RT555 - Operador y Mantenimiento - 12387

TEREX~CRANES
RT500 SERIES
OPERATOR AND MAINTENANCE
MANUAL
Revised: May 2002 12261-235

CONSTUCTION AND INDUSTRIAL EQUIPMENT
PRODUCT SAFETY
It is the responsibility of the owner of the con- signed and manufactured to perform heavy-duty
struction and industrial equipment products to be work. Under normal usage, the equipment will
knowledgeable about federal, state and local regu- wear. For this reason it is essential that the own-
lations that effect the total usage of his equip- er/user establish and perform a periodic inspec-
ment, and responsibility to working personal and tion of the equipment. The objective of inspection
the public. Since regulations are subject to programs is to prevent accidents, reduce down-
change, and also differ from one local to another, time and keep the equipment working efficiently.
this manual makes no attempt to provide such in- These inspection programs should be designed to
formation. discover worn, cracked, broken or deteriorated
parts and loose or missing fasteners before they
Terex Cranes provides appropriate operation and result in a problem.
maintenance manuals for various construction
and industrial equipment products that it manu-
factures and sells. In addition, where applicable, Proper training and inspection programs are es-
appropriate national consensus standards, indus- sential to avoiding injury to persons, damage to
try standards and safety related manuals are in- property and excessive maintenance costs.
cluded with the Terex manuals in the shipment of
each product. It is company policy to provide this
information for the owner or user of the equip- Read and understand the manuals provided with
ment. It is expected that the owner or user will uti- this equipment. Assistance is available from the
lize these manuals and standards to provide the distributors of your Terex product and from the
appropriate information and training to those peo- Terex manufacturing facility.
ple who are to operate, maintain and supervise the
use of equipment in a proper and safe manner.
Construction and industrial equipment is de-
When operating a hydraulic crane, the operator should realize that

hydraulic and structural competence, NOT TIPPING LOAD, is often
the determinant of lifting capacity.
Therefore, THE OPERATOR MUST BE GUIDED SOLELY BY THE AP-

PROPRIATE MANUFACTURER'S LOAD RATING CHART when consid-
ering load weights. The manufacturers rated loads must never be
exceeded.
Follow the recommended operating and mainte- various types of equipment, we ask that you in-
nance procedures and keep your machine operat- clude your machine model and serial number in
ing at MAXIMUM EFFICIENCY. Use the Suggested all correspondence so that we can provide the cor-
Crane Periodic Inspection Check List provided. In rect information.
addition, we STRONGLY URGE that a MAINTE-
NANCE LOG be kept in conjunction with all main- The information, specifications, and illustrations
tenance performed on the machine. in this publication are based on the information
in effect at the time of approval for printing. We re-
If you desire any special information regarding serve the right to make changes at any time with-
the care and operation of the machine, we will out obligation.
gladly furnish it upon request. Because we build
Issued: August 2000

SUGGESTED ROUGH TERAIN CRANE INSPECTION CHECK LIST
This check list is to be used in addition to the information provided in this manual to properly operate and maintain
the machine.
z fi: z fi:
ITEMS TO BE
0
i=LlJ ~ l-
(j)
II: ITEMS TO BE
0
i=LlJ ~ l-
(j)
II:
INSPECTED 00
LlJO
0
i1:
::::J
...., ~ INSPECTED 00
LlJO
0
i1:
::::J
...., ~
a.. 0 0 LlJ a.. 0 0 LlJ
& CHECKED (j)
(j)
« II: & CHECKED (j)
(j)
« II:
~ ~
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(j)
VISUAL INSPECTION
(Complete Machine)
* D
BOOM ANGLE
INDICATOR D
OVERALL HEADITAILIBRAKE LIGHTS

CLEANLINESS D & 4 - WAY FLASHERS D
HYDRAULIC SYSTEM HORN

(Leaks or Damage) D D
AIR SYSTEM CABLE SPOOLING

(Leaks or Damage) D PROPERLY D
HYDRAULIC WEDGE
FLUID D SOCKETS D
AXLE LOCKOUT AXLE FLUID

SYSTEM D LEVEL W
TRANSMISSION SWING REDUCER

FLUID LEVEL D FLUID LEVEL W
ENGINE CRANKCASE DRIVE SHAFTS

FLUID LEVEL D & U JOINTS W
FUEL TANK TIRE & WHEEL CONDITION &

FLUID LEVEL D INFLATION PRESSURE W
RADIATOR AIR
FLUID LEVEL D REGULATORS W
MACHINE AIR CLEANER

LUBRICATION D ELEMENT W
ATTACHMENT CLUTCH & BRAKE

PIN BOLTS D LINKAGE & PINS W
MUFFLER/EXHAUST WHEEL LUG

SYSTEM D NUT TORQUE W
ALL CONTROL FAN BELT

MECHANISMS D TENSION W
INSTRUMENT STRUCTURAL MEMBERS &

GAUGES D WELDS W
CLUTCHES BOOM INSPECTION

& BRAKES D W
WIRE ROPE, SHEAVES BATTERIES &

& GUARDS D STARTING SYSTEM M
TWO BLOCK DAMAGE ALCOHOL

PREVENTION SYSTEM D EVAPORATOR M
LOAD SUPPORTING SWING BEARING

COMPONENTS CONDITION D BOLT TORQUE P
FIRE EXTINGUISHER MACHINERY

D GUARDS P
BACKUP ALARM LOAD CHART &

D SAFETY WARNINGS P
* Inspect OVERALL machine (including carrier) for cracks, weld separation, leaks, damage, vandalism.
INSPECTION CODE INTERVALS NOTES:

D - DAILY M - MONTHLY 1. Indicate inspection result by checking in the satisfactory, adjust, or repair boxes provided.
W-WEEKLY P - PERIODIC 2. When appropriate, enter your diagnosis on back of page for repairs or adjustments made.
Revised: December 2002

REPAIRS - ADJUSTMENTS - REMARKS
ITEM REQUIREMENT DATE
Issued: August 2000

NOMENCLATURE
This manual contains instructions and informa- understanding of the material presented in the
tion on the operation, maintenance, lubrication following pages.
and adjustments of the Rough Terrain Crane. To aid in understanding the contents of this man-
The operator should not attempt to operate the ual, the following terms will always have the
machine before he has gained a thorough meanings given whenever they are used.
1.UPPERSTRUCTURE The upperstructure weldment, swing mecha-

nism, counterweight, cab.
2. BOOM ATfACHMENT The telescopic crane boom with hydraulic winch,

lift cylinder, hook block assembly, jib arrange-
ment.
3. CARRIER The chassis complete, power unit, swing bearing,

transmission, planetary axles, outrigger assem-
blies.
4. OUTRIGGERS The beams, cylinders, floats, boxes, hydraulic

control system.
RIGHT HAND /LEFT HAND All references to right or left hand will correspond
to the operator's right or left hand when he is fac-
ing forward from the operator's seat, with the rear
mounted engine to his back.
2
1
Issued: August 2000

- TABLE OF CONTENTS -
SAFETY
1
CONTROLS AND INSTRUMENT 2
OPERATING INSTRUCTIONS 3
PERIODIC MAINTENANCE AND LUBRICATION 4
TROUBLESHOOTING
5
SERVICE AND ADJUSTMENTS 6
MACHINE STORAGE 7
GENERAL INFORMATION & SPECIFICATIONS 8
WIRE ROPE USERS MANUAL 9
WORK PLATFORMS 10
Issued: August 2000

SAFETY
INDEX
SECTION 1
SUBJECT PAGE
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 1
Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 2
Handling Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 3
Training and Knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 3
Operator's Responsibilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 4
Signal Person's Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 5
Responsibilities of All Crew Members . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 6
Management Responsibilty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 6
Planning The Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Operator's Safety Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 8
Operator Aids Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 8
Operation Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 9
Operation Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Power Line Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 10
Slip and Fall Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 11
Travel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 11
Issued: August 2000

I INTRODUCTION I
Owners, Users, and Operators:
Terex Cranes appreciates your choice of our machine for your application. Our
number one priority is user safety, which is best achieved by our joint efforts. We
feel that you make a major contribution to safety if you as the equipment users and
operators:
1. Comply with OSHA, Federal, State, and Local Regulations.
2. Read, Understand, and Follow the instructions in this and other

manuals supplied with this machine.
3. Use Good, Safe Work Practices in a common sense way.
4. Only have trained operators - directed by informed and knowl-

edgeable supervision - running the machine.
NOTE: OSHA prohibits the alteration or modification of this crane without

written manufacturers approval. Use only factory approved parts to
service or repair this unit.
If there is anything in this manual that is not clear or which you believe should be
added, please send your comments to Manager of Publication, Terex Cranes, PO.
Box 260002 / Highway 501 East, Conway, South Carolina 29526; or contact us by
telephone at (843) 349-6900.
Thank you!
THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED!
A READ, UNDERSTAND, AND FOLLOW ALL DANGER,

WARNING, AND CAUTION DECALS ON YOUR
MACHINE.
Issued: August 2000 Page 1-1

INTRODUCTION
SYMBOLS
The symbols below are used to inform the operator of important information con-
cerning the operation of this unit.
DANGER Indicates an imminently

hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING Indicates a potentially

could result in death or serious injury.
CAUTION Indicates a potentially

may result in minor or moderate injury.
ATTENTION - Indicates a situation which, if

not avoided, may result in property or
equipment damage.
Page 1-2 Issued: August 2000

SAFETY
These are general safety rules, which must be followed.

You are also required to read and understand the Operators
Manual as there are instructions, which are more detailed
specific to this machine.
16 HANDLING PERSONNEL
1. Cranes can only be used to lift people when it is the least hazardous
way to do the job. (See OSHA 1926.550g, and ASME / ANSI 830.23.)
1 6 TRAINING AND KNOWLEDGE 1
1. Safety must always be the operators most important concern.
2. Do not operate this crane until you have been trained in its operation.
This crane must only be operated by trained personnel, who have
demonstrated their ability to do so safely.
3. Comply with the requirements of current Occupational Safety and

Health Administration (OSHA) standards, the current American
National Standards Institute (ANSI) 830.5 latest edition.
4. Read and Understand all Decals and Warnings.
5. Read and Understand the Rating Chart.
6. Know that the crane can safely lift each load before attempting to lift.

7. Operator must understand crane signals and take signals only from
designated signal people; except the operator must obey the stop signal
from anyone.
IA OPERATOR'S RESPONSIBILITIES
1. Read and understand the Operator's Manual.
2. Make sure the machine is in proper order and that all operational aids
and warning signals are functional before operating.
3. Keep the machine clean, including all instrumentation, windows, lights

and other glazed surfaces.
4. Remove all oil, grease, mud, ice and snow from walking surfaces.
5. Store tools and other necessary items in the tool box.
6. Never lift a load without a Rating Chart Manual in the cab.
7. Know the load to be lifted.
8. Be alert, physically fit and free from the influences of alcohol, drugs or
medications that might affect the operators eyesight, hearing, or
reactions.
9. Keep people, equipment and material out of the work area.
10. Signal person must be used when the operators vision is blocked or
working in hazardous areas such as power lines or people.
11. Keep a fully charged fire extinguisher and first aid kit in the cab at all
times, and be familiar with how to use these items.
12. Know about movements of other machinery, trucks and personnel at the
jobsite.
13. Never permit people on the machine platform while the machine is
working.

14. Make sure everyone is in a safe place before moving the hook, boom,
load or outriggers.
15. Start and stop movements smoothly and swing at speeds that will keep
the load under control.
16. Keep at least two full wraps of wire rope on drum when operating.
17. Feet must be kept on the pedals while foot pedal brake locks are in use.
18. Use tag lines to keep loads under control.
19. Keep load close to ground.
20. Use shortest boom possible.
21. Never leave a running machine unattended or load suspended.
22. Always use outriggers in accordance with requirements of Load Rating

Chart and operators manuals.
IA SIGNAL PERSON'S RESPONSIBILITY
1. Standard crane signals must be used, and understood.
2. Assist the operator in safe and efficient operation, without endangering

people or property.
3. Have a clear understanding of the work to be done.
4. Signal people must place themselves where they can be clearly seen
and where they can safely observe the entire operation.

1.6 RESPONSIBILITIES OF ALL CREW MEMBERS
1. Unsafe conditions or practices must be corrected.
2. Obey all warning signs.
3. Watch out for your safety and the safety of others.
4. Know and understand proper machine erection and rigging procedures.
5. Alert operator and signal person of dangers, such as power lines,

unstable ground etc.
1.6 MANAGEMENT RESPONSIBILITY
1. Operator's must be competent, physically fit and if required licensed.
2. Operator, signal people and riggers must be trained in correct crane

operation and use.
3. Operator and Signal people must know standard crane signals.
4. Have a supervisor at job site to be responsible for job safety.
5. Crew members given specific safety responsibilities and instructed to

report any unsafe conditions to supervisor.
6. Supply the weight on the load to be lifted to the operator.
7. Verify that all crew members are familiar with OSHA, ANSI 830.5
requirements as well as instructions in manuals.

IA PLANNING THE JOB
1. Have a clear understanding of work to be done.
2. Consider all dangers at jobsite.
3. Know what crew members are needed?
4. Assign responsibilities.
5. Know the weight of load to be lifted.
6. Determine lift radius, boom angle, and the rated lifting capacity of crane.
7. Establish how signal people will communicate with operator?
8. Utilize equipment which will do job safety.
9. Establish how equipment can be safety transported to job site?
10. Determine where gas lines, power lines, or structures are which must
be moved.
11. Ensure that surface is strong enough to support machine and load.
12. Determine how load will be rigged.
13. Establish special safety precautions, if necessary.
14. Consider weather conditions.
15. Keep unnecessary people and equipment away from work place.
16. Position machine to use shortest boom and radius possible.

IA OPERATOR'S SAFETY CHECK
1. Safety related items must be in place.
2. Check machine log book, to see if periodic maintenance and

inspections have been performed.
3. Ensure that necessary repairs have been completed.
4. Inspect wire rope for damage (kinks, broken wires etc.)
5. Be sure no unauthorized field modifications have been made.
6. Check for air and hydraulic oil leaks.
7. Check control positions before starting engine.
8. After starting engine, check all gauges and indicators for proper
readings.
9. Test all controls.
10. Check brakes and clutches.
11. Check load brakes by lifting a load a few inches off the ground and
holding it.
IA OPERATOR AIDS CHECK
Ensure that the listed items are in place and operational.
1. Boom hoist upper angle limit switch. (Lattice Boom).
2. Boom angle indicator.
3. Backup Alarms.
4. Anti-Two Block devices.
5. Overload Protection, Load Indicators, Rated Capacity Limiters

I A OPERATION OVERLOAD PREVENTION
1. Know the weight of the load.
2. Load radius will increase when the load is lifted. Reduce radius at start
of lift to allow for this.
3. Know the weight of hook, and rigging.
4. Know boom length, jib length, parts of line and operating area.
5. Use next lower rated capacity when working at boom lengths or radius
between the figures on the rated lifting capacity chart.
6. Never lift a load without knowing whether it is within the rated capacity.
7. Never operate with anything other than recommended counterweight.
Unauthorized reduction or additions of counterweight constitute a safety

hazard.
8. Do not lift loads if winds create a hazard. Lower the boom if necessary.
See the Rating Chart Manual for possible restrictions.
9. Avoid side loading.
10. Never let the load or any other object strike the boom.
11. Release load slowly, be sure boom never tightens against back stops.
(Lattice Boom).
12. Place the boom point directly above the load when lifting.
13. Be sure loads are freely suspended.

1& OPERATION SETUP
1. Be sure the load bearing surface is strong enough to support the

machine and load.
2. Be sure cranes are level, check frequently and relevel when necessary.
3. Stay away from rotating cranes, erect barricades to keep people away.
Make sure these area's are clear before swinging.
1& POWER LINE SAFETY
1. Determine whether there are power lines in the area before starting any
job. Only operate around power lines in accordance with Federal, State
and Local Regulations as well as ANSI B30.5 latest edition.
2. Never remove materials from under powerlines with a crane if the boom
or machine is capable of contacting them.
3. No part of crane or load must come in contact with, or violate the

minimum allowable clearance required for operation of crane dear
electrical lines.
4. Should contact occur stay on crane until the boom is cleared or until the
current is turned off.
5. If in contact keep all personnel off the crane. If you must leave the
crane, JUMp, DO NOT STEP OFF, leave area by jumping with feet
together.
6. Use a signal person when working around power lines.

1. Always wait until machine has stopped before getting on and off
equipment. Do not jump on or off.
2. Do not use controls and steering wheel as hand holds.
3. Keep the machine clean and dry.
4. Replace all broken ladders.
5. Keep non-slip surfaces in good condition.
1& TRAVEL
1. Care must be taken when cranes are driven (traveled) whether on or off
the job site.
2. Watch for people, power lines, low or narrow clearance, bridge or road
load limits, steep hills or uneven terrain.
3. Position boom in line with the direction of travel.
4. Inflate tires to specified pressure.
5. Travel slowly and avoid sudden stops and starts.
6. It is recommended that the seat belt be used during transit and travel.
7. Make sure travel surface can support weight of machine and load.
8. Always set parking brakes when parking machine.

INTRODUCTION
INDEX
SECTION 2
SUBJECT PAGE
UNIVERSAL SYMBOL IDENTIFICATION .............................................. 2 - 1
CONTROLS AND INSTRUMENTS ......................................................... 2 - 2
CONTROL AND INSTRUMENT KEY ..................................................... 2 - 3
ENGINE CONTROLS ........................................................................... 2 - 4
TRANSMISSION CONTROLS ................................................................ 2 - 5
AIR BRAKE SYSTEM ........................................................................... 2 - 5
STEERING CONTROLS ........................................................................ 2 - 5
OUTRIGGER CONTROLS .................................................................... 2 - 5
SWING CONTROLS ............................................................................. 2 - 6
ATIACHMENT CONTROLS .................................................................. 2 - 6
ACCESORIES ...................................................................................... 2 - 8
ANTI-TWO BLOCK SYSTEM ................................................................ 2 - 9
RT500 Series Issued: August 2000

CONTROLS AND INSTRUMENTS
This section is intended to familiarize the opera- Diagrams of the various carrier and upper con-
tor with the controls and instruments provided trols are illustrated on the following pages. A list
for the operation of this machine. It should be of these controls and instruments are shown
emphasized , however, that merely knowing the opposite each illustration. More detailed explana-
controls is inadequate preparation for operating tions of each control or instrument follow in the
hydraulic cranes. Do not attempt to operate the same order as they appear in the number key.
machine until the other sections of this manual
have been covered. Sections 1 and 3 are especial-
ly important with respect to machine operation.
I UNIVERSAL SYMBOL IDENTIFICATION I
~
ENGINE OIL
FLOODLIGHTS
//):) PARKING BRAKE
® PRESSURE
f COOLANT
-1=-
ELECTRICAL
ACCESSORIES ON
OUTRIGGERS
TEMPERATURE
-
ELECTRICAL
SYSTEM OFF 0 AIR PRESSURE WIPER
~
ELECTRICAL
SYSTEM ON CD HEADLIGHTS
0 WASHER
ffi
IGNITION ON
~
FAST
Iif
IGNITION
e SLOW .-.
ENGINE STOP AXLE
DISENGAGEI :H: AXl e 01$
.... RANGE
i:o
RANGE SHIFT SHIFT
RTSOO Series 2 - 1 Revised: August 2002

CONTROLS & INSTRUMENTS
28 29 36 37 43 42 45 43 26 27 40
38
RT500 Series 2 - 2 Revised: August 2002

CARRIER CONTROL AND INSTRUMENT KEY
1 IGNITION SWITCH 27 BUBBLE LEVEL

2 DIESEL STOP 28 SWING LEVER
3 COLD STARTING AID (OPT.) 29 HORN
4 PUMP DISCONNECT (ON REAR DECK) 30 SWING BRAKE PEDAL
5 ACCELERATOR 31 SWING BRAKE PEDAL RACHET RELEASE
6 HAND THROTTLE 32 SWING PIN LOCK
7 INSTRUMENT WARNING LIGHT 33 BOOM LOWER PEDAL AND LEVER
8 LOW COOLANT WARNING LIGHT 34 BOOM ANGLE INDICATOR ON BOOM (NOT
9 OIL PRESSURE GAUGE SHOWN)
10 FUEL GAUGE 35 BOOM RAISE PEDAL AND LEVER
11 ENGINE TEMPERATURE GAUGE 36 BOOM TELESCOPE LEVER
12 HOUR METER (ENGINE COMPARTMENT) 37 BOOM HOIST MOMENTARY SWITCH
13 VOLTMETER 38 MAIN WINCH LEVER
14 TRANSMISSION TEMP. GAUGE 39 AUXILIARY WINCH LEVER (OPT.)
15 TRANSMISSION OIL PRESSURE GAUGE 40 WINCH ROTATION INDICATOR(S)
16 TRANSMISSION SHIFT LEVER F-N-R 41 LIGHT SWITCH
17 TRANSMISSION GEAR SELECTOR LEVER 42 TURN SIGNALS
18 HI-LO RANGE SHIFT 43 DASH LIGHTS
19 AIR PRESSURE GAUGE (FRONT) 44 WORK LIGHT SWITCH (OPT.)
20 AIR PRESSURE GAUGE (REAR) 45 WIPER
21 LOW AIR WARNING LIGHT & BUZZER 46 DEFROSTER FAN
22 BRAKE PEDAL 47 HEATER CONTROLS
23 PARKING BRAKE / EMERGENCY 48 CIRCUIT BREAKERS
24 STEERING MODE SWITCH 49 FIRE EXTINGUISHER
25 OUTRIGGER EXTEND-RETRACT MASTER
SWITCH
26 OUTRIGGER SWITCHES
RT500 Series 2 - 3 Revised: August 2002

17
16
19
21
1. IGNITION KEY SWITCH - Turns "On" and "Off' 7. WARNING LIGHT - Indicates high engine tem-
electrical circuits. Stops engine. perature , high transmission temperature,
low engine oil pressure, low coolant. Stop
2. DIESEL STOP - Shuts off fuel to engine. Sole-
engine and check gauges on instrument
noid actuates governor lever.
panel.
3. "QUICK START'" - Recommended for ambient
8. LOW COOLANT WARNING LIGHT
temperatures below 32 F. Follow the manu-
factures instruction regarding its use and 9. OIL PRESSURE GAUGE
handling and storage of fluid capsules.
10. FUEL GAUGE
11. ENGINE TEMPERATURE GAUGE
12. HOUR METER (In engine compartment)
13. VOLTMETER - Indicates battery charging
condition.
14. TRANSMISSION TEMPERATURE GAUGE
15. TRANSMISSION OIL PRESSURE GAUGE -
Indicates transmission charge pressure.
4. PUMP DISCONNECT - For cold weather start-
Normal range is 240 to 260 psi.
ing or extended travel. Pull up to engage
pumps. The unit is equipped with a
mechanical type of disconnect. Engine must
be stopped to engage pumps (located on
rear deck).
5. ACCELERATOR - (Foot Throttle). Never drive the machine when the transmission
6. HAND THROTTLE - Vernier control with charge pressure is below 240 psi.
adjustment feature.
RT500 Series 2-4 Revised: August 2002

mal operating air pressure has been

reached on the air gauge. Then the service
TRANSMISSION CONTROLS brakes will release.
23. EMERGENCY / PARKING BRAKES - The

parking brake automatically engages when
the ignition is switched off. The dash switch
is for engaging the service brakes while the
ignition is switched on.
16. TRANSMISSION SHIFT LEVER - F-N-R - Do Optional centering indicator light located above
not make directional shifts between forward the shift quadrant
and reverse while the vehicle is in motion as 24 STEERING SWITCH - Provides the following:
damage to the drive train can occur.
17. TRANSMISSION GEAR SELECTOR LEVER -

1st, 2nd, and 3rd Gear ratios.
UPSHIFTING AND DOWNSHIFTING - Full power

shifts between ranges under load may be made
without endangering the transmission or drive
train components.
4-Wheel 2-Wheel Crab
Downshifts should not be made when the vehicle Steer Steer Steer
speed exceeds the maximum speed of the next
lower range. Downshifting at excessive speeds
will overs peed the drive train components with
possible resultant damage to drive shafts, trans-
mission, etc.
18. HI-LO RANGE SHIFT AND REAR AXLE DIS- Switch to crab or 4-wheel steering only when
CONNECT - Shifts only when transmission is axles are centered. Otherwise, steering will be
in neutral. Hi-Rangeautomatically shifts into limited and may lock.
2-wheel drive and Lo-Range into 4-wheel If wheels should become locked , switch to 2-
drive. The machine may have to be moved wheel steer, turn front wheels, switch back to
slightly to completely engage or disengage. Do crab or 4-wheel steer and center wheels.
NOT ATTEMPT TO SHIFT WHILE MACHINE
IS IN MOTION. Exercise caution when the upper structure is not
in the travel position as the steering will appear to
be reversed when boom is over rear.
AIR BRAKE SYSTEM

OUTRIGGER CONTROLS
19. AIR PRESSURE GAUGE (Front) - 105 - 125
psi optimum operating pressure.
25 OUTRIGGER EXTEND-RETRACT MASTER
20. AIR PRESSURE GAUGE (Rear) - 105 - 125 psi SWITCH - Selects direction of movement of
optimum operating pressure. cylinders (beams and jacks).
21. LOW AIR WARNING LIGHT & BUZZER - Will 26 OUTRIGGER SWITCHES - Four (4) switches
warn when pressure falls below 65 psi. control vertical jacks and right and left
22. BRAKE PEDAL - Actuates the air brakes. Do beams. Select cylinders (beams and jacks)
not attempt to drive the machine until nor- to be operated.
RT500 Series 2 -5 Revised: August 2002

38
47
48
27 BUBBLE LEVEL - The machine must be

levelled prior to lifting. ATTACHMENT CONTROLS
SWING CONTROLS
I 33 BOOM "LOWER" PEDAL AND BOOM "LOW-
ER" LEVER.
28 SWING LEVER - Push to swing right. pull to
swing left. When the upperstructure is swung
10 degrees off center. the rear axle pivot cylin- 34 BOOM ANGLE INDICATOR (PENDULUM
ders are locked into position to maintain sta- TYPE LOCATED ON BOOM) - Indicates boom
bility for crane work. angle relative to the upperstructure. (not
shown). May be part of Rated Load Indicator.
29 HORN if equipped).
30 SWING BRAKE PEDAL 35 BOOM "RAISE" PEDAL AND BOOM RAISE LE-
VER
31 SWING BRAKE PEDAL RATCHET RELEASE -
Pull and lock to permit operation of the pedal. 36 BOOM TELESCOPE LEVER - Push to extend
Release to allow pedal to be locked in applied boom. Pull to retract boom.
pOSition.
37 BOOM HOIST MOMENTARY BUTTON - Use
32 SWING LOCK - Positive mechanism engages in when the Two Mode switch is in the left posi-
carrier structure or swing gear teeth. Lower le- tion to allow momentary simultaneous inde-
ver to engage. raise to disengage. Never engage pendant normal speed boom hoist and
while swinging machine. telescope functions.
RT500 Series 2 -6 Revised: May 2005

37.BOOM HOIST MOMENTARY BUTTON - Use

when the Two Mode switch is in the left posi-
tion to allow momentary simultaneous inde-
pendant normal speed boom hoist and
telescope functions.
38. MAIN WINCH LEVER - Push to lower load.

Pull to raise load.
39. AUXILIARY WINCH LEVER (OPTIONAL)
40. WINCH ROTATION INDICATORS (OPTIONAL)

- Mounted on winch control levers.
41. LIGHT SWITCH
42. TURN SIGNAL SWITCH
43. DASH LIGHTS
44. WORK LIGHT SWITCH

47
48
ACCESORIES The amber FLAME SW indicator light must light

within 60 seconds after ignition. When it does, re-
lease the START -RUN-OFF switch to the RUN po-
45. WIPER sition. If the light goes off, again move the switch
to START and repeat the procedure until the light
46. DEFROSTER (OPTIONAL) stays on. Adjust the HI-LO control to the desired
temperature. Both indicator lights will remain on
Not Shown Tachometer (optional) until the burner cycles off under control of the
HI-LO control and the microswitch.
47. HEATER CONTROLS (OPTIONAL) - Turn the
HI-LO control to HI, and hold START -RUN- To shut off the heater, move the START -RUN-
OFF switch in START POSITION. The green OFF switch to the OFF position. The green HEAT-
HEATING indicator light must light immedi- ING indicator light should go out immediately.
ately. If it does not, refer to Section 5, "Trou- The heater may not shut off immediately because
bleshooting" . it incorporates purge cycle circuits. The blower
will continue to run until all the fuel in the burn-
47A. HEATER CONTROLS FOR DIESEL FUELED er is consumed and the heat exchanger cools suf-
HEATER - Use the preheat/choke switch to pre- ficiently to open the flame switch. When this oc-
heat the carburetor and burner head (refer to the curs, the blower motor will stop and the amber
Mfgs. Manual for the complete procedure) FLAME SW indicator will go out.
48. CIRCUIT BREAKERS
49. FIRE EXTINGUISHER

If the heater fails to produce heat within 30 sec-
onds, turn off power immediately to prevent
build-up of propane in the burner head. Refer to
Section 6 , "Troubleshooting", to determine the
cause of the malfunction.

OPERATING PROCEDURES
INDEX
SECTION 3
SUBJECT PAGE
PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
OPERATING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
COLD WEATHER STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
JUMP STARTING AN ENGINE WITH BOOSTER CABLES ........... 3 - 3
VEHICULAR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
MAKING A TYPICAL LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
CRANE HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
"ON TIRES" LIFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
HOIST LINE REEVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
HOIST LINE REEVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
WIRE ROPE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
AUXILIARY WINCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
TRANSPORTING THE CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
SIDE STOW OFFSET JIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
UNUSUAL OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 20
LOAD RATING CHART INTERPRETATION . . . . . . . . . . . . . . . . . . . . . . 3 - 23
RT500 Series Revised: February 2001

PRE-START INSPECTION
The following items should be checked each day been started and the transmission warmed to
before start-up and the start of operations. Also 180-200 deg. F allow the engine to idle and en-
see Section 4, "Daily Check." sure that the fluid level is between the "full" and
"add" marks.
ENGINE OIL The level should be at the full mark. FUEL FILTER Water should be drained from the
water separator on a Daily Basis. Both the water
COOLANT The level should be near the top of the separator and fuel filters have drain cocks locat-
radiator tank. ed at the bottom of each. Separator and filters are
located in the engine compartment on the right
LEAKAGE Make a ground check below the ma- side of the machine. For further information, See
chine for signs of leaks. Section 4, "Engine Maintenance Checks".
FUEL Engine fuel and propane/diesel for the up- ANTI-TWO BLOCK SYSTEM Inspect all anti-two
per unit heater should be adequate for sustained block switches found on boom, jib and auxiliary
operations. sheave heads for damage. Check the freedom of
counterweight attached to these switches; and al-
LUBRICATION Perform the daily lubrication as so, that counterweight is attached around correct
required in the Lubrication Recommendations. line of hoisting cable in the proper manner. In-
spect all electrical connections and wires as well
HYDRAULIC SYSTEM Check hoses, tubes, com- as the entire length of cable attached to the cable
ponents, reservoir sight gauge, valves, pumps, reel and it's connections for evidence of excessive
motors, connections, reservoir oil temperature, wear, damage or improper installation. Check
cylinder mounting bushings and pins. spring loaded cable reel for proper tension and to
insure that reel is free to rotate. Verify visual and
LINES AND BWCKS Inspect the hoist lines, audible warning devices by lifting each of the
hoist block, hook latch, and ball hook, as well as counter- weights.
the crane attachment in general for readiness.
NOTE: A warning light will appear on the dash
SAFETY EQUIPMENT Check the safety equip- mounted panel and an audible signal will be
ment, including all lights, brakes and hazard war heard thorn switch is in ON position.
ing devices.
The crane is equipped with a shut-off or discon-
TIRES The tires should be checked for proper nect system on the control linkage, a check of
pressure before traveling the machine. The tires this system should be made prior to lifting. Hoist
should only be checked when cold. Refer to the the hook block to the boom point so that actual
Tire Pressure Chart on the Load Rating Chart. contact between block and anti-two block coun-
terweight is made. If all functions are operating
WHEEL NUTS Torque wheel nuts to 400-500 Ft. properly, winch hoist will cease and boom cannot
Lbs. Tighten daily during the first 50 miles of ser- be extended or lowered. Should any of these
vice on new units and any time the wheels have functions continue, disconnect system is func-
been removed. Tighten nuts alternately around tioning improperly and a complete system check
the wheel. must be made. Boom retract, boom raise and
winch down functions remain active and will be
GENERAL CONDITION Inspect the machine in unaffected by the two block system.
general for wear, leakage and damage.
AIR TANKS Open the air tank drain cocks to

blowout moisture and sediment.
When performing disconnect test, care should be
TRANSMISSION OIL Check the transmission oil taken as damage may result if system malfunc-
level. If oil is 2-3 inches above the full mark there tions and the hook is drawn into the boom point.
is enough to start the engine. After the engine has
RT500 Series 3 - 1 Issued: August 2000

STARTING THE ENGINE
Once the pre-start inspection has been complet- up procedure, allow the engine to stop revolving
ed, the engine may be started. At ambient tem- before re-engaging the starter.
peratures over 32 deg. F. on Cummins Engines,
follow the starting procedure below: Do not engage the starter motor for more than 30
seconds at a time. Should the engine fail to start
1. Open the governor to the idle position. within 30 seconds, allow the starter motor to cool
for 2 minutes before attempting to start the en-
2. Move the transmission shift lever to the neu- gine again.
tral position.
Once the engine is started, check the gauges for
3. Put the parking brake switch in the "ON" posi- proper readings. If the gauges do not register nor-
tion. mal readings, stop the engine and determine the
cause. Avoid full Throttle operation when the en-
4. Turn the ignition switch to the "ON" position. gine is cold. Always allow the engine to reach nor-
mal operating temperature before commencing
5. Turn the ignition switch to the "START" posi- operations.
tion to start the engine.
NOTE: On machines equipped with a turbo-
Release the ignition switch key as soon as the en- charged engine, the oil pressure gauge MUST reg-
gine starts. If the engine stalls during the start- ister 10 psi (60 kpa) at idle speed to ensure full
lubrication of turbo-charger.
OPERATING THE ENGINE
If the engine oil pressure gauge does not register Throttle down to half speed or slower with no load
normal operating pressure within 30 seconds of for at least 5 minutes before stopping. This gives
starting, shut down the engine, determine the the engine a chance to cool off gradually before it
cause and effect repairs before re-starting the en- is stopped.
gine.
NOTE: This cool down period is extremely critical
When the engine reaches operating temperature, on machines equipped with turbocharged engines
operations may begin. While the engine is run- due to the excessive build up of heat during nor-
ning, check the gauges at frequent intervals and mal load operations.
be alert for any abnormal engine sounds or faulty
engine performance. Consult the engine manufacturer's manual for
further operating instructions.
NOTE: Most alternators have a speed which must
be exceeded to turn them on. It is recommended
that the engine be speeded up to at least 2/3
speed after start-up and before any extended peri-
ods of low rpm operation to maintain battery
charge.
When idling for extended periods, maintain an

idle speed sufficient to prevent the battery from
being discharged. Keeping the battery in a fully
charged state is important both for starting the
engine and for powering the emergency steering
pump.
RT500 Series 3-2 Issued: August 2000

6. Restart engine. Be alert for signs of pump cav-

COLD WEATHER STARTING itation as described in (3) above. Increase en-
gine speed GRADUALLY, allowing sufficient
At ambient temperatures below 32 deg. F. on all time to warm the system before commencing
Cummins Engines, the "Quick-Start" device operation.
should be used before engaging the starter. Push
the "Quick-Start" button for three seconds, re- JUMP STARTING AN ENGINE WITH
lease it and engage the starter. BOOSTER CABLES
Position the vehicle with the booster battery adja-

cent to the vehicle with the discharged battery so
that booster cables can be connected easily to the
batteries in both vehicles. Make certain vehicles
The handling and storage of "Quick-Start" should do not touch each other.
strictly conform to manufacturer's recommenda-
tions. 1. On both vehicles turn off all electrical loads.
Set the parking brake. Place transmission in
At very low temperatures, when the engine is dif- "PARK".
ficult to start and operator experience so indi-
cates, follow the starting procedure outlined be- 2. Determine whether the discharge battery has
low: the negative (-) or positive (+) terminal con-
nected to ground. The ground lead is connect-
1. Disengage the pumps. ed to the engine block, frame, or some other
good metallic ground. The battery terminal
2. Start the engine as described above, using the connected to the starter relay is the one which
"Quick-Start" device. ALLOW THE ENGINE TO is not grounded.
WARM UP. This is recommended so that opti-
mum engine power is obtained at low speed for 3. Be sure that the vent caps are tight and level
the protection of the hydraulic system. on both batteries. Place a damp cloth over the
vent caps of each battery making certain it is
clear of fan blades, belts and other moving
parts.
3. BE ALERT FOR SIGNS OF CAVITATION. The The following steps must be performed in se-
hydraulic oil provides lubrication for the quence.
pumps. When to heavy or stiff, it will not flow
fast enough to meet pump demand and a vac- 4. On a negative grounded system, connect both
uum or "cavitation" will be created. A "scream- ends of one cable to positive (+) terminals of
ing" noise indicates inadequate pump each battery.
lubrication, and, if allowed to continue for
more than a short period, will result in serious 5. Connect one end of the other cable to negative
damage to the pumps. (-) terminal of the booster battery.
If cavitation noise is noticed, the hydraulic oil 6. Connect other end of cable, away from bat-
must be warmed by use of a reservoir immersion tery, to engine block, frame or some other good
heater. When the reservoir is warm to the touch, metallic ground, except carburetor or tubing
the starting procedure may be continued. Refer on vehicle with discharged battery.
to the lubrication chart for the recommended oil
viscosity for the winter season. 7. Make certain that all cables are clear of fan
blades, belts and other moving parts of both
4. Stop engine. engines and be sure everyone is standing
away from vehicles. Then start the engine with
5. Re-engage pumps. the booster battery. Wait a few minutes, then
at tempt to start the engine of the vehicle with
the discharged battery.

when traveling, or to secure it to the bumper

8. After starting, allow the engine to return to idle ring, will result in excessive swinging of the
speed and remove the cable connection at the en- hook block and possible damage to crane.
gine block or good metallic ground. Then remove
the other end of the same cable from the booster
battery.
Continuing to pull the block up after contact has

been made may result in damage to the boom
WARNING - BATIERIES PRODUCE EXPLOSIVE head, sheaves and anti-two block switch.
GASES. These instructions are designed to mini-
mize the explosion hazard. Keep sparks, flames, 3. Check hydraulic outrigger beam retaining
cigarettes, etc. away from batteries at all times - pins.
protect eyes at all times - do not lean over batter-
ies during this operation. 4. Disconnect the main pump if the crane is to be
driven more than approximately 2 miles.
Both batteries should be of the same voltage.
5. Shift into high range (two wheel drive).
5. Connect one end of the other cable to negative
Both batteries should be of the same voltage. 6. Check the tires for proper inflation pressure as
indicated on the "Crane Load Chart".
VEHICULAR OPERATION 7. Check that the rear wheels are centered and
switch to 2-wheel steer.
The Rough Terrain Crane is capable of both off
road and limited on-road travel. The kind of trav- 8. Adjust the seat and mirrors for clear vision to
el undertaken will determine how the carrier is the rear.
operated.
9. Check that the transmission oil pressure is
Before moving the Before moving the crane, ei- within the normal operating range of 240 to
ther around the work site or between sites, care- 260 psi. Low pressure may indicate a worn
fully consider the terrain type, road conditions charge pump, clogged filter, or low oil level.
and any hazards likely to be encountered en-
route. Think the move through in advance and
carry it out safely.
PRE-MOVE CHECK LIST Before moving the

crane to and from job sites, make sure the follow- Never move the carrier if the transmission oil
ing safety check have been made: pressure is below 200 psi. Low pressure will
cause transmission slippage and consequent
NOTE: When properly adjusted the parking premature failure of the clutch packs.
brake will hold this machine on a 30%
grade, if the tires have adequate traction. MOVING THE CRANE TO A JOB SITE The pro-
It is recommended that when parked on a cedure for moving a crane is as follows:
grade that the wheels be chocked.
1. Start the engine, following the procedure given
1. Lock the upperstructure swing brake. Engage
in the topic "Starting the Engine".
the swing lock.
2. Allow air pressure build-up.
2. Secure hook block to the bumper loop. If this
is impractical, pull the two block system coun- 3. Apply the swing brake.
terweight up to within approximately 1" of the
load sheaves, or until block lightly contacts 4. Aplly the swing lock.
boom head. On machines equipped with con-
trol system disconnects, use override switch. 5. Apply the Service Brake.
Failure to pull the hook block up to the head

