-15-4
tion and hydraulic performance. Should meet John lowing types of oil are suitable under most operating
Deere specification J20A, viscosity 20W-30 for general conditions:
applications unless otherwise specified. When used as
a hydraulic fluid (HYDO),refer to viscosity provisions un- 1. Tractor Hydraulic Fluids of suitable viscosity.
der HYDRAULIC OIL RECOMMENDATIONS section.
2. Good quality anti-wear hydraulic oils of suitable
viscosity and specifically formulated to provide chatter-
GROVEXTRA HYDO High Performance Hydraulic
free operation of wet brakes.
Oil.
The most important factors in selecting an oil for hydrau-
Oil in a hydraulic system serves as the power transmis-
lic service are:
sion medium, system lubricant, and coolant. Selection
of the proper oil is essential to ensure satisfactory sys- 1. Viscosity.
tem performance and life. (See HYDRAULIC OIL REC-
OMMENDATIONS.) 2. Anti-wear additives.
GROVEXTRA HYDO may be further described using a Viscosity.

suffix as follows:
The oil must have proper viscosity to provide a lubricat-
RO - Rust and oxidation inhibited oil.
ing film at system operating temperature.
AW - A premium oil with antiwear additive.
LT - Low temperature hydraulic oil. Oil viscosity is important because it has a direct bearing
WPG Water Pump Grease.

3G
This is a multi-purpose high pressure lithium soap base
on efficient transmission of power. An oil must flow read-
ily through the system with a minimum of pressure and
flow loss. Positive lubrication depends on viscosity. The
oil must be sufficiently light to get between the compo-
grease. The following properties are recommended. nents machined surfaces, and maintain a lubricating
film at system operating temperatures. Cold weather
Dropping Point 3405F (1715C) min.
60
start-up procedures should allow for a gradual warm-up
Water Resistance Excellent
until the oil reaches a reasonably fluid state.
NLGI Grade NO. 2
Oil that is too light may cause the following conditions in
WRL Wire Rope Lubricant. the system.
86
Chemically neutral Wire Rope Lubricant used to prevent 1. Excessive leakage.

corrosion and reduce wear caused by internal fric-
tion.OGL is sometimes suitable. WRL should be se- 2. Lower volumetric efficiency of the pump.
lected and applied in accordance with operating condi-
3. Increased component wear.
tions and recommendations of a reputable lubricant
supplier. See WIRE ROPE LUBRICATION. 4. Loss of system pressure.
HYDRAULIC OIL RECOMMENDATIONS. 5. Lack of positive hydraulic control.
New cranes come from the factory with Grovextra Hydo 6. Lower overall efficiency.
high performance hydraulic oil.
Oil that is too heavy may cause the following conditions
Factory fill oil meets the optimum viscosity requirements in the system.
through a temperature range from -20°C to 46°C (-4°F to
1. System pressure drop.
115°F). When replenishment of the oil becomes neces-
sary, or when replacement of the oil is required as a re- 2. Increases system temperature.
sult of contamination or operation outside the recom-
mended temperature range for the factory fill oil, the fol- 3. Sluggish system operation.
2-15-5
4. Low mechanical efficiency. LUBRICATION POINTS
A regular frequency of lubrication must be established

5. Higher power consumption.
for all lubrication points. Normally, this is based on com-
ponent operating time. The most efficient method of
The following oil viscosity characteristics are recom-
keeping track of lube requirements is to maintain a job
mended.
log indicating crane usage. The log must use the engine
hourmeter to ensure coverage of lube points that will re-
80 to 180 SUS optimum at system operating tempera-
ceive attention based on their readings. Other lubrica-
ture
tion requirements must be made on a time basis, i.e.
60 SUS minimum at system operating temperature
weekly, monthly, etc.
7500 SUS maximum at starting temperature
90 Viscosity Index (VI), minimum All oil levels are to be checked with the crane parked on
Pour point at least 20 degrees F (11 degrees C) below a level surface in transport position, and while the oil is
start-up temperature cold, unless otherwise specified.
The following grades will usually meet the above viscos- On plug type check points, the oil levels are to be at the
ity requirements. bottom edge of the check port.
On all hoists with a check plug in the drum, the fill plug
SAE VISCOSITY DESIGNATION TEMPERATURE shall be directly on top of the hoist, and the check plug
-°F (°C)
3G level.
5W-20 -10 to 180 (-23 to 82) All grease fittings are SAE STANDARD unless other-
10W +10 to 180 (-12 to 82) wise indicated. Grease non-sealed fittings until grease
10W-30 +10 to 210 (-12 to 99) is seen extruding from the fitting. One ounce(28 grams)
of EP-MPG equals one pump on a standard one pound
Arctic Conditions (Below 0 degrees F [-18 degrees (0.45 kg) grease gun.
60
C]).
Over lubrication on non-sealed fittings will not harm the
fittings or components, but under lubrication will defi-
In general, petroleum based fluids developed especially
nitely lead to a shorter lifetime.
for low temperature service may be used with satisfac-
tory results. However, certain fluids, such as On sealed U-joints, care must be exercised to prevent
hologenated hydrocarbons, nitro hydrocarbons, and
86
rupturing seals. Fill only until expansion of the seals first

