Service Manual

HTC-8690, RTC-8090 2007-502

1207 SM17 --- 002 --- 083.00

2 3 4 5 6 7
1. Access Cover 5. T3 Section
2. Base Section 6. T4 Section
3. T1 Section 7. Boom Head Machinery
4. T2 Section

Figure 1
Five Section Latching Boom Nomenclature

2. Stabilize the crane for service as follows:

a. Park the crane, out of the way, on a firm and
level surface and engage the park brake.
b. Engage the travel swing lock.
c. Level the crane on fully extended outriggers.
Keep clear of 3. Position the boom at a zero degree boom angle or
moving parts to place it in the boom rest, if equipped.
prevent serious 4. Fully extend the two outer most boom sections, (T3
bodily injury. and T4 section).
5. Shutdown the engine.

Figure 2
Keep Clear Of Moving Parts Within The Boom
Latching Boom Mechanism
Retrofit
This procedure covers retrofit instructions to install an
improved latching mechanism and pin pullers in five
section latching booms. The following parts listed are
required for the rework of the boom latching
mechanism:
S Retrofit Kit
S Husco Boom Latching Controller
S Updated Boom Controller Software.
S Greer Flash Card for the RCL Display
Disassembly
Use the following procedure to disassemble the
latching mechanism. Unless otherwise stated, discard
all capscrews, washers, and locknuts removed. Save
all the other removed parts. Many of these parts will be
reused to assemble the new boom latching
mechanism.
1. Lower, detach, and secure the load, as required.
WARNING
To avoid personal injury, do not climb, stand,
or walk on the boom or fly. Use a ladder or
similar device to reach necessary areas.
Refer to Figure 4.
6. Remove the capscrews and washers which secure
the retaining strap (2) and access cover (3) to the
top rear of the boom base section (1). Remove the
retaining strap (2) and access cover (3).
Refer to Figure 3.
7. Use a ladder to access the pin puller assembly (4),
of the T4 section (2), through the access hole (3) in
the side of the boom.
8. Remove the capscrews and washers (9) which se-
cure the pin (5) to the legs (10) of the pin puller as-
sembly (4).
Note: The pin puller assembly will drop slightly
when the capscrews and washers are removed.
9. Install one of the capscrews (9) in the tapped hole
(7) on the top of the pin (5) and use it to lift the pin
(5) out of the boom.

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A
1 2 3
5 6 7 8 9 10

12 11

4
1. T3 Section 4. Pin Puller Assembly 7. Tapped Hole 10. Legs
2. T4 Section 5. Pin 8. Spring Assembly 11. Puller Base
3. Access Hole 6. Capscrews 9. Capscrews & Washers 12. Capscrews & Washers
Figure 3
T4 Pin Puller

11. Reach through the access hole (3) and support the
1 2 3 pin puller assembly (4) while removing the cap-
screws (6). Once the capscrews (6) are removed,
the pin puller assembly (4) can be lowered out of
the section and removed through the access hole
(3).
12. Remove the capscrews and washers (12) which
secure the the puller base (11) to the legs (10); sep-
arate the legs (10) and puller base (11). Discard
the puller base (11); the legs (10) will be reused.
Note: The new pin puller assembly will need to be
put together using the pin (5) to ensure the legs are
square with the puller base.

1. Boom Base Section 13. Apply Loctite 242 to the new capscrews (12)
2. Retaining Strap provided.
3. Access Cover
Note: Use new capscrews to secure the legs to
Figure 4
Boom Access Cover the new puller bases; all are 0.375 inches in dia-
meter. The T4 pin puller assembly uses 1.25 in
(32mm) long capscrews, the remaining pin
10. Note the orientation of the spring assembly (8) to
ensure proper installation later. Remove the spring puller assemblies use 1.50 in (38mm) long cap-
assembly (8) from the pin puller assembly (4). screws.

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Service Manual 1207 SM17 --- 002 --- 083.00
14. Loosely install the legs (10) to the new puller base
(11) using the capscrews and washers (12). Be
sure to orient the legs (10) so the capscrews (6),
when installed, will be facing the spring assembly
(8).
15. Position the pin (5) on top of the legs (10). Be sure T1 Pin
the legs (10) are tightly seated in the machined
groove along the entire length of the pin (5). Tem- T2 Pin
porarily install and tighten the capscrews and Access
washers (9). Hole
16. After ensuring the legs (10) are properly seated in
T3 Pin
the pin (5) torque the capscrews (12) to 50---55 ft
lbs (68 ---74Nm).
17. Remove the capscrews and washers (9) and sep-
arate the pin (5) from the pin puller assembly (4).
18. Install the partially assembled pin puller assembly
(4) back in the section through the access hole (3). Figure 5
Ensure the puller base (11) is properly positioned Accessing T3 And T2 Pin Puller Assemblies
so the open side of the c---channel faces the right
side of the boom. 25. Engage the latches in the T3 section and unpin the
19. Install the capscrews (6) in the legs (10). T3 pin. Manually extend the T3 section approxim-
20. Properly position the spring assembly (8) in the pin ately 10 in (25cm) so the T3 pin is located as shown
puller assembly (4). in Figure 5.
21. Install one of the capscrews (9) in the tapped hole 26. Rebuild the T2 and T3 pin puller assemblies by re-
(7) on the top of the pin (5) and set the pin (5) in peating Steps 8 through 22, as applicable.
place. 27. After the T2 and T3 pin puller assemblies have
22. Apply Loctite 242 to the capscrews (9). Install the been rebuilt, manually retract and pin all sections.
washers and capscrews (9), that secure the pin (5)
to the legs (10), and torque to 100---110 ft lb
(136 ---149Nm).
23. Start the engine and fully retract the boom.
24. Properly install the boom telescope remote control
box and prepare to observe boom section move-
ment through the access hole in the top of the base
section. Access T1 Pin
Note: All further operation of the boom telescope Hole
function will be performed in Manual Mode. See
“Emergency Telescope Operation” in the Opera-
tor’s Manual for complete instructions.