6. Release the Parking Brake. at excessive speeds will overspeed the drive train
components with possible resultant damage to
7. Select the desired transmission range. the drive shafts.
Good judgment in the selection of gear range and Do not travel for extended periods at wide open
route of travel is essential when operating off the throttle.
road.
Four wheel drive engagement is accomplished by
Though designed primarily for use in off-road a solenoid shifted coupling in the transmissions.
conditions, there may be instances when high- In the ranges F1 thru F3 and R2 and R3.
way travel is necessary. In such instances, the
crane is subject to the same regulations which
govern the operation of other heavy equipment on
public roads. Adequate lighting, flares, flags and
safety equipment should be on the cranes at all Observe the restrictions given in the following
times. chart during on-the-road operation. Maximum
permissible running intervals are given in terms
of miles and hours of travel time. Stop the crane
when either limit has been reached (whichever
comes first) and allow the crane to cool for the pe-
When operating on hard surfaces, use high range riod indicated.
F4 thru F6 two-wheel drive only. Failure to do so
Press. Running Cooling
may result in severe drive line "wind-up" and Tire Size Speed Period
PSI Interval
component failure.
20 2 HOURS 30 MIN.
MPH
The operator may start from rest in either forward 21 :00X25-28 PR 65
AVG.
or reverse in F4 or F2. MAX. 4 HOURS 1 HOUR
20 2 HOURS 30 MIN.
MPH
26:50X25-26 PR 50
AVG.
MAX. 4 HOURS 1 HOUR
In addition to conditions of terrain, gear selection

while traveling is also determined by transmis- 6. Stop the engine.
sion temperature. Normal operating temperature
is 160 to 200 deg. F. If the transmission temper- Before stopping the engine, put the transmission
ature rises above 250 deg. F. (121.1 deg. C.) while in neutral, and reduce the engine speed.
traveling, the crane must be stopped and allowed
to cool. Shift to neutral and run the engine at Always idle the engine for at least 5 minutes be-
1000-1200 rpm. The temperature should drop fore stopping it. This gives the engine a chance to
rapidly to the engine coolant temperature. If the cool down and prevents overheating which can be
temperature does not drop, trouble is indicated, caused by localized hot spots in the engine. The
and should be determined before moving again. idle speed must be high enough to charge the
Overheating generally occurs due to working in battery but not higher than half speed. This cool
too high a gear ratio. DO NOT SHUT OFF THE down period is extremely critical on machines
ENGINE WHEN THE TRANSMISSION IS OVER- equipped with a turbo-charged engine.
HEATING.
Mter several minutes at idle, the engine may be
shut off by pushing the engine stop button. Turn
the ignition switch to the OFF position after the
engine has stopped.
NEVER SHIFT BETWEEN FORWARD AND
REVERSE WHILE THE CRANE IS IN MOTION. VEHICLE TOWING If the vehicle is to be towed, it
wil be necessary to run the engine at idle speed to
Full power shifts under load may be made with- lubricate the transmission clutches. If the engine
out endangering the transmission or drive com- cannot be run, towing must be limited to 3 mph
ponents. However, downshifts should not be and and one mile (max. total). If exceeded drive
made when the vehicle speed exceeds the maxi- lines must be disconnected, tow at 20 mph max.
mum speed of the next lower range. Downshifting

TRAVELING AROUND THE JOB SITE
- Do not travel with boom above horizontal

unless the surface is firm, level and free of
bumps and potholes.
- Watch for overhead obstructions such as

When traveling around a job site, it is very trees, power lines, or bridges.
important that the crane operator is very
aware of what is happening with the crane - If the terrain is rough or uneven it may be
as well as with other vehicles and person- necessary to travel at a reduced speed to
nel on the job site. The crane operator prevent instability or damage to the crane.
should observe the following rules as well
as good common sense while moving a - Operating on steep grades requires caution
crane around a job site. because the oil in the engine or transmis-
sion will move to one side of the engine or
NOTE: See the "ON TIRES UFTS" instructions transmission. As a result, the engine or
found later in this section for instructions transmission may not be fully lubricated
on TTWVing the crane with a load. which could damage the engine or transmis-
sion.
- Carry the boom over the front only.
- The operator must be very careful on steep
- Lock the swing brake and swing lock. side slopes to avoid tipping the crane.
- Secure the hook block or ball to the bumper NOTE: This machine can travel on 15° side slopes
loop or raise the hook block or ball close to which have a firm level prepared surface.
the boom head sheaves before moving. Due to variations in surface, tire pressure,
bumps, potholes, etc., we recommend
- Make sure all outriggers are completely that travel on side slopes be limited to 5°
retracted before moving the crane. and that the boom be horizontal or below.
RT500 Series 3 - 5a Issued: August 2000

MAKING A TYPICAL LIFT
LIFT PROCEDURE In making lifts, the operator The outrigger beams MUST BE FULLY EX-
must successfully coordinate several crane func- TENDED, and the crane leveled prior to extend-
tions. These include the boom raise/lower, boom ing the boom or lifting loads. To achieve this con-
extend/retract, load hoist/lower and swing func- dition, the vertical jack cylinders should be
tions. Although experienced operators tend to op- extended only enough to lift the wheels off the
erate two or more of these functions simultan- ground.
eously, the lift procedure can be broken down
into the following sequence of operations.
OUTRIGGERS Set the outriggers as follows be-

I
FULL extension of the vertical jack cylinders
fore initiating any lifting operations:
should be avoided if not necessary to level crane
1. Remove the outrigger beam retaining pins (See and raise wheels clear of ground because oil ex-
the illustration below). pansion under extreme heat conditions can
cause cylinder seal failure. Check to ensure that
all beams are fully extended, swinging the upper
if necessary to visually check that each beam
reaches full extension. Level the crane using the
bubble indicator to determine when a level condi-
tion is achieved. While operating the crane, fre-
quently check and level the outriggers between
lifts.
I
The operator must exercise sound judgment in
positioning the outriggers. The outriggers should
not be set near holes, on rocky ground or on ex-
tremely soft ground. Setting the outriggers in
such locations may result in the crane tipping,
2. Set the outriggers with the boom over the end causing personal injury or property damage.
of the crane, not the side. The controls for the Where a firms footing or level ground is not oth-
out and down outriggers are mounted on the erwise available, it should be provided by sub-
dash. stantial timbers, solid blocking, or other
structural members sufficient to distribute the
Both the extend/retract switch and the appropri- load so as not to exceed the safe bearing capacity
ate function(s) switch must be actuated before of the underlying material, and to enable leveling
the outriggers can be operated. of the crane.
Proper positioning of the outriggers is critically

important to both the safety and effectiveness of
craning operations.
This is a safety feature to prevent accidental ac- Before making any crane lift, make sure the hook
tuation of the outriggers while the crane is in mo- is properly engaged with the slings, or lifting de-
tion because the STEERING IS NON- vice employed to make the lift. Be certain the
FUNCTIONAL WHILE THE OUTRIGGERS ARE hook latch is not supporting any of the load. Re-
BEING OPERATED. fer to the warning tag on the hook block.

winch drum, which could cause breakage of the

winch rope, or of unseating the rope wedge in the
A WARNING winch drum, which could result in the uncon-

trolled fall of the hook block and load.
HOOK LATCH IS INTENDED TO RETAIN LOOSE SLINGS 4. Raise the boom to the required angle, consult-
OR DmCEsUNDER SLACK CONDmONs.1T IS NOT
INTENDED TO lEAN Atm-FOUUNG DEVICE, SO, CAU· ing the boom angle indicator which indicates
noN SHOULD IE USED TO PREVENT THE LATCH boom angle relative to upperstructure.
FROM SUPPORTING ANY OF THE LOAD. PERIODIC
INSPECTION OF THE LATCH MUST 8E MADE TO
INSURE ITS PROPER OPERATING CONDITION 12400-2 The boom elevation is controlled by foot pedals or
hand lever. To RAISE the boom, slowly depress
the LEFT boom control pedal or pull the lever
3. Use the load rating chart attached to the crane back. To LOWER the boom, slowly depress the
to interpret the conditions and limitations that RIGHT boom control pedal or push the lever for-
exist when making a lift with the crane. The ward. Improved control is obtained by operating
determining factors are lifted load, radius, the engine at low speed while "metering" the con-
boom angle, working position, hoist line reev- trols. Always operate and release the controls
ing, tire pressure, travel data, and use of a jib. slowly to minimize dynamic effects of the load.
During a lift where precise control of the load is
The examples given in this section pages 3-21 required, do not attempt to use more than one
thru 3-29 are given for your interpretation of the function at a time.
terminology used on the chart. CAUTION: The
load rating chart values used in the examples
may not be the same as those on your load rating
chart. Use the numbers from the chart attached
to your crane whenever making lift calculation
Always consider possible obstructions when

varying boom height or length; not only those to
the front of the cab at the time of the adjustment,
but those which may be encountered during
swings.
Always consider, anticipate, and/or determine by
trial the maximum amount of wire rope which Think the swing through, considering all obsta-
will be payed off the winch drum to perform each cles, before making the swing.
different craning application of this crane. Be
sure to provide for no less than two full wraps of
wire rope remaining on the winch drum as spec-
ifIed in all applicable crane operating safety stan-
dards.
The increased possibility for inadequate wraps Never hold the controls in an "activated" pOSition
remaining on the winch drum occurs when oper- once the hOist/lower cylinder or extend/retract
ating with a higher number of parts of line than cylinders have reached the limits of their travel.
are required for the load being lifted, particularly This can cause overheating of the hydraulic oil if
at longer boom lengths and high boom angles. it is run over relief for prolonged periods.
Sufficient wire rope is initially prOvided to allow
the hook block to reach ground level when reeved 5. Swing the boom over the load.
for the required parts of line indicated on the ca-
pacity chart for all given loads. Reeving with more Upperstructure swing is controlled by the swing
parts of line than required may result in all of the lever. To swing the upperstructure to the RIGHT,
wire rope being payed off the winch drum. PUSH the lever forward. To swing LEFT, PULL the
lever backwards. Swing speed increases as the le-
The intent of this caution is to prevent any pos- ver is moved further forward or back. Swing
sibility of either reverse winding of the rope on the speed also varies with the engine speed.

Before attempting to swing the upperstructure,

make sure the swing brake is not set and the
swing lock is not engaged. Be certain that no ob-
structions will block the swing.
I
While extending the boom, be sure to payout suf-
When ready, try for a smooth, controlled, safe ficient hoist rope to prevent the hook block from
swing. The swing should be SLOW. Start the being drawn up to the boom peak. The force of
swing SLOWLY and allow the load to build up the extend cylinders can easily break the hoist
only enough momentum to carry it through to the line, dropping the hook block and load which
point where it is to be lowered. may result in personal injury or property dam-
age.
Begin slowing the swing in advance of the point
where the load is to be lowered. Slow the swing Be sure full powered sections are extended equal-
GRADUALLY, so that it appears to "coast" to a ly before lifting load. If sections are out of phase
stop over the desired spot. by more than one of the triangular decals, then
the sections must be resynchronized by either
GRADUALLY slow the swing by use of the swing fully extending or fully retracting the boom.
lever. First, move the lever to the neutral position
and then VERY SLOWLY into the opposite swing The boom extend function on this crane has two
direction position as required to slow the swing. positions and two speeds. When the lever is all
Apply the swing brake, with the foot pedal, when the way forward, the regenerative mode provides
the swing is stopped or when emergency situa- increased speed. With the lever approximately
tions dictate that the swing be terminated one half of the way forward, increased "PUSH" is
abruptly. available at reduced speed.
If properly executed, the load will hang motion- 7. Lower the hook block to the load and fasten the
less when the swing is terminated. If the load is hook.
oscillating, the swing was made too rapidly and/
or stopped too abruptly. Make certain the hook is properly engaged with
the slings, or lifting device employed to make the
lift. Be certain the hook latch is not supporting
any of the load. Refer to warning tag on hook
block.
Stopping the swing too abruptly will cause the Hoisting or lowering of the load with the winch is
load to oscillate and impose side loads on the controlled by the winch lever. LOWER the load by
boom. Because side loading can damage boom, pushing the lever FORWARD and RAISE the load
ALWAYS START AND STOP SWINGS GRADUAL- by pulling the lever BACK. Improved control is
LY. obtained by operating the engine at low speed
while "metering" the control. Always actuate and
release this lever slowly to minimize dynamic eff-
ects of the load and to prevent "birds-nesting" of
the cable on the winch drum.
Never pull sideways with a crane boom. Crane
booms are not designed for excessive side pull To shift the winch into the high-speed mode the
and may collapse if subjected to excessive side winch lever is moved through the normal "low
loading. speed" pOSition and then further, shifting a sec-
ond valve spool. When slowing the winch, reverse
6. Extend the boom to the desired length. Do not the above procedure to bring the load to a gradual
extend the boom further than necessary to stop. When the winch is operated in this mode,
perform the lift. available line pull is reduced to apprOximately
one- half of the normal value. NOTE: Two speed
EXTEND the boom by pushing the extend-retract winch will operate in low speed mode ONLY if op-
lever FORWARD and RETRACT it by pulling the erating telescope, auxiliary winch or a clam bucket
lever BACK. Simultaneously with the winch functions.

8. Lift the load to the desired height. For safety, When operating a hydraulic crane, the operator
lift the load no higher than necessary. should realize that hydraulic and structural com-
petence, NOT TIPPING LOAD, is often the deter-
The crane is equipped with a two block system, in minant of lifting capacity.
the event that the hook or block is raised beyond
a safe position, a warning light appears on the Therefore, THE OPERATOR MUST BE GUIDED
dash and, if horn switch is activated, an audible SOLELY BY THE APPROPRIATE MANUFACTUR-
warning will sound. Some cranes may be ER'S LOAD RATING CHART OR BY THE LOAD
equipped with control disconnects which will pre- RATING PLATE MOUNTED ON THE CRANE
vent the winch from raising the load and the when considering load weight. The manufactur-
boom from extending or lowering. To continue er's rated loads must never be exceeded.
crane operation, retract or raise the boom and/or
lower the hook. Cranes which are factory equipped with auxiliary
winches may require additional counteweight if
If the operator wishes to raise the hook block be- the auxiliary winch is removed. Refer to the ca-
yond the point at which the two block is activat- pacity chart (load rating plate) for the required
ed, he may override the system by using the key counterweight total.
switch (shown in control and instrwnent sections).
When lowering light loads, be sure to maintain

Continuing to pull the block up after contact has sufficient cable tension to prevent the cable from
been made with the boom head may result in becoming loose on the cable drum. Loose cable
damage to boom head and sheaves or the cable can slip and then bind suddenly, causing ''jerky''
may be broken causing the load to drop. lowering and shock loading of the boom. Loose
wraps may form loops which can be overlain
9. Swing and spot the load over the location when the cable is wound onto the winch drum.
where it is to be deposited. These conditions can result in personal injury or
property damage.
10. Lower the load and unfasten the hook.
When spotting the load it may be necessary to al-

ter the boom length or boom angle. In making
these adjustments, the operator must guard
against exceeding the rated load as determined
by the load rating charts.

CRANE HAND SIGNALS
..,.
-j.
..
l~ ""j~\--"
• I~'
HOIST. Wtth forearn vertical fore USE MAIN HOIST. Tap fist on USE WHIPLINE. (Auxiliary RAISE BOOM. Arm extended,
finger pointing up, move hand in head; then use regual signals. Hoist) Tap elbow with one hand, fingers closed, thumb pointing
small horizontal .circle. then use regular signals. upward.
1- \
It (
MOVE SLOWLY. Use one hand to RAISE THE BO ~
! ,.
ANi ER LOWER THE BOO AND'li E,
give any motion signal and place THE LOAD. Wtth arm extended, THE LOAD Wtth arm extended,
LOWER BOOM. Arm extended other hand motionless in front of thumb pointing up, flex fingers in thumb pointing dowm, flex fingers SWING. Arm extended, point with
fingers closed, thumb pointing hand gving the motion signal. (Hoist and out as load movement is in and out as long as load finger in direction of swing of boom.
downward. slowly shown as example.) desired. movement is desired.
~/ • )I
TRAVEL.( Both Tracks.) Use both
TRA'fIjArm extended forward,
STOP. Arm extended, palm EMERGENC s!6P. Both arms hand open and slightly raised, fists in front of body, making a
down, move arm back and forth extended, plams down, move arms make pushiing motion in direction DOG EVERYTHING. Clasp circular motion about each other,
horizontally. back and forth horizontally. of travel. hands in front of body. indicating direction of travel, forward
or backward. (for land cranes only.)
~'
TRAVEL. (One TrackiLock the
track on one side indicated by
raised fist. Travel oppostte track in EXTEND BOOM. (Telescoping
'f
I. '1'1
,1/ {I
RETRACT BOOM. Telescoping
i. o"
~'.
~"
k, \
\ )
EXTEND BOOM. (Telescoping
Boom.) One Hand Signal. One
I
RETRACT
/\~I
Bod~. (Telescoping
direction indicated by circular Booms.) Both fists in front of body Booms.) Both fists in front of Boom.) One Hand Signal. One fist in
body with thumbs pointing fist in front of chest with thumb front of chest, thumb pointing outward
motion of other fist, rotated in with thumbs pointing outward. tapping chest.
front of body. (land cranes only.) toward each other. and heel of fist tapping chest.
KNOW THE CRANE SIGNALS! Poor communica-

tion between the operator and personnel directing
lifts can result in property damage or personal in-
jury.

"ON TIRES" LIFTS
Listed below are special precautions for "On

Tires" lifts.
All crane load ratings are based on nonuse of the

travel function while handling loads. However,
cranes may be utilized for pick and carry opera- Insufficient tire pressure reduces the "ON TIRES"
tions. Traveling with suspended loads involves so capacity. Attempts to pick rated capacity without
many variables such as ground conditions, boom properly inflated tires may cause crane to tip
length, momentum in starting and stopping, etc., and/ or result in damage to tires and rims.
that it is impossible to devise a single standard
rating procedure with any assurance of safety.
For such operations the user must evaluate pre-
vailing conditions and determine safe practices,
exercising precautions, such as the following:
The axle lockout system should be bled and filled
I.The boom shall be carried straight over the whenever oil seepage, dirt or oil is detected at the
front of the crane. breather plug or on the rod.
2. Travel speed reduced to suit conditions. Air in the axle lockout system decreases stability.
Bleed and fill the system IMMEDIATELY when-
3. Maintain specified tire pressures. ever this condition occurs.
4. Avoid sudden starts and stops.
5.Provide tag or restraint lines to snub swinging

of the load.
Excessive high hydraulic oil temperatures cause
6. Keep the load as close to ground as possible. rapid deterioration of rubber components (hose,
O-rings, etc.). A hydraulic oil cooler is required if
7. Set the swing brake and swing lock. high cyclic operations (clam, concrete bucket,
unloading) are performed. If hydraulic reservoir
8. Travel must be on a smooth level surface that temperature reaches 200 deg. F, reduce the duty
is capable of supporting the weight of the load- cycle. Stop operations as required to prevent fur-
ed crane. The travel surface must also be free ther increase in the hydraulic oil temperature.
of holes or debris that can cause crane insta-
bility.
These precautions are necessary to prevent a

"pendulum" effect of a swinging load. The results
of this happening can cause a machine tip over.
Any variation from the above conditions will re-

quire the operator to consider the prevailing con-
ditions and reduce the lift capacities accordingly.

HOIST LINE REEVING
AUXILIARY WINCH SEE PAGES 3-13 AND 4-33

FOR CABLE AND SOCKET
MAIN WINCH SPECIFICATIONS
DEAD END FOR

EVEN PARTS
OF LINE
DEAD END FOR

5 SHEAVE ODD PARTS
OF LINE
WINCH
,
-~
PARTS LINE
2
BOOM HEAD
3D
HOOK BLOCK
CABLE SOCKET 3 23 3D
4 14D 14
NOTE: 5 234 24D

SHEAVES IN BOOM HEAD AND HOOK
BLOCK ARE NUMBERD FROM LEFT 6 234D 234
TO RIGHT AS VIEWED FROM THE OP-
7 1234 234D
ERATOR'S STATION. "D" INDICATES
PINNED END OF ROPE. 8 1234D 1234
9 12345 1234D
10 12345D 12345

L -_______ H
__
o_Is_T__L_IN_E
__R_E_E_V_I_N_G________ ~I LI______~__ R_E_R_O_P_E
__S_P_E_C_I_FI_C_~_T_I_O_N_S____~
MAIN~NCH
When reeving the crane in preparation for any
job, it should be kept in mind that hoisting and STD.-SIB" dia. 6X19 OR 6X37 CLASS
lowering speeds decrease as the number of parts
IWRC REG. LAY WIRE ROPE
of line increases. For the most efficient use of the
MINIMUM BREAKING STRENGTH-17.9 TONS
crane, it is therefore desirable to use the mini-
mum required number of parts for lifting the load
OPT.- SIB" ROTATION RESISTANT
as determined by referring to the load rating
COMPACTED STRAND IBX19 OR 19X19
chart.
MINIMUM BREAKING STRENGTH 22.7 TONS
This crane incorporates a "Quick Reeving" boom
head and block which do not require removal of
AUXILIARY ~NCH
the wedge and socket from the rope in order to
change the reeving. Removal of two pins in the
boom head and three in the hook block will allow
STD.-1/2" 6X19 OR 6X37 CLASS
the wedge and socket to pass through.
OPT.-9/16" ROTATION RESISTANT

COMPACTED STRAND IBX19 OR 19X19
MINIMUM BREAKING STRENGTH IB.5 TONS
Never use less than the number of parts called for
by the load rating chart.
If it is not practical to alter the reeving during the

course of the work, the required number of rope
parts must be determined on the basis of the
heaviest load to be lifted during operations.
UNDER NO CONDITIONS CAN ANY OTHER SIZE,
TYPE, OR LENGTH OF WIRE ROPE BE USED ON
When the required number of rope parts has THIS EQUIPMENT SINCE IT CONSTITUTES A
been determined, reeve the rope as shown on SAFTY HAZARD
page 3-14. attach a wedge type rope socket to the
wire rope dead end and secure it to either the
boom peak or hook block as required. Dead end
the rope on the hook block for an odd number of
line parts, and on the boom peak for an even
number of parts.
As shipped from the factory, the crane has suffi-

cient wire rope provided to allow the hook to each
ground level with any boom length and elevation
when reeved with minimum parts of line required
for the load being lifted. Refer to the Crane Ca-
pacity Chart for parts of line required.
RT500 Series 3 - 13 Revised: February 2001

TRANSPORTING THE CRANE
Restrain the boom extend sections by snugging

the hook block against the boom head, or secure
the boom head back to the base section of the
The boom must be stowed in the boom boom with chains or cable. An extended(ing)
rack before transporting the crane. boom can cause substantial damage.
The boom extend sections should be restrained to

prevent gradual roll-out when transporting the
crane on a semitrailer. The hydraulic system will
not hold the sections against the hard breaking
jolts while the crane is being transported.
SIDE STOW JIB
DESCRIPTION
Two optional jib extensions are available to pro-

vide additional boom reach. One is a 32ft (9.75
m) side stow swing-on one-piece lattice type jib
that is offsettable at 0 0 , 15 0 , or 30 0 •
The second jib option is a 33-57 ft. (10.05 -

17.37 m) side stow swing-on lattice type jib. The
jib is extendible to 57 ft. (17.37 m) by means of
a 25ft. (7.62 m) manual pullout tip section.
Each optional jib extension is pinned directly to

the ends of the sheave pins. When not in use,
the jib can be unpinned from the boom head
and stored on mounting brackets on the right
side of the boom base section.
The 32ft (9.75 m) jib weighs 1,280 pounds (581

kg). The 33-57 ft. (10.05-17.37 m) jib weighs Before erecting or stowing
2,070 pounds (939 kg). the jib, ensure that no
personnel or obstacles are in
the swing path of the jib.

ERECTING THE JIB
~ ! : b Mounting Pins (4)
r Anti Two-block Plug
Anti Two-block
Switch T - Handle
f----- Guide Rope Booming down to quickly can result in

damage to jib.
1. Extend and set the outriggers.
10. With the engine at idle, slowly boom down to
2. Rotate the upper structure to the "over rear" minimum boom angle while another operator
position. uses the guide rope to control the speed of the
jib rotation. The jib will swing around until
3. Retract the boom completely. the left side mounting holes line up.
4. Boom down to minimum boom angle to allow 11. If cable from main boom is to be used on jib,
ease of installation of the jib pins. If necessary remove cable from boom head load sheaves
raise rear outriggers till boom head can be and swing over top left jib cord before pinning
reached from ground level. jib to boom. Install the left upper and lower jib
mounting pins.
5. Install the upper and lower jib mounting pins
in the right side of the boom head. 12. Remove the guide rope.
6. Attach a guide rope to the eye on the bottom tip 13. Disconnect the anti two-block plug from the
of the jib. jib anti two-block socket and connect it to the
socket on the boom head. Move the dummy
7. Extend outriggers if retracted, to bring crane plug from the boom head socket to the anti
back to level. Raise the boom to horizontal. two-block socket on the jib.
8. Pull down and rotate the T - handle to unlock 14. Reeve the hoist line over the jib sheave.
the jib from the storage bracket.
15. Test the anti two-block system by lifting the
9. With the engine at idle, slowly extend the boom anti two-block weight. The light and audible
2-3 feet (.6-1 m). As the jib clears the storage alarms should be actuated in the cab and the
brackets, the jib will swing out approximately boom down, boom extend, and winch up con-
45°. trols should disconnect.

OPERATING INSTRUCTIONS
CHANGING THE OFFSET

OF JIB
Attach hoist line

dead end
Jib Offset
Pin Holes
Sheave Shaft
INCREASING OFFSET hole and place in the ISO hole or if you are
using 30° offset then place pins in tool box.
1. Retract the boom and set the outriggers.
7. With the engine at idle, slowly winch down to
2. Boom down to minimum boom angle. payout hoist cable. This will lower the tip of
the jib until the jib comes in contact with the
3. Loosen the two (2) cap screws on the left side of jib offset pins.
the upper and lower sheave shafts. This will
require a 3/4 inch hex wrench. NOTE: While lowering the tip of the jib, it may be
necessary to raise the boom to prevent the
4. Reeve the hoist line over the top center sheave tip of the jib from touching the ground.
on the boom head, around the jib sheave, and
attach to the eye on the bottom of the jib tip. 8. Remove the hoist line from the tip of the jib and
reeve the hoist line as needed.
S. Winch up to take the slack out of the hoist line
and to take the weight of the jib off of the jib DECREASING OFFSET
offset pins.
1. Reverse above procedure to return jib to 0° off-
NOTE: To prevent damaging the jib, do not winch set position.
up any more than is necessary to loosen
the jib offset pins.
6. Remove the jib offset pins from the 0° offset
RTSOO Series 3 - 16 Revised: February 2001

OPERATING INSTRUCTIONS
EXTENDING AND RETRACTING THE JIB PULWUT SECTION
Anti Two-block Weight
~
Pull out
Anti Two-block
Plug
Anti Two-block
Extended Socket
Anti Two-block
Retracted Socket
EXTENDING THE PULLOUT SECTION RETRACTING THE PULWUT SECTION
NOTE: The jib must be erected before extending the 1. Retract the boom completely and boom down
pullout section. Do not attempt to extend to minimum boom angle.
the pullout section while the jib is stowed.
2. Unplug the anti two-block plug from the anti
1. Retract the boom completely and boom down two-block Extended socket. Move the dummy
to minimum boom angle. plug from the retracted socket to the extended
socket.
2. Attach the dead end of the wire rope to the eye
on the bottom of the jib tip. This is done to pre-
3. Attach the dead end of the wire rope to the eye
vent the pullout from extending uncontrollably.
on the bottom of the jib tip.
3. Unplug the pull out anti two-block plug from
the anti two-block Retracted socket. Move the 4. Remove pullout retaining pin from the erected
dummy plug from the extended socket to the retaining pin hole.
retracted socket.
5. Winch up slowly to retract the pullout until the
4. Remove pullout retaining pin from the retain- retracted retaining pin holes line up and install
ing pin hole. retaining pin.
5. Payout cable and extend the pullout until the 6. Plug the anti two-block plug into the anti two-
retaining pin holes line up. Install retaining block Retracted socket.
pin.
7. Test the anti two-block system by lifting the
6. Plug the anti two-block plug into the anti two-
anti two-block weight. The light and audible
block Extended socket.
alarms should be actuated in the cab and the
7. Test the anti two-block system by lifting the boom down, boom extend, and winch up con-
anti two-block weight. The light and audible trols should disconnect.
alarms should be actuated in the cab and the
boom down, boom extend, and winch up con-
trols should disconnect.

STOWING THE JIB
Anti Two-block Plug
Anti Two-block Socket
Wear Pad
T - Handle
Anti Two-block -------jrllf?"
Switch
l~ Guide Rope
STOWING THE JIB 6. Disconnect the anti two-block plug from the
boom head and plug it in to the jib anti two-
block socket. Move the dummy plug from the
jib anti two-block socket to the boom head anti
two-block socket.
7. Extend the boom to 2-3 feet (.6-1 m).

Before erecting or stowing the jib,
ensure that no personnel or 8. Attach the guide rope to the eye on the bottom
obstacles are in the swing path of tip of the jib.
the jib.
9. Remove the left upper and lower jib mounting
1. Extend and set the outriggers. pins. With guide rope, pull left jib ears out of
left boom head ears.
2. Rotate the upper structure to the "over rear"
position. 10. With the engine at idle, slowly boom up while
a second operator holds the guide rope to con-
3. Make sure the stinger is in the stowed position trol the rotating speed of the jib.
and the jib offset is at 0° offset.
11. Boom up to approximately 30°. Allow the jib
4. Boom down to minimum boom angle. to swing around until the jib contacts the
wear pad on the boom. As the jib gets close to
5. Remove the hoist line from jib sheave and lay the side of the boom, make sure the jib does
to left side. not strike the side of the boom.

STOWING THE JIB
12. With the engine at idle, slowly retract the

boom completely. The jib will engage the jib
storage brackets as the boom is retracted.
13. Remove the guide rope from the tip of the jib.
Bracket mounted
to boom
14. As the boom is retracted, verify that the stow-

age bracket mounted to the jib is engaging
properly with the stowage bracket mounted to
the boom.
15. Rotate and release the T- handle to lock the

jib to the storage brackets.
16. Remove the right upper and lower jib mount-

ing pins.
17. Test the anti two-block system at the boom

head by lifting the anti two-block weight. The
light and audible alarms should be actuated
in the cab and the boom down, boom extend,
and winch up controls should disconnect.

UNUSUAL OPERATING CONDITIONS
Special problems in maintenance and operation repair any cooling system component found to be
are caused by unusual conditions such as ex- defective.
tremes in heat, cold and humidity, high altitude,
salt water, and dusty or sandy work sites. When 2. Condensation in the fuel tank contaminates
operating under such conditions, special precau- the fuel supply with water, which can freeze in
tions must be taken to prevent damage, minimize the fuel lines and block the fuel flow to the en-
wear, and avoid component deterioration. gine. To minimize this possibility, keep the
tank as full as is practical during cold weather.
EXTREME COLD In periods of extreme cold, the This may entail refilling the tank more fre-
problems of freeze damage, adequate lubrication quently than usual, but the inconvenience is
and battery failure may become particularly trou- small compared to clearing a blocked fuel line.
blesome. With the onset of very cold weather, it is
advisable to "winterize" the crane by servicing the If water should be noticed in the fuel supply,
cooling system and switching to the lubricants drain the tank and refill it with uncontaminated
recommended for cold weather usage. Follow the fuel.
recommendations in this manual when the crane
must be operated in very cold conditions. 3. Lubricate the crane with the lubricants recom-
mended for cold weather operation on the Lu-
1. To prevent freeze damage to the cooling system brication Chart. If necessary, change the en-
and cracking of the engine block or head, gine oil and other lubricants in order to con-
drain and flush the cooling system. Clean the form to the recommendations.
radiator exterior, making certain the air pas-
sages through the core and the cooling fins are 4. The battery is more likely to sustain freeze
free of foreign matter. damage if not kept fully charged because its
electrolyte will freeze at a higher temperature
Refill the cooling system, adding an anti-freeze than that in a fully charged battery. Be certain
solution recommended by the engine manufac- the battery is charging when the engine is run-
turer in an amount and strength appropriate to ning and use an external charger to restore
the anticipated temperatures. A corrosion inhibi- full charge when the crane is not being operat-
tor is recommended. ed.
The battery can discharge if snow or ice short cir-

cuits the terminals. Keep the battery posts and
cable connectors clean and dry. Remove any cor-
rosion with a solution of soda and water.
Never use a chromate base corrosion inhibitor During extremely cold weather, it is advisable to
when the coolant contains ethylene glycol. Use remove and store the battery in a heated area
only non-chromate base inhibitors. Chromate when the crane is to remain idle overnight or for
base inhibitors reacting with ethylene glycol can any extended period.
produce chromium hydroxide, commonly known
as "green slime". This substance reduces the heat AIR BRAKES At least once a day, drain the water
transfer rate and can cause serious engine over- accumulation from the air tanks, and check the
heating. alcohol evaporator fluid level. Fill with methyl al-
coholonly.
Inspect the thermostat, clamps, radiator hoses
and radiator core for proper condition. Replace or

5. Special attention must be given to the hydrau- eratures. Refer to the Lubrication Chart and
lic oil during very cold weather. lubricate the crane using the lubricants rec-
ommended for the expected temperatures.
Crankcase oil is particularly important because

it helps dissipate heat. Check the oil level fre-
quently and add oil as necessary to maintain re-
quired level. Too little oil will hinder heat dissipa-
NEVER ENGAGE THE HYDRAULIC PUMP AND tion.
ACTUATE THE HYDRUALIC SYSTEM BEFORE
THE HYDRAULIC OIL IS WARM. Cold, sluggish 2. To ensure proper coolant circulation, drain
oil can cause pump cavitation. If the crane is not and flush the cooling system, clean any for-
equipped with a reservoir immersion heater and eign matter from the radiator cooling fins and
running the oil over relief will not warm it suffi- through core air passages, replace defective
ciently to prevent pump cavitation with the en- hoses, tighten hose clamps, tension the water
gine running very slowly, cease attempts to pump drive belt properly, eliminate any leaks
engage the pump until an external heat source detected and fill the system with a 50% solu-
can be obtained. tion of ethylene glycol. A corrosion inhibitor is
recommended.
Once the reservoir is warm to the touch, actuate
the hydraulic system by engaging the hydraulic Engine overheating due to loss of coolant will
pump. Continue warming the oil and slowly cycle most often be corrected by SLOWLY adding cool-
all crane functions, actuating all cylinders in ant while the engine is running at FAST IDLE.
turn, swinging the upper and operating the Should this fail to correct the problem, drain and
winches in both directions. flush the system and refill with fresh coolant
(50% solution of ethylene glycol) and a corrosion
The hydraulic oil may be run over relief to aid in inhibitor.
the warm-up process. To do this, actuate a func-
tion, allow the cylinders involved to reach the lim-
its of their travel and hold the control in the en-
gaged position for a few seconds.
When running hydraulic oil over relief to warm it,

be sure to restrict the flow to as slow a speed as Allow the engine to cool before draining and
possible by moderating pressure on the controls flushing the cooling system.
being engaged and running the engine at low
speed. Water containing more than small concentra-
tions of salt or minerals should not be used in the
6. At the end of the work period, or whenever the cooling system. Salt facilitates corrosion and
crane is to be left idle for extended periods, minerals deposited on the coolant passage walls.
prevent it from being frozen to the ground by Both processes inhibit proper cooling.
parking it on a wood, concrete, asphalt or mat
surface. 3. Air circulation around the engine and battery
must not be restricted. Keep air intake and ex-
EXTREME HEAT Like extreme cold, requires haust openings clear of leaves, paper or other
that precautions be taken with respect to the foreign matter which may restrict air flow.
cooling system, the battery and lubrication. Pro-
tect the crane by performing the following recom- 4. Keep the engine clean of dirt, grease and other
mended procedures: substances which inhibit heat dissipation.
1. High temperatures necessitate the use of lubri- 5. Use sound judgment in operating the engine.
cants which are both more viscous and which Avoid the two extremes of racing and lugging.
resist deterioration at higher operating temp-

Advance the throttle only enough to handle the cation and service should be adjusted according-
load, yet be certain that the engine speed is high ly.
enough to maintain adequate fan speed for cool-
ing. HIGH HUMIDITY OR SALTWATER In some loca-
tions, such as coastal areas, the crane may be ex-
Run the engine only when engaged in work oper- posed to the deteriorating effects of salt,
tions or when traveling the crane. Avoid pro- moisture, or both. To protect exposed metallic
longed periods at idle and shut the engine down surfaces, wiring, hoist rope, paint and other
if operations are interrupted. items, keep them dry and well lubricated where
salt or high humidity are encountered. Follow the
SANDY OR DUSTY WORK SITES The presence recommendations below when operating in these
of large amounts of sand or dust at the work site conditions:
can contribute to accelerated component wear.
Either substance will act as an abrasive when de- 1. Make frequent inspections for rust and corro-
posited on moving parts of the crane. The prob- sion and remove them as soon as they are de-
lem is combated by more frequent lubrication tected. Dry and paint exposed surfaces after
and by the servicing of breathers and filters at rust and corrosion have been removed.
shorter intervals. Follow the recommendations
below when operating in sand or dust on a regu- 2. Where paint may not be applied, such as on
lar basis. polished or machined surfaces, coat the area
with grease or lubricant to repel water.
1. Keep sand and dust out of the hydraulic sys-
tem by keeping the reservoir filler cap tight 3. Keep bearings and their surrounding surfaces
and servicing the hydraulic system filters fre- well lubricated to prevent the entry of water.
quently.
4. Hoist rope must be kept well lubricated to pre-
2. The fuel system should be kept free of sand vent moisture and salt from penetrating the
and dust by keeping the tank filler cap tight cable strands.
and servicing the fuel filters frequently.
HIGH ALTITUDES Variations in altitude alter the
3. The engine breathers and air cleaner should fuel-air mixture burned in the engine and affect
also be serviced frequently to prevent sand the engine's performance. At high altitudes, at-
and dust from entering the engine. The engine mospheric pressures are lower and less oxygen is
oil and oil filter should be changed at shorter available for combustion of the fuel. Above
than normal intervals to ensure a clean oil 10,000' the engine fuel injectors may have to be
supply to the engine's moving parts. changed to ensure proper performance. Consult
engine manufacturer should this problem arise.
4. When lubricating the crane, thoroughly clean
each grease fitting before attaching the grease Keeping the air cleaner clean and free of obstruc-
gun. Pump generous amounts of grease into tions will help alleviate high altitude problems.
all lubrication points, using the fresh grease to
pump out the old. At high altitudes, closely monitor the engine tem-
perature for overheating.
5. Adequate ground bearing support must be
provided for the outrigger floats when operat-
ing in sand. Be alert for signs of carrier move-
ment during operations.
The increased frequency of lubrication and ser-

vice discussed above should be determined by
observations made at the work site. Inspection
will determine how long it takes for lubricants,
breathers and filters to accumulate unacceptable
amounts of sand or dust. The frequency of lubri-

of the crane is always the end opposite the en-

LOAD RATING CHART INTERPRETATION gine.
In the following pages are examples of a load "Front" when the crane is on outriggers is the
chart, these example charts may differ from the area inside the are bounded by lines from the
chart supplied with your crane. Always use the centerline of rotation through the front outrigger
load rating chart supplied with the crane to inter- vertical jack cylinders.
pret the conditions and limitations that exist
when making a lift with the crane. The determin- "St. over Front" when operating on tires means
ing factors are lifted load, radius, boom angle, the boom and load must be positioned straight to
working position, hoist line reeving, tire pressure, the front of crane and not swung to right or left.
travel data, use of a jib, and any other special
conditions that exist, such as wind velocity, soil 360° means the load can be swung to any posi-
conditions, etc. tion around the crane.
DEFINITIONS OF LOAD CHART TERMS