phosphate ester hydraulic fluids, might not be compat- becomes visible.
ible with hydraulic system seals and wear bands.If you
are in doubt about the suitability of a specific fluid, check Unless otherwise indicated, items not equipped with
with your authorized Grove distributor or Grove Cus- grease fittings, such as linkages, pins, levers,
tomer Services. etc.,should be lubricated with oil once a week. Motor
oil,applied sparingly, will provide the necessary lubrica-
Regardless of temperature and oil viscosity, always use tion and help prevent the formation of rust. An Anti-
suitable start-up procedures to ensure adequate lubri- Seize compound may be used if rust has not
cation during system warm-up. formed,otherwise the component must be cleaned first.
Grease fittings that are worn and will not hold the grease
Anti -wear Additives.
gun, or those that have a stuck check ball,must be re-
placed.Where wear pads are used, cycle the compo-
Excessive wear in the system may cause a loss in volu- nents and re-lubricate to ensure complete lubrication of
metric efficiency, and may cause shutdowns for mainte- the entire wear area.
nance. An efficient anti-wear oil protects the compo-
nents against rusting; resists oxidation, and helps pre- The following describe the lubrication points and gives
vent wear. the lube type, lube interval, lube amount, and applica-
2-15-6
tion of each. Each lubrication point is numbered, and 7. Fuel Tank (Carrier)
this number corresponds to the index number shown on
the Lubrication Diagram. Lube Type - Diesel
Lube Interval - Daily
Carrier - See Lubrication Diagram (Sheet 1 Of 2) Lube Amount - 432 litres
Application - Filler cap
1. + Engine
8. Fuel Line Filter Sediment Bowl
Lube Type - EO.
Lube Interval - Check daily. Drain and refill as per the en- Lube Type - Diesel
gine handbook Lube Interval - Daily
Application - Refer to the engine service manual. Lube Amount - Fed from fuel tank
2. + Fuel Filters 9. Drive Steer Axle (10 x 8 only) Differential
Lube Type - EPGL-5

3. + Lubricating Oil Filters
Lube Interval - Monthly or 200 hours or 5000 miles
+ Refer to engine manufacturers handbook supplied Lube Amount - 17 litres
with this manual for further details of engine lubrication Application - Filler plug
and fuel filter diagram.
10. Drive Steer Axle Hubs (10 x 8 only)
4. Torque Convertor and Gearbox
Lube Type - HTF

3G Lube Type - EPGL-5
Lube Amount - 1.3 litres
Application - Filler plugs 2 off one per hub
Lube Amount - Approximately 50 litres in the system.
Application - Dipstick 10. Non Drive Axle Hubs (10 x6 only)
60
5. Hydraulic Oil Tank Steering No lubrication required sealed for life.
Lube Type - GROVEXTRA HYDO 11. Drive Steer Axle Differential