WARNING
To avoid personal injury, only the mechanic
who’s hands are within the boom is to operate
the telescope remote control box. No one
should be handling the control box while the
mechanic is working within the boom.
Figure 6
Accessing T1 Pin Puller Assembly
28. Engage the latches in the T1 section and unpin the
T1 pin. Manually extend the T1 section approxim-
ately 32 in (81cm) so the T1 pin is located as shown
in Figure 6. Disengage the latching mechanism
from the T1 section and extend the telescope cylin-
der and latching mechanism out of the way, ap-
proximately 12 in (30cm).
29. Remove, but do not reinstall the T1 pin puller as-
sembly by repeating Steps 8 through 11, as applic-
able. The T1 pin puller will be installed after the
boom latching mechanism is rebuilt.

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SM17 --- 002 --- 083.00
Latching Mechanism
Centered In Access Hole
Figure 7
Accessing Latching Mechanism
30. Retract the telescope cylinder and engage the
latches with the T1 section. Visually inspect the
latches to ensure they are properly engaged. Ex-
tend the T1 section so that it is approximately 15 in
(38cm) beyond the access hole in the base sec-
tion.
CAUTION
The T1 pin puller must be removed before
extending the T1 section. Visually inspect the
latches to ensure they are properly engaged.
Damage to the T1 pin puller and boom
sections may occur if the T1 pin puller is not
removed first.
31. Release the latches from the T1 section and retract
the telescope cylinder so only 10 in (25cm) of the
chrome on the cylinder rod is exposed.
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1207 Service Manual
WARNING
Solvents and cleaning solutions can be
hazardous. Serious personal injury may
result from misuse of these products. Read
and follow all the manufacturer’s
recommendations concerning solvents and
cleaning solutions.
32. Thoroughly clean the boom latching mechanism
and surrounding areas to be disassembled with an
approved cleaning solvent to prevent contamina-
tion. Allow the area to air dry.
WARNING
Hydraulic oil is under pressure and may be
hot. A sudden release of hot oil could cause
burns or other serious injury. Shutdown the
engine and exhaust all trapped hydraulic
pressure from the system before removing
any line or component.
33. Relieve the hydraulic system pressure as follows:
a. Release any residual pressure in the hydraulic
reservoir by slowly loosening the filler/breather
cap, located on the top of the hydraulic
reservoir, until pressure is fully relieved.
b. Turn the ignition switch to “ON”, but DO NOT
START THE ENGINE. Move the function lock-
out switch to the “OPERATE” position.
c. Work the boom telescope remote control box
switches and crane control levers back and
forth several times.
d. Turn the ignition switch to the “OFF” position.
34. Check that all control levers are in the neutral posi-
tion and move the function lockout switch to the
“DISABLE” position.
Service Manual 1207 SM17 --- 002 --- 083.00

10
9
7 8
6
4 5
3
2
1

20

11
12
14 13
19
15
16
17
18

1. Magnetic Sensors --- Round 6. Locknuts & Clamps 11. Solenoid 16. Shoulder Bolts --- Large
2. Magnetic Sensors --- Round 7. Cable Ties 12. Directional/Relief Valve 17. Latch Block
3. Bellcrank 8. Capscrews & Washers 13. Capscrew, Washer, & Locknut 18. Shoulder Bolts --- Small
4. Hose Shield 9. Guide Tube 14. Slider Bracket 19. Magnetic Sensors --- Flat
5. Bellcrank Arm 10. Wire Harness 15. Latching Cylinder 20. Hoses

Figure 8
Disassembly -- Steps 35 through 41

Refer to Figure 8. 38. Remove any additional hardware as required so

35. Label, for assembly purposes, all the connections
from the wire harness (10) to the magnetic sensors
(1,2,19) and solenoid (11) on the directional/relief
valve (12).
36. Cut the cable ties (7) which secure the wire har-
ness (10) and unplug the connections from the
magnetic sensors (1,2,19) and solenoid (11) on
the directional/relief valve (12). Move the wire har-
ness (10) out of the way.
37. Remove the capscrews and washers (8) which se-
cure the hose shield (4); move the hose shield (4)
aside to gain access to parts.
the guide tube (9) can be moved aside to gain ac-
cess to parts below the guide tube (9).
39. Remove the two small shoulder bolts (18) that se-
cure the bellcrank (3) to the bellcrank arm (5); re-
move the bellcrank (3).
40. Remove the magnetic sensors (2) from the bell-
crank (3); save the magnetic sensors (2).
41. Remove the two large shoulder bolts (16) from the
latch block (17).