Deducts:
Lifted Load: The "on outriggers" rated capacities are for lifting
The lifted load is the total weight of all the items over the main boom point. Jibs, if so equipped,
suspended on the wire rope. are in the stowed position. Any specialty items at-
tached to the boom head should be removed. In
Example certain instances, it is advantageous, from a job
set-up point of view, to lift over the boom point
Hook block 7501bs. with the jib erected. In these instances, it is nec-
Slings 2151bs. essary to make deductions from the rated loads
Object Lifted 19.000Ibs. shown in the load rating chart to determine the
Lifted Load 19,965Ibs. correct rated load. Hook blocks or any specialty
items should be removed from the jib point when
Radius: lifting over the main boom point.
The radius is the horizontal distance from the
center of the swing bearing to the center of the
lifted load. REDUCTION IN MAIN
BOOM CAPACITY
ALL JIBS IN STOWED
POSITION 0 Lbs.
33'-58' OFFSET JIB
JIB ERECTED
WITHOUT STINGER _ _ 3,000 Lbs.
33'-58' OFFSET JIB
JIB ERECTED
Deflection of the crane boom will tend to increase STINGER RETRACTED _ _ 4,800 Lbs.
the radius as the load is lifted. To minimize this, 33'-58' OFFSET JIB
use the combinations of boom angle and length JIB ERECTED
STINGER EXTENDED _ _ 6,300 Lbs.
shown in the load rating chart. Do not allow the
AUX. BOOM HEAD
radius to exceed that given for the rated load. SHEAVE 110 Lbs.
Boom Angle HOOK BLOCK WEIGHTS

The boom angle is the angle of the boom mea- HOOK & BALL 239 Lbs.
sured from horizontal. Use the angles shown to HOOK BLOCK (3 SHEAVE) _ _ 650 Lbs.
approximate the loaded radius, but do not rely HOOK BLOCK (4 SHEAVE) - - 700 Lbs.
solely on a boom angle indicator to determine ra- HOOK BLOCK (5 SHEAVE) _ _ 750 Lbs.
dius. Always measure the actual radius when de-
termining main boom capacities. Also, there are deductions for jib operation due to
hook blocks hanging on the main boom point. In
Front and 360°: this circumstance, reduce the jib capacity by the
The "crane working position" diagram is a view weight of the hook block and/or other specialty
looking straight down on the crane with the up- items hanging from the main boom point.
perstructure and the boom removed. The "front"

CRANE WORKING POSITIONS
BOOM LENGTH ~
R
A ON TIRES
~.#.....-- 4
'}~ 21 :00
0 i'...,.WITH OUTRIGGERS WITHOUT OUTRIGGERs,. I-'"
~."z.s. ~R 26.5
I
~tl FRONT v; 60:\J ~ FRO ~.360·

OVER
(;
OOM
~o·
ST. OVER
OOM
It
D XN
I BG ~
u 0 T ~t
I PICK & CAR~
ARY CREEP 12.5 MPH STATIO
67 I~ 90;eC0· ~ FRON FRONT
10 75,OC S ~ f{ 360' J 1\ ST. OVER FRONT 360'
12 63 76,100· 76,100· 71 73)Q.C .0,
10 o /If.,400· 56,700· 49,709" 38,500· e
15 57 64,200· 63,200· 67 61,7C ............. '!2 33' 27,300 64,~ 49,200· ~O· 30,800· ~
20 46 45,800· 45,300· 60 46,1C . "?cENTER OF ' / ~ 1533' 18,400 49,700 40;700· 35,300· 21,000 4
25 31 34.700· 34,400· 52 35,1C ROTATIO 2045' 10,BOO 2B,500 2B,500 26,500· 12,400 2
30 43 27.8C 2545' 6,700 19,000 19,000. 19,000 7,800 1
32 30 45' 3,900 12,BOO 12,800 12,BOO 4,700 1
35 22.5C
THESE LINES DETER~INE THE LIMITS OF 3545' 2,400 9,500 9,500 9,500 3,000
WORKING POSITIONS WHICH CORRESPOND TO 40 57' 1,300 7,200 7,200 7,200 1,800
THOSE SHOWN ON THE CRANE CAPACITY CHART. 45 57' 5,500 5,500 5,500
50 57' 4,200 4,200 4,200
Cut-Offs:
Rated chart values of less than 1,000 lbs. for on
outriggers, side-stow and stow-away jibs are not
shown. On rubber values less than 600 lbs. are
not shown. This is done because the effects of
wind, pendulum action, jerking, etc., can cause a
tip over. Therefore:
SIDE STOW JIB ON OUTRIGGERS
33' OFFSET JIB 58' OFFSET JIB
I
MAX BOO),I I: MAX BOOM &: MAX BOOW a: IiIAX BOOM I: BOO"~y
WAX OfFSET WAX BOOt.! &
0" orFSET IS' orfSET 30' OffSET a orfSET IS" 30' OffSET
138.6' 137.S' 13"'.9' 163.6' 161.9' 156.5'
RAO RAO RAO RAO RAO RAO
REf 3&0' (REf) 360' (REf) 360' (REf) 360' (REf) 360\ REf) 360'
75 38 9,000· 46 7,200· 52 6,000" 50 5.000" 64 4,000" 75
73 43 7,700· 50 6,600· 57 5,500· 55 4,700· 69 3.BOO· 79 3.200·
73
Extending the boom or boom andjib combina- 70
67
50
57
6,300·
5,400*
56
63
5,700"
4.900·
63
69
4,900·
4,400·
63
71
4,300·
3,900*
76
83
3,500·
3.200·
86
92
2,900·
70
2,700·
67
tion into unrated areas of the chart can 64
61
63
70
4,500·
3,900~
69
76
4.200·
3,500"
75
81
3.800·
3.300"
78
86
3,300·
2,800·
90
97
2,800·
2,400"
98
104
2.500·
64
2.200·
61
cause tip over. See Note 19 on Load Chart. 58
54
50
46
76
3,300·
83
2,700·
90
2.100·
97
1.700·
81
88
95
101
3,000·
2,500·
1,600·
. 86
93
99
105
2.800·
2.300·
1,900·
1,500·
93
102
110
117
2.400*
1.900·
1,500·
1.100·
103
111
118
2,100·
1.600*
1,200·
110 1,900·
58
~ t ,sao· 54
123 1.200· 50
46
42 103 1.200· 107 1.200· 110 1,100· 42
LOAD CHART NOTE
19. CRANE LOAD RATINGS WITH AN ASTERICK (*) BESIDE
THEM ARE BASED ON THE CRANE'S STUCTURAL
STRENGTH. ALL OTHER RATINGS ARE BASED ON STABIL-
ITY AND DO NOT EXCEED THE SPEWCIFIED PERCENTAGE
OF TIPPING LOAD AS DETERMINED BY SAE CRANE STA-
BILITY TEST CODE J -765A.
Note on the accompanying examples that a sig-

nificant portion of the range of the machine is un- ON TIRES
rated. The side stow jib at 30° offset, with full R III
A AE 21 :00 X 25-28PR 26.5 X 25-26PR R
A
D XN
boom is longer than 123 ft. but is cutoff at 123 ft. I BG
I PICK & CARRY I PICK & CARRY D
STATIONARY 1 CREEP 12.5 MPH STATIONARY CREEP 2.5 MPH ~
radius. The "On Tire" chart shows the crane can- U 0T
S °H 360' ST. OVER FRONT 360' ST. OVER FRONT 5
not be operated beyond a 60 ft. radius on tires. 10 33' 36,300 74,400' 56,700· 49,700' 38,500· 65,600· 49,700· 41,600· 10
12 33' 27,300 64,900· 49,200· 42,900· 30,BOO· 57,000· 42,900' 35,800' 12
1533' lB,400 49,700 40,700· 35,300· 21,000 47,300' 35,300· 29,200' 15
2045' 10,800 28,500 28,500 26,500· 12,400 28,500 26,500· 21,600' 20
I 2545'
3045'
35 45'
40 57'
45 57'
50 57'
6,700 19,000 19,000 19,000
3,900 12,800 12,800 12,800
2,400 9,500
1.300 7,200
5,500
4,200
9,500
7,200
5,500
4,200
9,500
7,200
5,500
4,200
7,800 19,000
4,700 12,BOO
3,000
1,800
9,500
7,200
5,500
4,200
19,000 16,400·
12,800 12,400·
9,500
7,200
5,500
4,200
9,500
7,200
5,500
4,200
25
30
35
40
45
50
Do not operate at a longer radius than those 55 69' 3,100 3,100 3,100 3,100 3,100 3,100 55
listed on the applicable load rating charts as 60 69' 2,300 2,300 2,300 2,300 2,300 2,300 60
tipping can occur without a load on the hook.

On Outriggers Load Ratings: 6. Determine load radius, boom angle, and boom
To determine the boom extension capacities with length.
the crane on outriggers, use the following proce-
dure: 7. Compare load weight with chart rated capacity
for the boom length, radius, and boom angle.
1. Determine weight of load to be lifted.
8. The lifted load must not exceed the chart rated
2. Determine weight of slings and rigging hard- capacity for the boom length and radius.
ware.
In this example, the lifted load of 25,300 lbs. is
3. Determine weight of hook block. less than the rated load of 27,800 lbs. and can be
handled as long as the machine is on outriggers
4. Determine other capacity deductions. per Notes 6 & 7, the load stays at 30 feet of radius
or less, the conditions of Note 18 are met and the
5. Calculate weight of lifted load. machine is equipped per Lift Chart specifications.
LOAD CHART NOTES

CHART 6. CRANE LOAD RATINGS ARE BASED ON THE CRANE BEING LEV-
ELED AND STANDING ON FIRM, UNIFORM SUPPORTING SUR-
SPECIFICATIONS FACE.
7. CRANE WAD RATINGS ON OUTRIGGERS ARE BASED ON ALL OUT-
RIGGER BEAMS FULLY EXTENDED AND THE TIRES RAISED FREE
OF THE SUPPORTING SURFACE.
IFIl KOEHRING
~ CRANES ,INC.
PIN 12262-884 18.PRACTICAL WORKING WADS DEPEND ON THE SUPPORTING
SURFACE. WIND VEWCI1Y, PENDULUM ACTION, JERKING OR
SUDDEN STOPPING OF WADs. HAZARDOUS SURROUNDINGS.
MODEL LORAIN LRT 445 EXPERIENCE OF PERSONNEL AND PROPER OPERATION, TIRE IN-
FLATION, TIRE CONDITION. TRAVELING WITH WADS, MULTIPLE
45 TON CRANE P.C.S.A. CLASS 10-175 CRANE LIFTS, PROXIMI1Y OF ELECTRICAL WIRES, ETC. APPRO-
COUNTERWEIGHT: PRIATE REDUCTION OF WAD RATINGS MUST BE MADE FOR
THESE AND ANY OTHER CONDITIONS WHICH MAY AFFECT PRAC-
W/AUX. WINCH 10,900 lb •. TICAL WORKING WADS.
W/0 AUX. WINCH 12,000 lb ••
BOOM LENGTH 33-105 Ft.
OUTRIGGER SPREAD 22 Ft.

STABILITY PCT.
ON OUTRIGGERS 85%
ON TIRES 75%
CAUTION
WITHOUT OUTRIGGERS, NEVER ~ANUEVER BOOM INTO
A POSITION WHERE NO LIFT CAPACITY IS SHOWN.
TIPPING CAN OCCUR!
Example
Hook Block 7501bs.

: BOOM LENGTH BOOM LENGTH
Slings 3001bs. o 33' # 45'
I
Object Lifted 242501bs. u
S FRONT 360' • FRONT 360'
10 6790,000' 90,000' 7475,000' 75,000'
12 6376,100·76.100·1173,000·72.900·
Load Lifted = 25300 Ibs. 15
20
5764,200'63.200' 67 61,700'61,700'
46 45,800' 45,300' 6046,100' 45,600'
0' 34,400' 52 35,100' 34,800'
30 7,800 7,600'
32, 22,400'
1517,600'17,500'
~--30' ----*-- RADIUS

JIBS SIDE-STOW JIB

To determine the jib capacities of the crane with
all boom lengths, use the following procedure:
1. Determine weight of load to be lifted.
2. Determine weight of slings and rigging hard- Jibs are rated by boom angle #? only and not by
ware. radius. This means that as long as the boom is at
6P boom angle and the jib at 30° offset, before
3. Determine weight of hook block. loading, no matter if the boom is fully extended or
retracted, it can only lift a maximum of 3,300 lbs.
4. Determine capacity deductions. on a 33 foot side-stow jib. The radius shown in
the jib chart is the expected radius with a fully
5. Calculate weight of lifted load. extended boom and jib after loading and deflec-
tion.
6. Determine jib type and length, jib offset. main
boom angle.
7. Select correct jib load chart (stowaway or side-

stow).
Never use ajib for clamshell or magnet operation.
8. Compare load weight with chart rated capacity The heavy side load due to swinging and bounc-
for the jib length, boom angle, and jib offset (if ing that can occur could damage jib or boom
applicable). point. This is also true of pick and carry opera-
tions.
Example
Hook & Ball 2391bs.

Slings 3001bs.
Object Lifted 2,5001bs
Load Lifted = 3,039Ibs.
In this example the total load

lifted is 3,039 lbs. The boom
angle is 61 0, the jib is at the 30°
offset and the machine is on
outriggers. In this case the load
can be safly lifted.
3,039
POUNDS

JIBS In the following example the crane is set up as fol-

To determine the jib capacities of the crane with lows:
all boom lengths, use the following procedure: 1. On outriggers.
2. Side stow jib erected at 30° offset.
1. Determine weight of load to be lifted. 3. AUxiliary boom head sheave erected but not
used.
2. Determine weight of slings and rigging hard- 4. Hook block off the main head but not used.
ware. 5. Boom angle of 61°.
3. Determine weight of hook block. At first glance it appears that the 2,350 lb. object
to be lifted is well within the capacity of the jib
4. Determine capacity deductions. however after making the deductions for the
erected and unused equipment and figuring the
5. Calculate weight of lifted load. additional weight for slings and the hook & ball
this lift CANNOT be made.
6. Determine jib type and length, jib offset, main
boom angle. Note: Deductions for erected but unused equip-
ment can either be deducted from the capacity OR
7. Select correct jib load chart (stowaway or side- added to the weight to be lifted. In this case we
stow). will add the weight to the load.
8. Compare load weight with chart rated capacity

for the jib length, boom angle, and jib offset (if
applicable).
This lift cannot be made.
EXAMPLE
Hook & Ball 239lbs.

Slings 300lbs.
Auxiliary Head llO lbs.
Hook Block 750lbs.
Object 2,350lbs.
Actual Load = 3,749lbs.
3,749
POUNDS

ON TIRES
I
On tires operation, particularly pick and carry, Ensure that the tires are inflated as shown in the
must be done in a slow, smooth manner over level recommended tire pressure chart. Refer to pro-
terrain that will support the crane, with the loads cedure for tire inflation in Section 4, Page 4-12.
close to the ground and the boom as low as pos-
sible to avoid the load swinging unintentionally,
causing injury or tip over. Do not pick and carry
with the jib since the load is further extended RECOMMENDED TIRE PRESSURE
from the machine and the jib can be easily dam- TIRE SIZE STATIONARY CREEP 2 1/2 MPH TRAVEL
aged. 21:00 X 25-28 PR 85 PSI 85 PSI 85 PSI 65 PSI
26:50 X 25-26 PR 65 PSI 65 PSI 65 PSI 50 PSI
"Creep" means the crane can be moved at a max-

imum speed of one (1) MPH for a distance of 200
feet and then a 30 minute waiting period is nec-
essary to cool the tires. Overheating will greatly
reduce the life of the tires.
The maximum boom length shown on the On Tire

chart is the maximum boom length that can be
used at the radius shown. This is done to limit
the boom height when working on tires. Do not
exceed the maximum boom length for the given Never move the crane carrying a load with the
radius. boom in any position except straight over the
front.
ON TIRES 2.5 MPH means the crane can be driven at this
R ML R
A AE 21 :00 X 25-28PR 26.5 X 25-26PR A speed, or slower, with the tires at the proper infla-
o XN
I PICK & CARRY PICK & CARRY 0
I
u
8 G
0 T STATIONARY CREEP 2.5 MPH STATIONARY CREEP 2.5 MPH
I
U tion pressure with the boom straight over the
SOH 360' 360'
ST.
10 33' 36,300 74,400'
OVER FRONT
56,700' 49.700' 38,500·
ST. OVER FRONT
65,600* 49,700· 41,600*
S
10
front.
12 33' 27,300 64,900' 49,200* 42,900* 30,800* 57,000* 42,900* 35,800* 12
15 33' 18,400 49,700 40,700' 35,300' 21,000 47,300* 35,300* 29,200* 15
20 4S' 10,800 28,500 28,500 26,500' 12,400 28,500 26,500' 21,600' 20
25 45' 6,700 19,000 19,000 19,000 7.800 19,000 19.000 16,400* 25
30 45' 3,900 12,800 12,800 12,800 4,700 12,800 12,800 12,400* 30
35 45' 2,400 9,500 9,500 9,500 3,000 9,500 9,500 9,500 35
40 57' 1,300 7,200 7,200 7,200 1,800 7,200 7,200 7,200 40
45 57' 5,500 5,500 5,500 5,500 5,500 5,500 45
50 57' 4,200 4,200 4,200 4,200 4,200 4,200 50
55 69' 3,100 3,100 3,100 3,100 3,100 3,100 55
60 69' 2,300 2,300 2,300 2,300 2,300 2,300 60
"Stationary" means that the crane cannot be

moved when loaded to the levels shown in the on
tire load chart.

STABILITY/STRUCTURAL STRENGTH
-
ON OUTRIGGERS
R R
A BOOM LENGTH BOOM LENGTH BOOM LENGTH BOOM LENGTH BOOM LENGTH BOOM LENGTH BOOM LENGTH A
D 33'# 45' 57' 69' 81 ' 93' 105' D
I I
u
~~ FRONT 360' ~ FRONT 360' Ire FRONT 360'
I...... N FRONT 360' ~ FRONT 360' ~ FRONT 360'
ts FRONT 360' S
10 6790,000' 90,000' 7475,000' 75,000' 10
12 6376,100' 76,100' 71 73,000' 72,900' 7459,600' 59,600' 12
15 5764,200' 63,200' 6761,700' 61,700' 72 55,000' 55,000' 7543,900' 43,900' 15
20 4645,800' 45,300' 6046,100' 45,600' 6646,300' 45,700' 71 36,100' 36,100' 7533,400' 33,400' 20
25 31 34,700. 34,400· 5235,100' 34,800· 6035,300· 35,000· 6730,300' 30,300' 71 28,300' 28,300' 7422,100' 22,100' 25
30 4327,800' 27,600' 5428,000' 27,800' 6226,000' 26,000' 6724,200' 24,200' 71 18,900' 18,900' 7415,000' 15,000' 30
35 3222,500' 22,400· 4722,800' 22,600' 5722,700' 22,700' 6321,000' 21,000' 6816,200' 16,200' 71 13,300' 13,300' 35
40 15 17,600' 17,500' 40 18,900' 18,700 5219,000' 18,700 5918,600' 18,600' 6414,200· 14,200' 6811,900' 11,900' 40
45 3215,800' 14,700 4615,800' 15,000 5515,800' 15,000 61 12,300' 12,300' 6510,700' 10,700' 45
50 20 12,700 11,700 3912,800 12,100 5012,900 12,200 5710,800' 10,800' 62 9,500' 9,500' 50
55 3310,500 9,900 4510,600 10,100 53 9,600' 9,600' 59 8,500' B,500' 55
60 24 8,600 B,100 39 8,800 B,300 49 8,600' 8,400 55 7,500' 7,500' 60
65 33 7,300 6,900 44 7,400 7,000 52 6,600' 6,600' 65
70 26 6100 5700 39 6,100 5,700 48 5900' 5800 70
75 15 5,000 4,600 34 5,100 4,700 43 5,200' 4,800 75
80 28 4,200 3,900 39 4,200 3,900 80
85 19 3,400 3,100 33 3,500 3,200 85
90 29 2,800 2,500 90
95 20 2,200 1,900 95
00 11 1 600 1,400 0
Crane load ratings with an asterisk (*) beside

them are based on the machine's structural
strength. All other ratings are based on stability.
Therefore, when lifting in an area where the rated
load is governed by strength, an overload can
produce an abrupt failure. This may be in the Therefore: CAUTION - Do not attempt to tip the ma-
boom, outrigger beam, or elsewhere. For exam- chine to determine allowable load.
ple, this is particularly true when the operator
does not know the weight of the lifted load or fails MAXIMUM PERMISSIBLE HOIST LINE WAD
to account for the forces necessary to unstick a By lifting with the boom or telescope cylinders,
load from the mud or the extra ice, snow, mud, the crane can easily exceed the rated capacity of
etc. on the load. the wire rope and even the breaking strength of
the wire rope. It is mandatory that wire rope uti-
In the stability zone, some operators foolishly at- lized on the crane have adequate breaking
tempt to determine if the crane can lift the load strength as rated by the rope manufacturer, be in
by allowing the crane to tip. This can result in a good condition, and proper number of parts of
tip over, particularly if the boom point moves out line be used. See Page 4-32 for maintenance and
to a greater radius than the load centerline, inspection and consult PCSA Std. No.4 and ANSI
which it tends to do due to boom deflection and Standard B30.5 and the wire rope users manual.
machine tipping. In this condition, when the load
comes free of the ground, it swings out rapidly,
endangering workmen and can pull the crane
into a tip over condition. Also, if the load is heavy
enough and will not move and the boom point
moves out far enough, the rating can change
back to structural with the associated abrupt
failure discussed above

MAINTENANCE CHECKS
INDEX
SECTION 4
SUBJECT PAGE
LUBRICATION CHART ......................................................................... 4 - 1
MACHINE MAINTENANCE CHECK LIST .............................................. 4 - 2
WIRE ROPE INSPECTION RECORD ..................................................... 4 - 6
ENGINE MAINTENANCE ...................................................................... 4 - 7
ENGINE RADIATOR MAINTENANCE .................................................... 4 - 8
TRANSMISSION MAINTENANCE .......................................................... 4 - 9
TRANSMISSION ................................................................................... 4 - 10
AXLE MAINTENANCE .......................................................................... 4 - 11
TIRES .................................................................................................. 4 - 12
AIR SYSTEM MAINTENANCE ............................................................... 4 - 14
BRAKE SySTEM .................................................................................. 4 - 15
TURNTABLE & SWING PINION ............................................................ 4 - 17
SWING REDUCER ............................................................................... 4 - 18
HYDRAULIC SYSTEM MAINTENANCE ................................................. 4 - 19
HYDRAULIC OIL REQUIREMENTS ...................................................... 4 - 21
CABLE LUBRICATION METHODS ........................................................ 4 - 26
ELECTRICAL SYSTEM BATTERY CHECK ............................................ 4 - 27
ELECTRICAL SYSTEM COLLECTOR RING ........................................... 4 - 29
CABLE REEVING ................................................................................. 4 - 31
SPOOLING WIRE ROPE ON DRUMS .................................................... 4 - 31
WIRE ROPE & REEVING ..................................................................... 4 - 32
WIRE ROPE SPECIFICATIONS ............................................................. 4 - 32
CRANE BOOM ..................................................................................... 4 - 35

~
o
o
C/)
RT 500 SERIES LUBRICA TION TAlLE I
C1l
::1. INTERVAl POINT I UNIT DESCRIPTION ~~~I
NO.Of
POINTS
LUBRICANT
C1l 1.01. +
f':~~:r·~n&';:ra~:~U-
DAILY • CUIIIIINS IITA 5.' I
[Jl
I 01. flit..
S- lIanual Fo, Lube 011
M.r'. CAT 3111 DlTA
12~.Qln~ I Requirement.
Manual
COOLING SYSTEII CAPACITY Cum min. .2.5 01. I
COOLING SYSTEII CAPACITY Cat 5. 01. I
HO - SEE TABLE 2 KHp 011 IAnI _ _
DAILY I D HYDRAUUC RESERVOIR
lIarie. On Indlcato, Tube
~ I ~[[:~~G E~:NNION BEARINGS
~::::
a
I
a
STEERING CYUNDER PINS
AXLE PIVOT a: CYUNDERS
Pure·
•
a
YPG
IIPG
IIPG
Pure· I
II 10011 FOOT PEDALS Ao Roq'd. 2 EO - SAE 30
12 TURNTABLE GEAR .. 2 GG (IIPG 1.low 32· F)
I. UPPER a: LOWER THROTTLE UNICAGE Purge 2 IIPG
.oHRS.
II
17
la
CONTROL IELLCRANK SUPPORTS
ALL UNKAGE PINS
ALCOHOL EVAPORATOR
Ao Roq'd.
Ao Roq'd.
I 01.
•
1
IIPG
EO - SAE 30
lIoth,1 AI.ohol
\I CHAIN ROLLER Pure· 1 IIPG
22 10011 PIVOT PIN Purge 2 IIPG
23
2.
25
10011 CYUNDER BUSHINGS
10011 SIDE ROLLERS
10011 TIP SHEAVES
Pure·
Pure·
Purge
•
I
7
IIPG
IIPG
IIPG
27 HOOK lLOCK SHEAVES Purge 5 IIPG
2a HOOK lLOCK TRUNNION Purge 1 IIPG
~
-:':H~V:~ p~~TI~:'i~c,~~~RS
2. Pure· 2/. IIPG
30 Ao Roq'd. 2. IIPG
100 HRS. 13 TURNTABLE lEARING RACE .. Ao Roq'd. 2 IIPGA!!",::w3~Z;: Fkpt;;,1

CHECK
IIONTHLY
21 BOOII EXTEND AND RETRACT CHAINS Ao Roq'd.
• EO - SAE 30 Non-
Dotorg.nt
~1~. 21 TRANSIiISSION DlL FILTER 1 See Transmll.lon "
*" TOrQue Con••rt.r
~
,.... .,
1500 III.
IIONTHLY
5 • AXLE UNIVERSAL JOINTS • •
DRIVE SHAFTS (Tran•• - Axln)
Pure·
Pure· •
I
IIPG
IIPG
CHECK Chock Plug

•
~
IIONTHLY 2 AXLE HUI DRIVE " IAnI GL-5
CHANGE EA. 7 AXLE DIFFERENTIALS Chock Plug 2 GL-5
I IIONTHS IAnI
CHECK 15 SWING REDUCTION UNIT II 1/2 PT. 1 SYNTHETIC GL-5
I
WEEKLY
CHANGE EA. 20 TRANSIiISSION AND "I':ra••
500 HOURS TOROUE CONVERTER """ Gel. 2 -2.1" F a: Abo..: ATF
• See Operotor'. Manual.

.. Apply lubrfcant while . .Inglng the machine. See Operato,'. Manual
••• Change .,.tem all " fllte,. S.. Operator'. ManuaL
• Lubrt.at. P.d. (A) thru ...... hal•• In boom and by appl,lng groc" to tho top boom plat••
Ref.r fa Opwator I ManuaL
•• Lubrfcat. Ihru front or reor aceell hoi.. In axl. houllng. UDYII machine If nec•••ary to ace•••
...h flHlng.
NOTE: Red. . . .11 lubrt.atlon Inle"",l. undo, ....re op.ratlng .ondltlon •• R.f., to Oporat.,'. lIanu.1
fo' drain/refill procedure• • nd .ddltlon.1 Inform.tlon.
,& Check outrlgg.r beam. dally and rwmOVll ..... dirt.
......
[Jl
TAlLE 2
[Jl
, -~
~
~623t
SPECIFIED LUBRICANTS
C1l IlPO IIULTI-PURPOSE GREASE EP-2 *Afi.r to O.,.rator'.
~ GG OPEN GEAR GREASE Grad. B Manual for compl.t.
:~~"'orofa;:ii=br.ended
GL-S GEAR LUBRICANT, EP $A[ 90 (1I1I-L-210SB)
~ SYNTHETIC GL-5 GEAR WIRICANT, EP $A[ 75W10
E' HO
EO
HYDRAUUC OIL
ENGINE OIL
"Kaohrtng Spec. 805
A.P.I. CI.n •• LI_
temp.rature rang•• , and
for drain a: ...flll
aa
[Jl
,..
./
28
ATF TRANSIiISSION FlUID Typ. C-3 proceclu .....
..... PART NUIIBER 12.00-'22

~
o
o
o
MAINTENANCE CHECKS
INTRODUCTION OPERATOR OBSERVATION
A regular program of periodic preventive mainte- As the operator, it is your responsibility to ob-
nence is essential to prolong crane operating life, serve and report any unusual sounds, odors, or
maximize efficient service and minimize down- other signs of abnormal performance that could
time. This section details a series of checks and indicate trouble ahead. On a routine basis the
procedures which are to be performed at daily, following items should be checked before starting
weekly, monthly and semi-annual intervals. or while operating the crane.
These intervals are stated both in terms of calen-
dar periods and hours of operation. Visual Inspection - Check complete machine for
any unusual condition.
The checks prescribed for longer intervals in-
clude all the checks required for the shorter in- Check for any leaks or damage to the hydraulic
tervals. Thus, the weekly check includes all items system.
in the daily check, the monthly check includes
weekly and daily checks, and so on through the Check in the engine compartment:
semi-annual check, which includes the quarter- * Belts for tension and wear
ly, monthly, weekly and daily checks. * Coolant level
* Oil level
A convenient check chart provides a means of re- * Transmission oil level
cording preventive maintenance performed and * Air cleaner sight gauge
serves as a tool detecting problem areas and re- * Air intake
analyzing maintenance requirements. The items * Muffler and exhaust
in each check interval on the check chart are
grouped under their respective headings and cov- Check battery box - For battery condition
ered in detail over the course of Section 6.
Crane boom - Check for:
This maintenance schedule is a guide which en- * Hook block for wear or damage
sures that basic preventive maintenance require- * Two block system for proper function
ments will be met under average operating * Cable and cable spooling on winch
conditions. Conditions which impose greater * Cylinder pin connections for wear
wear, loads or strain on the crane may dictate re-
duced check intervals. Before altering the main- Check tires, axles, and drive lines, for wear or
tenance schedule, reevaluate crane operation damage.
and review the crane maintenance records. Con-
sider all factors involved and develop a revised Check in the cab for:
schedule adequate to meet routine maintenance * Instruments functioning properly
requirements. * Control operation
* Glass for good visibility
As a part of each periodic check, refer to the en- * Safety equipment is ready for use
gine manufacturer's manual for engine mainte- * All lights work properly
nance requirements. When servicing the engine, * Cleanliness - Free from mud and debris.
the engine manufacturer's recommendations
take precedence over those in this manual,
should any discrepancy be noted.

MAINTENANCE CHECKS
MACHINE MAINTENANCE
CHECKLIST
DAILY CHECK (8 HOURS)

Drain Air Tanks
Perform Daily Lubrication
Check Wire Rope And Related Components
Check Hydraulic Reservoir Fluid Level
Check Air Cleaner
Fill Fuel Tank
Check Controls
Check Engine Oil Level
Check Instruments, Gauges, & Safety Equip-
Check Coolant Level ment
Check Hydraulic Cylinder Mounting Bush- Make Overall Visual Inspection

ings And Pins
Torque Swing Bearing Bolts *
Check Hydraulic Components
Torque Wheel Nuts First 50 Miles*
Check Transmission Oil Level
Check Anti-Two Block System
Check Axle Lockout System
Check Engine Manufacturer's Manual For
Drain Fuel Filters or Water Separator Additional Maintenance Requirements
WEEKLY CHECK (40 HOURS)

Check Hydraulic Cylinders And Rods
Perform The Daily Check
Make Thorough Inspection Of Wire Rope
Perform Weekly Lubrication
Make Initial Replacement Of Hydraulic Re-
Check Swing Reducer Oil Level turn Line Filter*
Perform Initial Axle Oil Change* Check Alcohol Evaporator Fluid Level
Check Axle Oil Level (after initial change) Visuaily Inspect All Structural Members And
Welds For Cracks, Alignment and Wear
Check Battery Condition
Check Boom For Wear Cracked Welds, Align-
Check Tire Pressure And Condition ment And Missing Or Illegible Decals
Check Air System Safety Valve Check Engine Manufacturer's Manual For
Additional Maintenance Requirements
* Interval given applies only to initial period of use (break-in).

MAINTENANCE CHECKS
MONTHLY CHECK (160 HOURS)
Perform Daily And Weekly Checks Obtain Hydraulic Oil Sample for Analysis as
Required in Section 9.
Perform Monthly Lubrication
Clean Radiator Exterior
Check Engine Belts
Drain Hydraulic Reservoir Of Moisture Additional Maintenance Requirements
QUARTERLY CHECK (500 HOURS)
Perform Daily, Weekly And Monthly Checks Replenish Cooling System Corrosion Inhibi-
tor
Perform Quarterly Lubrication
Drain Fuel Tank Of Water And Sediment Additional Maintenance Requirements
Change Transmission Oil and Filter Lubricate Valve Disconnects
Change Hydraulic Return Line Filters
SEMI. ANNUAL CHECK (1000 HOURS)
Perform Daily, Weekly, Monthly And Quar- Change Axle Oil

terly Checks
Clean Crankcase Breather Check Brake Shoes for Wear Condition
Clean Cooling System Check Relief Valve Pressure Settings
Check Reservoir Relief Valve Torque Swing Bearing Bolts
Clean Reservoir Intake Suction Filter Check Engine Manufacturer's Manual For
Additional Maintenance Requirements
RT500 Series 4-4 Revised: January 2003

MAINTENANCE CHECKS
OTHER INTERVALS
200 HOURS: Change Transmission Oil Filter
250 HOURS - CUMMINS ENGINE:

Change Engine Oil and Filter
Check Engine Air Intake
Change Engine Air Cleaner Element All handles, steps, walkways and platforms must
Check Engine Drive Belt Tension be kept free of grease, oils, fuel, mud snow and
ice.
600 HOURS: Change Transmission Oil
1500 HOURS: Drain And Clean Hydraulic

Reservoir; Change Hydraulic Fluid
4000 HOURSj2 YEARS: Disassemble And

I
Inspect Winch Components
Sand-painted or other grit type anti-slip surfaces
must be renewed when ever the surface begins to
SPECIAL BREAK IN REQUIREMENTS FOR appear worn.
NEWCRANES
8 HOURS - During the first 50 miles of ser-

vice and any time the wheels have been re-
moved, retorque the wheel nuts to 400-
500ft.lbs.
40 HOURS - Mter forty hours of travel, drain

and refill the transmission with new fluid.
40 HOURS - Retorque the swing bearing

bolts to a torque of 600 ft. lbs. Recheck every
40 hours until all bolt are found properly
torqued. Thereafter checks should be per-
formed quarterly.
100 HOURS - Mter one hundred hours drain

and change the winch lubricant.
100 HOURS - Retighten winch base mount-

ing caps crews to 225 ft. lbs. of torque after
one hundred hours of operation.
100 HOURS - Retighten counterweight cap-

screws to 845 ft. lbs.

WIRE ROPE INSPECTION RECORD
(Refer to Wire Rope Users Manual For Criteria
PLACE OF INSPECTION DATE
DESCRIPTION OF CRANE
Make Model Serial No.
Type and Arrangement of Attachments
DATE OF LAST ROPE INSPECTION
HOURS AND TIME OF SERVICE SINCE LAST INSPECTION
RESULTS OF INSPECTION
Rope Inspected Type and Size Conditions Noted Recommendations
INSPECTOR:

MAINTENANCE AND LUBRICATION
ENGINE MAINTENANCE
For Cummins engine maintenance refer to Cummins Operation and Maintenance Manual for "8" Series engines.
Engine productivity, longevity, and low-cost per- curate reading, allow 15 minutes for the oil to
formance depend on a regular program of period- drain into the sump before checking. Keep the oil
ic maintenance. The materials presented here are level as close to the full mark as possible. DO
listed in accordance with the MAINTENANCE NOT OVERFILL
CHECK LIST in Section 4. Consideration may
dictate a revision in scheduling for the periodic
checks.
As a part of each periodic check, refer to the en-

gine manufacturer's manual for engine mainte- Never operate the machine when the oil is above
nance requirements. When servicing the engine, the full mark or below the low mark.
the engine manufacturer's recommendations
WATER SEPARATOR
take precedence over those in this manual,
A water separator is used to remove water contamina-
should any discrepancy be noted.
tion from the fuel before it enters the engine. Water
contamination should be drained daily or before it be-
DAILY:
comes 1/2 full.
FUEL LEVEL The fuel tank is located on the left
side of the machine. Keep the tank as full as pos-
AIR CLEANER Inspect the air cleaner and it's
sible to minimize condensation in cold weather.
connections for leaks, dents and damage.
A vacuum actuated indicator mounted on the air

cleaner assembly indicates conditions of restrict-
ed flow through the air cleaner. With the engine
running at maximum governed rpm, observe the
yellow band on the indicator piston. If the yellow
band reaches the red band on the plastic cylin-
der, service is necessary. At this time, change the
air cleaner filter element and clean the intake
screen
Use a good grade of No. 2 diesel fuel. The tank ca- When using a degreasing agent to clean the en-
pacity is 50 gallons. gine, be sure to cover the vacuum actuated indi-
cator (filter minder) with a protective material.
ENGINE OIL LEVEL The engine oil level is
Engine degreasing solvents have a polycarbonate
checked with the dipstick located on the left side
base and can damage or destroy the indicator.
of the engine (right side of machine). DO not
check the oil level while the engine is running nor
immediately after stopping the engine. For an ac-

Reset the filter indicator each time the hood is If a large amount of sediment has accumulated,
opened as it provides a built-in check to assure drain the tank completely and flush liberally with
proper functioning. If it does not reset then the kerosene until all sediment has been removed. Al-
orifice is plugged and must be cleaned. low the tank to drain completely before refilling
with fuel.
A clogged filter restricts engine power output.
SEMI ANNUALLY:
ENGINE BELTS Check all engine belts for condi- CRANKCASE BREATHER Service the crankcase
tion and proper adjustment. Consult the engine breather following the procedures given in the
manufacturer's manual for the recommended manufacturer's manual.
belt tension and tensioning methods.
FUEL FILTER ELEMENTS On all machines with
QUARTERLY: Drain accumulated water and sed- Cat engines, remove the fuel filter casings and re-
iment from the fuel tank by removing the drain place the fuel filter elements every six months
plug and allowing the tank to drain until all water (1000 hours) or when there is evidence of plug-
is removed and the fuel flowing from the tank is ging.
free of sediment.
ENGINE RADIATOR
MAINTENANCE
DAILY/8 HOURS: MONTHLY/160 HOURS:

COOLANT LEVEL Check the engine radiator RADIATOR EXTERIOR Clean any foreign matter
coolant level and add coolant if necessary. A so- from the radiator cooling fins and through-core
lution of 50% ethylene glycol by volume is the cooling passages by directing compressed air and
recommended year-round coolant. Replenish flushing water over the entire area of the core in
the corrosion inhibitor if necessary. Refer to the the reverse direction of normal air flow.
"Operation Guide" supplied with the engine, or
the nearest Engine manufacturer's service cen- QUARTERLY:
ter for guidance in selecting the proper condi- CORROSION INHIBITOR Replenish the cooling
tioner for the cooling system. system corrosion inhibitor every 500 hours of op-
eration.,
Never use a chromate based inhibitor corrosion

inhibitor when the cooling system contains ethyl-
ene glycol. Use only non-chromate based inhibi-
tors. Chromate base inhibitors reacting with
ethylene glycol can produce hydroxide, commonly
known as "green slime". This substance reduces
the heat transfer rate and can cause serious en-
gine overheating.
SEMI ANNUALLY:
In climates where freezing does not occur, use a COOLING SYSTEM Clean the cooling system
solution of clean water with a corrosion inhibitor 1,000 hours or annually whichever comes first.
Use a radiator cleaning compound, following the
for optimum cooling.
instructions on the container. Flush the system
with fresh water and refill with an ethylene glycol
solution of 50% by volume.