Lube Amount - 164 Litres Lube Type - EPGL-5
86
Application - Filler cap Lube Interval - Monthly or 200 hours or 5000 miles
Lube Amount - 15 litres
6. Steering Oil Filters Application - Filler plug
Lube Type - GROVEXTRA HYDO - Fed from the hy- 12. Drive Steer Axle Hubs
draulic steer tank.
Lube Interval - Lube Type - EPGL-5
DAILY - When commissioning a new crane unknown Lube Interval - Monthly or 200 hours or 5000 miles
quantities of dirt can be present in the system therefore Lube Amount - 1.3 litres
the filter should be checked DAILY. Replace the element Application - Filler plugs 2 off one per hub
after 50 hours.
13. Non Drive Axle Hubs
WEEKLY or 50 hours - Thereafter the inspection period
can be increased to weekly or 50 hours.
No lubrication required sealed for life.
3 MONTHS or 600 hours - The element should be re-
placed after 600 hours. 14. Drive Steer Axle Hubs
Lube Amount - Supplied from the hydraulic tank.
Application - Refer to the Service Manual for changing Lube Type - EPGL-5
element procedure. Lube Interval - Monthly or 200 hours or 5000 miles
2-15-7
Lube Amount - 1.5 litres 22. Propshafts
Application - 2 Filler plugs one per hub
Lube Type - EP-MPG
15. Drive Steer Axle Differential
Lube Amount - Until grease extrudes
Application - 18 or 21 grease nipples 3 per shaft
Lube Type - EPGL-5
Lube Interval - Monthly or 200 hours or 5000 miles 23. Suspension Cylinders
Application - Filler plug Lube Type - EP-MPG
16. Drive Steer Axle Differential Lube Amount - Until grease extrudes
Application - 16 or 20 grease nipples 2 per cylinder
Lube Type - EPGL-5 24. Oil Cooler Pump Drive Filter (Fitted to Serial
Lube Interval - Monthly or 200 hours or 5000 miles No 50477 only)
Lube Amount - 17 litres
Application - Filler plug Lube Type - GROVEXTRA HYDO - Fed from the hy-
draulic steer tank.
17. Drive Steer Axle Hubs Lube Interval -
DAILY - When commissioning a new crane unknown
Lube Type - EPGL-5 quantities of dirt can be present in the system therefore

Application - 2 Filler plugs one per hub
3G
Lube Interval - Monthly or 200 hours or 5000 miles the filter should be checked DAILY. Replace the element
after 50 hours.
WEEKLY or 50 hours - Thereafter the inspection period
18. Steering Wormbox 3 MONTHS or 600 hours - The element should be re-
placed after 600 hours.
Lube Amount - Supplied from the hydraulic tank.
60
Automatically lubricated from steering hydraulic system
Application - Refer to the Service Manual for changing
element procedure.
19. Bevel Box
25. Steering Cylinders
Lube Type - EP-MPG
Lube Interval - During major overhaul Lube Type - EP-MPG
86
Lube Amount - Grease packed Lube Interval - Monthly or 200 hours or 5000 miles
Application - 1 grease point Lube Amount - Until grease extrudes
Application - 16 grease nipples 2 per cylinder
20. Axle King Pins (4 Per Axle) and CV Joints (2 26. Door Hinges
Per Joint)
Lube Type - EP-MPG
Lube Type - EP-MPG Lube Interval - Monthly or 200 hours or 5000 miles
Lube Interval - Monthly or 200 hours or 5000 miles Lube Amount - Until grease extrudes
Lube Amount - Until grease extrudes Application - 3 grease nipples per door.
Application - 32 grease nipples 8 per axle 27. Transmission Filters
21. Steering Relay Levers Lube Interval - 3 months or 600 hours or 15000 miles
Application - Check element
Lube Type - EP-MPG
28. Outrigger and Suspension Filter
Lube Amount - Until grease extrudes Lube Interval - 3 months or 600 hours or 15000 miles
Application - 6 grease nipple Application - Check element
2-15-8
29. Vapour Corrosion Inhibitor 6. Teleram Extension Sheave
Lube Type - EP-MPG

Vapour Corrosion Inhibitors are fitted in the outrigger
Lube Interval - Weekly or 50 hours or 1000 miles
control boxes and junction box. To retain efficiency the
Vapour Corrosion Inhibitors should be replaced at least
Application - 1 grease nipple, access through hole in the
every 2 years.
boom
Super And Boom - See Lubrication Diagram 7. Teleram Bearing Pad

(Sheet 2 Of 2)
Lube Type - EP-MPG
1. Hookblock Bearing Lube Interval - Weekly or 50 hours or 1000 miles
Lube Amount - Liberally
Application - By brush, access through hole in the boom
Lube Type - EP-MPG
Lube Interval - Monthly or 200 hours or 5000 miles 8. Lift Cylinder
Application - 1 grease nipple Lube Type - EP-MPG
2. Hookblock Sheaves Lube Amount - Until grease extrudes
Application - 4 grease nipples, two on each pivot
Lube Type - EP-MPG
3G 9. Retraction Sheaves
Lube Type - EP-MPG