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7 8
5 6
3 4
1 2

10

11

16
12

13

15
14

1. Sensor Bracket --- Round 5. Capscrews & Washers 9. Latching Cylinder 13. Capscrews & Washers
2. Cable Guide 6. Bellcrank Arm 10. Pin, Cotter Pin & Washer 14. Sensor Bracket --- Flat
3. Arm Stop 7. Capscrews & Washers 11. Latch Plate 15. Magnetic Sensors --- Flat
4. Connecting Link 8. Latch Block 12. Latches --- Top 16. Magnetic Sensors --- Round

Figure 9
Disassembly -- Steps 42 through 47

Refer to Figure 9.
42. Remove the connecting link (4) from above the
latch plate (11). Remove the bushing (not shown)
from the connecting link (4).
43. Remove the pin, cotter pin, and washer (10) which
secures the latching cylinder (9) to the bellcrank
arm (6); remove the bellcrank arm (6).
44. Remove the capscrews and washers (7) which se-
cure the latch block (8) and latch plate (11); re-
move the latch block (8) and latch plate (11).
45. Remove the capscrews and washers (5) which se-
cure the cable guide (2) to the latch plate (11); sep-
arate the cable guide (2) from the latch plate (11).
46. Remove the capscrews and washers (13) which
secure the sensor brackets (1,14) to the arm stop
(3); remove the sensor brackets (1,14) with the
magnetic sensors (15,16) attached.
47. Remove only the round magnetic sensors (16)
from the sensor bracket (1), the flat magnetic
sensors (15) can remain installed on the sensor
brackets (14).

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9
8
7
5 6
4
3
2
1

1. Wedge Stop 4. Arm Stop 6. Spacer Bushing 8. Capscrew & Washer

2. Washers 5. Latches 7. Interlock Wedge 9. Slider Bracket
3. Stop Bolts

Figure 10
Disassembly -- Steps 48 through 50

Refer to Figure 10.
48. Remove the latches (5) and spacer bushings (6).
49. Remove the capscrew and washer (8) that secures
the interlock wedge (7) to the slider bracket (9); re-
move the interlock wedge (7).
50. The initial assembly of the latching mechanism will
require two washers (2) be installed in the top of the
arm stop (4) and two washers (2) be installed in the
bottom of the arm stop (4). Remove the stop bolts
(3), and change the quantity of washers (2), as re-
quired.

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SM17 --- 002 --- 083.00
1 6
2 3
1. V--- Block --- (Add) 4. Arm Stop
2. Stop Base 5. Wear Pad
3. Wedge Stop --- (Remove)
Figure 11
Modifications -- Steps 51 through 57
Refer to Figure 11.
51. Measure the thickness of the wear pad (5) located
on the trunnion (7) of the telescope cylinder (8).
The nominal thickness of the wear pad (5) should
be 0.25 in (6.4mm). If a 0.375 (9.5mm) thick wear
pad (5) is present, it must be replaced with the new
0.25 in (6.4mm) wear pad (5) provided. Remove
the capscrews (6) and replace the wear pad (5), if
required.
52. Modifications to the trunnion (7) of the boom tele-
scope cylinder (8) and removal of the wedge stop
(3), which require grinding and welding, will now
be performed. Precautions must be taken to pre-
vent damage to the chrome plated rod of the tele-
scope cylinder, latching cylinder, hoses, and other
heat sensitive components.
Refer to Figure 8.
53. Reinstall hardware as required so the guide tube
(9) and hose shield (4) can be temporarily installed
and the telescope cylinder extended to provide ac-
cess and avoid heat damage to parts.
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1207 Service Manual
8
7
5
4
6. Capscrews 8. Telescope Cylinder
7. Trunnion 9. Plates --- ( Add If Required)
CAUTION
Secure the guide tube and hose shield before
extending the telescope cylinder. Loose
hoses and cables may be damaged if they are
left unsecured. Temporarily secure parts
before operating the telescope cylinder.
Refer to Figure 11.
54. Unlatch and extend the telescope cylinder (8) to
obtain the optimum access to the trunnion (7) and
wedge stop (3) areas for modification.
55. Cover any exposed parts, which could be subject
to damage from sparks or weld splatter, with an ap-
propriate flame proof material.
56. Inspect for the presence of the plates (9) on each
side of the telescope cylinder (8) trunnion (7); add
as required per the instructions given in Figure 12.
57. Using a torch and/or grinding tool, remove the ex-
isting wedge stop (3). Use care not to unnecessar-
ily damage the arm stop (4) or stop base (2). Grind
the top surface of the stop base (2) smooth and flat.
Add the v---block (1) per the instructions given in
Figure 13.
Service Manual 1207 SM17 --- 002 --- 083.00

Before Rework After Rework

A A

B B
A A
Trunnion Trunnion

Trunnion 3.188 Trunnion 3.188

(8.1cm) (8.1cm)
2 Places 2 Places

2.625 2.375
Section A---A (6.7cm) Section A---A (6.0cm)
2 Places Trunnion 2 Places
Add Plate
2 Places

Grind Smooth
To Top Of Plate
4 Places
Section B---B

Figure 12
Welded Modifications

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SM17 --- 002 --- 083.00 1207 Service Manual