TRANSMISSION MAINTENANCE
DAILY MAINTENANCE CHECK On a daily basis, hours of operation and the lubricant be changed
check the TRANSMISSION OIL LEVEL. quarterly or after 500 hours of operation
Note: In cold weather operation and/or initial
Start the engine and run it at 1000 to 1500 rpm start up (when the transmission oil is cold) the oil
until the transmission reaches a normal operat- will have a higher viscosity which may allow the
ing temperature of (160° to 200°F.). Then idle the filter to bypass intermittently. When this hap-
engine and shift through all range positions slow- pens, the filter bypass indicator will be activated.
ly. This will ensure that all parts of the system are
filled with oil. Shift to neutral and set the engine
speed at idle rpm. Remove the dipstick located If this happens, check the converter out oil tem-
under the access door on the rear deck. The oil perature. If the temperature is in the normal
should be at the "full" level. Add or drain oil to working range, the filter should be changed. If the
bring it to this level. converter out oil temperature is below the normal
working range, stop the machine and warm the
SERVICING MACHINE AFTER oil up to the normal working range by stalling the
TRANSMISSION OVERHAUL converter, and observing the bypass indicator to
When servicing the unit for the first time after ve- be deactivated as the oil warms up. If this dis-
hicle installation and/or after repair, the unit is arms the system, work the transmission in a
filled as follows: higher gear to keep the converter out oil temper-
ature in the normal working range. If this does
A. Fill the unit with 4 gallons (15.1 liters) of the not disarm the system, change the filter.
recommended lubricant.
B. Start the engine and run at idle speed to let the
converter and oil lines fill.
C. With the engine at idle speed, finish filling the
unit to the full level. The amount needed will
vary with each application.
WHEN STALLING THE CONVERTER MAKE
Note: The oil level is always checked with the en- SURE THE TRANSMISSION IS IN HIGH GEAR,
gine running at idle speed, the transmission in THE VEHICLE BRAKES SET, AND THE IMMEDI-
neutral, and the oil temperature at 160-200° F. ATE AREA IS CLEAR OF PERSONNEL AND OB-
(71.93.5° C). STRUCTIONS. DO NOT EXCEED 30 SECONDS
OR 250°F CONVERTER OUT OIL TEMPRATURE,
DO NOT OVERFILL THE TRANSMISSION. WHICHEVER COMES FIRST, AT FULL GOV-
ERNED ENGINE RPM STALL SPEED.
Recommended lubricant and Filter Change In-
tervals
Refer to page 4-10 for lubricant recommenda- Note: The preceding lubricant change recom-
tions. mendations can be neglected if a lubricant anal-
ysis indicates that the following limits are not
Recommendations utilizing the Funk Filter with exceeded:
the bypass indicator inoperative or not connect-
ed:
The lubricant and filter should be changed after

the first 20 hours of transmission operation. Mter
the initial lubricant and filter change, it is recom-
mended that the filter be changed every 250

TRANSMISSION
Lubrication Recommendations, Series Shift-O-Matic Transmission

Recommended Oils: Commercial Powershift Transmissions
Prevailing Ambient Temperature Oil Recommendation
Above -23 0 C (_10 0 F) Hydraulic Transmission Fluid

Type C-3 (Except Grade 30)
Below -23 0 C (_10 0 F) Hydraulic Transmission Fluid

Type C-3 (Except Grade 30)
Auxiliary preheat required to
raise temperature in the sump
to above -23 0 C (_10 0 F)
Above 0 0 C (32 0 F) Hydraulic Transmission Fluid

Type C-3 or C-3 Grade 30
Funk Manufacturing does not recommend the use of any hydraulic transmission fluid that uses an "EP"
(Extreme Pressure) additive.

AXLE MAINTENANCE
MAINTENANCE CHECK As a part of the WEEK-

LY MAINTENANCE CHECK, inspect the axle and
DIFFERENTIAL
differential levels. When checking the AXLE OIL FILL & CHECK
PLUG
LEVEL, rotate each wheel until the planet cover
is positioned as shown in the illustration below.
the arrow on the planet cover points horizontal
when the cover is properly positioned for check-
ing the oil.
LUBRICANT
LEVEL
HORIZ
CHECK OIL FILL0
PLUG --+-l--fo +-- 0
LEVEL
@
On a SEMI-ANNUAL basis, drain the oil from the
DRAIN PLUG differential by removing the drain plug at the bot-
(ROTATES TO
BOTTOf.1)
00 0 tom of the differential housing. Replace the plug
and refill the differential with the lubricant speci-
fied on the lubrication chart. To the level specified
Remove the oil level plug in the planet cover and above.
add oil as necessary to bring the oil level to the
bottom of the fill and check hole See the lubrica- Drain the oil from hubs removing the fill and
tion chart. check plug by rotating the hub until the hole is at
the extreme low pOSition. Mter draining, rotate the
Check the DIFFERENTIAL OIL LEVEL by remov- hub until the hole is at the check pOSition. Refill
ing the fill and check plug indicated in the illus- the hub with the lubricant specified on the lubri-
tration . Add oil as necessary to bring the oil level cation chart. Refill to the level of the bottom of the
to the bottom of the hole. See lubrication chart. check plug.

TIRES
MAINTENANCE CHECK As a part of the WEEK-

LY MAINTENANCE checks, inspect the tires and
rims for damage. Cuts and bruises, snags, punc-
tures, and abrasions should be repaired before
they can cause tire failure. Bent, cracked or loose
rims should be repaired or replaced. The explosive stored in a tire and rim assembly
under pressure makes changing truck and off-
Check tire valve condition and make sure each road tires hazardous. Death or personal injury
valve has a cap. can occur while handling or maintaining these
tires. Special procedures must be followed and
Check the wheel retaining nuts for proper tight- special tools must be used if tires are to be
ness. Wheel retaining nuts should be torqued to changed safely. Whenever possible, let your ser-
400-500 fUbs. vice company handle this job. If you must change
a tire, follow the step by step instructions detailed
TIRE PRESSURES Always maintain the recom- in a tire repair manual. Should low pressures
mended tire inflation pressures in all tires. make it necessary to add air, never stand beside
the tire tread. Instead use a extension hose long
When driving, some increase in tire pressures enough to permit you to stand behind the tire
can be expected due to heat generated by friction. tread. Always use a tire cage or equivalent protec-
Overspeeds may also produce increased tire tion when adding air.
pressures. In such circumstances, NEVER RIGHT WAY
BLEEED THE TIRES. Instead slow down or stop
until the tires cool.
Inflation pressure should be checked when tires

are cool, using an accurate tire pressure gauge.
Check pressures at regular intervals.
Bleeding the air from hot tires is dangerous and

should not be attempted. While the pressure will
be reduced, an increase in temperature of the tire
will take place as soon as driving is resumed and
tire failure will result.
UNDERINFLATION Too little air pressure in-

creases deflection, causes the tread to wipe and
scuff over the road, results in extra strain on the
tire, and increases the chances for bruising. WRONG WAY
PROPER INFLATION Maintaining the proper air

pressure provides maximum road contact and re-
sults in increased tire life.
OVERINFLATION Overinflation reduces tire de-

flection and tire contact area, causing the tire to
ride on the crown, and results in rapid wear in
the center of the tread.

SAFETY PRECAUTIONS
FOR MOUNTING OR DEMOUNTING
RIMS AND WHEELS
DO'S AND DON'TS
DO DON'T
1. Follow mounting and demounting proce- 1. Don't use mis-matched parts. Mis-matched
dures outlined in the manufacturer's instruc- parts are dangerous. Make sure side ring
tion manual or other recognized industry and lock ring designations match those of
instruction manual. the base.
2. Deflate tires completely prior to demounting 2. Do not use loads or inflation pressures ex-
by removing the valve core. ceeding the manufacturer's recommenda-
tions.
3. Replace bent, cracked,worn, corroded, or
damaged parts. 3. Don't re-inflate a tire that has been run flat
or seriously underinflated without first de-
4. Double check to see that removable rings are mounting and inspecting the tire and rim as-
seated properly before inflating. sembly.
5. Check for excessive side ring play and ring 4. Never use tire and rim combinations that are
butting. Either one of these conditions is an not approved by the Tire & Rim Association.
indication of mismatched parts.
6. Inflate tires in a safety cage.
7. Mter inflating the tire, be sure that between a

1/16" minimum and a 1/4" maximum re-
mains in a split ring or lock ring.
8. Inspect wheel nuts and rim clamps periodi-

cally for excessive wear, corrosion, proper
centering and nut torque.

AIR SYSTEM MAINTENANCE
Inadequate delivery pressure or defective compo-

nents operations can generally be traced to leak-
age, blocked lines, or the buildup of moisture and
sediment in the system. A regular program of pre-
ventive maintenance is an essential part of air
system operation. The materials presented here
are listed in accordance with the MAINTENACE
CHECK LIST in this section. Consideration of se-
vere working conditions may dictate a revision in
schedule periodic checks.
DAILY:
AIR TANKS Open the air tank drain cocks at

least once daily to blowout moisture and accu-
mulated sediment. The drain cocks are located
on the frame rail by the battery box.
BATTERY
FU EL I--;=::::::;:~ BOX
TANK \-
/
AIR SYSTEM
DRAIN COCKS
WEEKLY:
AIR SYSTEM SAFTY VALVE Manually actuate

the air system safety relief valve by pushing in on
the stem. This will ensure that the valve is not
sticking. If the valve cannot be actuated in this
manner, it should be repaired or replaced
SAFETY VALVE
--
-
..... ::::,...----
RIGHT SIDE
AIR TANK

BRAKE SYSTEM
BRAKE PEDAL: damaged. Check for proper operation before

placing vehicle in service.
NOTE:
All rubber components in the treadle valve

should be replaced yearly.
ADJUSTING SCREW IMPORTANT!