Application - 1 grease nipple per sheave Lube Interval - Weekly or 50 hours or 1000 miles
3. Lower Nose Sheaves Application - 2 grease nipples
60
There are two grease nipples fitted per sheave, to facili-
Lube Type - EP-MPG
tate access when greasing it is only necessary to grease
one nipple per sheave.
Application - 1 grease nipple per sheave 10. Boom Pivot Shaft
86
4. Upper Nose Sheaves Lube Type - EP-MPG

Lube Type - EP-MPG
Application - 2 grease nipples
Lube Amount - Until grease extrudes 11. Swing Bearing and Pinion Teeth
Application - 1 grease nipple per sheave
Lube Type - EP-MPG
5. Boom Sections Lube Interval - Weekly or 50 hours or 1000 miles
Lube Type - EP-MPG Application - By brush
12. + Engine
Application - By brush Lube Type - EO.
Lube Interval - Check daily. Drain and refill as per the en-
All boom sections should be extended and coated with gine handbook
grease where the bearing pads move on. Application - Refer to the engine service manual.
2-15-9
13. + Lubricating Oil Filters Lube Amount - 6 litres
Application - 1 Filler plug
14. + Fuel Filters
NOTE
+ Refer to engine manufacturers handbook supplied
with this manual for further details of engine lubrication The crane must be level before draining
and fuel filtration. or topping up the hoist unit.
15. Fuel Line Filter Sediment Bowl 20 Hoist Unit Pedestal Bearing
Lube Type - Diesel Lube Type - EP-MPG

Lube Interval - Daily Lube Interval - Weekly or 50 hours or 1000 miles
Lube Amount - Fed from fuel tank Lube Amount - Until grease extrudes
Application - 1 grease nipple
16. Main Hydraulic Filters
21. Auxiliary Hoist Unit
Lube Type - GROVEXTRA HYDO
Lube Interval - Lube Type - EPGL-5
DAILY - When commissioning a new crane unknown Lube Interval - Monthly or 200 hours or 5000 miles
quantities of dirt can be present in the system therefore Lube Amount - 14 litres
the filter should be checked DAILY. Replace the element Application - 1 Filler plug
after 50 hours.

3 MONTHS or 600 hours - The element should be re-
3G
WEEKLY or 50 hours - Thereafter the inspection period 22 Auxiliary Hoist Unit Pedestal Bearing
Lube Type - EP-MPG

placed after 600 hours. Lube Interval - Weekly or 50 hours or 1000 miles
Lube Amount - Supplied from the hydraulic tank. Lube Amount - Until grease extrudes
Application - Refer to the Service Manual for changing Application - 1 grease nipple
60
element procedure.
23. Hydraulic Reservoir
17. Fuel Tank (Superstructure)
Lube Type - GROVEXTRA HYDO
Lube Type - Diesel Lube Interval - Daily
Lube Interval - Daily Lube Amount - 1100 Litres
86
Lube Amount - 209 litres Application - 1 Filler Cap

Application - Filler cap
24. Swing Bearing
18. Counterweight Removal Hydraulic Cylinder
Pins Lube Type - EP-MPG
Lube Type - EP-MPG Lube Amount - Until grease extrudes
Lube Interval - Weekly or 50 hours or 1000 miles Application - 4 grease nipples
Application - 2 grease nipples 25. Swing Gearbox
19. Main Hoist Unit Lube Type - GROVEXTRA HYDO