No Weld On
Angled Or Top
Surface

No Weld
Within
“V”
0.25 0.25

A A

OK to Weld Over
Tapped Hole 0.25

V ---Block Flush
With Edge Of
Stop Base

V ---Block

Stop Base

SECTION A---A

Figure 13
Welded Modifications

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Service Manual
Cleaning And Inspection
WARNING
Solvents and cleaning solutions can be
hazardous. Serious personal injury may
result from misuse of these products. Read
and follow all the manufacturer’s
recommendations concerning solvents and
cleaning solutions.
1. All components should be thoroughly cleaned with
an approved cleaning solvent, air dried, and care-
fully inspected.
2. Thoroughly inspect all parts for damage, wear, fa-
tigue or stress fractures, and corrosion. Repair or
replace as required.
3. All Loctite, Permatex, or other sealant residue
should be removed from threads of hardware and
the mounting surfaces of parts that are going to be
reused. Prior to applying new thread locking com-
pounds or sealants, clean threads and surfaces
with Loctite 7070 Cleaner to ensure best perfor-
mance of products.
4. Inspect the integrity of the hydraulic lines/hoses
that are connected to the valve and cylinders in the
latching mechanism. Repair or replace if required.
5. Inspect the integrity of the electrical wires and con-
nectors that supply the solenoid and magnetic
sensors in the latching mechanism. Repair or re-
place if required.
6. In the event of severe defects, contact factory per-
sonnel for directions whether to repair or replace
any major component.
Assembly
WARNING
Solvents and cleaning solutions can be
hazardous. Serious personal injury may
result from misuse of these products. Read
and follow all the manufacturer’s
recommendations concerning solvents and
cleaning solutions.
1. Sweep clean any dust, ash, and other grinding and
welding residue. Thoroughly clean the boom
latching mechanism, latching cylinder, and sur-
rounding areas to be assembled with an approved
cleaning solvent to prevent contamination from en-
tering the hydraulic system. Allow the area to air
dry.
1207 SM17 --- 002 --- 083.00
1
2
3
5 1.875 in
(4.75cm)
4
1. Capscrews 4. Jam Nut
2. Wear Block 5. Magnetic Sensors
3. Bellcrank
Figure 14
Bellcrank Subassembly
2. Apply a protective coat of paint over any of the bare
metal surfaces created from grinding and welding.
Allow the paint to adequately dry.
3. Extend/Retract the telescope cylinder to obtain op-
timum access to the latching mechanism.
Refer to Figure 8.
4. Remove hardware as required so the hose shield
(4) can be removed and the guide tube (9) can be
temporarily positioned out of the way.
Refer to Figure 14.
5. Apply Loctite 242 to the capscrews (1).
6. Align the wear block (2) on the new bellcrank (3)
and install the capscrews (1). Torque the cap-
screws (1) to 60---70 ft lb (82 ---94Nm).
7. Install the magnetic sensors (5) and jam nuts (4) on
the bellcrank (3). The top of the magnetic sensors
(5) must be 1.875 (4.75cm) below the top surface
of the wear block (2). Hand tighten the jam nuts
(4).
CAUTION
Adjust the magnetic sensors per Figure 14. If
the magnetic sensors are adjusted higher
than the dimension given, the magnetic
sensors may be damaged upon the initial
operation of the latching mechanism. Do not
over extend the magnetic sensors.
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11
10
9
8
7
6
5
4
3
2
1

1. V--- Block 5. Spacers 9. Guide Tube

2. Rollers 6. Trunnion 10. Glide Block
3. Interlock Wedge 7. Capscrew & Washer 11. Capscrew , Washer, & Locknut
4. Latches 8. Slider Bracket

Figure 15
Assembly -- Steps 8 through 13

Refer to Figure 15. Refer to Figure 15.

8. Install the new rollers (2) in the new interlock
wedge (3). Tighten the locknuts (not shown) to
fully seat the shaft of the rollers (2) in the interlock
wedge (3). Torque the locknuts to 60---70 ft lb
(82 ---94Nm). Ensure the rollers (2) rotate smoothly.
Refer to Figure 8.
9. Remove the capscrew, washer, and locknut (13)
that secures the latching cylinder (15) to the slider
bracket (14).
10. Push the slider bracket (8) forward to allow room
for placement of the interlock wedge (3) in front of
the V ---block (1).
11. Apply Loctite 242 to the capscrew (7).
12. Place the interlock wedge (3) on the slider bracket
(8) and install the capscrew and washer (7).
Torque the capscrew (7) to 100---110 ft lb
(136 ---149Nm).
13. Properly position the new latches (4) and spacers
(5) and align them with the mounting holes in the
trunnion (6).