An increase in stopping distance or a low pres-
~~~~~~..-JAMNUT sure warning light indicated a malfunction in the
brake system, and although the vehicle brake
system may continue to function, the vehicle
should not be operated until the necessary re-
pairs have been made and both braking circuits
are operating normally.
LEAKAGE CHECK
1. Make and hold full brake application.
MAINTENANCE Every 3 months or quarterly: 2. Coat the exhaust port and body of the brake
valve with soap solution.
1. Lubricate fulcrum and roller pin with oil.
3. Leakage is not to exceed a 1" bubble in 3 sec-
2. Free pedal travel should be checked as follows: onds in both the applied and released posi-
Check to be certain plunger is in contact with tion.
spring seat. The stop button should be adjust-
ed so that the roller and plunger just contact. If the brake does not function as described above
or leakage is excessive, it is recommended that it
3. Apply oil or light grease between plunger and be replaced with a new or remanufactured unit,
valve body. Do not overoil. or repaired with genuine Bendix parts available
at Bendix outlets.
4. Clean exhaust check depending on type of ser-
vice.
Every 12 months or annually:
1. Disassemble, clean parts with mineral spirits.

Replace all rubber parts or any part worn or

DISC PARKING BRAKE
ROUTINE MAINTENANCE The routine mainte- 4. Check disc surface condition. Replace if it is
nance presented below is suggested to keep the badly warped or pitted.
brake system in good working order.
5. Check that 0.010" to 0.020" clearance exists
1. Check that floating parts move freely and all between pad and the disc. Remove cotter pin
other parts are mounted securely. Tighten and adjust castle nut to achieve these dimen-
hardware as required. sions.
2. Clean and lubricate cam and push pins with 6. Check to see if friction pads are worn to less
molybdenum disulfide or graphite-based dry than 1 /32', thick. Replace if they are. In nor-
lubricant. mal service, pads will need replacing only after
prolonged use. Always replace both pads at
3. Check actuator linkage and see that there is the same time.
adequate freedom of movement for positive
brake operation. Generally, if the disc is still running true within
0.010" and the pad clearance is still adjustable,
no other maintenance is required .
•390 MAX. ADJUSTMENT

PAD WEAROUT
1.-

TURNTABLE & SWING PINION
Lubricate every 100 operating hours as follows: Under extremely dirty or dusty conditions, suffi-
cient grease should be added to flush out con-
Inject grease as recommended below through one taminated grease. Under less severe conditions,
fitting located beneath an access panel in the op- add grease until it appears at the bottom seal.
erator's cab just behind the shift lever, as the ma-
chine is rotated at least two complete revolutions. While swinging the machine, apply gear grease to
When complete rotation is impractical, inject the external ring gear with sufficient frequency to
grease through each fitting and rotate machine insure that the teeth remain coated.
back and forth as far as possible as each fitting is
greased. Some lubricants recommended by the manufac-
turer are:
MOBIL TEXACO SUNOCO AMOCO EXON
RACE Mobilux Mutifak Prestige Amolith Beacon

EPI EPI 742EP EPI EPI
GEAR Mobiltac Crater 407 Amovis Surett

375NC 2X Compound B 8-X Fluid 4k
NOTE: Other manufacturers' lubricants of the same quality are suitable.

SWING REDUCER
MAINTENANCE CHECK On a WEEKLY basis,

check the swing reducer oil level and add oil as
needed to maintain the level at the "FULL" mark
on the dipstick. Recommended lubricant is
Sunep # 1060 or equivalent.

HYDRAULIC SYSTEM MAINTENANCE
MAINTENANCE CHECKS A regular program of

periodic maintenance is an essential part of con-
tinued hydraulic system operation. Allowing ac-
cumulations of moisture and sediment to build-
up in the system will damage hydraulic valves,
pumps and motors. The presence of leaking con- The hydraulic reservoir is sealed and has a 14 psi
nections or damaged components effect the effi- relief valve. Exercise extreme care when removing
ciency of operation and are dangerous. The the filter cap. The pressure is relieved by turning
materials presented here are listed in accordance the reservoir cap counterclockwise to the first
with the MAINTENANCE CHECK LIST. Consider- stop. DO NOT turn the cap beyond the first stop
ation of severe working conditions may dictate a until all pressure has been released. This will
revision in scheduling periodic checks. cause the cap to be blown off the reservoir with
sufficient force to cause personal injury. DO NOT
DAILY: place any portion of your body above the reservoir
HYDRAULIC FLUID LEVEL The hydraulic reser- cap while relieving the pressure or removing the
voir, fluid level indicators, and filler cap are on cap.
the right side of the machine.
HYDRAULIC COMPONENTS Check the hydrau-
lic valves, motors, pumps, hoses, tubes and con-
nections for excess dirt, oil and grease. Clean
these items if necessary and check for leaks and
damage. Tighten leaky connections and repair
any damaged components.
WEEKLY:
RETURN LINE FILTER Change the hydraulic
reservoir return line filters after the first 40 hours
of the break-in period; thereafter follow the quar-
terly check recommendation.
MONTHLY:
HYDRAULIC RESERVOIR Drain anyaccumu-
lated moisture from the hydraulic reservoir by
Retract all cylinders to return the maximum parking the machine on a slight incline and loos-
amount of oil to the reservoir and note the oil lev- en the pipe plug in the bottom of the reservoir.
el indicators. The fluid level should be between
the indicators. The top mark indicates system ca- HYDRAULIC OIL Visually check the condition of
pacity with all cylinders retracted. Reservoir ca- the hydraulic oil once each month. Thickening of
pacity is 81 gallons and system capacity varies the oil or a change in its appearance, such as
with equipment up to a maximum of approxi- darkening, may serve as a rough indicator of
mately 130 gallons. when an oil change is needed. Periodic testing of
the oil is the safest, most accurate method of de-
Do not overfill. termining the condition of the oil. An oil supplier
can be consulted for assistance in testing the oil.
Refer to Section 4, page 23 for hydraulic oils
meeting the manufacturer's specifications. Do Change the oil whenever testing and/or inspec-
not use oils which have detergent additives. tion reveals the oil to be unsuitable for safe and
efficient operation.

QUARTERLY: Clean the filter by immersing it in a non-caustic

HYDRAULIC FILTER Remove and replace the cleaning solvent. Rub the screen surface with a
hydraulic reservoir return line filters. Access is soft brush to dislodge accumulated foreign mat-
gained by removing the cover plate on the reser- ter. Reinstall filter, filter hold-down device and
voir. cover.
When replacing the filters, clean the spring and RESERVOIR RELIEF VALVE Check the hydrau-
bypass valves. Inspect the gasket for damage and lic reservoir relief valve for proper functioning.
replace if necessary. The valve is located in the filler cap and is
checked by extending all the boom cylinders and
then retracting them to slightly pressurize the
reservoir. When the cap is turned to the first
notch, air should be heard escaping if the system
is holding pressure. The system is sealed and has
a relief valve pressure setting of 14 psi.
RETURN LINE
FILTER . __"=~
1500 HOURS:
HYDRAULIC RESERVOIR Drain and clean the
hydraulic reservoir. Change the hydraulic oil.
A change interval cannot be established which

would apply to all oils and all operating condi-
tions of temperature and cleanliness. However, a
reputable brand of turbine grade oil can be ex-
pected to deliver 1500 hours of service under av-
IMMERSION erage operating conditions. Although conditions
HEATER
may necessitate shorter change intervals, do not
DRAIN - use hydraulic oil for more than 1500 hours.
PLUGS
Whenever a visual inspection, chemical test or

Before discarding the old filter element, examine light test indicates that an oil change is neces-
the type of material trapped in it. This may indi- sary, proceed as follows:
cate which, if any, hydraulic system components
are deteriorating. 1. Warm the oil prior to draining but avoid drain-
ing immediately after prolonged continuous use
SEMI ANNUALLY: to reduce the danger of being burned by hot oil.
SUCTION FILTER Remove and clean the hy-
draulic reservoir intake suction filter. This per- 2. Retract all cylinders to return the maximum
manent screen type filter is located inside the res- amount of oil to the reservoir. Loosen the top cov-
ervoir on the intake to the pump manifold. Access ers and remove the drain plug(s) at the bottom
to the filter is accomplished by removing the cov- of the reservoir. Allow sufficient time for the res-
er with filler neck and filter holding device from ervoir to drain thoroughly.
the top of the reservoir. Move the lever towards
the front of the machine and lift out the filter. 3. Remove the return filters, clean springs, by-
pass valves and inspect cover gasket for damage
Remove the "0" ring from the adapter and check and deterioration. Replace gasket if necessary.
it for damage or deterioration. If the ring is at all
damaged, replace it.

A good lubrication program requires that all nor- tions take precedence should any discrepancy
mal wear points be lubricated according to a set occur. If there is any doubt about the proper lu-
schedule with specific types of lubricants. Refer bricants, intervals or lubrication procedures, re-
to the lubrication chart and the special items cov- fer to the original manufacturer's manual.
ered in this section for the recommended lubri- The lubrication intervals recommended in this
cants, time intervals and lubrication procedures. section assume normal operating conditions.
Where components such as the engine, transmis- Where dust, dirt, high humidity or extreme heat
sion and axles are not manufactured by this com- are encountered, lubrication intervals should be
pany, the original manufacturer's recommenda- shortened accordingly.
HYDRAULIC OIL REQUIREMENTS
The hydraulic system is filled with KOEHRING 3. Check the oil viscosity versus the recommend-
SPEC 805 hydraulic oil to give the unit the high- ed
est performance as a hydraulic machine and to Ambient Temperature may require an oil
provide proper lubrication for the hydraulic com- change.
ponents. To ensure the longest life for this piece
of equipment, particular attention must be paid 4. Check the hydraulic system efficiency a pump
to maintain oil at the proper level with an ap- may be failing or a relief valve set low.
proved hydraulic oil and to keep the circuit sys-
tem clean. 5. Reduce the duty cycle of the machine.
The oil for the hydraulic system performs the 6. Consult an authorized DISTRIBUTOR.
dual function of lubrication and transmission of
power. Oil must, therefore, be selected with care ENGINE OILS: Engine oils that meet Mil Spec
and with the assistance of a reputable supplier. 2104 and have the anti-wear additive zinc DO
To guide in the selection of this oil, the general re- dithiophosphate can be used as hydraulic oils.
quirements are speCified below. Good oils are NOT USE C.D. rated engine oil, some of which
economical in the long run. Check with the oil will not protect against wear in hydraulic pumps
manufacturer prior to the use of his product. and motor'"
.....;;;;;;;:;;;;;:;;;;:;;;1
Oils which conform to Koehring Specification 805
are recommended for most conditions. Under
certain climate and operating conditions, it may
be advisable to use a fluid of heavier or lighter
viscosity in order to maintain a viscosity less Not all motor oils have zinc dithiophosphate.
than 7500 SSU at start-up and more than 50 Those that do not have this heavy duty additive
SSU during operation. These machines should can cause immediate failure of pumps.
not be operated with hydraulic reservoir temper-
atures in excess of 200°F (87°C) due to possible Engine oils tend to form sludge in the presence of
excessive damage to the hydraulic oil and rubber water. This sludge can plug the filters so they will
components (hoses, seals, shaft seals, motor require frequent changing. This is not detrimen-
seals etc.). If over-heating occurs, discontinue tal to the machine unless the filters are allowed
operation and: to plug so badly that they by-pass oil.
1. Check the hydraulic fluid level. Never use multi-viscosity grades of engine oil be-
cause of the shear and thin out characteristics of
2. Check the oil cooler for cleanliness. this type of oil.
TRANSMISSION FLUIDS: DO NOT use trans-

mission fluids. These fluids have been designed
to work in automatic transmissions and they will

MIXING: Mixing different brands of oil is not rec- reaching the limit of its oxidation life and should
ommended. Various companies use different ad- be replaced.
ditive packages, which when mixed together, may
cause problems in a hydraulic system. This type Water Contamination - All hydraulic oils in the
of problem is rare but can cause sludge which following charts will readily separate water which
can plug the filters or acid which will etch the will settle to the bottom of the reservoir. This wa-
pump plates. ter should be drained off. The water that is mea-
sured in the oil sample will be dissolved water.
PRE-FILTER: Oil should be filtered through a 10 This should be less than .05%. If it is greater than
micron nominal filter before it enters the hydrau- .05%, the oil in the system should be drained and
lic system. New hydraulic fluid as received by the replaced.
user is generally NOT in a satisfactory cleanliness
condition for long component life. Particle Contamination - Excess contamination
in a hydraulic system will greatly shorten the life
OIL MAINTENANCE: Optimum life from hydrau- of pumps and motors. Your oil sample analysis
lic equipment can only be obtained with proper will show the number of particles per milliliter
hydraulic oil maintenance. This includes check- greater than a given micron size. The number of
ing the oil every three to six months. An oil particles in your sample should be less than the
should be checked for viscosity, oxidation, water following:
content, contamination and copper particles. A
record should be kept of each check to detect Particle Size No. of Particles /Milliliter
signs of progressive deterioration. Oil samples
should be taken with the system running at nor- 10 micron or larger 3,000
mal operating temperature. It is important to use
good technique in obtaining an oil sample. The 20 micron or larger 300
exact same procedure should be followed each
time an oil sample is taken. Most fluid suppliers 30 micron or larger 100
will provide assistance in analyzing your oil sam-
ple. The following are some gUidelines to use in 40 micron or larger 30
this analysis.
50 micron or larger 10
Viscosity - Many hydraulic fluids will shear or
thin out with use. The viscosity at each check 100 micron or larger 1
should be compared to the viscosity when new. At
no time should the viscosity be less than 45 SSU If your oil sample shows numbers greater than in
at 210°F. Ifviscosity is less than 45 SSU at 210°F, the chart, your hydraulic system is contaminat-
the oil must be replaced immediately. ed. The system should be checked for broken or
torn filters, plugged filters, stuck filter bypass
Oxidation - Oil oxidation will occur with age and valves and so forth. Continued operation with
use and is evidenced by a change in color and/or particle counts greater than those shown in the
odor, increased acidity, and possible formation of chart will result in short pump and motor life.
sludge, gum or varnish in the system. The rate of
oxidation increases significantly with operations Copper Particle Counts - The oil sample analysis
at temperatures over 140°F (60°C). The oil should should include a copper particle count in parts/
be checked more often if operation is at high tem- million. This number should normally be less
perature. The oxidation process increases the than 100. A high copper particle count indicates
acidity of the fluid and is measured by a neutral- that a gear pump or motor is rapidly deteriorat-
ization number. The oxidation process is typically ing. A count of 200 or more would be cause for
slow at first and then increases sharply in the fi- concern. The most important thing to look for is
nal stages of complete oxidation. A sharp in- a sudden increase in the copper particle count.
crease (by factor of 2-3) in a neutralization This indicates that a gear pump or motor has
number is a good indication that the fluid is suddenly begun deteriorating and a catastrophic
failure can be expected shortly.

VISCOSITY: Oils are available in various grades

(viscosities). The ISO (International Organization
for Standardization) viscosity classification sys-
tem is currently being adopted. The ISO grade ap- This machine is factory filled with Koehring
plies strictly to viscosity and does NOT imply type spec 805 hydraulic fluid that is acceptable
of oil. (engine, anti-wear, hydraulic, gear.etc.). A for start-up at ambient temperatures of 20°F
viscosity grade should be selected that will meet and should not be operated above a hydrau-
the minimum start up temperature requirement lic reservoir temperature of 200°F. If these
and the maximum operating hydraulic oil tem- limits are exceeded damage can result. For
perature. operation outside these ranges, select the
proper hydraulic fluid from the charts on
HYDRAULIC OIL (Initial Fill) this and the following pages or from a repu-
KOEHRING SPEC 805 DATA table supplier.
PHYSICAL
PROPERTIES TESTMETHOO REQUIRMENT
A. A.P.1. Gravity ASTM 0287 28 Min.
B. FLash Point ASTM 092 380° F Min.
C. Viscosity Index 100°F ASTM 0445 200-220 SSU

210°F ASTM 0445 46 SSUMIn.
O. Viscosity Index ASTM 02270 95 Min.
E. Pour Point ASTM 097 -25° F Max.
F. Oxidation Test ASTM 0943 2500 Hours Min.

to 2.0 Neut. No. ASTM 0943 2500 Hours Min.
G. Rust Test ASTM 0665 Procedure A Pass
H. Foam Test ASTM 0892 Foam Tendency Foam Stability

Sequence 1 25 ml Max. Nil
Sequence 11 50ml Max. 10 ml Max.
Sequence 111 25 ml Max. Nil
I. Oemulsibility ASTM 01401to 40-37-3 point 30 Min. Max.
J. Aniline Point ASTM 0611 200-230° F
K. Pump Wear Oennison HFO Satisfactory

or Vickers M2905 (100
Hrs.@150° F)
L. %Zn ASTM 01549 .07 Min.
M. Filterability Fluid shall show no additive loss when

filtered through 5.0 micron filter.
N. Cleanliness Fluid shall appear bright and clear

and shall be free of visible contami-
nants or sludge.

GRADE SELECTION CHART
Maximum life of pumps, motors, hoses, and seals will be obtained by selecting an oil as far down the
chart as possible.
Viscosity Minimum Ideal Cont. Maximum
Grade Start-UP Operating Operating Selection Guide
I.S.O. A.S.L.E. Temp. Hyd. Oil Hyd. Oil Lines
Temp. Temp.
(New) (Old)
*
-30°F l60°F 19soF
Extreme cold start can
be used year round in
Synthetic (-8°C) (71°C) (91 DC)
most machines in tem-
perature climates
Cold Climate Year
Multi. Round. Must Be
Viscosity OaF 130°F 190°F Changed More
(-17.8°C) (S4°C) (88°C) Frequently Than
Straight Grades
Winter Oil For

22 0° F lOS of l60°F Ambient Temperatures
(-17.8°C) (41°C) (71 DC) Up TO 60°F
(16°C)
ISO SOF 120°F 180°F

(-lS0C) (49°C) (82°C) For Ambient
Temperatures Up To
80°F
32 10°F 120°F 180°F (27°C)
(-12.2°C) (49°C) (82°C)
21S lsoF 140°F 200°F Can Be Used Year

(-9.4°C) (60°C) (93°C) Round In Most Ma-
chines In Temperate
Climates
46 20°F 14soF 200°F
(-6.7°C) (63°C) (93°C)
31S 2soF lSsoF 200°F Well Suited For Most

(-3.9°C) (68°C) (93°C) Machines In Southern
U.S. And As Summer
Oil For Heavily Loaded
68 30°F l60°F 200°F Machines In Central
(-l.l°C) (71°C) (93°C) And Northern U.S.
Especially Suited For

100 3soF 17soF 200°F Regions With Ambient
(-l.l°C) (80°C) (93°C) Temp. Range From
100°F To 120°F
* Minimum temperature for starting without extended warm-up. For lower temperatures, follow
warm up procedure in the operators manual.
RTSOO Series 4 - 24 Issued: August 2000

PREMIUM GRADE ANTI-WEAR

HYDRAULIC OILS
OIL COMPANY ISO BRAND NAME OIL COMPANY ISO BRAND NAME
32 Ama-Oil R&O 100 AW 32 Kenoil R&O AW 32

Amalie Refining Co. 46 Ama-Oil R&O 200 AW Kendll Refining Co. 46 Kenoil R&O AW 46
(USA) 68 Ama-Oil R&O 300 AW (USA) 68 Kenoil R&O AW 68
100 Ama-Oil R&O 500 AW 100 Kenoil R&O AW 100
32 AmocoAW 32 32 DTE 24/DTE-13M

Amoco Oil Co. 46 Amoco AW 46 Mobil Oil Corp. 46 DTE 25/DTE-15M
(USA) 68 AmocoAW68 68 DTE 26/DTE-16M
32 DuroAW32 Northland 32 Talamar 150

Arco 46 DuroAW46 Products 46 Talamar 215
68
100
DuroAW68
DuroAW 100
(USA) 68
100
Talamar
Talamar
315
465
*
Conoco DN 600 (Artic) AWX Multi-Viscosity
Conoco Super Hyd. 5W-20 Pennzoil Products 32 AW 32 Hyd. Fluids
Conoco (Multi Vicosity) Co. 46 AW 46 Hyd. Fluids
32 Conoco Super Hyd. 32 (USA) 68 AW 68 Hyd. Fluids
46 Conoco Super Hyd. 46 100 AW 100 Hyd. Fluids
68 Conoco Super Hyd. 68
100 Conoco Super Hyd. 100 Shell Co. (Canada) 37 Tellus T37 (Multigrade)
D-A Lubricant Co. 32 D-A Hydra Shield 32 23 Tellus 23

Inc 46 D-A Hydra Shield 46 Shell Co. 32 Tellus 32
(USA) 68 D-A Hydra Shield 68 (USA) 46 Tellus 46 (XSL 9101)
100 D-A Hydra Shield 100 68 Tellus 68
100 Tellus 100
32 Paradene Anti-Wear 32 AW
Dryden Oil Co. 46 Paradene Anti-Wear 46 AW 32 Sunvis 816 WR
(USA) 68 Paradene Anti-Wear 68 AW Sun Oil Co. 46 Sunvis 821 WR
100 Paradene Anti-Wear 100 AW (USA) 68 Sunvis 831 WR
100 Sunvis 851 WR
32 Nuto-H 32
Exxon Co. 46 Nuto-H 46 Rando Oil HD A2 (5w-20)
(USA) 68 Nuto-H 68 Texaco Inc. 32 Rando Oil HD 32
100 Nuto-H 100 (USA) 46 Rando Oil HD 46
68 Rando Oil HD 68
32 Gulf Harmony AW 32
Gulf Oil Co.
(USA)
46
68
Gulf Harmony AW 46
Gulf Harmony AW 68 * Factory filled with Northland Talamar 215 or
100 Gulf Harmony AW 100 equivalent.
32 Nuto H 32
Imperial Oil Limited 46 Nuto H 46
(Canada) 68 Nuto H 68
80 Nuto H 80
100 Nuto H 100
KOEHRING SPEC 805 IS EQUIVALENT TO HYDRAULIC OILS SHOWN ABOVE

CABLE LUBRICATION METHODS

Hot Application
GENERAL We are covering the more commonly
used methods oflubricating cable (wire rope). For
special cable lubrication problems consult the
cable manufacturer.
HOT APPLICATION A heated bath is placed in

the path of the wire rope, and the rope is passed
through the hot lubrication over sheaves and a
center guide wheel. Hot oils or greases have ex-
cellent penetrating qualities and upon cooling
Continuous Bath
have high adhesive and film strength around
each wire.
CONTINUOUS BATH Run an operating rope

through a specially constructed casing that has
been packed with swabbing and loaded with lu-
bricant. This affords continuous lubrication.
DRIPPING A container can be placed above the

Dripping
sheave, so that the rope can be lubricated by
opening a spigot. Sheaves are the best location
for lubricating operating wire ropes, because the
wires and strands open somewhat as they bend
along the groove.
POURING Lubricant can be poured on. The rope

should be lightly loaded and run slowly while be-
ing lubricated.
Pouring
SWABBING AND PAINTING Lubricant can be
swabbed on with rags, or painted on with a
brush. Both are quick methods which can be
made pact of the operating routine.
1 SPRAYING A light lubricant containing solvents

can be applied to a wire rope by a properly direct-
ed spray nozzle.
Swabbing
And Painting
AEROSOL SPRAYING Installations requiring
only small amounts of lubricants, or only occa-
sional applications, may find the new aerosol
cans of lubricant useful. They are available from
several lubricant manufacturers.
Aerosol Spraying

ELECTRICAL SYSTEM
BATTERY CHECK
MAINTENANCE CHECK Observe all instruments nals. Make certain the negative cable is making a
and gauges while operating machine and carry- good connection where it is grounded to the en-
ing out your DAILY MAINTENANCE checks. Re- gine and the positive cable to. the starter relay. If
place or repair any malfunctioning instruments the "Visual Inspection" is satisfactory, proceed to
or gauges. Step 2.
BATTERY The maintenance free battery is locat- Step 2 -Electrolyte Levels And State OF
ed under the battery cover on the left hand side Charge- Check the electrolyte level in the cells if
of machine. Use maintenance free battery charg- possible. The level can be seen through translu-
ing information. cent plastic cases. It can also be checked in bat-
teries which are not sealed. If the electrolyte level
A maintenance-free battery does not require the is below the tops of the plates in any cell, add wa-
addition of water during its life in normal service. ter if the vents are removable. If the battery is
This is due to the fact that maintenance-free bat- sealed, and water cannot be added to it, replace
teries produce little gas at normal charging volt- the battery and check the charging system for a
ages. malfunction such as a high voltage regulator set-
ting. Follow instructions of manufacturer if the
TESTING MAINTENANCE-FREE BATTERIES battery has a special indicating device.
If the level is O.K., unknown or water can be add-

ed to the battery, and the stabilized open circuit
voltage is below 12.4 volts, charge the battery as
described under "Charging". The voltage is stabi-
Whenever the battery is placed on charge. Wear lized if the battery has stood overnight without
safety glasses. Do not break "live" circuits at the being charged or discharged. If the battery has
battery terminals. Maintenance-free batteries of been on charge, the voltage can be stabilized by
the latest design incorporate flame arrester vents placing a 15 ampere load across the terminals for
to reduce the possibility of explosions caused by 15 seconds. Another method of stabilization is to
external sparks. Therefore, during charging, the turn on the headlamps for 15 seconds. Read the
vents, if removable, should remain in place. A wet voltage at least three minutes after the discharge
cloth should be placed over the vent openings as load is removed. When a hydrometer reading can
an additional precaution. be taken, a value of 1.225 @ 80°F (26.7°C) can be
used instead of the 12.4 voltage reading. If the
Step 1 -Visual Inspection- Visually inspect the battery has a test indicator follow the instruc-
outside of the battery for obvious damage such as tions of the manufacturer. Mter the battery is re-
a cracked or broken case or cover which would al- charged, stabilize the voltage as described above,
low electrolyte loss. Check for terminal damage. then proceed to Step 3.
If obvious physical damage is found, replace the
battery. If possible, determine the cause of dam- If the stabilized voltage of the battery was above
age and correct. 12.4 volts when it was first examined, or the test
indicator indicated the battery is charged, pro-
Check the condition and size of the cables. Are ceed to Step 3 without charging the battery.
the cable clamps tight? Check for corrosion on
the terminal or clamps. Clean corroded parts Step 3 -Load Test Procedure- The load test pro-
and/or tighten clamps if necessary. Replace bad- cedure is conducted to determine if the battery
ly corroded cables or cables with defective termi- requires recharging or replacement.

A. Disconnect the battery cables (ground con- also may have a safety feature that prevents
nection first) and connect the voltmeter and sparks and reverse charging when the clamps are
load test leads to the battery terminals, mak- connected in reverse, by mistake.
ing sure the load switch on the tester is in the
"OFF" position.
B. Apply a test load equal to 1 /2 the Cold
Cranking Amperes @ OaF (-18°C) Rating of the
battery, for 15 seconds. (Example: a battery B'lTTffiV 155
IJO..TS
has a Cold Cranking Rating @ OaF (- 18°C) of 150
350 amperes. Use a test load of 175 amperes.) (CMEF)
C. Read the voltage at 15 seconds and remove 145
the load. If the voltage is less than the mini-
mum specified in the "Voltage Chart" (see
"Maintenance-Free Battery Testing Chart", in
Troubleshooting section) replace the battery.
If the voltage meets or exceeds the specified 314 RJLL
minimum, clean and return battery to ser- B'lTTERVSTATEOFa-tAffiE
vice.
If the state of charge of a battery cannot be deter-
mined and the battery fails the load test, it must Place a wet cloth over the vent opening or open-
be recharged and retested. If it meets the speci- ings. If, when charging the battery, violent gas-
fied voltage on the second test return it to service. sing or spewing of electrolyte occurs, or the bat-
If it does not meet the speCified voltage on the tery case feels hot (125°F, 52°C), reduce or
second test, replace the battery. temporarily halt charging to avoid damaging the
battery.
The above is a standard test procedure to deter-
mine the ability of a battery to function properly. Follow the manufacturer's instructions on the
If a commercially available tester is being used to charger. If they can no longer be read and a copy
analyze the battery, follow the instructions of the of them is not available, write to the manufactur-
equipment manufacturer. er for a copy and paste it on the charger. Never
use a charger without these instructions.
CHARGING MAINTENANCE-FREE BATTERIES
Always turn the charger to the "OFF" position be-
Maintenance-free batteries contain sulfuric acid fore connecting the leads to the battery. If you
and generate explosive hydrogen and oxygen gas- have any doubts that the charger is actually
es the same as all lead acid batteries. No one "OFF", disconnect it from the power source.
should charge a battery unless they have been
thoroughly instructed concerning the step by The state-of-charge of maintenance-free batteries
step procedures to use and the safety precau- can be determined with an accurate voltmeter. A
tions to take. voltmeter should not be used unless it can be
checked frequently against one of known accura-
It must be realized that maintenance-free batter- cy. If the stabilized voltage of a battery at room
ies cannot be charged at ampere rates or periods temperature is 12.2 volts, is should be charged
of time greater than specified in the "12-Volt for one-half the time shown in the "Slow Charge"
Maintenance-Free Battery Charging Guide". If column of the Charging Guide, at the applicable
the battery is charged more than specified, it los- rate in amperes. If the voltage is 12.4 volts, it
es water which cannot be replaced in some con- should be charged for one-fourth the time shown
structions so the life of the battery is shortened. in the "Slow Charge" column, at the applicable
Battery chargers for maintenance-free batteries charging rate. Follow the manufacturers instruc-
should include a charge duration control of some tions on batteries equipped with state-of-charge
sort. The simplest control is a timer which the op- indicators.
erator sets. Voltage controls can limit the charge
more conSistently and accurately. Such controls

Any battery which is known to be discharged or BOOST CHARGE If a battery requires a boost
has a stabilized voltage below 12.2 volts should be charge, it should be charged at 45 amperes for 20
charged as shown below. minutes. This cannot be used for a new battery
being prepared for installation.
12-VOLT MAINTENANCE-FREE BATTERY
CHARGING GUIDE MODIFIED CONSTANT POTENTIAL TAPER
Battery Capacity CHARGING It is recommended that mainte-
(Reserve Minutes) Slow Charge nance-free batteries be recharged on a modified
constant potential taper chargers. The total
Above 125 to 170 20 Hours @ 5 Amps charge must not exceed the ampere-hour equiva-
Minutes 10 Hours @ 10 Amps lent of the values shown in the "Charging Guide".
It is recommended that the initial charging rate
NOTE: If a battery is to be charged overnight, (16 not exceed 30 amperes.
hours) a timer or voltage controlled charger is rec-
ommended. If the charger does not have such con-
trols, a 3 ampere rate should be used for batteries
of 80 minutes or less capacity and 5 amperes for
above 80 to 125 minutes reserve capacity batter-
ies. Batteries over 125 minutes should be charged
at the specified SLow Charge rate.
ELECTRICAL SYSTEM COLLECTOR RING
ELECTRICAL COLLECTOR RING When trouble- COLLECTOR RING MAINTENANCE If not re-
shooting the electrical system, always check the volved for some time, under some conditions, the
collector ring first to see that the spring-loaded ring will have a tendency to collect fine silt, or salt
brushes are centered in the bands. Keep free of atmosphere will cause corrosion. If this happens,
any foreign material. the crane should be rotated through several revo-
lutions if possible. The cleaning action of the
Keep the set screws on the collector ring tight. brushes should clean the ring surfaces. If it does
Otherwise the wire harness may wrap up as the not, or it is not practical to revolve the machine, it
machine is swung. may be necessary to use a standard non-residue
solvent to clean the ring. Then lightly sand the
The cover should allow for free operation of the brushes and rings with a fine grade of sandpaper
collector ring and the brake. If linkages bind, er- and dust off with compressed air.
ratic operation may result. Check for unrestricted
operation.

MAINTENANCE CHECKS On a daily basis, in- MAINTENANCE CHECK Every 1WO YEARS OR
spect the cylinder mounting brackets, bushings, 4000 HOURS disassemble and inspect the winch
and pins for wear, tightness and damage. If mis- components. These include the gearing, bear-
alignment or excessive play or wear are detected, ings, and brake friction discs. Refer to the Service
replace the defective pin or bushing. Check the Manual for disassembly procedures.
rod eye welds for cracks and breaks.
LUBRICATION Lubrication for the winch is pro-
Inspect the hydraulic cylinder rods for nicks, vided by weepage flow from the drive motor. Oil
dents, and scoring as part of your WEEKLY enters the final drive end through the drive shaft
MAINTENANCE check. Also check the cylinders tube in the drum. A drain line on the main drive
for leaks at the wiper seals. Repair or replace any end cover returns excess oil to the reservoir.
damaged components.

CABLE REEVING
CABLE REEVING When reeving the machine for This machine incorporates a "Quick Reeving"
any job, remember that hoisting and lowering boom head and block which do not require re-
speeds decrease as the number of parts ofline in- moval of the wedge and socket from the rope in
creases. For the most efficient use of the ma- order to change the reeving. Removal of two pins
chine, it is desirable to use the minimum number in the boom head and three in the hook block
of required parts for lifting the anticipated loads. will allow the wedge and socket to pass through.
Never use less than the number of parts called NOTE: If a socket is changed or replaced, or if
for by the load rating chart. The minimum re- you are changing hook block weights, it is IM-
quired - number of parts is determined by refer- PORTANT to use the correct socket.
ring to the load rating chart.
SPOOLING WIRE ROPE ON DRUMS
Care must be exercised when installing wire rope If cable is wound from the storage reel onto the
on the winch drum. Improper spooling can. re- drum, the reel should be rotated in the same di-
sult in rope damage through crushing, kinking, rection as the hoist.
doglegs, abrasion and cutting. Poorly installed
wire rope will also adversely affect the operating
characteristics of the machine by causing uneven
application of force and motion. This, in turn, can
cause premature fatiguing and failure of the
rope.
Thoroughly inspect and clean the winch before

proceeding with the installation. Check the lag-
ging and drum flanges for cracks, breaks and ex-
cessive wear. Deformed or outsized drum and
excessive undercutting at the base of the flange
also indicate that repair or replacement of the
drum is necessary.
Check the bearings for excessive wear and play.

Mter correcting any defects revealed by the in-
spection and determining that the winch is in
good operating condition, spool the wire rope as
follows: Apply braking force to the reel flange in order to
prevent overrun as the rope is being drawn off.
Mount the cable shipping reel vertically on jacks Loops formed by overrun can cause kinks and
or a suitable supporting structure, with a pipe or doglegs in the rope, resulting in damage and pre-
bar through the reel center. The cable should be mature rope failure. A timber or block forced
drawn from the top of the reel, as shown, in order against the shipping reel flange can be used to
to avoid reverse bending as it is spooled onto the provide the required braking force.

WIRE ROPE AND REEVING
MAINTENANCE All wire ropes in active service Replace or repair any items found to be in unsat-
should be inspected DAILY along with spooling, isfactory condition.
sheaves, wedge sockets, and any otherwire rope
fittings for damage. Once WEEKLY a through
wire rope inspection should be made by a compe- In addition to damage such as kinking, crushing
tent inspector. A record should be kept of the in- and broken wires, factors such as corrosion, abra-
spections on 4-5. sion, pitting, peening and scrubing of the outside
wires, redution of rope diameter, the condition of
Refer to Wire Rope Users Manual, section 9 and other components and proper lubrication are con-
ANSI Standard B30.5 for guidlines covering the
sidered. Refer to page 4-26 for wire rope lubricat-
inspection, maintenance, repair, and replace-
ment of wire rope. Worn, kinked, birdcaged, fa- ing procedures.
tigued or otherwise damaged wire rope must be
removed immediately. Wire rope when properly Before installing a new or replacement rope, make
installed, lubricated and employed, will give certain the rope to be used is the proper type and
many hours of satisfactory use. Whereas, a new size. The wrong rope will not fuction properly and
piece of wire rope can be immediately ruined if
may even be dangerous.
misused.
WIRE ROPE SPECIFICATIONS
MAIN WINCH
STD.-5/8" dia. 6X19 OR 6X37 CLASS

MINIMUM BREAKING STRENGTH-17.9 TONS
CRUSHED ROPE
REMOVE AT ONCEI OPT.- 5/8" ROTATION RESISTANT
COMPACTED STRAND 18X19 OR 19X19
AUXILIARY WINCH
STD.-l/2" 6X19 OR 6X37 CLASS

KINKED ROPE
REMOVE AT ONCEI
OPT.-9/16" ROTATION RESISTANT
COMPACTED STRAND 18X19 OR 19X19
Koehring permits the use of rotation resistant wire

rope, other types are not approved. When this rope
is used the working load shall not exceed 1/5th
(20%) of the rated breaking strenght. The retire-
BIRD CAGING ment criteria shall be as follows: two broken wires
REMOVE AT ONCEI
in six rope diameters or four broken wires in thirty
rope diameters.

Install cable on the winch drum in accordance The end of the cable should be even with the bot-
with the following procedure. tom of the anchor wedge.
l.Position the cable over the boom tip sheave and NOTE: If the wedge does not seat properly in the
route back to the winch drum. slot, carefully tap the top of the wedge with a mal-
let.
2.Position the winch drum with the cable anchor
slot on top. WEDGE
3.1nsert cable through slot and position around

the cable wedge.
4.Position the anchor wedge in the drum slot;

pull firmly on the free end of the cable to secure
the wedge.
5.Slowly rotate the drum, ensuring the first layer

of cable is evenly wound on the drum.
6.1nstall the remainder of the cable, as applica-

ble.
WINCH DRUM WEDGES
WHERE USED PART NUMBER

-
MAIN WINCH B49411
1
AUXILIARY WINCH B52661 -
CABLE SOCKETS AND WEDGES
WHERE USED PART NUMBER
5/8" CABLE SOCKET 1234-18
5/8" SOCKET WEDGE 1234-19
9/16" CABLE SOCKET B4070
9/16' SOCKET WEDGE 7076999
1/2" CABLE SOCKET B4070
1/2" SOCKET WEDGE B17006

The wrong cable wedge could permit the wire

rope to work lose and detach itself from the
drum; possibly causing property damage or per- 2. Insert the wedge and allow the rope strands to
sonal injury. adjust around it.
Tension the wire rope by braking the shipping

reel and slowly operate the winch in the raise
mode to wind the cable onto the winch drum. As
the spooling proceeds, make sure the adjacent
turns are tight against one another. A lead or
brass hammer may be used to tap the rope over
against preceding turns. Tight winding on the WORKING END
drum is absolutely essential.
3. Seat the wedge and loop just tightly enough to

allow handling by attaching the socket to a
strong support and engaging the winch to take
a strain on the rope.
Never use a steel hammer or pry bar to move the 4. Final seating of the wedge is accomplished by
rope over on the drum. These tools can easily making lifts of gradually increasing loads. avoid
damage the rope. imposing shock loads on the rope until the
wedge is firmly in place.
Mter the rope is wound onto the winch drum,
reeve the cable as desired.
Use only factory supplied sockets, wedges and

pins of the proper size; make no substitutions.
5. Mter the wedge has been firmly seated, a short
Follow the procedure below when installing length (6 inches) of the cable should be secured
wedge type sockets on wire rope. Be certain the to the free end of the wire rope to act as a stop
correct socket and wedge are used. as shown. DO NOT clamp the free end to the
load supporting end as this will weaken the
1. Lead the rope through the socket, form a large rope.
loop and draw the rope end back through the
socket. A length of rope equal to at least one
rope lay should be drawn back through.

CRANE BOOM
WEEKLY:
STRUCTURAL MEMBERS AND WELDS Visually
inspect all structural members and welds includ-
ing (but not limited to) the extended boom for
straightness, roller (or pad) adjustment, and
cracks. Pay special attention to the longitudinal
welds joining the top, side and bottom plates.
If any cracks in either fillet welds or plates are
Check the welds attaching the jib ears to the
noted, the particular component must be re-
boom head and the welds attaching the boom
placed before any further crane operations are
head to the tip section. Inspect the cylinder at-
performed. This is necessary to maintain the
taching supports and the boom pivot area.
structural strength of the boom and prevent pos-
sible catastrophic failure resulting in injury or
On the superstructure, inspect the superstruc-
property damage.
ture as well as the welds on the hoist cylinder
supports and the welds between the bottom
Field repair of boom sections is NOT recommend-
mounting plate and the vertical plates. This is es-
ed because distortion may be introduced and
pecially important if the machine is being used
original structural strength not restored.
extensively in clamshell, pile driving, concrete
pouring, headache ball, or other high duty cycle
Boom extension indicator decals are extremely
applications.
important and must be maintained in place at all
times. Boom section failures can occur due to
On the carrier, inspect the swing bearing weld
overstressing within rated capacities if the sec-
band and supporting header welds. Check the
tions are not equally extended within one indica-
outrigger attaching welds, outrigger box ends at
tor mark difference between the telescoping
the collar, jack cylinder mounting tube, and the
sections.
beam welds.
NOTE: Sections are equalized byfully extending or ful-
ly retracting the boom. When the boom reaches either
BOOM Visually inspect all boom sections a mini-
full extension or retraction continuing to hold the tele-
mum of weekly or every fifty (50) hours, whichev-
scope lever in the extended or retracted position will al-
er occurs first. Preparatory to making the
low the boom sections to be proportioned equally.
inspection, set the outriggers and rotate the up-
per to an area where the boom can be fully low-
If any indicator decals are missing or illegible (ei-
ered and extended.
ther triangle markers or boom length numbers),
order the applicable items through your distribu-
With the boom fully lowered and extended, visu-
tor and apply them using the dimensions given
ally inspect the sides, top and bottom of each sec-
on the following page.
tion for any unusual deformation, scrubbing,
wear, or cracking in either the plates or welds,
particularly the fillet welds along the bottom edge
of the side plates of the telescoping sections. In
addition, note any missing or illegible indicator
mark decals on the telescoping sections.

Markers and numbers are located on the left

hand side of the boom sections. Apply them with
the boom fully extended. Start at the rear of each
section and apply the first marker, or appropriate
number, at the first over-lap point. Measure for-
ward for each subsequent location.
I~\ q
LJ/
0 0 0 70 0 6 81 9
I--
96.000
10"
48.000 --
r
t::r
BASE
2nd 144.000
S ECTION
SECTION 192.000
240.000
144.00 -------;~
2nd
3rd 195.09 - - - - - - - - - - 1 SECTION
SECTION 243.09 - - - - - - - - - - - - 1
150.78 - - - - - - 1
4th 3rd
SECTION 198.78 - - - - - - - - - 1 SECTION
246.78 - - - - - - - - - - - - - 1

TROUBLESHOOTING
INDEX
SECTION 5
SUBJECT PAGE
General Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
Hydraulic - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2
Operator Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 13
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
Engine Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
Parking Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
Air Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20
Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 21
Boom Hoist Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
Boom Telescope Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23
Winch Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24
Outrigger Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 28
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 31
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 33
Fluid Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -34
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 36
Cylinder Leakage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 37
Excessive Heating Of Oil In System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 38
Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 39
Propane Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 40
Maintenance Free Battery Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 43
Anti 1'wo Block System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 45
RT500 Issued: August 2000

TROUBLESHOOTING
As the operator, it is your responsibility to detect If you can't answer YES to all three questions, rely
any unusual, sounds, odors, or other signs of ab- on your Distributor Serviceman. He has the right
normal performance that could indicate trouble tools, testing equipment and service knowledge to
ahead. pin-point the problem in minutes instead of the
hours consumed in hit-or-miss methods. TIME IS
By detecting any problems in their early stages, MONEY! He will save it for you.
you can save yourself unnecessary downtime and
your employer a lot of money! Therefore, it is also If you decide to attempt an adjustment yourself,
your responsibility to use good judgment in de- follow a logical TROUBLE SHOOTING PROCE-
tecting failures in quickly and repairing them. If DURE. Don't simply replace pacts until the trouble
you don't, one failure can lead to another. is found.
Before attempting to make an adjustment your-

self, ask yourself if you have the RIGHT TOOLS, IF
you have the PROPER TEST EQUIPMENT and IF
you can accurately DIAGNOSE the cause of the
problem.
GENERAL PROCEDURE
I - KNOW THE SYSTEM Study this manual and 6 - TEST YOUR CONCLUSION Test your conclu-
learn what makes the machine "tick", how it sions' in order of obviousness, until the source of
should behave, sound and smell. the failure is found. The machine can then be re-
paired at minimal cost and downtime. Make the
2 - OPERATE THE MACHINE Test operate all ma- repair. Recheck to ensure that nothing has been
chine functions. Note all abnormal sounds, odors overlooked, functionally test the repaired pact in
and movements. Always proceed in the most logi- the system.
cal order to determine the cause.
7 - REVIEW MAINTENANCE PROCEDURES Pre-
3 - INSPECT THE MACHINE Look for leaks, listen vent recurrences of all premature failures by reg-
for the source of abnormal sounds, detect the ori- ularly checking the filters, temperature, adjust-
gin of unusual odors. Check the condition of the ments and lubrication. Make daily inspections.
oil and filters.
NOTE: Your safety and that of others is always the
4 - LIST THE POSSIBLE CAUSES Use your best number one consideration when working around
judgment in listing all possible causes of the fail- cranes. Safety is a matter of thoroughly under-
ure. standing the job to be done and the application of
good common sense. It is notjust a matter of "do's"
5 - REACH A CONCLUSION Review your list of and "don'ts". Stay clear of all moving parts.
possible causes and decide which are the most
likely to cause the failure. Consider the most obvi-
ous first.
RT500 Series Page 5 - 1 Issued: August 2000

TROUBLESHOOTING
HYDRAULICS - GENERAL
Before any troubleshooting is attempted, become If, in spite of these precautions, improper opera-
fully acquainted with the following two (2) basic tion does occur, the cause can generally be traced
fundamental facts of a hydraulic system: to one of the following:
1 - SPEED The speed of a hydraulic function is di- l. Use of the wrong viscosity or type of oil.
rectly related to the system flow. A reduction in
speed of a cylinder or motor is caused by an insuf- 2. Insufficient fluid in the system.
ficient quantity of oil being delivered to the compo-
nent. 3. Presence of air in the system.
2 - POWER The power or force of a hydraulic func- 4. Mechanical damage or structural failure.
tion is related to pressure.
5. Internal or external leakage.
If an understanding of the differences between
speed and power of a hydraulic system is under- 6. Dirt, decomposed packing, water, sludge, rust,
stood correctly, then accurate troubleshooting etc., in the system.
can be accomplished in a minimum amount of
time. 7. Improper adjustments.
8. Oil cooler plugged, dirty or leaking.
Whenever hydraulic, fuel, lubricating oil lines, or

air lines are to be disconnected, clean the adjacent
area as well as the point of disconnect. As soon
disconnected, cap, plug or tape each line or open-
ing to prevent the entry of foreign material. The
same recommendations for cleaning and covering
NEVER resort to increasing the valve relief apply when access covers or inspection plates are
pressure in an attempt to cure the ills of the removed.
system. Fully diagnose the problem.
Clean and inspect all parts. Be sure all passages
Hydraulic components are precision units and and holes are open. Cover all parts to keep them
their continued smooth operation depends on clean. Be sure parts are clean when they are in-
proper care. Therefore, do not neglect hydraulic stalled. Leave new parts in their containers until
systems. Keep them clean and change the oil and ready for assembly.
oil filter at established intervals.
Clean the preservative compound from all ma-
chined surfaces of new parts before installing
them.

TROUBLESHOOTING
OPERATOR - CONTROLS
CONTROL LEVER STICKS OR BINDS WITH THE ELECTRICALLY CONTROLLED

VALVES on the outriggers, three (3) spools must
Disconnect linkage at valve and again check for be checked.
binding.
The diverter valve should be checked by using a
If binding is still present, check linkage. Starting test gauge on the test port and activating the out-
from the valve end, disconnect the components rigger controls. If pressure (2500 psi) is indicated,
one at a time until the malfunction is located, and the spool is shifting.
then repair or replace that component. Note: Bind-
ing push-pull cables may simply have too tight a Check the outrigger extend-retract and function
bend at some point in their length. valves by pushing the. pins in prior to activating
the functions. Check to see if the appropriate pin
If the linkage is free, see the section on trouble- has been pushed back out as the functions are ac-
shooting of the particular circuit involved. tivated. If they have, the spools are shifting.
NO MOVEMENT OF THE FUNCTION If the spools do not all shift, check the electrical
connections. Frequently ground connection are a
Check to see that valve spool actuates when con- problem.
trol is operated.
If no electrical power is present at the valve, check
WITH CABLE CONTROLLED VALVES, visually the electrical wiring and correct the fault. Most
check spool for full travel when control is fully controls require a minimum of 10 volts.
shifted.
If power is present, repair or replace the solenoid
If spool does not shift, check linkage and repair or or valve section which is not shifting.
replace faulty component.
If the spools shift, see page 5-26, "Outrigger Cir-
If spool shifts, refer to sections on 1) Relief Valve cuit".
Troubleshooting; 2) Motor, Cylinder or Winch
Troubleshooting according to circuit being
checked; 3) Pump Troubleshooting; 4) Control
Valve Troubleshooting.

TROUBLESHOOTING
POWER STEERING
GENERAL DIAGNOSIS Whenever steering com- VISUAL INSPECTION

plaints are encountered, it is important that the
complete steering system be inspected. Special a. Look for poor loading practices.
body or equipment installations should also be b. Check tires for mismatch and proper air pres-
considered for their effect on steering perfor- sure.
mance. c. Check suspension for sagging or shifting (out
of line rear axles will tend to steer the front end
The steering system consists of the Sheppard In- of the vehicle).
tegral Power Steering Gear, a hydraulic supply
pump with pressure and flow controls and an oil MECHANICAL COMPONENTS INSPECTION
reservoir, the front axle and mechanical compo-
nents and the steering column or input shaft and a. Check all front axle components for wear,
connecting linkages. The front tires and wheels looseness or seizure.
must also be considered as part of the total steer- b. Inspect front and rear suspension components.
ing system. c. Check steering gear mounting to be sure it is
tight and not shifting on the chassis or axle.
Steering performance can be affected by out of d. Inspect steering column components.
line conditions anywhere in the total steering sys-
tem. Other factors outside the steering system Note: Keep in mind that the same problems that
can also contribute to poor steering performance. upset manual steering will also affect power
steering.
Many times a steering gear is removed and disas-
sembled needlessly, because an organized diagno- HYDRAULIC SUPPLY SYSTEM INSPECTION
sis procedure has not been followed. Start your
diagnosis by: Evaluate hydraulic supply system performance.
Follow procedures in the "Hydraulic Supply Diag-
DEFINING THE COMPLAINT nosis" section of Power Steering Manual. Oil
pressure and oil flow must be within the vehicle
a. Talk to and question the driver. manufacturer's specifications.
b. Drive the vehicle.
For specifIC diagnosis and repair of power steering

components refer to the manufacturer's manualfor
special procedures to follow.

TROUBLESHOOTING
FRONT AXLES
RAPID OR UNEVEN TIRE WEAR
CAUSE REMEDY
Incorrect toe-setting ........................................................ Check and reset toe-in if necessary.
Improper tire inflation ..................................................... InOate to proper pressure.
Unbalanced Tires ............................................................ Balance.
HARD STEERING
CAUSE REMEDY
Inadequate or improper lubrication of knuckle pins ........ Consult lubrication chart for proper lubri-
cant, lubrication intervals and procedures.
Improper caster ............................................................. .Adjust caster.
RAPID WEAR OF TIE ROD ENDS
CAUSE REMEDY
Inadequate or improper lubrication ................................. Consult lubrication chart for proper lubri-
Severely contaminative environment ............................... Clean and lubricate more often.

TROUBLESHOOTING
FRONT AXLES
BENT OR BROKEN TIE ROD, STEERING ARM,

TIE ROD ARM, OR BALL STUD
CAUSE REMEDY
Excessive power steering pressure .................................. Check steering pump relief setting, check
steering system relief setting; adjust as
required.
Misadjusted steering relief plungers ............................... .Adjust plungers to unload steering system
when wheels are turned to extreme posi-
tions.
HEAVILY WORN STEERING ARM

BALL STUD
CAUSE REMEDY
Spring and seat in drag link worn ................................... Replace spring and seat, replace ball stud.
EXCESSIVE WEAR OF KNUCKLE PINS

AND BUSHINGS
CAUSE REMEDY
Increase lubrication frequency when oper-
ating in extrem conditions.
FRONT AXLE SHIMMY OR VIBRATION
CAUSE REMEDY
Incorrect caster setting .................................................. .Adjust caster.
Wheels and/or tires not properly balanced ...................... Balance.
Worn shock absorbers ..................................................... Replace.

TROUBLESHOOTING
STEERING CIRCUIT
OIL LEAKING AT OUTPUT SHAFT OF STEERING GEAR
CAUSE REMEDY
Clogged oil filter in reservoir (high back pressure) ........... Replace filter.
Increase change frequency.
Pinched or restricted oil return line ................................. Locate and correct.

Check back pressure.
Damaged quad ring seal.. ................................................ Re place quad ring seal.
Damaged bronze bearings ............................................... Replace bronze bearings.

Polish output shaft or replace to remove
bronze deposits.
Damaged roller bearings ................................................. Replace roller bearings.

Polish output shaft or replace to remove
pitting & grooving in seal area.
OIL LEAKING AT ACTUATING SHAFT OF STEERING GEAR
CAUSE REMEDY
Worn or damaged oil seal ................................................ Re place seals.
Damaged actuating seal surface ...................................... Replace damaged parts

Lube bearing cap more often.
OIL LEAKING AT SUPPLY PUMP DRIVE SHAFT
CAUSE REMEDY
Damaged oil seaL ........................................................... Replace oil seal.
Oil seal heat damaged ..................................................... Check operating temperature.
Loose or damaged bushing on pump drive shaft .............. Repair pump per pump service instruc-
tions.
OIL LEAKING BETWEEN RESERVOIR AND PUMP BODY
CAUSE REMEDY
Seal or gasket damaged .................................................. Repl ace damaged parts.

TROUBLESHOOTING
LUBRICANT MILKY OR WHITE IN APPEARANCE
CAUSE REMEDY
Water entry through reservoir venting system ................. Clean vent system or replace cap assembly.
OIL FORCED OUT OF RESERVOIR
CAUSE REMEDY
Clogged oil filter .............................................................. Change oil and oil filter.

Increase change intervals.
Air in system .................................................................. Bleed air from system. Check for air leak
on suction side of supply pump.
Faulty supply pump (Cavitation) ..................................... Check supply pump following "Hydraulic
Supply-Diagnosis". Repair pump per pump
service instruction.
Relief plungers of steering gear

not adjusted properly ..................................................... .Adjust relief plungers
(see final adjustments)
LUBRICATING OIL DISCOWRED OR SMELLS BAD
CAUSE REMEDY
Operating temperatures too high ..................................... Check and correct cause of overheating.
Change intervals too long ................................................ Increase oil change frequency.
Incorrect lubricant used .................................................. Drain, flush and refill with lOW-40 motor
oil.

TROUBLESHOOTING
OIL IN RESERVOIR - FOAMING
CAUSE REMEDY
Air leak in suction side of supply pump .......................... Refer to pump servicing instructions.
Pump cavitating .............................................................. Check for restriction in pump supply.
Oil overheating ................................................................ See high operating temperatures.
Incorrect lubricanL ........................................................ Change to lOW-40 motor oil.
EXCESSIVE PUMP PRESSURE WITH STEERING GEAR IN NEUTRAL POSITION