Lube Type - EPGL-5 Lube Amount - 6 litres
Lube Interval - Monthly or 200 hours or 5000 miles Application - 1 filler plug
2-15-10
WIRE ROPE LUBRICATION
Wire rope is lubricated during manufacturing so the on, sprayed on, or put on by brushing, but in any case it
strands, and individual wires in strands, may move and should be applied at a place where the rope is being
adjust as the rope moves and bends. A wire rope cannot bent, such as a sheave. It should be applied at the tope
be lubricated sufficiently during manufacture to last its of the bend, at the point the strands are spread by bend-
entire life. Therefore, new lubricant must be added peri- ing and are more easily penetrated. The service life of
odically throughout the life of a rope to replace factory rope will be directly proportional to the effectiveness of
lubricant which is used or lost. the method used and amount of lubricant reaching the
working parts of the rope.
The surface of some ropes may become covered with
dirt, rock dust, or other material during their operation.
A proper lubricant must reduce friction, protect against
This covering can prevent field applied lubricants from
corrosion, adhere to every wire and be pliable and not
properly penetrating into the rope. Therefore, these
crack or separate when cold and yet not drip when
ropes should be cleaned before being lubricated.
warm.
The lubricant applied should be light bodied enough to
penetrate to the core of the tope. Lubricant may be ap- Special lubricant can be applied at the factory to meet
plied effectively by various methods. It may be dripped usual conditions.
3G
60
86
Wire Rope Lubrication
2-15-11
3G
60
86
Lubrication Diagram (Sheet 1 of 2)
2-15-12
3G
60
86
Lubrication Diagram (Sheet 2 of 2)
2-15-13
86
60
3G
CHAPTER THREE
OPTIONAL EQUIPMENT
3G
60
86
3-0-1 , 3-0-2
86
60
3G
SECTION 1
MISCELLANEOUS OPTIONAL EQUIPMENT
TABLE OF CONTENTS
Page
MISCELLANEOUS OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3
Rotating Beacon Liight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3
Spotlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3
Boom Flood Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1-3
3G
60
86
3-1-1, 3-1-2
86
60
3G
MISCELLANEOUS OPTIONAL EQUIPMENT
DESCRIPTION
This section is provided to give a description of the op- the right front corner. The light can be tilted 180 degrees
tional equipment not discussed elsewhere in this Serv- and rotated 360 degrees.
ice Manual.
BOOM FLOOD LIGHTS
ROTATING BEACON LIGHT
The boom flood lights are mounted on the bottom of the
The rotating beacon light is located on the cab roof.
base section. The lights are controlled by a switch on the
SPOTLIGHT console.
The spotlight is mounted on the outside of the cab roof in
3G
60
86
3-1-3

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GROVE CRANE

PUBLISHED: APRIL 1994

Page Numbers Change in Effect Page Numbers Change in Effect

Title Page thru xi Original

Change No. Effective Date Date Entered Entered By

_____________ _____________ _____________ _____________

_____________ _____________ _____________ _____________

_____________ _____________ _____________ _____________

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_____________ _____________ _____________ _____________

_____________ _____________ _____________ _____________

A WARNING IS USED TO EMPHASIZE

LOWED EXACTLY,DEATH OR INJURY

A CAUTION IS USED TO EMPHASIZE

A note is used to emphasize an impor-

NEW EQUIPMENT WARRANTY

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EX-

Should this crane become involved in an accident, please

SECTION 1 - GENERAL DESCRIPTION

SECTION 2 - GENERAL MAINTENANCE

Air Intake System - Turntable Engine

SECTION 3 - DRIVE TRAIN

SECTION 4 -AXLES AND BRAKE SYSTEM

SECTION 5 - STEERING SYSTEMS

SECTION 7 -AIR SYSTEM

SECTION 8 - HYDRAULIC SYSTEM

Emergency Steering Pump

SECTION 9 - SWING SYSTEM

SECTION 14 - ELECTRICAL SYSTEM

SECTION 1 - MISCELLANEOUS OPTIONAL EQUIPMENT

SERVICE MAINTENANCE PACKAGES

IT IS MANDATORY THAT ALL HYDRAULIC HOSES AND FITTINGS BE COR-

CORRECTIVE ACTION REQUEST FORM

Name . . . . . . . . . . . . . . . . . . . . . . . . . . Title . . . . . . . . . . . . . . . . Date . . . . . . . . . . . . . . . . .

Manual Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Production/Page No. . . . . . . . . . . . . .

Forward To:- Technical Publications Dept.

DO NOT SLING ANY OTHER PART OF

ALWAYS ENSURE THAT SUITABLE

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AT9120E Speeds . . . . . . . . . . . . Forward . . . . . . . . . . . Reverse

Type . . . . . . . . . . . . . . . . . . . . . . . . . Single wire ground

Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-6

EXERCISE EXTREME CARE AROUND

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_______ _ _ _______

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