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8 9 10
6 7
4 5
2 3
1

11
12
13
14
19

18 15
17 16
1. Sensor Bracket --- Round 6. Capscrew & Washer 11. Pin, Cotter Pin, & Washer 16. Latches
2. Arm Stop 7. Bellcrank Arm 12. Latching Cylinder 17. Sensor Bracket --- Flat
3. Shoulder Bolt (Small) 8. Latch Block 13. Slider Bracket 18. Magnetic Sensor --- Flat
4. Connecting Link 9. Shoulder Bolt (Large) 14. Connector Orifice 19. Magnetic Sensor --- Round
5. Bellcrank 10. Hose 15. Pin, Cotter Pin, & Washer

Figure 16
Assembly Steps 14 through 27

Refer to Figure 16. 22. Align the case end of the latching cylinder (12) with
14. Apply Loctite 7070 Cleaner, or equivalent, to the the latch block (8) and install the pin, cotter pin,
shoulder bolts (3,9) and allow them to air cure. See and washer (15).
the manufacturer’s instructions for complete in-
structions on application of cleaner to ensure best
performance of products. WARNING
15. Place the new latch block (8) on the latches (16).
Hydraulic oil is under pressure and may be
16. Apply Loctite 242 to the capscrews (6). hot. A sudden release of hot oil could cause
17. Install the capscrews and washers (6) and torque
burns or other serious injury. Shutdown the
to 325---380 ft lb (441 ---515Nm).
engine and exhaust all trapped hydraulic
18. Apply Loctite 262 to the shoulder bolts (9).
pressure from the system before removing
19. Properly position the bellcrank arm (7) and con-
any line or component.
necting link (4) and install the shoulder bolts (9).
Torque the shoulder bolts (9) to 155---205 ft lb 23. Relieve the hydraulic system pressure as follows:
(211 ---277Nm). a. Release any residual pressure in the hydraulic
20. Apply Loctite 262 to the shoulder bolts (3). reservoir by slowly loosening the filler/breather
21. Install the new bushing (not shown) in the oblong cap, located on the top of the hydraulic
hole of the connecting link (4). Properly position reservoir, until pressure is fully relieved.
the bellcrank (5) and and connecting link (4) and
install the shoulder bolts (3). Torque the shoulder
bolts (3) to 100---110 ft lb (136 ---149Nm).

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8
7
6
5
9

4
10
3

1. V--- Block 5. Sensor Bracket --- Round 8. Sensor Bracket --- Flat
2. Capscrews & Washers 6. Magnetic Sensors --- Flat 9. Capscrews & Washers
3. Magnetic Sensors --- Round 7. Capscrews, Locknuts, & Washers 10. Arm Stop
4. Jam Nuts
Figure 17
Sensor Switches Steps 28 through 32

b. Turn the ignition switch to “ON”, but DO NOT
START THE ENGINE. Move the function lock-
out switch to the “OPERATE” position.
c. Work the boom telescope remote control box
switches and crane control levers back and
forth several times.
d. Turn the ignition switch to the “OFF” position.
24. Place a shallow container or some type of absorb-
ent material under the latching cylinder (12) to
catch any hydraulic oil that might spill when dis-
connecting the hose (10).
25. Slowly disconnect the hose (10) from the latching
cylinder (12) and remove the existing connector fit-
ting.
26. Align the clevis end of the latching cylinder (12)
with the slider bracket (13) and install the new pin,
cotter pin, and washer (11).
Note: The clevis end of the latching cylinder
was previously secured with a capscrew, wash-
er, and locknut.
27. Install the new connector orifice (14) in the latching
cylinder (12) and connect the hose (10).
Refer to Figure 17.
28. Install the magnetic sensors (3) in the sensor
bracket (5) using the jam nuts (4). Set the depth of
the magnetic sensors (3) so only the protective
cap, on the end, is protruding through the sensor
bracket (5) with only enough threads exposed to
install the jam nuts (4).
29. Apply Loctite 242 to the capscrews (2).
30. Align the sensor bracket (5) with the v---block (1)
and install the capscrews and washers (2). Torque
the capscrews (2) to 11---12 ft lb (15 ---16Nm).
31. Check that the magnetic sensors (6) are securely
fastened to the sensor brackets (8) with the cap-
screws, washers, and locknuts (7).
32. Align the sensor brackets (8) with the arm stop (10)
and loosely install the capscrews and washers (9).
Position the upper sensor bracket (8) at the top of
its adjustment range and the lower sensor bracket
(8) at the bottom of its adjustment range. Tempor-
arily tighten the capscrews (9).
Refer to Figure 15.
33. Remove the capscrew, washers, and locknut (11)
that secures the guide tube (9) within the glide
block (10).

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Service Manual 1207 SM17 --- 002 --- 083.00
1 2 3

11 10 9 8 7 6 5 4

Secure Cables
To Top Of
Sensor

Bend
Clamp
Up

1. Directional/Relief Valve 5. Clamp --- Bent Up 90 Degrees 9. Guide Tube

2. Capscrew, Washers, & Locknut 6. Capscrew & Washer 10. Capscrew, Washers, & Locknut
3. Magnetic Sensors 7. Clamps & Capscrews 11. Clamp
4. Wire Harness 8. Wire Harness Tray