CAUSE REMEDY
Pinched oil return line. High back pressure ................... Relocate line.
Binding steering column ................................................. Repair steering column.
Damaged actuating shaft bearing .................................... Replace damaged parts as required.
WHEEL CUTS RESTRICTED
CAUSE REMEDY
Relief plungers misadjusted ........................................... .Adjust relief plungers

(see final adjustments).
ERRATIC STEERING OR NO STEERING AT ALL
CAUSE REMEDY
Insufficient volume of oil being metered by

flow divider to steering gear induced by foreign
particles on flow divider valve, causing the
valve to hang up in the bore ............................................ Polish flow divider valve to remove foreign
particles and burrs. Refer to pump servic-
ing instructions.

TROUBLESHOOTING
HARD STEERING
CAUSE REMEDY
Faulty supply pump ........................................................ Refer to pump servicing procedures.
Front axle overloaded ...................................................... Correct loading practices.
Faulty steering geometry ................................................ .Align front end.
High operating temperature ............................................ Locate and correct cause of overheating.
WHEEL STEERING HARD IN ONE OR BOTH DIRECTIONS
CAUSE REMEDY
Bent or damaged king pins and tie rods .......................... Repair or replace king pins and tie rods.
Refer to servicing instructions.
Front end load too great for rated axle capacity ............... Lighten load or install larger steering gear.
Fatigued by-pass valve spring in pump ........................... Replace with flow control valve assembly.
Refer to pump servicing instructions.
Low oil level in steering system ....................................... Fill oil reservoir as required.
See "Lubrication".
Air in system .................................................................. Bleed system and check for cause of air.
Caster and camber degree incorrect ................................ Correct to "Specifications".
Metal or foreign material caught in actuating valve ......... Remove actuating valve. Clean and check
parts for damage.
Actuating valve worn or chipped by dirt .......................... If damage is excessive replace damaged
parts as required.
WHEEL STEERING HARD IN ONE DIRECTION
CAUSE REMEDY
Broken reversing springs in steering gear ........................ Replace reversing springs and damaged
parts. Refer to repair procedures to check
for additional damage.

TROUBLESHOOTING
WHEEL STEERING HARD IN ONE DIRECTION (CONTINUED)
CAUSE REMEDY
Metal or foreign material in relief

ball seat in piston of steering gear................................... Remove piston and clean relief valve seats
or replace damaged parts.
Foreign material in relief valve ........................................ Clean relief valve.
STEERING EXTREMELY LIGHT IN ONE OR BOTH DIRECTIONS
CAUSE REMEDY
Bent or damaged reversing springs ................................. Check for impact or accident damage.
Replace damaged parts.
EXCESSIVE BACKLASH
CAUSE REMEDY
Worn universal joint.. ...................................................... Replace universal joint.
Worn pins and keys in universal joint

to actuating shaft and universal joint
to steering shaft.. ............................................................ Replace pins and keys.
Low oil volume ................................................................ Check flow divider and pump drive belts.
Pitman arm ball worn "egg-shaped" ................................ Replace pitman arm assembly where riv-
eted ball is used or only where bolted ball
is used (vertical socket).
Improperly adjusted drag link, pitman arm

to drag link and steering arm to drag link ...................... .Adjust drag link, drag link to pitman arm
and drag link to steering arm.
Loose bracket frame to bracket or bracket to gear ........... Remove bracket. Clean frame and bracket.
Check radius of frame making sure bracket
is not bearing on radius surface. Check
bracket for wear from working. Replace
bracket and tighten to recommended
torque rating according to size and grade
of bolts. If necessary, replace bracket with
new one.

TROUBLESHOOTING
EXCESSIVE BACKLASH (CONTINUED)
CAUSE REMEDY
Rack on piston damaged ................................................. Replace parts as required.
Damaged pinion gear on output shaft ............................. Replace pinion gear.
Damaged output shaft splines ......................................... Replace output shaft.
Worn output shaft bushings ............................................ Re place bushings and polish shaft to
remove bronze deposits.
Worn pitman arm splines ................................................ Replace worn parts.
Worn actuating shaft and valve threads .......................... Replace worn parts as required. Follow
"Hydraulic Supply Diagnosis" procedures
to locate cause of wear.
Damaged reversing springs ............................................. Check and repair as required.
Universal joint yoke loose on actuating shaft ................... Repair or replace damaged parts, check for
spline wear.
NO ATTEMPT TO RETURN STRAIGHT AHEAD FROM TURNS
CAUSE REMEDY
No positive caster. ........................................................... Set to 4° to 6° positive caster.
Steering column bind .................................................. .... Check and repair U-joints and support
bearings.
Steering gear mounting distorted .................................... Shim mounting pads to correct piston to
bore interference.
Linkage ball sockets seized or binding ............................. Check and repair or replace.

TROUBLESHOOTING
REAR AXLE
HUMMING NOISE WHILE DRIVING
CAUSE REMEDY
Improper or inadequate lubrication ................................. Consult lubrication chart for proper lubri-
cant, lubrication interval, and procedure.
Bearing rollers worn ....................................................... Replace bearing. Always replace both cups
and cones.
EXCESSIVE VIBRATION
CAUSE REMEDY
Twisted or broken axle shaft ........................................... Replace axle shaft.
Fractured axle shaft at fiange .......................................... Replace axle shaft. Examine axle housing
for bent condition. Make certain wheel
bearings are correctly adjusted.
See page 6 - 12.
ALTERNATOR
OPERATION NOISY
CAUSE REMEDY
Worn or dry bearings ...................................................... Replace worn bearings.
Alternator mounting loose ............................................... Tighten alternator mounting.
Belt loose ........................................................................ Replace worn belt or tighten loose belt.
Brush holders out of alignment.. ..................................... Replace brush holders.
Brushes not seated properly ........................................... Reseat or replace brushes.
Armature unbalanced ..................................................... Replace armature.
Commutator out-of-round .......................................... ..... Dress commutator.

TROUBLESHOOTING
OPERATION NOISY (CONTINUED)
CAUSE REMEDY
Loose windings ............................................................... Replace defective windings.
Armature rubbing ........................................................... Replace bearings.
EXCESSIVELY HIGH ALTERNATOR ELECTRICAL OUTPUT
CAUSE REMEDY
Alternator regulator out of adjustment.. ....................... ... Replace regulator.
Field leads shorted .......................................................... Replace or repair alternator.
Alternator regulator shorted ............................................ Replace regulator.
ALTERNATOR MECHANICALLY INOPERATIVE
CAUSE REMEDY
Belt loose ........................................................................ Tighten belt.
Armature shaft sheared .................................................. Repl ace or repair alternator.
LOW OR NO ALTERNATOR ELECTRICAL OUPUT
CAUSE REMEDY
Field coil open ................................................................. Replace or repair alternator.
Brushes dirty, worn, pitted, or burned ......................... ... Replace or repair alternator.
Alternator regulator defective .......................................... Replace regulator.
Alternator to regulator field leads

open or connections loose ............................................... Tighten connections or replace field leads.

TROUBLESHOOTING
ALTERNATOR OVERHEATS
CAUSE REMEDY
Loose or worn belt or pulley ........................................... .Adjust belt, or replace worn belt or pulleys.
Misalignment .................................................................. Inspect mounting brackets and tension

adjusting arm for looseness. Tighten or
replace parts as required.
STARTER
STARTER INOPERATIVE
CAUSE REMEDY
Commutator dirty ...................................................... ..... Clean commutator.
Brushes worn ................................................................. Replace brushes.
Starter relay malfunctioning ........................................... Repair or replace relay.
Pinion spring broken or weak .......................................... Replace or repair starter.
Frame housing defective ................................................. Replace or repair starter.
ENGINE CLUTCH
CLUTCH SLIPPAGE
CAUSE REMEDY
Insufficient clutch pedal free play .................................. .Adjust release bearing position, then
adjust linkage if necessary.
Linkage blocked from complete return ............................ Remove blockage.
Linkage needs lubrication ............................................... Lubricate linkage.
Release bearing locknut loose ........................................ .Adjust release bearing length and tighten
locknut.

TROUBLESHOOTING
CLUTCH SLIPPAGE (CONTINUED)
CAUSE REMEDY
Worn clutch disc facings ................................................. Replace clutch disc.
Worn or damaged fiywheel .............................................. Resurface or replace flywheel.
Worn or damaged clutch pressure plate .......................... Replace pressure plate and cover assembly.
Grease or oil contamination on facings ............................ Clean facings and repair cause of contami-
nation. If contaminant cannot be
removed, replace clutch disc.
New clutch installation needs break-in ......................... ... Perform clutch break-in procedure.
CLUTCH DRAG/HARD SHIFTING
CAUSE REMEDY
Linkage blocked from full travel ...................................... Remove blockage.
Linkage incorrectly adjusted .......................................... .Adjust clutch linkage.
Linkage worn/damaged .................................................. Replace faulty linkage components.
Clutch damaged
- damaged clutch disc hub splines
- bent clutch disc
- bent drive straps
- broken/warped pressure plate ...................................... Replace damaged component.
Contamination/ grease in release bearing bore ................ Clean release bearing bore and transmis-
sion input shaft.
Excessive side loading on release bearing ........................ Eliminate source of excessive side loading
(worn/ damaged cross shaft bushings,
worn/ damaged cross shaft, worn/damaged
or bent release yoke tips, worn/damaged
or uneven release bearing yoke contact
wear pads, excessive release bearing travel
during disengagement, worn/ damaged
pilot bearing, excessive flywheel runout,
excessive engine to transmission misalign-
ment, etc.).

TROUBLESHOOTING
CLUTCH DRAG/HARD SHIFTING (CONTINUED)
CAUSE REMEDY
Failed pilot bearing ...................................................... ... Replace pilot bearing and input shaft if
damaged.
Transmission input shaft splines worn/damaged ............ Replace input shaft.
Tight or contaminated clutch disc splines ....................... Clean clutch disc and input shaft splines or
replace clutch disc as necessary.
Flywheel housing to clutch housing
excessive misalignment ................................................... Replace faulty housing.
Grease or oil contamination on facings ............................ Clean facings and repair cause of contami-
nation. If contaminant cannot be
removed, replace clutch disc.
BRAKES
INSUFFICENT BRAKE ACTION
CAUSE REMEDY
Improper brake shoe adjustment ................................... .Adjust brake shoes.
Worn brake linings .......................................................... Adjust for lining wear or replace brake
shoes.
Blocked. bent, or broken tubing or hose .......................... Remove obstructions in line or replace
faulty tubing.
Brake valve delivery pressure below normal .................... Clean and replace worn parts if brake valve
is defective, replace unit.
Insufficient parking brake valve delivery pressure ........... Clean and replace worn parts, or if valve is
defective, replace unit.

TROUBLESHOOTING
BRAKES RELEASE TOO SWWLY WITH PEDAL RELEASED
CAUSE REMEDY
Insufficient brake shoe clearance ................................... .Adjust brake shoes.
Weak or broken valve diaphragm return spring ............... Replace brake valve.
Relay or qUick-release valve exhaust

ports obstructed ...................................................... ....... Clean or replace faulty unit.
ONE BRAKE DRAGS WITH PEDAL RELEASED
CAUSE REMEDY
Insufficient brake shoe clearance ................................... .Adjust brake shoe clearance.
Brake shoe binding on anchor pin .................................. Remove shoe, clean and lubricate anchor
pins.
Weak or broken brake shoe return springs ...................... Replace faulty spring
BRAKES ACT UNEVENLY OR GRAB WHEN PEDAL IS DEPRESSED
CAUSE REMEDY
Brake shoe clearance is too great. .................................. .Adjust clearance.
Grease or oil on linings ................................................... Clean linings or replace linings or shoe

assemblies.
Drums out of round ........................................................ Replace drum.
Defective brake valve ................................................. ...... Replace faulty unit.
Brakes need relining ....................................................... Replace brake shoes.
Brake chamber diaphragm leaking .................................. Tighten all fittings; if caused by broken or
faulty unit, replace the unit.

TROUBLESHOOTING
PARKING BRAKE
MAXI-BRAKES WON'T APPLY

(From Park Brake Button)
CAUSE REMEDY
Restricted hose or tube ................................................... Rem ove restriction or replace.
Defective relay valve ................................................. ....... Repair or replace.
Defective spring brake valve ............................................ Repair or replace.
Defective control valve ................................................. .... Repair or replace.
MAXI-BRAKES WON'T APPLY

(With loss of air pressure in one service reservoir)
CAUSE REMEDY
Defective control valve ................................................. .... Repair or replace control valve.
BRAKES WON'T APPLY ON REAR AXLE

(With loss of air pressure in one service reservoir)
CAUSE REMEDY
Defective spring brake valve ............................................ Repair or replace spring brake valve.

TROUBLESHOOTING
MAXI-BRAKES WON'T RELEASE
CAUSE REMEDY
Control valve not pulled out. ........................................... Pull out.
Insufficient system air pressure ..................................... .Allow engine to run to increase pressure to
above 70 p.s.i.
Insufficient hold off pressure .......................................... Check for system (or excessive valve)
leaks.
Leaking brake actuator diaphragm .................................. Replace brake actuator (spring pot).
Defective relay valve ................................................. ....... Repair or replace relay valve.
Defective spring brake valve ............................................ Repair or replace spring brake valve.
Defective control valve ................................................. .... Repair or replace control valve.
AIR PRESSURE
INADEQUATE AIR PRESSURE
CAUSE REMEDY
Leaks in system ...................................................... ........ Repair leaks.
Frozen lines .................................................................... Thaw out lines.
Defective compressor ...................................................... Inspect for sticking unloader valve, replace

if necessary.
Reservoir leaking ...................................................... ...... Replace.
Tank to compressor supply line damaged ........................ Replace.

TROUBLESHOOTING
SWING CIRCUIT
SWING COMPLETELY INOPERATIVE
CAUSE REMEDY
Mechanical swing lock applied, if equipped ..................... Disengage the swing lock.
Swing brake applied ........................................................ Disengage the swing brake.
Spring brake stuck in applied position ............................ Disassemble swing brake and free-up unit.
Swing valve main relief valve stuck in open position ........ See section on "Relief Valves".
Swing motor leaks excessively internally ......................... See section of "Fluid Motor".
Mechanical fault in swing reducer

gear box or swing bearing ............................................... Repair swing reducer or replace swing bear-
ing.
Hose plugged or liner collapsed ....................................... Replace hose.
Rotary manifold leaking internally .................................. Reseal rotary manifold.
Swing pump faulty .......................................................... See section on "Pumps".
SWING MOTION SLUGGISH
CAUSE REMEDY
Main relief valve stuck in open pOsition ........................... Replace.
Faulty swing pump ......................................................... Repair or replace swing pump.
Swing motor leaks excessively, internally ........................ Replace or reseal motor.
Excessive leakage around swing control valve spool ........ Replace or replace control valve.
SWING MOTION ERRATIC
CAUSE REMEDY
Brake not releasing completely ........................................ Check operation of swing brake and/or
swing lock.
Low hydraulic oillevel.. ................................................... Add oil as required.

TROUBLESHOOTING
SWING MOTION ERRATIC (CONTINUED)
CAUSE REMEDY
Swing bearing not lubricated properly ............................. Lubricate swing bearing.
Main relief malfunctioning ............................................. .See section on "Relief Valves".
BOOM HOIST CIRCUIT
BOOM DRIFTS DOWN
CAUSE REMEDY
Hold valve not seating properly ....................................... Replace hold valve.
Hoist cylinder by-passing ................................................ See section on "Cylinder Leakage".
BOOM HOIST ONLY - INOPERATIVE OR ERRATIC
CAUSE REMEDY
Boom will drift down ....................................................... Repair or replace hold valve.
Boom won't lower. ........................................................... Repair, replace, or backflush hold valve.
Boom hoist cylinder binding ............................................ Repair or replace.
Load is too great ............................................................. Consult capacity chart, check RCI.
Piston packings damaged ................................................ Replace packings.
Low oil level ................................................................... .Add oil as required.
Air in cylinder ................................................................. Bleed cylinder.
BOOM DROPS SLIGHTLY AS RAISE CONTROL IS RELEASED
CAUSE REMEDY
Air in cylinder ................................................................. Bleed cylinder.
Boom hoist hold valve free flow check

not seating properly ...................................................... .. Replace hold valve.

TROUBLESHOOTING
BOOM HOIST AND TELESCOPE INOPERATIVE OR ERRATIC
CAUSE REMEDY
Pump disconnect not engaged ......................................... Engage pump disconnect.
Main relief valve malfunctioning ...................................... See section on "Relief Valves".
Rotary manifold leaking internally .................................. Reset rotary manifold.
Tandem pump faulty ....................................................... See section on "Pumps".
BOOM TELESCOPE CIRCUIT
TELESCOPE FUNCTION ONLY - WILL NOT OPERATE
CAUSE REMEDY
Load too great.. ............................................................... Move lever to first position, not "high
speed". Reduce load or set boom length
before lifting load.
Both port relief valves sticking ....................................... .See section on "Relief Valves".
BOOM EXTENSION JERKY OR ERRATIC
CAUSE REMEDY
Inadequate grease on boom pad surfaces ........................ Lubricate boom where pads contact boom.
Wear pads damaged ........................................................ Replace wear pads.
Wear pads shimmed to boom too tight.. ........................... Reshim wear pads.
Faulty counter balance valve ........................................... Replace counter balance valve.
Loose chain system ........................................................ .Adjust chains as required.

TROUBLESHOOTING
TELESCOPE CYLINDER EXTENDS BUT WILL NOT RETRACT
CAUSE REMEDY
Port relief valve sticking .................................................. See section on "Relief Valves" .
Hold valve malfunctioning ............................................... Repair or replace.
Internal leakage in cylinder. ............................................ See section on "Cylinder Leakage".
Extend valve malfunctioning ........................................... Repair or replace.
BOOM SECTIONS RETRACT UNDER WAD
CAUSE REMEDY
"0" ring around hold valve damaged ............................... Replace "0" rings.
Hold valve not seating properly ....................................... Repair or replace.
Telescope cylinder by-passing ......................................... See section on "Cylinder Leakage".
WINCH CIRCUIT
WINCH WILL NOT DEVEWP MAXIMUM LINE PULL
CAUSE REMEDY
Main relief valve is set too low ......................................... Readjust the main relief.
Main relief valve is sticking ............................................. See section on "Relief Valves" .
Winch motor worn excessively or damaged ...................... See section on "Fluid Motor".
Tandem pump worn excessively or damaged ................... See section on "Pumps".
Rotary manifold leaking internally .................................. Reseal rotary manifold.
Low oil level .................................................................... Add oil as required.

TROUBLESHOOTING
WINCH WILL LOWER BUT WILL NOT RAISE
CAUSE REMEDY
The sprag clutch is assembled backwards ...................... . Be certain that the winch is assembled
properly.
Insufficient parts of line for the load being lifted .............. See the reeving diagram on the capacity
chart.
WINCH WILL RAISE BUT WILL NOT LOWER
CAUSE REMEDY
The winch hold valve is mounted

on the winch motor incorrectiy ........................................ Be certain that the winch is assembled
properly.
The winch hold valve spool is sticking ............................. Repair or replace.
The winch brake is not releasing ..................................... Be certain that the brake release line is
open. If necessary, disassemble and
inspect the brake components.
Winch brake piston "0" ring damaged ............................. Replace "0" ring.
WINCH WILL NOT HOLD LOAD

(LOAD DRIFTS DOWN)
CAUSE REMEDY
System back pressure too high ....................................... Warm oil: check for restriction in down
stream flow.
The over-running sprag on the brake is broken ............... Inspect and replace, if necessary.
The automatic brake is not applying ............................... Be certain that the winch brake release
line is not plugged and no foreign objects
are in the brake assembly.
The winch brake friction plates are worn ......................... Replace friction plates.

TROUBLESHOOTING
WINCH CHATTERS WHEN LOWERING
CAUSE REMEDY
The winch hold valve is set

wrong or is malfunctioning ............................................. Check the hold valve setting. If the winch
continues to chatter, the holding valve is
sticking. Inspect it for worn or damaged
seals or contamination.
OUTRIGGER CIRCUIT
ALL OUTRIGGERS INOPERATIVE
CAUSE REMEDY
Electrical malfunction .................................................... .See section on "Electrical Controls".
Outrigger relief valve malfunctioning ............................... See section on "Relief Valves".
Outrigger diverter valve malfunctioning ........................... Repair or replace.
Line to or from steer pump

plugged or liner collapsed ............................................... Clear blockage or replace hose.
Steer pump worn or damaged ..................................... .... See section on "Pumps".

TROUBLESHOOTING
INDIVIDUAL OUTRIGGER INOPERATIVE
CAUSE REMEDY
Electrical malfunction .................................................... .See section on "Electrical Controls".
Cylinder leaking internally .............................................. See section on "Cylinders".
Hold valve on jack cylinder not operating ........................ Repair or replace.
Line plugged or collapsed between

outrigger valve and cylinder ............................................ Replace hose.
Beam wedged in extended pOsition .................................. Extend jack far enough to pick up end of
beam and retract. Replace slider pad block
on top of outrigger box: to pick up end of
beams.
OUTRIGGERS WILL NOT LIFT MACHINE
CAUSE REMEDY
Outrigger relief valve malfunctioning ............................... See section on "Relief Valves".
Outrigger diverter valve malfunctioning ........................... Repair or replace.
Outrigger pump worn or damaged .................................. .See section on "Pumps".
Cylinder by-passing ...................................................... .. See section on "Cylinders".
JACK CYLINDER DRIFTS DOWN (OUT & DOWN)
CAUSE REMEDY
Hold valve on top of cylinder malfunctioning ................... Replace cartridge.
Thermal relief cartridge mounted in wrong end ............... Check for proper assembly.
Cylinder by-passing ...................................................... .. See section on "Cylinders".

TROUBLESHOOTING
PUMPS
FAILURE OF PUMP TO DELIVER FLUID
CAUSE REMEDY
Pumps not engaged ...................................................... ... Engage pumps.
Low fluid level in reservoir .............................................. .Add recommended oil and check level.
Oil intake suction filter plugged ...................................... Clean filter.
Air leak in suction line, preventing priming or causing

noise and irregular action of control circuit. .................... Repair leaks.
Oil viscosity too heavy to pick up prime .......................... Use lighter viscosity oil. Follow recom-
mendation for temperatures encountered.
Broken pump shaft or parts broken inside pump ............ Contact your local distributor; if neces-
sary, refer to the manufacturer's manual
for the correct instructions in pump disas-
sembly and repair.
NO PRESSURE IN SYSTEM
CAUSE REMEDY
Pump not delivering oil for any of

the reasons listed previously ........................................... Follow remedies given previously.
Relief valve not functioning due to:
Valve setting not high enough ......................................... Increase pressure setting of valves.
Valve leaking ................................................................... Check seat for score marks and reseat.
Spring in relief valve broken ............................................ Repl ace spring and readjust valve.
Internal leakage in control valves or cylinders ................. To determine location, progressively block
off various parts of circuit. When trouble
is located, repair. (Do not block between
pump and relief valve).

TROUBLESHOOTING
NO PRESSURE IN SYSTEM (CONTINUED)
CAUSE REMEDY
Relief valve not functioning due to:
Cold fluid ........................................................................ Warm up system. Work with oil at recom-

mended operating temperature range.
(See Operation section).
Air leak or restriction at inlet line .................................... Repair or clean.
Internal parts of pump are worn excessively ................... Replace pump.
PUMP MAKING NOISE
CAUSE REMEDY
Pump disconnect notengaged .......................................... Shut engine off and engage pump discon-
nect.
Partially clogged intake line, intake filter

or restricted intake pipe .................................................. Clean out intake filter screen or eliminate
restriction. Be sure suction line is com-
pletely open.
Air leaks:
At pump intake pipe jOints .............................................. Test by pouring oil on joints while listening
for change in sound of operation. Tighten
as required.
Air drawn in through inlet opening ................................. Check and add oil to reservoir if necessary.
Air bubbles in oil ............................................................ Use hydraulic oil containing a foam depres-
sant.
Too high oil viscosity ....................................................... Work only with oil at recommended opera-
tion temperature.
Oil intake suction filter plugged ...................................... Clean filter.
Rag, paper, etc., pulled into suction line or pump ............ Remove.
Worn or broken parts ................................................... ... Replace.

TROUBLESHOOTING
EXTERNAL OIL LEAKAGE AROUND PUMP
CAUSE REMEDY
Shaft seal worn causing oil to

leak into gear drive housing ............................................ Replace.
Loose fitting on pump intake or discharge ...................... . Keep all joints tight.
Damaged "0" ring seals between pump sections .............. Replace.
Damaged "0" rings at fittings .......................................... Replace.
EXCESSIVE WEAR
CAUSE REMEDY
Abrasive matter in the hydraulic oil

being circulated through the pump ................................. Clean suction filter and replace return fil-
ter. Drain & flush system as necessary.
Viscosity of oil too low at working conditions 1 ................. Check oil recommendation.
Sustained high pressure above

maximum pump rating ................................................... Check relief valve setting.
Air recirculation causing chatter in system ..................... Check for air being drawn into system. Use
hydraulic oil with a foam depressant.
BREAKAGE OF PARTS INSIDE PUMP HOUSING
CAUSE REMEDY
Excessive pressure above maximum pump rating ........... Check relief valve setting.
Seizure due to lack of oil ................................................. Che ck reservoir level, oil filter and possi-
bility of restriction in suction line more
often.
Solid matter being wedged in pump ................................ Check suction line filter, drain and flush
system as necessary.

TROUBLESHOOTING
CONTROL VALVES
STICKING PLUNGERS
CAUSE REMEDY
Excessively high oil temperature ..................................... See section on "Excessive Heating of Oil in
System".
Dirt in oil ........................................................................ Change oil. Clean system.
Fittings too tight ............................................................. Check torque.
Valve warped from mounting ........................................... Loosen valve mounting bolts and check.
Excessively high flow in valve .......................................... Check to see if hoses from pump are not
crossed or reversed.
Linkage binding .............................................................. Free up linkage.
Plunger damaged ............................................................ Replace valve.
Return spring damaged ................................................... Replace faulty parts.
Spring or detent cap binding ........................................... Looseneap. re-center and re-tighten.
Valve not at thermal equilibrium ..................................... Let system warm up.
LEAKING SEALS
CAUSE REMEDY
Paint on or under seal ..................................................... Remove and clean.
Excessive back pressure ................................................. Open or enlarge line to reservoir.
Dirt under seal ............................................................... Remove and clean.
Scored plunger ............................................................... Replace valve.
Loose seal plates ............................................................. Clean and tighten.
Cut or scored seal ........................................................... Replace faulty parts.

TROUBLESHOOTING
UNABLE TO MOVE PLUNGER IN OR OUT
CAUSE REMEDY
Water frozen in plunger caps ........................................... Remove caps to clean out.
Dirt in valve .................................................................... Clean and flush out.
Plunger cap full of oil .................................................... .. Replace seals.
Bind in linkage ............................................................... Free up linkage.
LOAD DROPS WHEN PLUNGER MOVED FROM NEUTRAL
CAUSE REMEDY
Dirt in check valve ...................................................... .... Disassemble and clean.
Scored check valve poppet or seat.. ................................. Replace poppet or lap poppet to seat.
POOR HYDRAULIC SYSTEM PERFORMANCE OR FAILURE
CAUSE REMEDY
Dirt in relief valve ...................................................... ..... Disassemble and clean.
Relief valve defective ....................................................... See section on "Relief Valves".
Load too heavy ................................................................ Check line pressure.
Internal valve crack ...................................................... .. Replace valve.
Plunger not at full stroke ................................................ Check movement and linkage.

TROUBLESHOOTING
RELIEF VALVES
CAN'T GET PRESSURE
CAUSE REMEDY
Poppet stuck open or dirt under seal.. ............................. Check for foreign matter between poppets
and their mating members. Members must
slide freely.
ERRATIC PRESSURE
CAUSE REMEDY
Poppet seal damaged ...................................................... Replace damaged parts. Clean dirt and
remove surface marks for free movement.
PRESSURE SETTING NOT CORRECT
CAUSE REMEDY
Wear due to dirt. Lock nut adj. screw loose .................... See section on "Valve Adjustments".

TROUBLESHOOTING
LEAK
CAUSE REMEDY
Damaged seats, worn "0" rings,

parts sticking due to dirt ................................................. Re place worn or damaged parts. Inspect
for free movement of components. Check
seats for scratches, nicks, or other marks.
FLUID MOTOR
MOTOR WILL NOT TURN
No oil .............................................................................. Fill reservoir to proper oil level.
Pump broken .................................................................. Replace pump.
Relief valve stuck open or set too low .............................. Clean and free relief valve spool and adjust
to proper setting.
Work load jammed or stuck. ............................................ Remove obstruction from work load.
Large contaminating foreign bodies in fluid ..................... Flush hydraulic system completely. Use
new oil and install new filters.
SLOW OPERATION
CAUSE REMEDY
Wrong oil viscosity .......................................................... Use proper viscosity oil.
Rotary manifold leaking .................................................. Rese al rotary manifold.
Worn pump ..................................................................... Repair or replace pump.
Extremely high fluid temperatures causing

pump and motor to slip (temperature increases
as pump and motor wear) .............................................. .Add heat exchangers.
Relief setting too low ................................................... .... Set relief valve for proper psi.

TROUBLESHOOTING
MOTOR TURNS IN WRONG DIRECTION
CAUSE REMEDY
Hose connections wrong ................................................. Reverse connections.
Wrong timing .................................................................. Re-time motor.
ERRATIC MOTOR OPERATION
CAUSE REMEDY
Relief valve pressure set too low ..................................... .Adjust relief valve setting.
Low oil level in reservoir permitting air

to enter system ............................................................... FiII reservoir to proper level.
Air being "sucked in" on inlet side of pump ..................... Tighten fitting(s) on pump inlet side.
LEAK AT SHAFT
CAUSE REMEDY
Worn or cut shaft seaL ................................................... Replace shaft seal.
LEAK BETWEEN HOUSING AND WEAR PLATE OR

BETWEEN WEAR PLATE AND GEROLER ASSEMBLY
CAUSE REMEDY
Motor housing bolts loose ............................................... Clean mating surfaces and tighten nuts to
appropriate value.
Pinched "0" ring seal ...................................................... Replace.
LEAK AT OIL PORTS
CAUSE REMEDY
Damaged seal or "0" ring ................................................ Replace "0" ring or seal.

TROUBLESHOOTING
LEAK AT OIL PORTS (CONTINUED)
CAUSE REMEDY
Poor fittings .................................................................... Replace fittings carefully.
Damaged threads ............................................................ Replace housing.
CYLINDERS
CYLINDER STICKING OR BINDING
CAUSE REMEDY
Damaged parts ............................................................... Repair or replace.
Dirt or contamination ..................................................... Check oil condition. Check filters. Clean

or replace filter elements. Change oil if
condition requires it.
Loose parts ..................................................................... Tighten cylinder rod eyes, if loose. Check

cylinder heads and tighten, if loose.
Misalignment .................................................................. Check mounting pins and bushings.

Tighten rod eyes.
ERRATIC ACTION OF CYLINDERS
CAUSE REMEDY
Air in system:
Oil level is too low .......................................................... .Add or change.
Air leak ........................................................................... Locate and correct.
Foaming in reservoir ....................................................... Use hydraulic oil containing a foam depres-

sant.
Internal leakage ............................................................. .See "Cylinder Leakage" next page.
Main Relief pressure too low or valve sticking ................. .See section on "Relief Valve".

TROUBLESHOOTING
CYLINDER LEAKAGE
Hydraulic cylinders may retract due to the cooling backup washers. Retest per the procedure above
of the oil in cylinder. Oil shrinks approximately to determine if hold was defective.
1% per lOO°F of cooling, or as an example, if a cyl-
inder is extended 100" and it cools 1OO°F, it would An alternate method to test hold valve would be to
shorten approximately 1". elevate boom and then disconnect the two hoses
coming from valve bank. If oil continues to flow
TELESCOPE CYLINDER slowly from line to extend then it is a hold prob-
lem. If oil continues to flow from retract, then it is
If excessive leak-down is encountered, check faulty or leaking by piston in cylinder.
items in the following sequence:
IF THE HOW VALVE IS NOT FOUND DEFECTIVE,
1 With boom offside and horizontal, extend the the cylinder must be removed from the boom
boom approximately 6 ft. per section. Mark assembly for repacking and checking. Prior to
the first telescoping section at the end of the reassembly of the cylinder, conduct an air test on
base section. the piston rod by blocking the retract ports on the
rod near the piston end. Slip a plastic bag over
2 Elevate the boom to maximum angle and sus- piston end of rod and retain and seal with rubber
pend a load on the hook. (7 tons on a 2-part band. Apply and hold a slight amount of air pres-
line would approximate manufacturer's sure at the retract port of the rod. (Port stamped
inspection procedures.) with "R".) Expansion of the plastic bag indicates
a defective rod weldment or seals on the port tube
3 With engine shut off, hold or tie the telescope in the rod.
function lever in the full "extend" position for
approximately 15 minutes. WHEN REASSEMBUNG THE CYLINDER, care
should be taken to keep the piston rod assembly
4 Return the telescope lever to neutral, start parallel in all planes with the cylinder barrel as
engine, ground the load, and return the boom the piston enters and is pushed down the barrel
to horizontal. Re-mark the boom section as in prior to gland engagement.
(1). Measure the distance between marks to
determine leak-down of the cylinder. NOTE: An external leak from telescope cylinders
or hydraulic line within the boom assembly does
The manufacturer's allowable drift specification not cause leak-down without also having one or
for production machines is as follows: more of the above conditions present.
With 14,300 lb. hook load, 2-part hoist line, boom BOOM LIFT CYLINDER
extended about 6 ft. per section at maximum
boom angle, and 160 degree F. hydraulic oil tem- The suggested procedure for identifying the spe-
perature, the leak-down per cylinder is not to cific cause of leak-down should be performed in
exceed 3/4 inch in a 15-minute period. the following sequence:
IDENTIFY A DEFECTIVE HOW VALVE in the cyl- ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE,
inder which drifts excessively by interchanging not completely extended, with a boom length suf-
the hold valve cartridge with one removed from a ficient to winch up a convenient payload approxi-
cylinder that is not drifting, or by replacement mately one (1) foot from ground level. Shut of
with a new cartridge. Before installing the car- engine.
tridge, visually inspect the external "0" rings and

TROUBLESHOOTING
BOOM LIFT CYLINDER (CONTINUED) SET THE OUTRIGGERS.
DISCONNECT THE EXTEND HOSE, PIWT DRAIN ELEVATE THE BOOM TO NEAR MAXIMUM ANGLE,
HOSE, AND THE SMALL PILOT UNE HOSE at the not completely extended, with a boom length suf-
holding valve ports and cap the pilot line hose and ficient to winch up a convenient payload approxi-
drain hose ends. mately one (1) foot from ground level. Shut off
engine and remove pressure from the hydraulic
IF HYDRAUUC OIL CONTINUES TO RUN after the reservoir by loosening the filler cap.
initial draining from either port of the hold valve
as the hoist cylinder continues to leak-down, the DISCONNECT THE EXTEND HOSE FROM THE
cause is within the hold valve. HOW VALVE. This is a hose farthest away from
the port tube and should have an "E" stamped
IF CYLINDER LEAK-DOWN OCCURS with no oil next to it.
leak from the hold valve ports, the cause is within
the cylinder. IF HYDRAULIC OIL CONTINUES TO RUN after
the initial draining from the port of the hold valve
OUTRIGGER JACK CYLINDER as the jack cylinder continues to leak-down, the
cause is within the hold valve.
The suggested procedure for identifying the specif-
ic cause of leak-down is similar to the boom lift IF CYLINDER LEAK-DOWN OCCURS with no oil
cylinder procedure: leak from the hold valve port, the cause is within
the cylinder.
DO NOT START THE ENGINE UNTIL THE HOSES

HAVE BEEN RECONNECTED. The control valve
spool is open-center to reservoir in the neutral
position and return line oil would be pumped out.
EXCESSIVE HEATING OF OIL

IN SYSTEM
HEATING CAUSED BY POWER UNIT

(RESERVOIR, PUMP, RELIEF VALVE, AND COOLERS)
CAUSE REMEDY
Relief valve set at a higher or lower pressure than

specified. Excess oil dissipated through increased
slippage in various parts, or through relief valve ............. Reset relief valve to recommended pres-
sure.
Internal oil leakage due to wear ...................................... Repair or replace faulty component.
Viscosity of oil too high or too low ................................... Follow recommendations for correct vis-
cosity grade to be used.
Pumps assembled after overhaul may be assembled

too tightly. This reduces clearances and increases
rubbing friction ............................................................... Follow instructions when reassembling.

TROUBLESHOOTING
HEATING CAUSED BY POWER UNIT

(RESERVOIR, PUMP, RELIEF VALVE AND COOLERS) (CONTINUED)
CAUSE REMEDY
Leaking relief valves ........................................................ Repair.
Improper functioning of oil cooler .................................... Inspect cooler and see that it is working
properly.
Improper machine operation ........................................... Return control to neutral when stalled, cyl-
inder at end of stroke, etc.
HEATING BECAUSE OF CONDITIONS IN SYSTEM
CAUSE REMEDY
Restricted lines ............................................................... If lines are crimped, replace; if partially

plugged for any reason, remove obstruc-
tion.
Internal leaks ................................................................. Locate leaks and correct.
Low oil level .................................................................... Check oil level and fill if necessary.
ELECTRICAL CONTROLS
ELECTRICAL FAILURE
CAUSE REMEDY
Rocker switch sticking .................................................... Re move switch, check if hole is too tight.
Cut out decal or file hole larger.
Tripped circuit breakers .................................................. Reset breaker
Disconnected or broken wires ......................................... Replace or repair.
Open circuit.. .................................................................. Check with test light. Repair or replace.
Low voltage ..................................................................... Check wires and grounds.
Poor engine solenoid connection ..................................... Clean and tighten.
Defective solenoid ........................................................... Replace.
Solenoid failure ............................................................... Replace.
Poor ground connections ................................................. Clean and tighten connections.

TROUBLESHOOTING
PROPANE HEATER
HEATER FAILS TO START

(MOTOR DOES NOT RUN)
CAUSE REMEDY
Fuse defective or burnt out ............................................. Check fuse; replace if necessary.
Electrical connection(s) defective ..................................... Check all electrical connections, including

ground; repair any defects.
Full voltage not available at heater .................................. Check for power at the heater: at least 11
VDC with heater turned on. Trace system
to find any fault(s).
Motor defective ............................................................... Check motor. Replace if necessary.
MOTOR RUNS, BUT NO COMBUSTION
CAUSE REMEDY
Fuel supply blocked ........................................................ Check fuel supply by loosening the fitting
on the outside of the heater and checking
for propane odor. If propane odor is
present, pull off the igniter wire com-
pletely and remove the igniter. Try to
start the heater and listen for the solenoid
click. Check for the odor of propane in the
burner. If propane odor is present at bulk-
head fitting, but not the burner head, the
solenoid valve is defective or contami-
nated with some foreign object. The sole-
noid valve can become contaminated when
a liquid take-off bottle is used instead of
the required vapor take-off bottle. If the
fuel system is contaminated, the lines and
solenoid must be cleaned with a degreasing
solvent.
Temperature control &/ or microswitch

defective or out of adjustment ......................................... Check temperature control switch and
microswitch and microswitch for adjust-
ment. Adjust, repair, or replace as neces-
sary. See Section 6, "Repairs and
Adjustments" .

TROUBLESHOOTING
MOTOR RUNS, BUT NO COMBUSTION (CONTINUED)
CAUSE REMEDY
Ignition pack defective or inoperative .............................. Check for spark by holding an insulated-
handle screwdriver with the shaft
grounded and the tip approximately 1/8"
away from the high tension lug of the igni-
tion coil. There should be a continuous
strong spark. If no spark is produced,
check that there is voltage applied to the
ignition pack. If input voltage is present
and no spark or a weak spark is produced,
replace or repair the ignition pack.
Tilt switch defective, improperly

mounted or not getting power ......................................... Check tilt switch. The switch must be
secure in its bracket and be in the vertical
position with the electrical leads pointing
down. Check leads on both sides of switch
for power. Replace if defective.
Igniter defective or inoperative ........................................ Check the igniter. To check, shut off the
fuel tank and depress the start switch until
the lines are purged of fuel. Remove the
burner head and check the gap between
the igniter and the burner tube. It should
be 1/16" to 1/8". With the burner head
grounded, move the START-RUN-OFF
switch to the START position and check
the gap for spark. If no spark is produced,
the igniter may be dirty or defective.
Before removing the igniter from burner
head, check inside the burner head to
determine if any carbon threads or chips
are present which could short the plug.
Fuel not suitable for temperatures encountered .............. Check with your propane supplier to be
sure your fuel is suitable for the tempera-
tures encountered. Around -10°F, propane
may not produce enough pressure to pass
through the regulator.

TROUBLESHOOTING
HEATER REMAINS ON BURNER CYCLE AFTER HEAT DEMANDS ARE MET
CAUSE REMEDY
Temperature control &/ or microswitch

defective or out of adjustment ......................................... Check temperature control switch and
microswitch and microswitch for adjust-
ment. Adjust, repair, or replace as neces-
sary.
Bi-metal blade broken or linkage out of adjustment ........ Check bi-metal blade and linkage and
adjust, repair or replace as necessary.
Dirt on fuel solenoid valve lip .......................................... Clean solenoid valve lip.
EXCESSIVE POPPING OR BACKFIRING
Ignition pack defective or inoperative .............................. Check for spark by holding an insulated-
handle screw driver with the shaft
grounded and the tip approximately I/S"
away from the high tension lug of the igni-
tion coil. There should be a continuous
strong spark. If no spark is produced,
check that here is voltage applied to the
ignition pack. If input voltage is present
and no spark or a weak spark is produced,
replace or repair the ignition pack.
Full voltage not available at heater. ................................. Using voltmeter, check to be sure full volt-
age is available for heater operation, at
least 11 VDC with heater turned on. Trace
system to find fault.
Solenoid defective ........................................................... Check solenoid. When the START-RUN-

OFF switch is in the RUN position, the
solenoid should produce an audible click
and remain open until heater cycles off.
In extremely cold weather, the regulator may

become frosted. As it thaws and freezes, the
heater will burn intermittently ........................................ No action recommended.
Clogged or restricted exhaust .......................................... Check exhaust for blockage or restrictions.

Clean and clear as necessary.

TROUBLESHOOTING
EXCESSIVE SMOKING AT EXHAUST PORT AND BUILDUP OF CARBON IN HEAT EXCHANGER
CAUSE REMEDY
Air inlet tube blocked ...................................................... Check for plugged or blocked air inlet tube
and clear if necessary.
Low voltage ..................................................................... Check for low voltage. at least 11 VDC.
Defective pressure regulator ............................................ Check for defective pressure regulator.

There should be 11 inches water pressure
in the propane supply line at the connec-
tor.
HEATER DOESN'T SWITCH OFF AFTER PURGE (COOL DOWN) CYCLE
CAUSE REMEDY
Flame switch will not open .............................................. Repl ace.
MAINTENANCE FREE BATTERY TESTING
VISUAL INSPECTION
CAUSE REMEDY
Visible damage, terminal leakage, etc .............................. Cannot be used. Replace.
ELECTROLYTE LEVELS & STATE OF CHARGE

NOTE: PROCEED DIRECTLY TO CAUSE THAT APPLIES
CAUSE REMEDY
Level at top of plates. Water cannot be added ................. Replace.
If there is an indicator and it shows low level .................. Replace.

TROUBLESHOOTING
ELECTROLYTE LEVELS & STATE OF CHARGE (CONTINUED)

NOTE: PROCEED DIRECTLY TO CAUSE THAT APPUES
CAUSE REMEDY
Level OK, unknown, or water can be added.

Stabilized voltage below 12.4 volts* ................................. Add water if needed (if possible). Charge,
then turn on high-beam head lamps (or 15
amp load for 15 seconds). Proceed to load
test.
If there is an indicator and it shows low charge ............... Charge, then turn on high-beam head
lamps (or 15 amp load for 15 seconds).
Proceed to load test.
Stabilized voltage above 12.4 volts* or indicator

indicates charged ............................................................ Perform load test.
LOAD TEST
CAUSE REMEDY
Perform load test using the following procedure:

1. Connect voltmeter and ampere load equal to 1/2
cold cranking amperes @ OaF (-18°C) rating of battery
for 15 seconds.
2. Observe voltage at 15 seconds with load on.
3. Refer to voltage chart .................................................. If the voltage remains below the voltage
chart levels, replace battery. If the voltage
is equal to or above chart values, return to
service.
VOLTAGE CHART
MINIMUM REQUIRED VOLTAGE UNDER 15
ESTIMATED ELECTROLYTE TEMPERATURE
SECOND LOAD
70° F (21 ° e) & ABOVE 9.6

60° F (16° e) 9.5
50° F (10° e) 9.4
40° F we) 9.3
30° F (-1 ° e) 9.1
20° F (_7° e) 8.9
10° F (_12° e) 8.7
0° F (-18° e) 8.5
* IF WATER CAN BE ADDED TO A BATTERY, A HYDROMETER READING OF 1.225 @ 80 0 F (27 0 C)

CAN BE USED INSTEAD OF THE 12.4 VOLTAGE READING.

TROUBLESHOOTING
TWO BWCK SYSTEM
PANEL LIGHT & HORN WILL NOT COME ON WITH BOOM SWITCH WEIGHT LIFTED
(IF EQUIPPED WITH DISCONNECTS, CONTROLS WILL NOT ENGAGE)
CAUSE REMEDY
Burned out fuse .............................................................. Check and replace fuse (8 amp only).
Broken wire .................................................................... Check voltage in control panel between

terminals #0 and #37. If 0 volts, check
between ignition post of ignition switch
and ground. If 12 volts available, wire to
control panel is bad. Correct.
HORN WORKS, BUT NO LIGHT WITH SWITCH WEIGHT LIFTED

(AND IF EQUIPPED WI DISCONNECTS, CONTROLS WILL ENGAGE)
CAUSE REMEDY
Light bulb burned out.. ................................................... Replace bulb.
LIGHT AND HORN ARE ON WITH HOOK BWCK NOT CONTACTING SWITCH WEIGHT
(IF EQUIPPED WI DISCONNECTS, CONTROLS WILL NOT ENGAGE)
CAUSE REMEDY
Jumper wire or jib/rooster sheave not

plugged in boom head ..................................................... Plug in.
Boom head weight wire rope broken or hung up .............. Check that weight is attached to wire and
hanging freely. If rope is caught up on
something, correct.
Jib or auxiliary boom head switch plugged in,

but no weight. ................................................................. Attach weight.
Broken electrical cable or bad connection ....................... Check all cable for visible damage, then
remove wire from terminals #3 and #6 in
control panel and check for continuity. If
circuit is open, check the wires inside
cable reel, and wires from the reel to the
boom head switch. If the wires are OK,
check the anti-two block switch. If there
is continuity between #3 and #6 check the
relay in the panel.

TROUBLESHOOTING
LIGHT AND HORN ARE ON WITH HOOK BLOCK NOT

CONTACTING SWITCH WEIGHT (CONTINUED)
(IF EQUIPPED WITH DISCONNECTS, CONTROLS WILL NOT ENGAGE)
CAUSE REMEDY
Defective two block switch .............................................. Check for correct mechanical operation. If
OK, remove cover and wires from terminals
# 1 and #2. With arm pulled down, there
should be a closed circuit between them.
With the arm up, the circuit should be
open. If all conditions are not met, replace
switch.
Defective relay in panel ................................................... Check for 12 volts between relay pins #30
(hot) and #86 (ground). If voltage is 0,
check for voltage between pin #87a and
ground. If 12 volt, replace relay (With no
electrical power to the relay, pins #30 and
#87a should show continuity. With 12
volts to either #85 or #86 and the other
grounded, there should be continuity
between pins #87 and #30.)
ANTI-TWO BLOCK SYSTEM

FOR CRANES EQUIPPED WITH FUNCTION DISCONNECTS ONLY
LIGHT AND HORN ARE ON, BUT CONTROLS WILL NOT DISENGAGE
CAUSE REMEDY
Defective function disconnect.. ........................................ Check voltage across disconnect termi-

nals. If 12 volts, check override key
switch in control panel. If 0 volts, repair
or replace disconnect. (Check other dis-
connects for condition.) To operate the
crane the solenoid must have 12 volts sup-
plied to one side and have a good ground
on the other side. Under this condition,
the disconnect should act as a solid link.
With the 12 volts removed, the disconnect
should allow free motion of the control
lever in one direction and operate the
valve spool in the other direction.
Defective override key switch .......................................... Check to insure that the switch is in the
off position and the key removed. Check
for 12 volts in the control panel. If so,
replace the switch or control panel.

TROUBLESHOOTING
NO LIGHT AND HORN, BUT CONTROL WILL NOT ENGAGE
CAUSE REMEDY
Broken wire or bad connection ........................................ Check voltage across disconnect termi-
nals. If 0 volts, check voltage across ter-
minals in the control panel. If 12 volts,
replace wire. If 12 volts across disconnect,
then disconnect is defective.
Defective function disconnect.. ........................................ Check solenoid for function. Applying 12

volts to disconnect, solenoid should
engage with a distinct snap. If not, the
solenoid must be replaced. If the solenoid
engages, but the disconnect "breaks"
under load, the spool, ball, and case should
be replaced.
Contaminated function disconnect.. ................................ 1. Ensure that a drain hole is present in

the end of the rubber tube covering the
solenoid.
2. Lubricate solenoid with SAE 30 oil.
3. Remove solenoid from disconnect and

check for proper operation. DO NOT lose
the stainless steel ball under the solenoid.
If the solenoid does not operate replace the
disconnect. If disassembly and cleaning
corrects the problem reassemble and
replace the silicon sealant.

SERIES
PD12C
PD15B
PD17A HYDRAULIC HOIST
INSTALLATION, MAINTENANCE, AND SERVICE MANUAL

LlT21 03 R4
12-2008
PRINTED IN U.S.A.
MCCAR WINCH DIVISION
P.o. Box 547 Broken Arrow, Oklahoma 74013
PHONE: (918) 251-8511 FAX: (918) 259-1575
www.paccarwinch.com
Table of Contents
GENERAL SAFETY RECOMMENDATIONS ................................................................ 4

THEORY OF OPERATION ............................................................................................ 5
HOIST INSTALLATION .................................................................................................. 7
RECOMMENDED FASTENER TORQUE ..................................................................... 9
WIRE AND BRAIDED ROPE INSTALLATION .............................................................. 9
TWO SPEED MOTOR CASE DRAIN PLUMBING ...................................................... 10