Figure 18
Assembly -- Steps 34 through 41

Refer to Figure 18.
34. Secure the wire harness tray (8) with the new,
longer capscrew, washers, and locknut (10) at the
guide tube (9) end of the wire harness tray (8).
35. Apply Loctite 242 to the capscrew (6).
36. Install the capscrew and washer (6) at the other
end of the harness tray (8). Torque the capscrew
(6) to 40---44 ft lb (54 ---60Nm).
37. Remove the convoluted material from the magnet-
ic sensor (3) end of the wire harness (4) to the dir-
ectional/relief valve (1).
38. Connect the magnetic sensors (3) to the wire har-
ness (4), as labeled during disassembly.
39. Neatly layout the wire harness (4) along the wire
harness tray (8) and secure it with the clamps and
capscrews (7). Use cable ties to further secure the
wire harness (4), as required. Use care to ensure
the wire harness (4) is not overly taught.
40. Install an additional clamp (11), to secure the wire
harness (4), using the upper capscrew, washers,
and locknut (2) that mounts the directional/relief
valve (1).
CAUTION
Secure wires, sensor cables, and all parts of
the wire harness with cable ties. Damage to
any loose wires or electrical connections will
occur. Do not leave any cables, wires, or any
part of the wire harness loose or vulnerable to
moving parts.
41. After routing the wire harness (4) and cables of the
magnetic sensors (3), bend the clamp (5) up 90˚.
Also cable tie the wire harness (4) and cables of the
magnetic sensors (3) directly to the magnetic
sensors (3). Do not leave any cables, wires, or any
part of the wire harness (4) loose or vulnerable to
moving parts.

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SM17 --- 002 --- 083.00 1207 Service Manual

5
4
3
2

1. Wire Harness 4. Hoses

2. Capscrews & Washers 5. Clamps & Capscrews
3. Hose Tray 6. Capscrews & Washers

Figure 19
Assembly -- Steps 42 through 44

Refer to Figure 19.

42. Apply Loctite 242 to the capscrews (2,6).
43. Properly position the the hose tray (3) and install
the capscrews and washers (2,6). Torque the cap-
screws (2,6) to 96---108 ft lb (130 ---146Nm).
44. Install the hose clamps and capscrews (5) along
Access
the length of the hose tray (3). Ensure that hoses
T1 Pin (4) are relaxed and not twisted before tightening
Hole
the clamps and capscrews (5).
45. Slowly retract the telescope cylinder, as required,
to position the T1 section as shown in Figure 20.
Visually inspect the hoses (4) and wire harness (1)
as the telescope cylinder is retracted to ensure
both are properly routed and secured. No moving
parts are to contact the hoses (4) or wire harness
(1).
Figure 20
46. After the T1 section is properly positioned, extend
Accessing T1 Pin Puller Assembly
the telescope cylinder out of the way.
47. Rebuild the T1 pin puller assembly by repeating
Steps 12 through 22 of the Disassembly procedure
beginning on Page 2.

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Service Manual 1207 SM17 --- 002 --- 083.00

6 7
5
4

3
2

1
8

10

1. Magnetic Sensor --- Flat 4. Washers 7. Wear Block 9. Sensor Brackets

2. Arm Stop 5. Bellcrank Arm 8. Bellcrank 10. Capscrews & Washers
3. Stop Bolts 6. C --- Channel

Figure 21
Bellcrank Arm Adjustment -- Steps 2 through 8

Bellcrank Arm Adjustment

The bellcrank arm of the latching mechanism must be Pin Puller
adjusted to ensure proper operation of the pin pullers.
This is accomplished by adding or removing washers C ---Channel
located under the stop bolts inside the arm stop. Wear Block

Refer to Figure 22.

1. With the pin puller in the “PINNED” position, care-
fully extend/retract the telescope cylinder while ob-
serving the wear block as it passes through the
c---channel of the T1 section pin puller. The optim-
um adjustment will allow the wear block to pass
through the pin puller without contacting the
c---channel. If contact must occur, it should only
slightly touch the top of the c---channel. The wear Figure 22
block must be adjusted so it will not contact the Inspect Wear Block Clearance
bottom of the c---channel at any time.

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SM17 --- 002 --- 083.00
Inspect With Latches In Released Position
Figure 23
Visually Inspect Wear Block Clearance Through Each C-- Channel Of All Pin Pullers
Refer to Figure 21.
2. Adjust the upper stop bolt (3) and washers (4) in-
side the arm stop (2) first.
3. Remove the stop bolt (3) and add washers (4) to
increase the clearance between the wear block (7)
and the top of the c---channel (6) or remove wash-
ers (4) to decrease. Optimum clearance between
the wear block (7) and the bottom of the c---chan-
nel (6) will be 0.040 in (1.0mm).
4. After adjusting the quantity of washers (4), install
the stop bolt (3).
5. Again, carefully extend/retract the telescope cylin-
der while observing the wear block (7) as it passes
through the c---channel (6) of the pin puller.
6. Repeat Steps 3 through 5 until the upper stop bolt
(3) is properly adjusted within the T1 section.
7. Extend and retract the telescope cylinder through
all four pin puller c---channels to visually inspect for
clearance with the remaining c---channels in the
T2, T3, and T4 sections:
a. The wear block (7) on the bellcrank (8) must
pass freely through all of the c---channels (6)
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1207 Service Manual
without excessively pushing in either the up-
ward or downward direction; the c---channels
(6) must not “bottom out”. There cannot be
any marring or binding between the wear
block (7) and c---channels (6).
b. If the wear block (7) excessively contacts any
of the c---channels (6), in the upward direction,
adjust the number of washer (4) on the upper
stop bolt (3) stack and check again.
c. If the wear block (7) excessively bottoms out in
the downward direction, on any of the c---
channels (6), adjust the number of washers (4)
from the lower stop bolt (3) stack and check
again.
8. After the upper and lower stop bolts (3) are prop-
erly adjusted, record the number of washers (4) on
each stop bolt (3). Remove the stop bolts (3) and
apply Loctite 242. Reinstall the stop bolts (3), with
the recorded number of washers (4), and torque to
40---44 ft lb (54 ---60Nm).
Service Manual
Inspect With Pins In Pinned Position
Figure 24
Inspect The Boom Pins And “NOT PINNED” Stop Bolt For Proper Adjustment
9. Extend/Retract the telescope cylinder, as required,
to position the T1 section as shown in Figure 20.
10. Operate the telescope cylinder and latching mech-
anism, as required, to position the boom pin of the
T1 Section where it is accessible through the ac-
cess hole in the top rear of the base section. Refer
to Figure 20.
11. Operate the latching mechanism so the “PIN
PRESENT”, “PIN CENTERED”, “LATCHED” and
“NOT PINNED” indicator lights on the boom tele-
scope remote control box are illuminated.
a. The top of boom pin must be flush with, or no
more than 0.125 in (3mm) above, the top of the
subweldment of the boom section.
b. If the boom pin protrudes beyond the subweld-
ment of the boom section, remove washers
from the lower stop bolt. See“not pinned” stop
bolt washer stack in Figure 25.
c. Switch the latching cylinder to “pinned”.
1207 SM17 --- 002 --- 083.00
d. Grasp the top of pin and check for freedom of
movement, as shown in Figure 24. If the wear
block and c---channel of the pin puller are in a
bind, movement of the boom pin will be very
difficult if not impossible. In this case adjust
the number of washers on the upper stop bolt.
See“pinned” stop bolt washer stack in
Figure 25.
12. Operate the telescope cylinder and latching mech-
anism, as required, to position the boom pin of the
T2 section where it is accessible through the ac-
cess hole in the top of the base section.
13. Repeat Step 11 for the boom pins of the remaining
boom sections.
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SM17 --- 002 --- 083.00 1207 Service Manual

Flat Magnetic Sensor 0.19-- 0.31 inch

(5---7mm)
“PINNED” Stop Bolt

“NOT PINNED” Stop Bolt

Flat Magnetic Sensor

Flat Magnetic Sensor

Adjustment Screws

Figure 25
Inspect The Two Flat Magnetic Sensors For Proper Adjustment

Refer to Figure 25.
14. Operate the telescope cylinder, and position the
latching mechanism, so one of the flat magnetic
sensors is sensing the bellcrank arm.
15. The flat sensors must have 0.19---0.31 in (5 ---7mm)
gap between it and the surface of the bellcrank
arm.
16. Remove the sensor adjustment screws and apply
Loctite 242 to the adjustment screws.
17. Properly position the flat sensor and install the ad-
justment screws Fully tighten the adjustment
screws once the sensor is correctly positioned;
torque to 11---12 ft lb (15 ---16Nm).
18. Repeat Steps 14 through 17 for the other flat
sensor.

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Service Manual 1207 SM17 --- 002 --- 083.00

0.06---0.18 in
0.06---0.18 in (1.5 ---4.5mm)
(1.5 ---4.5mm)

Jam Nut

Figure 26
Inspect The Four Round Magnetic Sensors For Proper Adjustment

Refer to Figure 26. 22. Reposition the round sensors by loosening/tight-

19. Locate the four round magnetic sensors within the
latching mechanism.
20. Operate the telescope cylinder, and position the
latching mechanism, so one of the round magnetic
sensors is located in its “sensing location”.
21. The round sensors must have 0.06---0.18 in
(1.5 ---4.5mm) gap between it and the surface it is
intended to locate.
ening the jam nuts on either side of the switch
mounting bracket. Fully tighten the jam nuts once
the sensor is correctly positioned.
23. Repeat Steps 20 through 22 for the other round
sensors.

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SM17 --- 002 --- 083.00 1207 Service Manual

0.12-- 0.25 inch

(3---6mm)

Front Of Boom

Figure 27
Inspect The Boom Pin Of The T4 For Proper Clearance

26. If adjustment is required to the T4 section stops,

the fly storage brackets must be adjusted after the
T4 section stops are properly adjusted.
27. Fully retract the boom. To facilitate the calibration
process, visually confirm that the T4 section is
Route And Secure latched and not pinned. Leave the manual control
Encoder Cable With box connected as well.
Cable Tie As Shown
Refer to Figure 4.
28. Install the access cover (3) on the top, rear of the
boom base section (1) and secure it with retaining
Disconnect Both Ends Of
strap (2).
Encoder Cable And Reinstall
Using Dielectric Grease. Refer to Figure 28.
29. Disconnect each end of the encoder cable and in-
Figure 28 spect for the presence of moisture; remove any
Encoder Cable Routing moisture found.
30. Apply an appropriate amount of dielectric grease
24. Operate the telescope cylinder and latching mech- to the inside of each connector and reconnect.
anism, as required, to ensure the T4 section is fully 31. Check that the encoder cable is routed and se-
retracted within the T3 Section. cured as shown in Figure 28.

Refer to Figure 27.