PREVENTIVE MAINTENANCE ................................................................................... 10
RECOMMENDED OIL CHANGE INFORMATION ....................................................... 11
TROUBLE SHOOTING ............................................................................................... 12
HOIST DiSASSEMBLy ................................................................................................ 16
EXPLODED VIEW DRAWING AND PARTS KEY .................................................. 18-19
PLANET CARRIER SERViCE ..................................................................................... 20
MOTOR SUPPORT - BRAKE CYLINDER SERViCE ................................................. 22
BRAKE CLUTCH SERViCE ........................................................................................ 26
HOIST ASSEMBLy ...................................................................................................... 28
BRAKE VALVE SERViCE ............................................................................................ 32
REVERSING DIRECTION OF DRUM ROTATION ...................................................... 34
PD17A ROTATION INDICATION PROXIMITY SENSOR ............................................ 36
2
FOREWORD
Read this entire publication and retain it for future reference.
If you have any questions regarding your Braden Planetary Hoist or this publication, call the Braden Service Depart-
ment at 1-918-251-8511,08:00-1630 hours, CT, Monday through Friday.
The minimum service intervals specified are for operating hours of the prime mover.
The following service instructions have been prepared to provide assembly, disassembly and maintenance informa-
tion for the BRADEN Model PD12C, PD15B and PD17A series hoist. It is suggested that before doing any work on
these units, all assembly and disassembly instructions should be read and understood.
Some pictures in this manual may show details or attachments that are different from your hoist. Also, some compo-
nents have been removed for illustrative purposes. Illustrations and pictures in this manual are of a "typical" unit sold
through our distribution channels. Some hoists, particularly those sold directly to original equipment manufacturers
(OEM), may differ in appearance and options.
Whenever a question arises regarding your BRADEN HOIST, please contact BRADEN Service Department for the
latest available information.
Serial Numbers and Model Numbers are located to

the left hand side of the hydraulic motor, stamped
into the base. Always refer to the Serial Number and
Model Number when requesting information or ser-
vice parts. ,,
,,
, ,,
,,
\ """"",::=:CW::::llIlE:::C=;:z.
! ............ -
: I I
L-i-r--------------------------i--r..J :
EXPLANATION OF SERIAL NUMBER
PO
T
12
T
C
T
29
T
064
I
- 02
T
- U
T
- L
T
- T1
POWER MAX DESIGN GEAR MOTOR DRUM ROTATION BASE OPTION
DRUM RATING SERIES RATIO SIZE OPTION
PO DESIGNATES POWER DRUM
12 DESIGNATES 12,000 LB. APPROXIMATE FIRST LAYER LINE PULL
C DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES
29 DESIGNATES TOTAL GEAR REDUCTION (OTHER RATIOS INCLUDE 21, 41, 59, 34, ETC.)
064 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU. IN/REV
(DECIMAL POINT ELIMINATED. EXAMPLE 064 =6.4 CU IN/REV)
02 DESIGNATES THE DRUM OPTION (OTHER DRUMS INCLUDE 01, 04, 05, 23G, ETC.)
U DESIGNATES UNDERWOUND CABLE DRUM - OPTIONAL
L DESIGNATES LEFT HAND BASE - OPTIONAL, BLANK IS STANDARD RIGHT HAND BASE
1 PERMITS TESTING AND INSPECTION PER API 2C FOR OFFSHORE CRANES - OPTIONAL
3
GENERAL SAFETY RECOMMENDATIONS
Safety and informational callouts used in this manual include:
A. WARNING A. &CAUTION&
WARNING - This emblem is used to warn against CAUTION - This emblem is used to warn against
hazards and unsafe practice which COULD result in potential or unsafe practices which COULD result
severe personal injury or death if proper procedures in personal injury and product or property damage if
are not followed. proper procedures are not followed.
Safety for operators and ground personnel is of prime concern. Always take the necessary precautions to ensure
safety to others as well as yourself. To ensure safety, the prime mover and hoist must be operated with care and
concern by the operator for the equipment and a thorough knowledge of the machine's performance capabilities.
The following recommendations are offered as a general safety guide. Local rules and regulations will also apply.
1. Be certain equipment (boom, sheave blocks, pen- 16. Do not use knots to secure or attach wire rope.
dants, etc.) is either lowered to the ground or 17. The BRADEN designed wire rope anchors are ca-
blocked securely before servicing, adjusting, or re- pable of supporting the rated load when installed
pairing hoist. properly. For additional safety, ALWAYS maintain
2. Be sure personnel are clear of work area BEFORE a minimum of five (5) wraps of wire rope on the
operating hoist. drum.
3. Read all warning and caution tag information provid- 18. Never attempt to clean, oil or perform any mainte-
ed for safe operation and service of hoist. nance on a machine with the engine or prime mover
4. Inspect rigging and hoist at the beginning of each running, unless instructed to do so in this manual.
work shift. Defects should be corrected immediate- 19. Never operate hoist controls unless you are prop-
ly. erly positioned at the operators station and you are
5. Keep equipment in good operating condition. Perform sure personnel are clear of the work area.
scheduled servicing and adjustments listed in the 20.Assure that personnel who are responsible for hand
"Preventive Maintenance" section of this manual. signals are clearly visible and that the signals to be
6. An equipment warm-up procedure is recommended used are thoroughly understood by everyone.
for all start-ups and essential at ambient tempera- 21.Ground personnel should stay in view of the opera-
tures below +40°F (4°C). Refer to "Warm-up Proce- tor and clear of hoist drum. Do not allow ground per-
dure" listed in the "Preventive Maintenance" section sonnel near hoist line under tension. A safe distance
of this manual. of at least 1-1/2 times the length of the cable should
7. Operate hoist line speeds to match job conditions. be maintained.
8. Leather gloves should be used when handling wire 22. Do not exceed the maximum pressure, PSI (kPa),
rope. or flow, GPM (LPM), stated in the hoist specifica-
tions.
9. Never attempt to handle wire rope when the hook
23. Install guarding to prevent personnel from get-
end is not free. Keep all parts of body and clothing
clear of cable rollers, cable entry area of fairleads ting any part of body or clothing caught at a point
and hoist drum. where the cable is wrapped onto the drum or drawn
through guide rollers.
10. When winding wire rope on the hoist drum, never
24. "Deadman" controls, which automatically shut off
attempt to maintain tension by allowing wire rope to
slip through hands. Always use "Hand-Over-Hand" power to the hoist whenever the operator leaves his
station, should be installed whenever practicable.
technique.
11. Never use wire rope with broken strands. Replace 25. Never allow anyone to stand under a suspended
wire rope. load.
26. Avoid sudden "shock" loads or attempting to "jerk"
12. Do not weld on any part of the hoist.
load free. This type of operation may cause heavy
13.Use recommended hydraulic oil and gear lubricant. loads, in excess of rated capacity, which may result
14. Keep hydraulic system clean and free from contami- in failure of cable and hoist.
nation at all times.
15. Use correct anchor for wire rope and pocket in
drum.
4
THEORY OF OPERATION
DESCRIPTION OF HOIST
The hoist has four basic component parts: The static brake system has three operating compo-
1. Hoist base nents:
2. Hydraulic motor and brake valve 1. Spring Applied, Multiple Friction Disc Static Brake
3. Brake cylinder and motor support 2. Overrunning Brake Clutch Assembly
4. Drum assembly 3. Hydraulic Piston and Cylinder
The drum assembly consists of three basic assem-
blies:
1. Drum with integral ring gear Figure 1
2. Output planetary gear set
3. Primary planetary gear set HOISTING
The hydraulic motor is bolted to the motor support which Static Brake
in turn is bolted to the brake cylinder and the base. The
motor end of the drum, running on a ball bearing, is
supported by the brake cylinder. The other end of the
drum runs on a ball bearing on the support bolted to the
base. The ring gear for both planetary sets is machined BrakeValve r1t=~~~~~l
into the drum's inside surface.
HOIST OPERATION
The hydraulic motor drives the sun gear of the primary
planetary gear set through the splined inner race of the
overrunning brake clutch. When driven by the sun gear,
the primary planet gears walk around the ring gear in
the drum and drive the primary planet carrier.
w/wA ~
Low Medium High
The primary planet carrier drives the output planet
Pressure Pressure Pressure
sun gear which, in turn drives the output planet gears.
The output planet carrier is splined to the bearing sup-
port and cannot rotate. Therefore, as the output planet
gears are driven by the sun gear, they will drive the ring
gear/drum.
Figure 2
DUAL BRAKE SYSTEM - DESCRIPTION
LOWERING 1
The dual brake system consists of a dynamic brake
system and a static brake system.
The dynamic brake system has two operating compo-
nents:
1. Brake valve assembly
2. Hydraulic motor
The brake valve is basically a counterbalance valve
with good metering characteristics. It contains a check ToTank
valve to allow free flow of oil to the motor in the hoist-
ing direction and a pilot operated, spring-loaded spool
valve that blocks the flow of oil out of the motor when
the control valve is placed in neutral. When the control
valve is placed in the lowering position, the spool valve
remains closed until sufficient pilot pressure is applied
to the end of the spool to shift it against spring pres-
sure and open a passage. After the spool valve cracks
open, the pilot pressure becomes flow-dependent and
VZZZ2l w/wA
Low Medium High
modulates the spool valve opening which controls the Pressure Pressure Pressure
lowering speed. Refer to figures 1, 2, and 3.
Figures 1, 2, and 3.
5
Figure 3 determine the amount of oil that can flow through it and
the speed at which the load will be lowered. Increasing
LOWERING 2
Static Brake the flow of oil to the----- motor will cause the pressure
to rise and the opening in the brake valve to enlarge,
speeding up the descent of the load. Decreasing this
flow causes the pressure to lower and the opening in
the brake valve to decrease thus slowing the descent
Brakevalver1t::~~~~~l of the load.
When the control valve is shifted to neutral, the pres-
ToTank
sure will drop and the brake valve will close, stopping
the load. The friction brake will engage and hold the
load after the brake valve has closed.
When lowering a load very slowly for precise position-
ing, no oil flow actually occurs through the hoist motor.
The pressure will build up to a point where the brake will
release sufficiently to allow the load to rotate the motor
W0WM ~ through its own internal leakage. This feature results in
Low Medium High a very slow speed and extremely accurate positioning.
Pressure Pressure Pressure
The friction brake receives very little wear in the lower-
ing operation. All of the heat generated by the lowering
The static brake is released by the brake valve pilot
and stopping of a load is absorbed by the hydraulic oil
pressure at a pressure lower than that required to open
where it can be readily dissipated.
the pilot operated spool valve. This sequence assures
that dynamic braking takes place in the brake valve and
that little, if any, heat is absorbed by the friction brake.
The friction brake is a load holding brake only and has Figure 4
nothing to do with dynamic braking or rate of descent Sprag Cams
of a load.
The overrunning brake clutch is splined to the primary
sun gear shaft between the motor and the primary sun
gear. It will allow this shaft to turn freely in the direction
to raise a load and lock up to force the brake discs to
turn with the shaft in the direction to lower a load. Refer
to figures 4 and 5.
The hydraulic cylinder, when pressurized, will release
the spring pressure on the brake discs, allowing the
brake discs to turn freely.
Dual Brake System - Operation while hoisting

When hoisting a load, the brake clutch which connects
the motor shaft to the primary sun gear, allows free rota-
tion. The sprag cams layover and permit the inner race
to turn free of the outer race. Figure 4. The friction brake Figure 5
remains fully engaged. The hoist, in raising a load, is Sprag Cams
not affected by any braking action. Figure 1.
When the lifting operation is stopped, the load attempts
to turn the primary sun gear in the opposite direction.
This reversed input causes the sprag cams to instantly
roll upward and firmly lock the shaft to the fully engaged
friction brake. Figure 5.
When the hoist is powered in reverse, to lower the load,
the motor cannot rotate until sufficient pilot pressure is
present to open the brake valve. Figures 2 & 3. The
friction brake within the hoist will completely release at
a pressure lower than that required to open the brake
valve. The extent to which the brake valve opens will Load attempts to rotate shaft in opposite direction
Brake clutch locks sun gear shaft to friction brake
6
HOIST INSTALLATION
1. The hoist should be mounted with the centerline of
VENT PLUG
the drum in a horizontal position. The mounting plane
ABOVE CENTERLINE
of the base may be rotated in any position around this
centerline.
4. The vent plug must always be located above the hori-

zontal centerline. If the hoist is mounted on a pivoting
surface, be sure vent plug remains above the centerline
in all positions. If necessary, reposition bearing support
and vent plug as follows:
A. Remove bearing support bolts.
B. Rotate bearing support until vent plug
is positioned correctly and bolt holes
are aligned.
C. Evenly tighten bolts to recommended
torque.
5. Hydraulic lines and components that operate the
hoist must be of sufficient size to assure minimum back-
pressure at the hoist motor ports. The hydraulic back-
pressure measured at the motor work ports must be
less than 100 PSI (690 kPa) at full operating flow. Back-
pressure in excess of 100 PSI (690 kPa) will shorten
motor shaft seal life and partially release the load hold-
2. Because of the design of the mounting base, the di- ing brake. The standard hoist is supplied with the gear
rection of line pull should only be as shown in the above motor internally drained and connected the drain by-
illustration. Line pulls in any other direction must be ap- pass port on the Braden brake valve. If high back-pres-
proved by BRADEN Engineering. sures are encountered, the motor should be externally
3. When mounting the hoist, use all eight (8) mount- drained directly to the reservoir and the "DRAIN" port
ing holes and grade 8 capscrews and nuts. Tighten to on the brake valve capped. All piston motors MUST be
recommended torque. drained directly to the reservoir. The piston motor case
drain port must NEVER be exposed to more than 42
It is important that the hoist is mounted on a surface PSI (290 kPa); shaft seal damage will occur.
that will not flex when in use, and cause binding of the
gear train. Binding in the gear train will result in acceler- 6. The hoist should be mounted perpendicular to an
ated wear and heat. Also, be sure the hoist is mounted imaginary line from the center of the drum to the first
on a flat surface. If necessary, use shim stock to insure sheave to insure even spooling. Make certain the fleet
the mounting surface is flat within 0.020 in. (0.5 mm). angle does not exceed 1-1/2 degrees.
Use stainless steel shim stock as required.
FLEET ANGLE
I I
A TO LOAD
-------- ~
r-------------------------------
112° MIN
_I
---- OR
FIRST SHEAVE
1112° MAX
I I
T A=B
7
',.--- - - - - - - - - - ,- ---, --------1
iMNCH P.SSEM8L'r'
\M~AKE 'lALVE
& STATIC BRAKE
I
I
WINCH ASSEMBLY
W/BRAKE VALVE
I & ST:T'1 BRAKE
IL..J.-+--,-,---,-", I - ...,
BRAKE - - --j I l
VALVE I I
I r WINCH BRAKE I I
~ I I
I --r
BR A
-~ I I I
I
~ _~_~=-- __ - 1 I I
---=--:J~ I
I
CONTROL
VALVE
CONTROL
VALVE
LLJ
Oil having 150 to 330 SUS (30-60 cSt) viscosity at 104 OF
A. WARNING A. (40°C) and viscosity index of 100 or greater will give
good results under normal temperature conditions. The
use of an oil having a high viscosity index will minimize
DO NOT use a control valve with any detents or cold-start trouble and reduce the length of warm-up pe-
latching mechanism that would hold the control valve riods. A high viscosity index will minimize changes in
in an actuated or running position when the operator viscosity with corresponding changes in temperature.
releases the control handle. Use of the wrong type
of control valve could lead to unintentional operation Maximum cold weather start-up viscosity should not
of the hoist, which could result in property damage, exceed 5000 SUS (1000cSt) with a pour point at least
personal injury, or death. 20°F (11°C) lower than the minimum temperature.
Under continuous operating conditions the temperature
of the oil at any point in the system must not exceed
180° (82°C). Optimum oil temperature is generally con-
sidered to be 120-140°F (49-60°C).
In general terms; for continuous operation at ambient
temperatures between 50 and 110°F (10 to 43°C) use
ISO 46; for continuous operation between 10 and 90°F
(-12 to 32°C) use ISO 32; for applications colder than
The directional control valve must be a three position, 10°F (-12°C), contact the BRADEN Service Depart-
four- way valve without detents and with a spring cen- ment. The use of multi-viscosity oils is generally not
tered motor spool such that the valve returns to the recommended.
centered position whenever the handle is released, and
both work ports are open to tank (open center, open 8. The hydraulic oil filter should have a 10 micron nomi-
port). nal rating and be full flow type and meet the require-
ments of the hydraulic pump manufacturer.
7. High quality hydraulic oil is essential for satisfactory
performance and long hydraulic system component
life.
8
RECOMMENDED FASTENER TORQUE
Higher or lower torques for special applications will be specified such as the use of spanner nuts, nuts on shaft
ends, jam nuts and where distortion of parts or gaskets is critical.
Lubricated torque values based on use of SAE 30wt engine oil applied to threads and face of bolt or nut.
Avoid using thread lubricants (such as anti-seize compound) as the applied torque may vary by 10 - 40%, de-
pending upon the product used.
Torque LB-FT (N.m) Torque LB-FT (N.m)
Bolt Thread GradeS Grade 8 Bolt Thread Grade 5 GradeS

Diam. per Diam. per
Inches inch Dry Lubed Dry Lubed Inches inch Dry Lubed Dry Lubed
20 8 6 12 9 10 265 200 380 280

1/4 3/4
28 (11) (8) (16) (12) 16 (359) (271) (515) (380)
18 17 13 24 18 9 420 325 600 450
5/16 7/8
24 (23) (17) (33) (24) 14 (569) (441) (813) (610)
16 31 23 45 35 8 640 485 910 680
3/8 1
24 (42) (31) (61) (47) 14 (868) (658) (1234) (922)
14 50 35 70 50 7 790 590 1290 970
7/16 11/8
20 (68) (47) (95) (68) 12 (1071) (800) (1749) (1315)
13 75 55 110 80 7 1120 835 1820 1360
1/2 11/4
20 (102) (75) (149) (108) 12 (1518) (1132) (2468) (1817)
12 110 80 150 110 6 1460 1095 2385 1790
9/16 13/8
18 (149) (108) (203) (149) 12 (1979) (1485) (3234) (2427)
11 150 115 210 160 6 1940 1460 3160 .2370
5/8 11/2
18 (203) (156) (285) (217) 12 (2360) (1979) (4284) (3214)
8-2008
To convert LB·FT to Kg·m, multiply LB·FT value by 0.1383
WIRE AND BRAIDED ROPE INSTALLATION

ANCHORING WIRE ROPE ANCHORING BRAIDED ROPE
'1,.- Va in. (11·13 mm) wire rope.
Insert large end first. 1-1'1. in. braided rope
";.. -,;, in. (14-16 mm) wire rope.
Insert small end first.
'€).. 1
(25-28 mm)
Early Style
Wire Rope
Anchor
Take the free end of the wire rope and insert it through A special wedge is used to anchor 1 and 1 1/8 in. (25
the small opening of the anchor pocket. Loop the wire & 28 m) braided synthetic rope. The installation proce-
rope and push the free end about half of the way back dure is the same as for anchoring wire rope.
through the pocket. Install the wedge, then pull the slack
out of the wire rope. The wedge will slip into the pocket
and secure the wire rope into the drum. The early style
anchor wedge is designed to accommodate several dif-
ferent sizes of wire rope. You may anchor 7/16 and 1/2
in. (11 & 13 mm) wire rope by inserting the wedge, large
end first. Anchor 9/16 and 5/8 in. (14 & 16 mm) wire
rope by inserting the wedge, small end first.
CORRECT INSTALLATION INCORRECT INSTALLATION

Drive from
this side
Wedge and wire

I Wedge not
fully Seated
I
rope fully seated
in pocket n
Figure 7 Figure 8 Figure 9 Figure 10
9
TWO SPEED MOTOR CASE DRAIN PLUMBING
Some hoists with two speed gear motors may have
been installed with the motor case drain connected to
the drain port of the brake valve. This system may result
in accelerated motor shaft seal wear and leakage. The
following modification should be made to the motor hy-
draulic piping to prevent this type of seal damage.
1. Remove the motor case drain hose from the

brake valve drain port and install plug, Item
1, into the valve port. Remove the hose from
the case drain port elbow, Item 4.
2. Install a new case drain hose, Item 2, onto
the motor case drain elbow, Item 4.
3. Install the tee adapter, Item 3, into the two- ,,
speed motor shift valve drain port (identified ,,
,,
by long end cap). ,
:, n
, '
, , '
4. Install the new motor case drain hose, Item L -:-i ~ -- --- --- --- --- -- --- --- --- -~! ~-~ :
2, onto the tee adapter.
5. Install a case drain hose for the tee directly
to the reservoir. Minimum hose size is -6, ITEM DESCRIPTION QTY PART #
3/8 in. (9.5 mm). Maximum drain line back 1 Plug, -4 ORB 1 25663
pressure is 100 PSI (690 kPa) measured at Hose, 17-in. OAL
the motor case drain port. 2 1 13707
(-4 JIC Fml SVI/-4 Hose/1/8 NPT ml)
3 Tee -4 (ORB Branch -4 JIC Run) 1 29078
PREVENTIVE MAINTENANCE
A regular program of preventive maintenance for your planetary hoist is strongly recommended to minimize the
need for emergency servicing and promote safe, reliable hoist operation.
Field experience, supported by engineering tests, indicate the three (3) service procedures listed below are the
MOST critical to safe, reliable hoist operation and must be observed.
• Regular Gear Oil Changes - every 1000 hours or six (6) months
• Use of Proper Gear Oil - recommended type for prevailing ambient temperature
• Periodic disassembly and inspection of all wear items.
The following minimum service intervals are speci-

fied for operating hours of the prime mover.
1. OIL LEVEL
The gear oil level should be checked every 500
operating hours or three (3) months, whichever occurs
first. To check the oil level, remove the large plug locat-
ed in the center of the drum support. The oil should be
level with the bottom of this opening or approximately
half-way up in a sight glass. This is extremely impor-
tant due to the accelerated wear that can be caused
by insufficient lubricating oil in the hoist. If addi-
tional oil in needed, refer to "Recommended Planetary
Gear Oil".
10
AWARNINGA
Failure to properly warm up the hoist, particularly un-
der low ambient temperature conditions, may result
in temporary brake slippage due to high back pres-
sures attempting to release the brake, which could
result in property damage, severe personal injury or
death.
7. WARM-UP PROCEDURES
A warm-up procedure is recommended at each
2. OIL CHANGE start-up and is essential at ambient temperatures below
The gear oil should be changed after the first +40°F (4°C).
one hundred (100) hours of operation, then every 1,000 The prime mover should be run at its lowest
operating hours or six (6) months, whichever occurs recommended RPM with the hydraulic hoist control
first. The gear oil must be changed to remove wear valve in neutral allowing sufficient time to warm up
particles that impede the reliable and safe operation of the system. The hoist should then be operated at low
the brake clutch and erode bearings, gears and seals. speeds, raise and lower, several times to prime all lines
Failure to change gear oil at these suggested minimum with warm hydraulic oil, and to circulate gear lubricant
intervals may contribute to intermittent brake slippage through the planetary gear sets.
which could result in property damage, severe personal 8. INSPECTION
injury or death.
The gear oil should also be changed whenever A. Bearings and Gears - Refer to
the ambient temperature changes significantly and an DISASSEMBLY OF Hoist, page 15; and
oil from a different temperature range would be more PLANET CARRIER SERVICE, page 20.
appropriate. Oil viscosity with regard to ambient tem- B. Brake Cylinder - Refer to MOTOR
perature is critical to reliable brake clutch operation. SUPPORT - BRAKE CYLINDER SERVICE,
Our tests indicate that excessively heavy or thick gear pages 22 and 23.
oil may contribute to intermittent brake clutch slippage.
C. Brake Clutch - Refer to BRAKE CLUTCH
Make certain that the gear oil viscosity used in your
SERVICE, page 26.
hoist is correct for your prevailing ambient temperature.
Failure to use the proper type and viscosity of planetary
gear oil may contribute to brake clutch slippage which AWARNINGA
could result in property damage, severe personal injury
or death. Refer to "Recommended Planetary Gear Oil" Failure to use the proper type and viscosity of plan-
for additional information. etary gear oil may contribute to intermittent brake
3. VENT PLUG clutch slippage which could result in property dam-
The vent plug is located in the drum support as age, severe personal injury or death. Some gear lu-
shown. It is very important to keep this vent clean and bricants contain large amounts of EP (extreme pres-
unobstructed. Whenever gear oil is changed, remove sure) and anti-friction additives which may contribute
vent plug, clean in solvent and reinstall. to brake clutch slippage and damage to brake friction
discs or seals. Oil viscosity with regard to ambient
Do not paint over the vent or replace with a solid plug.
temperature is also critical to reliable brake clutch
4. HYDRAULIC SYSTEM operation. Our tests indicate that excessively heavy
The original filter element should be replaced or thick gear oil may contribute to intermittent brake
after the first fifty (50) hours of operation, then every clutch slippage. Make certain that the gear oil viscos-
500 operating hours or three (3) months, or in accor- ity used in your hoist is correct for your prevailing
dance with the equipment manufacturer's recommen- ambient temperature.
dations.
5. WIRE ROPE 9. RECOMMENDED PLANETARY GEAR OIL
Inspect entire length of wire rope according to Use of the proper planetary gear oil is essential
wire rope manufacturers recommendations. to reliable and safe operation of the brake clutch and
6. MOUNTING BOLTS obtaining long gear train life.
Tighten all hoist base mounting bolts to recom- For simplicity, BRADEN has listed one (1) read-
mended torque after the first one hundred (100) hours ily available product in each temperature range which
of operation, then every 1000 operating hours or six (6) has been tested and found to meet our specifications.
months, whichever occurs first.
11
RECOMMENDED PLANETARY GEAR OIL
PREVAILING AMBIENT TEMPERATURE
OF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 OF
MOBILGEAR 600 XP 150 OR EQUIVALENT

AGMA 4 EP, ISO VG 150
MOBILGEAR SHC 150

SYNTHETIC OR EQUIVALENT
°C -40 -30 -20 -10 o 10 20 30 40 50 °C

1:1. NOTE: SHADED TEMPERA TURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICA TlONS SUCH AS: OFFSHORE
L!J CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.
Planetary hoists are factory filled with Mobilgear 600 XP 150, or equivalent. Consult your oil supplier for other equivalent
oils if required.
Mobil Shell Chevron Texaco

Mobilgear 600 XP 150 Omala 150 Gear Compounds EP 150 Meropa 150
Mobilgear 600 XP 220 Omala 220 Gear Compounds EP 220 Meropa 220
OIL CAPACITIES:
(PD12C/PD15B) 01,02 & 22 DRUM - 6 PINTS (2.8 L) NOTE: Capacities are approximate. Refer to "Oil
(PD12C/PD15B) 04,05 & 23G DRUM - 7 PINTS (3.3 L) Level" earlier in this section
(PD17A) - 14 PINTS (6.6 L)
TROUBLESHOOTING
A.WARNINGA.
If a hoist ever exhibits any sign of erratic operation, or load control difficulties (i.e. load creeping or chattering)
appropriate troubleshooting tests and repairs should be performed immediately. Continued operation in this
manner may result in property damage, serious personal injury or death.
TROUBLE PROBABLE CAUSE REMEDY

A
The hoist will not lower the load or 1. The problem could be a plugged Remove the pilot hose and fitting
not lower the load smoothly. or loose pilot orifice. The pilot ori- from the brake valve, then use a
fice is a small pipe plug with a hole 5/32 inch Allen wrench to remove
drilled through it, located behind the the pilot orifice. The diameter of the
pilot port fitting on the brake valve. orifice is approximately .020 inches.
If it becomes plugged, it will prevent Clean and install the pilot orifice
the pilot pressure, from the mani- tightly in the brake valve.
fold, from opening the brake valve.
If it becomes loose, it will allow an
unregulated amount of oil in to op-
erate the brake valve which cause
erratic brake valve operation.
2. The friction brake may not be Check brake cylinder seal as fol-
releasing as a result of a defective lows:
brake cylinder seal.
A. Disconnect the swivel tee from
NOTE: If the brake cylinder seal the brake release port. Connect a
is defective you will usually find oil hand pump with accurate 0-2000
leaking from the hoist vent plug. psi gauge and shut-off valve to the
-4 J.I.C. fitting in the brake release
port.
12
A
The hoist will not lower the load or 1. Friction brake will not release as A. Apply 1000 PSI (6,900 kPa) to
not lower the load smoothly. a result of damaged brake discs. the brake. Close shut-off valve and
let stand for five (5) minutes.
B. If there is any loss of pressure

in five (5) minutes, the brake cylin-
der should be disassembled for in-
spection of the sealing surfaces and
replacement of the seals. Refer to
"Motor Support-Brake Cylinder Ser-
vice".
Disassemble brake to inspect brake

discs. Check stack-up height as
described in "Motor Support-Brake
Cylinder Service".
Oil leaks from vent plug. 1. Same as A2. Same asA2.
2. Motor seal may be defective as System back pressure must not ex-
a result of high system back pres- ceed 150 PSI (1,035 kPa). Inspect
sure or contaminated oil. hydraulic system for a restriction in
the return line from the control valve
to the reservoir. Be sure control
valve and plumbing is properly sized
to hoist motor.
Oil analysis may indicate contami-

nation has worn motor shaft and
seal. Thoroughly flush entire hy-
draulic system and install new filters
and oil. Install new motor seal.
c
The brake will not hold a load with 1. Excessive system back pressure The same as Remedy 2 of Trouble
the control lever in neutral. acting on the brake release port. B2.
2. Friction brake will not hold due to Same as Remedy 3 of Trouble A3.
worn or damaged brake discs.
3. Brake clutch is slipping. Improper planetary gear oil may

cause the brake clutch to slip. Drain
old gear oil and flush hoist with sol-
vent. Thoroughly drain solvent and
refill hoist with recommended plan-
etary gear oil listed in "Preventive
Maintenance".
Brake clutch may be damaged or

worn. Disassemble and inspect
brake clutch as described in "Brake
Clutch Service".
13
D
The hoist will not hoist the rated 1. The hoist may be mounted on Reinforce mounting surface.
load. an uneven or flexible surface which If necessary, use shim stock to level
causes distortion of the hoist base hoist. Refer to "Hoist Installation".
and binding of the gear train. Bind-
ing in the gear train will absorb First loosen, then evenly retighten
horsepower needed to hoist the all hoist mounting bolts to recom-
rated load and cause heat. mended torque.
2. System relief valve may be set Check relief pressure as follows:

too low. Relief valve needs adjust- A. Install an accurate 0-4000 psi
ment or repair. (27,580 kPa) gauge into the inlet
port of the brake valve.
B. Apply a stall pull load on the hoist
while monitoring pressure.
C. Compare gauge reading to hoist
specifications. Adjust relief valve as
required.
NOTE: If pressure does not in-
crease in proportion to adjustment,
relief valve may be contaminated or
worn out. In either case, the relief
valve may require disassembly or
replacement.
3. Be certain hydraulic system tem- Same as remedies for Trouble 01 &

perature is not more than 180 de- 02.
grees F. Excessive hydraulic oil
temperatures increase motor inter- Same as remedies for Trouble E2.
nal leakage and reduce motor per-
formance.
4. Hoist line pull rating is based on Refer to hoist performance charts

1st layer of wire rope. for additional information.
5. Rigging and sheaves not operat- Perform rigging service as recom-

ing efficiently. mended by crane manufacturer.
The hoist runs hot. 1. Same as 01. Same as remedies for Trouble 01.
2. Be certain that the hydraulic sys-

tem temperature is not more than
180 degrees F. Excessive hydrau-
lic oil temperatures may be caused
by:
A. Plugged heat exchanger. Thoroughly clean exterior and flush

interior.
B. Too low or too high oil level in hy- Fill/drain to proper level.
draulic reservoir.
C. Same as 02. Same remedies as 02

14
E
The hoist runs hot. D. Hydraulic pump not operating Same as remedies for Trouble D2.
efficiently.
Prime mover low on horsepower or
R.P.M. Tune/adjust prime mover.
Check suction line for damage.
If pump is belt driven, belts are slip-

ping. Replace/tighten belts.
Pump worn. Replace pump.
3. Excessively worn or damaged Disassemble hoist to inspectlre-

internal hoist parts. place worn parts.
Hoist "chatters" while raising rated 1. Same as D2. Same as remedies for Trouble D2.
load.
2. Hydraulic oil flow to motor may Same as remedies for Trouble E2.
be too low.
3. Controls being operated too Conduct operator training as re-

quickly. quired.
The wire rope does not spool 1. The hoist may be mounted too Check mounting distance and fleet
smoothly on the drum. close to the main sheave, caus- angle. Reposition hoist as required.
ing the fleet angle to be more than
1-1/2 degrees.
2. The hoist may not be mounted Refer to "Hoist Installation".

perpendicular to an imaginary line
between the center of the cable
drum and the first sheave.
3. Could possibly be using the Consult wire rope manufacturer for

wrong lay rope. There is a distinct recommendation of wire rope that
advantage in applying rope of the best suits your application.
proper direction of lay. When the
load is slacked off, the several coils
on the drum will stay closer to-
gether and maintain an even layer.
If rope of improper lay is used, the
coils will spread apart each time
the load is removed. Then, when
winding is resumed, the rope has a
tendency to criss-cross and overlap
on the drum. The result is apt to be
a flattened and crushed rope.
4. The hoist may have been over- Replace wire rope and conduct
loaded, causing permanent set in operator/rigger training as required.
the wire rope.
15
DISASSEMBLY OF HOIST
SERVICE PRECAUTIONS
Before any part is removed from the hoist, all service instructions should be read and understood.
Work in a clean, dust free area as cleanliness is of utmost importance when servicing hydraulic equipment.
Inspect all replacement parts, prior to installation, to detect any damage which might have occurred in ship-
ment.
Use only genuine BRADEN replacement parts for optimum results. Never reuse expendable parts such as oil
seals and a-rings.
Inspect all machined surfaces for excessive wear or damage ... before reassembly operations are begun.
Lubricate all a-rings and oil seals with gear oil prior to installation.
Use a sealing compound on the outside surface of oil seals and a light coat of thread sealing compound on
pipe threads. Avoid getting thread compound inside parts or passages which conduct oil.
Thoroughly clean all parts in a good grade of non-flammable safety solvent. Wear protective clothing as re-
quired.
After troubleshooting the hoist and its hydraulic system as covered in the "Troubleshooting" section, and the prob-
lem is determined to be in the hoist, use the following procedure to disassemble the hoist.
1. Remove the wire rope from the cable drum and align 3. Begin disassembly by removing the oil level plug or
the drain hole in the drum with a hole in the support sight glass and standing the hoist on the bearing support
side plate before removing the hoses and mounting end. Tag and remove the hydraulic hoses that connect
bolts. After the hoist is removed from its mounting, thor- the brake valve and manifold to the brake cylinder.
oughly clean the outside surfaces. To drain the oil, in-
stall a short piece of 1 inch pipe in the larger threads of 4. Remove the capscrews securing the motor, and lift
the drain hole. If necessary, insert a bar into the anchor the motor off the hoist. Remove and discard the a-ring
pocket and manually rotate the drum in the direction to installed on the pilot of the motor.
hoist a load until the drain holes are aligned.
2. Use a 5/16 inch Allen wrench to remove the drain

plug through the pipe. 5. Tag and remove the hoses and fittings from the brake
cylinder release port.
16
9. Using two heel type pry bars placed between the pri-
mary planet carrier and the drum closure, pry upward to
6. Remove the brake clutch assembly from the motor remove the drum closure. Remove and discard the 0-
support. Refer to "Brake Clutch Service" for additional ring from the outside of the drum closure. Some drum
information. closures have 3/8-16 tapped lifting eye holes that may
be used in place of the heel bars
10. Remove the seal and bearing from inside of clo-

sure.
7. Remove the motor support capscrews and install two

(2) capscrews and a short piece of chain into the motor
mounting bolt holes. Using the chain as a handle, lift 11. Remove the primary sun gear and thrust washer
the motor support out of the brake cylinder being care- from the primary planet carrier.
ful to avoid damaging the sealing surfaces. Remove
and discard the O-ring and back-up ring from the motor
support. Refer to "Motor Support-Brake Cylinder Ser-
vice" for additional information. Note the location of the
brake release port in relation to hoist prior to removing
the brake cylinder
8. Remove the brake cylinder capscrews and install two

(2) capscrews and a short piece of chain into the mo-
tor support mounting bolt holes. Using the chain as a
handle, lift the brake cylinder out of the drum and base,
being careful to avoid damaging the sealing or bearing
surfaces. Refer to "Motor Support-Brake Cylinder Ser-
vice" for additional information. 12. Remove the primary planet carrier from the drum.
Refer to "Planet Carrier Service" for additional informa-
For PD15B hoists, the drum closure cannot be re- tion.
moved through the opening in the base. If your hoist
has a one-piece cast base, remove the bearing sup-
port, as described in step 15, and remove the drum
from the base. Then proceed with steps 9 thru 14. If
your hoist has a three piece base, remove the motor
end side plate and continue with step 9.
17
15. Stand hoist on motor end with bearing support up;
then remove eight (8) bearing support capscrews and
bearing support being careful to avoid damaging the
sealing or bearing surfaces.
16. Slide drum out of base onto a work bench and re-
move seal and bearing from support end.
17. Thoroughly clean and inspect drum and base.

Check ring gear (machined into inside surface of drum)
teeth for nicks, spalling or excessive wear. Replace if
wear is greater than 0.015 in. (0.4 mm) when compared
to unworn area of teeth.
13. Remove the output sun gear and thrust washer from
the output planet carrier.
14. Remove the output planet carrier from the drum.

Refer to "Planet Carrier Service" for additional informa-
tion.
BRADEN PD12C/15B17A COMPONENTS

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION
1 1 Brake Cylinder 42 4 Capscrew
2 1 Piston Seal 43 1 Thrust Washer
3 1 Pressure Plate 44 1 Plug- Hex Head
4 1 Piston Back-up Ring 45 1 Plug- Flush
5 12 Sprina 46 1 Vent Plua
6 7 Friction Disc 47 1 O-Rina
7 8 Brake Disc 48 1 Back-up Rina
10 1 Primary Planet Carrier 49 1 Brake Race- Outer
11 3 Primary Planet Gear 50 1 Brake Race- Inner
12 3 Primary Planet Gear Shaft 51 2 Spraa Bushina
13 3 Roller Bearina 52 2 Spraa Bushina Retainer
14 6 Thrust Washer 53 2 Retainina Rina
15 6 Spirol Pin 54 1 Sprage Clutch
16 1 Output Planet Carrier 55 1 Retaining Ring
17 3 Output Planet Gear 57 1 Cable Clamp
18 3 Output Planet Gear Shaft 58 1 Manifold
19 6 Roller Bearing 59 2 O-ring
20 3 Bearing Spacer 60 4 Capscrew
21 6 Thrust Washer 61 4 Capscrew
22 1 One-Piece Base 62 1 Brake Valve
23 1 Bearing Support 63 1 Hose Assembly
24 1 Cable Drum 64 2 Hose Assembly 12-inch
25 1 Cable Drum Closure 65 1 Adapter- straight
26 2 Ball Bearina 66 1 Elbow
27 1 Oil Seal 67 1 swivel tee
28 1 O-rina 68 1 elbow
29 1 Oil Seal 69 1 Reducer elbow
30 1 Retainina Rina 70 4 Capscrew
31 1 Thrust Washer 72 1 Hvdraulic Motor
32 1 Motor Support 90 1 Base Plate
33 1 O-Rina 91 1 Side Plate (bearina support end)
34 1 Output Sun Gear 92 1 Side Plate (motor end)
35 1 Primary Sun Gear 93 16 Capscrew (special)
36 2 Spacer 94 16 Washer
37 1 Primary Sun Gear 95 1\2 Tie Bar
38 1 Output Thrust Plate 96 2\4 Capscrew
40 16 Capscrew 97 2\4 Lockwasher
41 24 Lockwasher 99 1 Spring Spacer
18
PD17A
hoists
use only
1 each of
items 52
and 53
due to the
shoulder
on item 50.
(shoulder
is toward
motor)
19
PLANET CARRIER SERVICE
OUTPUT PLANET CARRIER
DISASSEMBLY
©U o
3. Now you can remove the planet shafts, bearings,
spacer, thrust washers and gears. Thoroughly clean all
parts and inspect for damage and wear. The bearing
rollers should not exhibit any irregularities. If the roll-
ers show any sign of spalling, corrosion, discoloration,
1. Remove the planet gears by driving the roll pins into material displacement or abnormal wear, the bearing
the center of the planet shafts. should be replaced. Likewise, the cage should be in-
spected for unusual wear or deformation, particularly
the cage bars. If there is any damage that will impair
the cage's ability to separate, retain and guide the roll-
ers properly, the bearing should be replaced. The thrust
washer contact areas should be free from any surface
irregularities that may cause abrasions or friction. The
gears and shafts should be inspected for abnormal
wear or pitting. Replace if necessary.
ASSEMBLY
2. Use a punch to drive the roll pins from the planet

shafts. Do not reuse the roll pins.
o
1. Place the output planet carrier on workbench with

splined coupling side down. Install output thrust plate in
center of carrier.
&CAUTION&
PD17A hoists have an internal retaining ring to hold
the thrust plate into the carrier. This retaining ring
MUST be properly installed and fully seated before
the planet gears are installed.
20
PRIMARY PLANET CARRIER
1.To service the primary planet carrier, the steps are the
same as for the output carrier except there is only one
bearing for each gear and no bearing spacer.
2. Insert two (2) bearings and a bearing spacer into a

gear with the spacer between the bearings. Place a
thrust washer on each side of the gear and position in
a carrier opening. Slide the shaft through the carrier,
thrust washer, bearing-gear sub-assembly and remain-
ing thrust washer. Be careful to avoid damaging thrust
washers when installing planet shafts.
3. Carefully align the pin hole in the carrier with the hole
in the planet gear shaft and drive the roll pin into place.
Always use NEW roll pins. When properly positioned,
50% of the roll pin will engage the planet gear shaft and
50% will remain in the planet carrier.
o
4. Note that the roll pin is slightly recessed in the carrier
when properly installed. With a center punch, stake
the carrier next to the pin hole as shown. This will dis-
tort the hole so the pin will not back out. Repeat these
steps for each of the three planet gears.
21
MOTOR SUPPORT-BRAKE CYLINDER SERVICE
NOTE: Starting mid-year 1996, Braden changed the
steel brake separator discs from a splined tooth design
to a lobed design. This required a change to the motor
support and brake cylinder and the addition of a spring
spacer. A hoist with the lobed discs can be identified
by a machined groove on the outside diameter of the
motor support. When replacing steel brake discs, the
motor support or brake cylinder, care must be taken to
properly identify the correct parts. Splined discs will re-
main available as spare parts.
New lobed steel brake separator plates and motor sup-

port. Note groove on outside diameter of motor sup-
port.
Although most photos in this section show splined discs,

all procedures are the same except where specifically 3.Remove the brake springs.
noted.
CLEAN AND INSPECT
DISASSEMBLY
1. After removing the motor support and brake clutch 1. Thoroughly clean and inspect all parts at this time.
assembly, continue brake cylinder disassembly by re- Check brake piston sealing surfaces on brake cylinder
moving the spacers, friction brake discs and steel brake and motor support. Be sure brake release port is free
discs. of contamination.
2. Remove the piston back-up ring and pressure 2. Check oil seal and bearing surfaces on brake cylin-
plate. der for damage or wear.
22
ASSEMBLY
&CAUTION&
Failure to replace brake springs as a set may result
in uneven brake application pressure and repeated
brake spring failure.
1. Begin assembly by placing motor support on work-

bench with motor mounting surface down. Install new
O-ring and back-up ring as shown.
3. Place friction brake disc on flat surface and check for

distortion with a straight edge. Friction material should
appear even across entire surface with groove pattern
visible. Replace friction disc if splines are worn to a
point, disc is distorted, friction material is worn uneven-
ly, or groove pattern is worn away.
4. Place steel brake disc on flat surface and check for

distortion with a straight edge. Check surface for signs
of material transfer or heat. Replace steel disc if splines
are worn to a point, disc is distorted or heat discolored.
2. Install a brake spacer into the motor support. (NOT

REQUIRED WITH LOBED DISCS.)
5. Check brake spring free length; minimum free length

is 1 3/16 in. (30.2 mm). Check springs for any sign of
cracking or failure. If a brake spring must be replaced for
any reason, then ALL brake springs must be replaced.
3. Insert first, a steel brake disc against the spacer fol-

lowed by a friction brake disc then alternate steel and
friction discs until seven (7) friction and eight (8) steel
discs have been installed. Finish with a steel brake
disc on top.
NOTE: It is a good practice to pre-lubricate the discs in

hydraulic oil prior to assembly.
23
4. Install the remaining brake spacer on top of the last OLDER STYLE BRAKE CYLINDER
steel brake disc. (This is the only spacer used with 7.lnstall brake springs into brake cylinder
lobed discs.)
5. To check brake stack height, place pressure plate on NEW STYLE BRAKE CYLINDER
top of brake spacer. Hold pressure plate down firmly by 7A. When using the new style brake cylinder without
hand and measure clearance in three places between milled spring pockets, install the spring spacer, then the
motor support and pressure plate. Average gap must brake springs.
measure between .153 in. (4 mm) maximum and .080
in. (2 mm) minimum. If the gap exceeds the maximum
limit, there are too many brake discs in stack-up or the A. WARNING A.
discs are distorted. If the gap is less than the minimum,
there are too few discs in stack-up or the discs are worn Always use the molded spring spacer with the new
out. When stack height is correct, remove pressure brake cylinder. The brake springs must be properly
plate and continue assembly. positioned by the spring spacer. Failure to install
the spring spacer may allow the springs to contact
each other and become damaged. This could result
in loss of load control, property damage, injury or
death.
8. Install pressure plate into brake cylinder followed

by the piston back-up ring. The close-fitting piston
back-up ring may be depressed slightly to one side
to lodge the back-up ring in the brake cylinder bore
and temporarily hold the pressure plate and springs
in place while you lower the brake cylinder over the
motor support.
6. Lubricate the brake piston seal and motor support

sealing surface with petroleum jelly or hydraulic oil. In-
stall new piston seal to motor support, seal lip down.
24
9. Apply petroleum jelly to the entire sealing surface
of the brake cylinder and to the piston seal. Install the
brake cylinder over the motor support being careful to 2. WHILE PRESSURE IS APPLIED AND THE BRAKE
avoid damaging the piston seal or motor support O-ring. RELEASED, install the brake clutch assembly in the
(A press may be necessary to avoid cocking the brake brake pack, short end of the inner race toward motor.
cylinder during installation.) Turn the clutch back and forth as you align the outer
race splines with the brake disc splines.
3. Release the pressure on the brake cylinder then re-

move the brake clutch assembly. The brake cylinder
assembly is now complete and ready to be installed in
the hoist.
10. Install motor support capscrews and evenly tighten

to recommended torque.
BRAKE CYLINDER PRESSURE TEST

1. Install the -4 J.I.C. fitting into the brake release
port. Connect a hand pump with accurate 0-2000 psi
(0-13,800 kPa) gauge and shut-off valve to this fitting.
Apply 1000 psi (6,900 kPa) to the brake. Close shut-off
valve and let stand for five (5) minutes. If there is any
loss of pressure in five (5) minutes, the brake cylinder
should be disassembled for inspection of the sealing
surfaces and brake piston.
25
BRAKE CLUTCH SERVICE
DISASSEMBLY
1. Remove the snap ring and sprag bushing retainer

from one end only. 4. Next, slide the sprag clutch out, inspect the sprag
clutch closely for abnormal wear, cracks, pitting or cor-
NOTE: The brake clutch on PD17A hoists use a rosion. Check small clips for breakage or bright spots;
stepped inner race, which eliminates one retaining ring the signs of excessive wear. Unless the outer race or
and bushing retainer. The larger end of the inner race remaining sprag bushing is damaged or shows exces-
is toward the motor. sive wear, there is no need for further disassembly.
If disassembly is necessary, remove the bushing ac-
cording to the procedure covered in Step No. three (3).
All brake clutch assembly parts should be thoroughly
cleaned and inspected before assembly.
A.WARNINGA.
The polished surfaces of the races and sprag cams
must be perfectly smooth to insure positive engage-
ment of the clutch. The slightest defect may reduce
brake clutch effectiveness, which may lead to loss of
load control and result in property damage, personal
injury or death. It is generally recommended to re-
2. Pull the inner race out. Examine the race for scoring, place the entire brake clutch assembly if any compo-
wear or indentations caused by the sprag cams. nent is defective.
ASSEMBLY
1. Press a sprag bushing into the outer race, using a

mechanical or hydraulic press. A flat plate of approxi-
3. Use a screwdriver and mallet to remove the sprag mately the same diameter as the bushing flange out-
bushing from one end of the outer race. There are four side diameter should be placed between the press and
special cut-outs in the bushing for this purpose. Be bushing during assembly to protect the bushing. Be
careful not to damage the bushing inside surface. If certain the bushing flange is against the shoulder in the
a bushing's inside surface is damaged or shows wear, outer race.
replace it.
26
6. Turn the assembly over with the snap ring down. In-
stall the second retainer and snap ring. Make certain
the snap ring is seated in the groove properly.
2. Turn the assembly over and install the sprag clutch in
the bore of the outer race.
3. Press the remaining bushing into the race. Again,

make sure the bushing is against the shoulder.
7. This is a completed brake clutch assembly.
4. Next, install a sprag bushing retainer, then a snap

ring on the inner race. Be sure the snap ring is seated
in the snap ring groove. NOT necessary on PD17Adue
to stepped design.
A. WARNING A.
Be certain the snap ring is seated in the groove in
the splined bore of the inner race. This snap ring will
keep the brake clutch assembly correctly positioned
in the center of the friction brake pack. Binding of the
brake or brake failure may occur if this snap ring is
5. Slide the inner race through the bushings and sprag omitted.
clutch (the race will have to be rotated in the free-
wheeling direction to start it through the sprag clutch).
If the inner race will not go through the bushings, the
bushings have probably been damaged and should be
replaced.
27
HOIST ASSEMBLY
NOTE: PD15B HOISTS ONLY
The drum closure will not fit through the opening in the base. For hoists with a three piece base, first assemble the
bearing support side plate (91) to the base plate (90). Go to step 1 and follow the assembly procedure. Install the
motor end side plate and tie bar(s) after installing the drum closure in step 10.
For hoists with a one piece cast base, use the following assembly procedure. With the drum horizontal, install the
output planet carrier assembly, output sun gear (34), thrust washer (43), primary planet carrier assembly, thrust
washer (31) and drum closure. (Apply a light coat of grease to the thrust washer to hold them in position.) Position
the drum in the base and install the bearing support. (Refer to step 3 for two caution statements.) You may have to
rotate the bearing support or planet gears to engage the bearing support with the output planet carrier. Install and
hand tighten the bearing support capscrews. Stand hoist on bearing support end and visually check to verify the
primary thrust plate is properly positioned. (Refer to caution and drawings in step 16.) Install the primary sun gear
and proceed to step 11 to complete hoist assembly. Tighten bearing support capscrews to recommended torque
after motor is installed.
&CAUTION&
Hoists with a three piece fabricated base use spe-
cial shoulder capscrews to fasten side plates to the
base plate. DO NOT use standard capscrews in their
place.
PD12C,PD15B,PD17A
&CAUTION&
Make certain the snap ring is installed on the bearing
support. This snap ring will keep the output planet
carrier correctly positioned in the hoist. Gear train
damage may occur if this snap ring is omitted.
1. Place hoist base on side with bearing support end

up.
2. Install a new bearing in the drum if replacement is

necessary. Apply a non-hardening sealant on the out-
side diameter of the new seal. Install the spring side of
the seal next to the bearing, then press into the drum,
using a flat plate to avoid distortion. Be sure drain plug
is installed securely.
3. Center the drum in the opening of the base. Lubri-

cate the bearing support with petroleum jelly or gear oil
and install in base and drum.
28
&CAUTION&
Be sure the vent plug is located above the horizontal
centerline for the intended application. Oil leakage
may occur if vent is positioned incorrectly.
4. Tighten the bearing support capscrews to the recom-

mended torque.
8. Install the primary planet carrier, meshing the planet

gears with the ring gear and the planet housing with the
output sun gear.
5. Stand hoist on bearing support end. Install the output
sun gear and thrust washer into output planet carrier.
9. Install a new bearing in the drum closure as required.

Use sealant on the outside surface of the oil seal. In-
stall with spring side of the seal toward bearing, using a
6. Install the output planet carrier into the drum while flat plate to avoid distortion.
meshing the planet gears with the ring gear and the
planet housing with the bearing support. Install a new a-ring in the groove on the 0.0. of the
drum closure.
7. Install the primary sun gear and thrust washer into
the primary planet carrier.
10. Lubricate the a-ring and drum opening with petro-

leum jelly or gear oil and install the drum closure into
the drum.
29
11. Lubricate the pilot, oil seal and bearing surfaces of 13. If the brake discs are misaligned, preventing the
the brake cylinder and carefully install brake cylinder installation of the clutch, then with a hand pump, ap-
into base and drum. Locate the brake release port to- ply 750-1000 psi to the brake release port. The brake
ward the lower rear corner of the base. Tighten brake discs will move freely with the brake released, permit-
cylinder capscrews to recommended torque. ting alignment of the discs, brake clutch and input sun
gear.
12. Install the brake clutch assembly with the short end
of the inner race toward motor. 14. Install the hoses and fittings to the brake cylinder
release port.
When installed correctly, the inner race should turn free-
ly in the opposite direction the drum turns to pull wire 15. Install a new O-ring on the motor pilot then lubricate
rope in. An easy way to check the rotation is to hold the with petroleum jelly or gear oil.
outer race in one hand, and rotate the inner race.
NOTE: The following caution DOES NOT apply to
If the clutch free wheels in the wrong direction, disas- PD17A hoists. Proceed to step 16.
semble the clutch and reverse the inner race. Refer to
"Brake Clutch Service" for additional information.
&CAUTION&
Care must be taken to assure the primary thrust plate
remains properly located in its counterbore when the
motor is installed for the first time, or is being rein-
stalled on the hoist. It is possible for the primary
thrust plate to drop out of its counterbore and become
wedged between the planet gears and the planet car-
rier. If the hoist is operated with the primary thrust
plate wedged between primary gears and the planet
carrier, or with a thrust washer out of position, severe
damage to internal hoist components could result.
A. WARNING A.
the splined bore of the inner race. This snap ring will
keep the brake clutch assembly correctly positioned
in the center of the friction brake pack. Binding of the
brake or brake failure may occur if this snap ring is
omitted.
30
17. Install the hoses that connect the manifold and
brake valve to the brake cylinder.
Measure the distance from the motor mounting surface
to the inner brake race. With all components properly
18. After the hoist assembly is complete, check all cap-
installed, this distance should be 11/16 in. (17.5 mm) to
screws and fittings to make certain they have been
3/4 in. (19.1 mm). If this distance is less than 9/16 in.
tightened correctly.
(14.3 mm), the primary spacer may be positioned as
shown below and should be checked.
Refill the hoist with the recommended oil listed under
"Preventive Maintenance", and install the oil level plug.
PRIMARY THRUST PLATE BRAKE CWTCH

INNER BRAKE RACE
The Primary Thrust Plate is shown wedged between the
planet gears and the planet carrier. Note that the Pri-
mary Sun Gear and the entire Brake Clutch Assembly
have moved to the right (toward the hydraulic motor).
16. Engage the motor shaft with the brake clutch inner
race and lower motor into place. Tighten capscrews to
recommended torque.
31
BRAKE VALVE SERVICE
~~~~~~ SECTION A-A
BRAKE VALVE ASSEMBLY
ITEM DESCRIPTION QTY.
1 Valve Housing (NSS) 1
2 Check Valve Retainer INSS) 1
3 Sorina Retainer INSS) 1
4 Plua INSS) 1
5 SoooIINSS) 1
6 Damoer Piston (NSS) 1
7 O-Rina 1
8 Check Valve Poppet (NSS) 1
9 Pilot Orifice 1
10 Check Valve Spring 1
11 Spool Spring 1
12 O-Rina 2
13 O-Rina 1
14 O-Rina 1
15 Back-up Rina 1
16 Back-up Ring 1
17 Check Ball (1/4 in.) 1
18 Check Ball Spring 1
19 Elbow Filling 1
22 Shim A.R.
NSS - NOT SERVICED SEPARATELY. REPLACE
COMPLETE VALVE ASSEMBLY
The BRADEN brake valve is a reliable hydraulic valve