25. Inspect the gap between the back side of the T4
section boom pin. There must be a 0.125---0.25
inch (3 ---6mm) clearance between the pin and
weldment. If necessary, adjust the T4 section
stops located between the T3 and T4 sections.

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Service Manual 1207 SM17 --- 002 --- 083.00

Inside Left Upper Frame Rail

R102
744K A
744R B
1

R101
743A A
743B B
2
743C A R100
743D B

Resistor Module Wiring Diagram

1. Boom Latching Control Unit

2. Resistor Modules
3. Capscrews & Washers
4. Diode Pack
5. Wire Harnesses 3 4 5 6
6. Upper Frame

Figure 29
Resistor Modules

Refer to Figure 29 RCL Flash Card Installation

32. Label, for assembly purposes, all the connections
from the wire harnesses (5) to the boom latching
control unit (1).
33. Disconnect the wire harnesses (5) from the boom
latching control unit (1).
34. Remove the capscrews and washers (3) that se-
cure the latching control unit (1) to the upper frame
(6); remove the latching control unit (1).
35. Locate the resistor modules within the wire har-
ness (5) on the left rail of the upper frame (6), just
below the boom latching control unit (1).
36. Remove the three resistor modules (2) that have
the yellow wires numbered 743A, B, C, D, 744K,
and R. Install the new resistor modules provided.
Note: Cranes are also equipped with a diode
pack (4); do not replace it. Replace only the res-
istor modules associated with the specified
wire numbers shown on the resistor module
wiring diagram in Figure 29.
37. Position the new boom latching control unit (1) on
the upper frame (6) and install the capscrews and
washers (3).
38. Connect the wire harnesses (5) to the boom latch-
ing control unit (1).
39. Secure the wire harnesses (5), resistor modules
(2), and diode pack (4) with cable ties, as required.
40. Return the old boom latching control unit (1) to
your distributor.
1. The updated latching mechanism will require new
software.
2. Remove the four screws from the face of the RCL
display in the upper cab.
3. Lift the display up and out of the console and re-
place the old flash card with the new or repro-
grammed flash card provided.
4. Unplug the cable from the back of the display and
then plug it in again. This resets the display.
5. Install the display and secure with the four cap---
screws.
6. Return the old flash card back to your distributor.
Boom Telescope Cylinder Calibration
After the new boom latching control and RCL flash card
have been installed, the latching system must be
calibrated to define the boom telescope positions for
latching and pinning of the boom sections. See SM
Keysheet Area 17---002 for Boom Telescope Cylinder
Calibration. If an error message happens to be
displayed on the RCL Display during the calibration
process, Figure 30 is provided to give you a quick
reference to the meaning and solutions to error
messages. Complete operating instructions for the
RCL are available in the Crane Operator’s Manual.

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SM17 --- 002 --- 083.00 1207 Service Manual
Error Messages
Message Meaning How To Clear Message
Check all wires and connectors between the
Telescope valve section 1 current error. Control- telescope controller and the telescope valve so-
Cur1Err
ler is not detecting the correct current. lenoids. Error may occur during manual boom
operation. Shutdown and restart crane to clear.
Telescope valve section 2 current error. Control- Check wires and connectors between tele-
Cur2Err
ler is not seeing the correct current. scope controller and telescope valve solenoids.
RCL system has detected an overload condition
OvrLoad Decrease radius or reduce load.
while operator is trying to extend boom.
Check all wires and connectors to the Cylinder
Position Encoder. Using the remote control
Invalid Cylinder Position (Cylinder position was box, fully retract the boom, pin the boom, and
CylErr not received by the controller or position re- unlatch the telescope cylinder. Using the re-
ported is outside of the valid range.) mote control box, fully retract the telescope cyl-
inder until it bottoms out. Request to Zero Tele-
scope Cylinder Position.
Check all wires and connectors to the pedal. Do
not press the pedal to it’s maximum stroke in the
direction that gives the error.
Invalid Pedal Input Signal. (Anytime arm rest is
PdlErr
in the up position, PdlErr will be displayed). CAUTION
The boom section may start moving as soon
as the pedal is moved from maximum stroke.
Something is wrong internally in the telescope
Int_Err Internally Detected Error valve controller. Controller must be repaired or
replaced by a qualified technician.
Continue holding down extend/retract pedal for
Pin Pulled and Latch Pulled inputs both active at at least 30 seconds to ensure error does not cor-
LtchErr the same time or Latch Pulled signal expected rect itself. Check pin/latch relays first. Check all
but not received. wiring in the pin and latch switch circuits. Check
pin and latch switches.
Telescope pedal was not centered upon start-
PdlCtr? Center the pedal.
ing the crane.
Shutdown crane and restart to see if error cor-
Switch Error --- invalid or unexpected combina- rects itself. Check all switches for proper opera-
Sw_Err
tion of switch inputs. tion and that switch inputs are getting to the tele-
scope valve controller.
Using the remote control box, fully retract the
Telescope cylinder needs to be rezeroed. Oc-
boom, pin the boom, and unlatch the telescope
curs when a “Sw_Err” message appears when
Rezero cylinder. Using the remote control box, fully re-
operating the boom with the boom telescope re-
tract the telescope cylinder until it bottoms out.
mote control box.
Request to Zero Telescope Cylinder Position.
Figure 30
RCL Display Error Messages

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