with internal components manufactured to close toler-
ances. Due to the close tolerances and mating of com-
ponents, the valve housing, spool, piston and check
poppet are not available as replacement parts.
Before disassembling the brake valve, be sure you have

conducted all applicable troubleshooting operations and
are certain the brake valve is causing the malfunction.
Thoroughly clean the outside surfaces of the valve and

work in a clean dust free area, as cleanliness is of utmost 2. Remove the elbow fitting, motor drain check ball and
importance when servicing hydraulic components. spring.
DISASSEMBLY 3. Remove the spool spring retainer and spool spring.

Check spring free length. Replace spring if less than 1
15/16 in. (49.2 mm) long.
1. Remove the pilot orifice from the brake release (BR)

port using a 5/32 in. Allen wrench. 4. Remove spool plug and carefully remove spool as-
sembly.
32
5. Remove the damper piston from the spool. The pis- ASSEMBLY
ton will come out slowly, because of a partial vacuum
formed as it is removed. Use extreme care to avoid 1. Install new O-rings on the plug and spring retainers.
damaging the polished surfaces of the piston or spool. ,-'--- Jr\
T';
'---
'----j
2. Install new O-rings and back-up rings on the spool

and damper piston as shown. It is important that each
6. Remove the check valve spring retainer, spring and back-up ring is on the correct side of its O-ring. Take
check valve poppet. Check spring free length. Replace care not to cut the O-rings during assembly. Let the
spring if less than 1-1/2 in. (38.1 mm) long. spool and damper piston set for ten minutes before in-
stalling them in their respective bores. This will allow
CLEAN AND INSPECT the O-rings to return to their original size after being
stretched.
1. Discard all O-rings and back-up rings. Clean all parts
in solvent and blow dry. Inspect polished surfaces of 3. Lubricate the spool and damper piston O-rings with
spool and damper piston for damage that may cause hydraulic oil. Carefully install the damper piston into
binding or leakage. Inspect spool bore in valve hous- the spool.
ing for damage or scoring. Inspect check valve seat in
valve housing and check valve poppet. If the spools,
bores or valves are damaged, the entire valve must be
replaced as these parts are not serviced separately.
4. Lubricate the spool bore and spool O-rings with

hydraulic oil. Carefully install the spool into the valve
housing. Always install the spool from the plug end as
shown to minimize the possibility of damaging the 0-
ring. Install the plug, spool spring and spring retainer.
2. Inspect the .020 inch (.5 mm) orifice in the end of the
spool and the pilot orifice to be certain they are open. 5. Install the check valve poppet, spring and check
valve spring retainer.
6. Install the motor drain check ball, spring and elbow

fitting.
7. Install the pilot orifice into the valve housing.
8. The brake valve is complete and ready to be installed

on hoist motor.
33
REVERSING DIRECTION OF DRUM ROTATION
Motor
Case Drain
Motor
DRN
Case Drain
DRN
Brake Lowering Brake Lowering

Motor M Motor M
Valve Port Valve Port
"-
BR BR "-
Hoisting
Port
Brake Release Brake Release

Circuit M = Manifold Block Circuit
"A" "8"
In order to change the direction of rotation and brake operation, 2 components must be changed on the hoist. First,
the motor must be made to rotate in the opposite direction. This is done by exchanging positions of the brake valve
and manifold block on the motor. Secondly, the brake clutch assembly must be made effective for the opposite
direction of rotation. This is done by reversing the inner race of the brake clutch assembly.
Figures "A" and "B" above show typical PD12C motor installations. Note that the only difference between the two
drawings is the motor is rotated 180 (the "belly" of the motor moves to the opposite side). If the motor shaft rotates
0
clockwise in figure 'A" when the hoisting port is pressurized, it will rotate counterclockwise in figure "B".
1. Remove the four capscrews securing the brake valve

to the motor. Remove the four capscrews securing the
manifold block to the motor. Disconnect the motor case
drain hose at the motor. NOTE: Some installations
have the brake release hose connected directly to the
motor, instead of to the manifold block. In this case,
disconnect the brake release hose at the motor port.
Stand hoist up on drum support with the motor end up
and secure in this position.
2. Before removing the motor, it is a good idea to note

or mark the position of the motor in relation to the hoist,
since it will be rotated 180 when reinstalled. Remove
0 4. Remove the snap ring and sprag bushing retainer
the capscrews securing the motor to the hoist and care- from one end only of the brake clutch assembly.
fully remove the motor.
5. Pull the inner race out. Examine the race for scor-
ing, wear or indentations caused by the sprag cams. If
3. Remove the brake clutch assembly from the motor the inner race is not completely smooth, the assembly
support. should be replaced.
34
7. Before installing the brake clutch, be sure the inner
race turns free in the opposite direction the drum will
turn to haul-in wire rope. An easy way to check the
rotation is to hold the outer race in one hand and rotate
the inner race. Install the brake clutch with the short
end of the inner race toward the motor.
8. Install a new O-ring on the motor pilot. Rotate the

motor 180 from its original position and install it onto
0
the hoist. Install and tighten motor capscrews to rec-

ommended torque.
9. Install new O-rings in the brake valve and manifold

6. Turn the sprag assembly around and slide the inner block. Attach the brake valve and manifold block to the
race (with 1 snap ring and bushing retainer) through motor using the original capscrews and tighten to rec-
the bushings and sprag clutch (the race will have to be ommended torque.
rotated in the free-wheeling direction to start it through
the sprag clutch). Install the remaining bushing retainer 10. Connect the motor case drain hose to the motor
and snap ring. Make certain the snap ring is properly case drain port. NOTE: On two speed motors, the case
seated in the groove. drain and shift drain should be connected directly to
tank. DO NOT use the drain connection on the brake
valve. See "TWO SPEED MOTOR CASE DRAIN
PLUMBING" for additional information.
11. If your hoist had the brake release hose connected

directly to the motor, the original motor port must be
plugged and the hose connected to the motor pressure
port near the manifold block (lowering port).
12. Operate the hoist slowly in both directions and check

for oil leaks and/or unusual sounds. The hoist should
operate smoothly in both directions. Refer to "WIRE
A. WARNING A. AND BRAIDED ROPE INSTALLATION" and properly
install rope onto the hoist drum.
the splined bore of the inner race. This snap ring will 13. Before returning the hoist to full service, a light load
keep the brake clutch assembly correctly positioned should be lifted and held three feet (1 meter) off the
in the center of the friction brake pack. Binding of the ground to be sure the static brake is functioning prop-
brake or brake failure may occur if this snap ring is erly. The hoist should also be able to slowly lower the
omitted. load in a smooth and controlled manner. If the hoist
does not perform either of these functions, refer to
"TROUBLESHOOTING" for additional information.
35
PD17 ROTATION INDICATION PROXIMITY SENSOR
Early PD17 A models have a rotation indicator proximity sensor and hub between the motor and the hoist. If the
sensor is removed or replaced, use the following procedure for adjustment and testing. Refer to the drawing below
for item numbers.
Install a new a-ring (item 108) onto motor pilot. Install sensor hub (item 123) onto motor shaft, positioning the
sensor hub so that one of the lobes will be directly under the sensor port. Install the motor onto the hoist. Install
capscrews and lockwashers (items 101 & 102) securing the motor to motor adapter.
&CAUTION&
If sensor hub is not correctly positioned with a lobe directly under the sensor port, proper adjustment may not
be possible and severe damage to the sensor and internal hoist components may result.
Install flatwasher (item 121) and a-ring (item 122) onto new sensor (item 120). Apply a small amount of silicone
sealant to the threads just below the washer and a-ring. DO NOT apply sealant to the end of the sensor or to the
threads of the sensor port where it could be pushed into the hoist. Install the sensor into the motor adapter until
it contacts the sensor hub. Back sensor out of the port 2 complete turns. Attach wire harness to sensor to verify
proper sensor operation. IT IS NOT necessary to operate the hoist motor. If sensor light is on, hold sensor from
turning and tighten jam nut against motor adapter. If light is off or blinks intermittently, adjust sensor inward toward
sensor hub until light remains on, then tighten jam nut.
36
THIS PAGE INTENTIONALLY LEFT BLANK
37
THIS PAGE INTENTIONALLY LEFT BLANK
38
METRIC CONVERSION TABLE
r h to Metnc
Englls r h
Metncto Englls
LINEAR
inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.3937 = inches (in.)
feet (ft.) X 0.3048 = meters (m) meters(m) X 3.281 = feet (ft.)
miles (mi.) X 1.6093 = kilometers (km) kilometers (km) X 0.6214 = miles (mi.)
AREA
inches 2 (sq.in.) X 645.15 = millimeters 2 (mm2) millimeters 2 (mm 2) X 0.000155 = inches 2 (sq.in.)
feet' (sq.ft.) X 0.0929 = meters 2 (m 2) meters 2 (m 2) X 10.764 = feet 2 (sq.ft.)
VOLUME
inches 3 (cu.in.) X 0.01639 = liters (I) liters (I) X 61.024 = inches 3 (cu.in.)
quarts (qts.) X 0.94635 = liters (I) liters (I) X 1.0567 = quarts (qts.)
gallons (gal.) X 3.7854 = liters (I) liters (I) X 0.2642 = gallon (gal.)
inches 3 (cu.in.) X 16.39 = centimeters 3 (cc) centimeters3 (cc) X 0.06102 = inches 3 (cu.in.)
feet 3 (cu.ft.) X 28.317 = liters (I) liters (I) X 0.03531 = feet 3 (cu.ft.)
feet 3 (cu.ft.) X 0.02832 = meters 3 (m 3) meters3 (m3) X 35.315 = feet 3 (cu.ft.)
fluid ounce (fI.oz.) X 29.57 = millileters (ml) milliliters (ml) X 0.03381 = fluid ounce (fI.oz.)
MASS
ounces (oz.) X 28.35 = grams (g) grams (g) X 0.03527 = ounces (oz.)
pounds (Ibs.) X 0.4536 = kilograms (kg) kilograms (kg) X 2.2046 = pounds (lbs.)
tons (2000 Ibs.) X 907.18 = kilograms (kg) kilograms (kg) X 0.001102 = tons (2000 Ibs.)
tons (2000 Ibs.) X 0.90718 = metric tons (t) metric tons (t) X 1.1023 = tons (2000 Ibs.)
tons (long) (2240 Ibs.) X 1013.05 = kilograms (kg) kilograms (kg) X 0.000984 = tons (long) (2240 Ibs.)
PRESSURE
inches Hg (60 'F) X 3600 = kilopascals (kPa) kilopascals (kPa) X 0.2961 = inches Hg (60 'F)
pounds/sq.in. (PSI) X 6.895 = kilopascals (kPa) kilopascals (kPa) X 0.145 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.0703 = kilograms/sq.cm. (kg!cm 2) kiloqrams/sq.cm. (kq!cm2) X 14.22 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.069 = bars bars X 14.5 = pounds/sq.in. (PSI)
inches H 20 (60 of) X 0.2488 = kilopascals (kPa) kilopascals (kPa) X 4.0193 = inches H 20 (60 of)
bars X 100 = kilopascals (kPa) kilopascals (kPa) X 0.01 = bars
POWER
horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)
ft.-Ibs.!min. X 0.0226 = watts (W) watts (W) X 44.25 = ft.-Ibs.!min.
TORQUE
pound-inches (in.-Ibs.) X 0.11298 = newton-meters (N-m) newton-meters (N-m) X 8.851 = pound-inches (in.lbs.)
pound-feet (ft.-Ibs.) X 1.3558 = newton-meters (N-m) newton-meters (N-m) X 0.7376 = pound-feet (ft.-Ibs.)
pound-feet (ft.-Ibs.) X .1383 = kilograms/meter (kg-m) kilogram/meter (kg-m) X 7.233 = pound-feet (ft.-Ibs.)
VELOCITY
miles/hour (m/h) X 0.11298 = kilometers/hour (km/hr) kilometers/hour (km/hr) X 0.6214 = miles/hour (m/h)
feet/second (ft.!sec.) X 0.3048 = meter/second (m/s) meters/second (m/s) X 3.281 = feet/second (ft.!sec.)
feet/minute (ft.!min.) X 0.3048 = meter/minute (m/min) meters/minute (m/min) X 3.281 = feet/minute (ft.!min.)
TEMPERATURE
'Celsius = 0.556 ( 'F - 32) 'Fahrenheit = (1.8 X 'C) + 32
COMMON METRIC PREFIXES

6
mega (M) = 1,000,000 or 10 deci (d) = 0.1 orl0·'
kilo (k) = 1,000 or 10 3 centi (c) = 0.01 or 10 2
hecto (h) = 1000r 10 2 milli (m) = 0.001 or 10 3
·6
deka (da) =lOorl0' micro (11) = 0.000.001 or 10
39
FOR BEST RESULTS,
ALWAYS USE GENUINE BRADEN PARTS.
Copyright 2008 PACCAR Winch Division. All Rights Reserved

TROUBLESHOOTING
INDEX
SECTION 6
SUBJECT PAGE
VALVE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
ROTARY MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
STEERING PRIORI1Y VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . 6 - 7
SWING RELIEF VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8
BOOM ALIGNMENT AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
BOOM CHAIN ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
AXLE LOCKOUT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 13
SWING BRAKE CONTROL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 6 - 14
RING GEAR BOLTING SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16
TORQUE WRENCH EXTENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
WELDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 20
WINCH MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22
WIRE ROPE AND REEVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 54
SPOOLING WIRE ROPE ON DRUMS . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 55
CABLE SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 56

SERVICE AND ADJUSTMENTS
As the operator, it is your responsibility to de- If you can't answer YES to all three ques-
tect any unusual, sounds, odors, or other tions, rely on your Distributor Serviceman.
signs of abnormal performance that could in- He has the right tools, testing equipment
dicate trouble ahead. and service knowledge to pin-point the prob-
lem in minutes instead of the hours con-
By detecting any problems in their early stag- sumed in hit-or-miss methods. TIME IS
es, you can save yourself unnecessary down- MONEY! He will save it for you.
time and your employer a lot of money!
Therefore, it is also your responsibility to use If you decide to attempt an adjustment your-
good judgment in detecting failures in quickly self, follow a logical TROUBLE SHOOTING
and repairing them. If you don't, one failure PROCEDURE. Don't simply replace parts
can lead to another. until the trouble is found.
Before attempting to make an adjustment

yourself, ask yourself if you have the RIGHT
TOOLS, IF you have the PROPER TEST
EQUIPMENT and IF you can accurately DIAG-
NOSE the cause of the problem.
VALVE ADJUSTMENTS
Setting hydraulic pressure is an complex opera- MAINTENANCE CHECKS All the relief valve
tion and should be performed only after satisfy- maintenance checks are conducted an a
ing the following conditions. SEMI-ANNUAL BASIS. Check the relief
valves and make the necessary adjustments
1. Warm the hydraulic oil to 1300 F in normal by the following procedures.
conditions. NOTE: If the normal hydraulic op-
erating temperature is substantially above or The relief valves used on this hydraulic
below 130" F use that value instead. crane have a screw type adjustment. If it is
determined that the valve is out of adjust-
2. Be sure the correct engine speed is used as ment, follow this general adjustment proce-
the relief valve setting will vary with the flow dure.
rate.
NOTE: Some machines are equipped with
3. Be certain to calibrate the pressure gauge auxiliary winch plumbing even though an
used. Gauge calibration can be lost if the auxiliary winch is not installed. on these ma-
gauge is subjected to pulsating pressure for a chines you mustfollow the procedurefor set-
few seconds. The gauge must have a proper ting the auxiliary winch relief valve.
snubber to read center of pump pressure rip-
ple or erroneous readings will result.

VALVE ADJUSTMENTS
adjusting screw in to increase pressure or back-

ing it off to lower pressure. Retighten the jam nut
when the desired pressure is obtained.
THIS MACHINE USES A PRESSURIZED
Set extend/retract by the following procedure:
HYDRAULIC RESERVOIR. THE PRESSURE MUST
BE RELEASED BEFORE ANY HYDRAULIC LINE
First. retract the boom completely and continue
OR CONNECTION IS OPENED.
to retract over relief with the engine running at
Failure to do so will result in substantial loss of
full governed rpm. Initially. set the retract port
oil and may cause personal injury. The pressure
relief valve (located on spring cap end of telescope
is relieved by turning the reservoir cap counter-
section) to obtain a reading of 3500 psi. Then
clockwise to the first stop. DO NOT turn the cap
turn it an additional 1/2 turn clockwise.
beyond the first stop until all pressure has been
released. This will cause the cap to be blown off
MAIN WINCH RELIEF Check the winch relief set-
the reservoir with sufficient force to cause per-
ting using the following procedure:
sonal injury. DO NOT place any portion of your
body above the reservoir cap while relieving pres-
1. Attach a pressure gauge to the test port on
sure or removing cap.
the mid-section inlet port.
BOOM HOIST & MAIN RELIEFS Check the boom
relief settings as follows: 2. Disconnect and plug the brake line at the piS-
ton housing on the winch.
1. Operate the boom over relief to warm the oil if
necessary. 3. Restart the engine and run at high idle speed.
2. Attach a calibrated pressure gauge to test port 4. Winch and hold the lever in the "raise" posi-
on the inlet pressure port at the valve bank. tion while obtaining a reading. The proper set-
ting is 3500 psi at idle. The winch relief is
3. Lower the boom completely and continue to located on the mid inlet section of the valve
boom down with the engine running at full bank. It is adjusted in the same manner as
governed rpm. The relief setting should b the boom relief.
3500 psi. If necessary. adjust relief valve.
AUXILIARY WINCH RELIEF Check the pressure
BOOM RELIEF ADJUSTMENTS Adjust the boom using the following procedure. The auxiliary
hoist. retract, and telescope reliefs using the fol- winch pressure is controlled with a relief valve in
lowing procedures. the auxiliary winch valve.
Adjust the boom hoist relief by loosening jam lock 1. Attach a pressure gauge to the main winch
nut on relief valve. Adjust valve with adjusting test port which is also used to check auxiliary
screw while booming up or down over relief withe winch pressure.
engine at maximum governed rpm. Screw in to
increase pressure setting; out to decrease it. 2. Disconnect and plug the brake line at the piS-
Retighten lock nut when proper setting is ton housing of the auxiliary winch.
obtained.
EXTEND /RETRACT RELIEFS The initial range

has been preset. Adjustment is accomplished by
loosening the jam nut and either turning the
adjusting

VALVE ADJUSTMENTS
AUXILIARY WINCH RELIEF (continued)
3. Restart the engine and run at high idle speed.
4. Winch down and hold the lever in the "lower"

position while obtaining a pressure reading.
The proper setting is 3500 psi. If required,
adjust the relief valve at the auxiliary winch
valve. This relief is adjusted in the same man-
ner at the boom relief.
SETfING RELIEF VALVE PRESSURES
SWING RELIEF Check the swing relief setting by
ON SWING VALVE Attach the pressure gauge on
means of the following procedure:
the swing valve test port, and follow these steps:
1. Attach a gauge to swing test port.
Remove acorn nut and loosen jam nut, make sure
several threads on adjusting screw are engaged in
2. Set the swing brake and attempt to swing pilot section.
against the brake with the engine running at
maximum governed rpm. Adjust the swing Use a screw driver and set adjusting screw as fol-
relief valve, if necessary, to obtain a reading of lows:
2000 psi.
a. Run the pump at low operating speed
(approximately 1/4 of full engine rpm) but
SWING RELIEF ADJUSTMENT Remove acorn fast enough so that the pump is developing
nut from relief valve and loosen lock nut. the required pressure.
While stalling out the swing motor with swing b. Operate the control valve at its extreme posi-
brake applied at maximum rpm, adjust valve with tion long enough to get a pressure reading on
screwdriver until proper pressure is obtained; the gauge.
screwing in adjustment screw to increase pres-
sure setting and out to decrease it.
c. Turn the adjusting screw clockwise to
Retighten lock nut and replace acorn nut. increase pressure or counterclockwise to
decrease pressure until desired setting is
obtained.
SWING d. Hold the adjusting screw, tighten jam nut and

VALVE install and tighten acorn nut.
e. Retest to check pressure setting.
NOTE: Results of the above settings will indicate

a relatively constant relief valve setting across
REUEF full engine rpm.
~~~--CARTRIOGE
TORQUE
LOCK NUTS TO
10 FT. LBS.

VALVE ADJUSTMENTS
RELIEF VALVE REPAIR RECOMMENDATIONS

The cartridge type service port reliefs used in the OUTRIGGER RELIEF ADJUSTMENT With the test
swing valve are of the pilot poppet type with exter- gauge still attached to the test port, remove the
nal adjustment. Any malfunctioning is usually hex cap, insert an allen wrench. adjust to the
the result of foreign matter lodging between the proper setting while holding the outrigger in the
piston, relief valve poppet, and check valve. retract position. Turn in to increase pressure, out
to decrease. Mter completing adjustment, replace
To perform service, clean the surrounding area cap on the relief valve.
and remove the complete relief valve cartridge.
Examine the seat in the main valve housing for
grooves or ridges. If damaged, either replace the
valve or have it re-machined.
The design of the pilot poppet and its seat pro-

vides positive seating and very seldom requires
any maintenance. The pilot section can be
removed from the cartridge housing without dis-
turbing the setting.
With it will come the check valve poppet and other

internal parts. These are easily disassembled and
should be examined for foreign matter. All seats
and seating surfaces should be free of nicks,
scratches, or grooves. Examine "0" rings and
back-up washers for any damage. If any parts are
found to be faulty, replace the relief cartridge. All
moving parts should slide freely, with only seal
friction being present. Mter inspecting and clean-
ing, immerse all parts in hydraulic oil and re-
assemble. If pressure setting was not disturbed,
unit can be tested for proper functioning under
normal working conditions. If operating difficul-
ties indicate that the pilot poppet is still leaking or
sticking, replace the relief.
OUTRIGGER RELIEF Use the 4000 psi test gauge

and check as follows:
1. Attach the gauge at the quick disconnect on

the diverter valve (B), located on the L.H. side
of the front outrigger box.
2. Start engine and run at full throttle.
3. Set the outrigger extend/retract switch to the

retract position and read the gauge. The cor-
rect pressure setting is 2500 psi outrigger
relief. The relief valve is located above the out-
rigger diverter valve. Adjust to proper setting
as follows:

ROTARY MANIFOLD
ENDPLATE------~
THRUSTWASHER------__ "0" RING
BACK-UP RING
"0" RING
WEAR RING
CASE----I.w-
RECTANGULAR RING _ _~-v-:n.

SEAL
SPOOL - - - - - + ,
Use the following procedures when disassem- DISASSEMBLY

bling, inspecting, repairing, and reassembling the The rotary manifold may be disassembled by
rotary manifold. removing the four capscrews and the top
plate.
NOTE: Be sure to mark an index point on the case

and spool to insure proper reassembly.
AS SOON AS THE ROTARY MANIFOLD IS READY
TO BE PLACED INTO OPERATION, IT SHOULD INSPECTION AND SEAL REPLACEMENT
BE SLOWLY ROTATED SEVERAL MINUTES TO
ALLOW ANY ENTRAPPED AIR TO ESCAPE AND 1. The "case" bore should be thoroughly washed
TO FACILITATE REFORMING OF SEALS THAT with solvent or diesel fuel and inspected for
MAY HAVE TEMPORARILY DEFORMED DURING
signs of "scoring" or deep scratches. This type
STORAGE.
of damage is generally caused by the presence
All overhaul should be done in a clean, enclosed of foreign material in the hydraulic system. No
facility with personnel familiar with hydraulic sys- satisfactory method of repairing this type of
tems and cleanliness procedures. damage can be conducted in the field.

SERVICE & ADJUSTMENTS
ROTARY MANIFOLD
INSPECTION AND SEAL REPLACEMENT and, preferably, oil filled without pressure.
(continued)
NOTE: If the rotary manifold is oil filled and
2. The "spool" should be carefully washed in sol- plugged, ample air space should be
vent or diesel fuel. The seals and "0" rings allowed for the expansion of oil due to tem-
should not be removed from the spool unless perature changes.
they show signs of wear or damage. NOTE: If
the seal is removedfor any reason, it should be
replaced since removal will almost always
damage it beyond use.
When installing a new seal and ring, it must be IT IS IMPORTANT THAT THE SPOOL FLOATS
"walked" into place past other seals and oil FREELY WITH THE CASE TO PREVENT WEAR
grooves and then into its own groove in the same AND LEAKAGE. THE SPOOL IS HELD STATION-
manner that the bead of a tire is "walked" into the ARY WITH RESPECT TO THE LOWER BY A
wheel rim. The spool should be well oiled to aid in RESTRAINING BRACKET DESIGNED TO ALLOW
this assembly. Best results can be achieved if the FOR SOME ECCENTRICIlY. THE ROTARY MANI-
spool, with the seals mounted on the end, is FOLD SHOULD BE SHIMMED AT THE MOUNT-
allowed to sit overnight. This gives the seals a ING EARS AS NECESSARY TO INSURE
chance to adjust to normal size. CONCENTRIC ROTATION. ROTATE THE
MACHINE WHILE VISUALLY CHECKING THE
REASSEMBLY ALIGNMENT. THE BRACKET MUST NOT BIND
DURING ROTATION.
1. The top and bottom "0" rings and back-up
washers can be replaced without removing the
spool. Removing the top cover exposes the top
"0" ring. The spool will drop out of the case,
exposing the bottom "0" ring.
UPON REASSEMBLY, INSTALL THE UPPER "0"

RING AND BACK-UP RING AFTER THE SPOOL IS
IN THE CASE. THIS WILL PREVENT ANY DAM-
AGE WHICH MIGHT RESULT FROM SLIDING
PAST PORT OPENINGS.
2. The rotary manifold should be reassembled

using a generous coat of oil on the case ID
and spool OD. Generally, reassembly is most
successful by placing the case in a vertical
position and inserting the spool into the case.
Each seal and wear ring should be com-
pressed by hand to initially enter the case
bore. With the spool fully inserted into the
case, the assembly may be "up-ended" to
replace the end plate.
3. Ports should be properly protected, capped,

STEERING PRIORITY VALVE STEERING PRIORITY VALVE ADJUSTMENT

Adjust this valve using the following procedure:
The steering priority valve is preset at the factory
and will normally not require any additional ad- 1. Remove the hydraulic hose connected to fit-
justment. In the event that a new valve is installed ting "A".
or steering performance is poor and all other com-
ponents and adjustments have been verified, ad- 2. Remove fitting "A".
justment of the valve may be required.
3. Turn adjustment "B" clockwise until it bot-
The steering priority valve is located inside the su- toms out.
per structure just to the right of the rotary mani-
fold. 4. Turn adjustment "B" counterclockwise 2 full
turns.
5. Reinstall Fitting "A" and the hydraulic hose.
FITTING "A"
STEERING PRIORITY VALVE
ADJUSTMENT "B"
TURN IN UNTILL BOTTOMED
OUT THEN OUT 2 FULL TURNS
6-7

SWING RELIEF Check the swing relief using the Once you have verified that the swing brake is
following procedure: holding the engine RPM should be brought up
to full governed speed slowly. The swing pres-
NOTE: Prior to checking the swing relief valve pressure should be 2000 PSI ± 50 PSI. If necessary
sure setting the outrigger relief MUST be set to the adjust the relief.
proper pressure.
NOTE: If the swing pressure is low be certain to
1. Operate the boom over relief to warm the oil if use cation when adjusting, if the swing brake is
necessary. not in proper working order the increase in pres-
sure may allow the machine to swing through the
2. Attach a calibrated pressure gauge in test port brake.
"D" see illustration below.
SWING RELIEF VALVE ADJUSTMENT Adjust
NOTE: Test port "D" is located on the swing valve this relief using the following procedure:
which is mounted inside the super structurejust to
the left of the swing reduction unit. Remove the acorn nut and loosen the jam nut on
the relief valve. Adjust the relief valve with the ad-
justing screw while attempting to swing against
the swing brake at full engine RPM. Screw in the
adjustment to increase the pressure and out to
decrease it. When the pressure is at 2000 PSI ±
50 PSI tighten the jam nut.
Recheck the pressure after tightening the jam

3. Set the swing brake and begin to attempt to nut as the pressure may change due to tightening
swing the machine against the swing brake. the jam nut.
You should exercise caution in doing this until
you know that the swing brake is in good work-
ing order and will hold against the swing pres-
sure.
FRONT OF MACHINE
TEST PORT
"0"
SWING RELIEF
VALVE
6-8
RT500 Series Revised: April 2002

BASE SECTION #2 #4 000
L
J
B D F
BOOM ADJUSTMENT
The 105 foot boom installed on this machine 2. With the boom still retracted adjust eccentrics
must be kept in proper alignment and adjusted on lower front rollers "D", "H", and "L" to center
as required. Boom lubrication intervals should the boom sections at the front and allow ap-
also be used to inspect boom alignment. Should proximately 1/16 inch clearance on each side
adjustment be necessary use the following proce- between the roller and the boom section.
dure:
3. Lubricate pads "A", "C", "E", "G", "I", and "K"
1. With the boom retracted and level, remove the and extend the boom.
three top covers on the base section. If pad "C"
is installed remove the shims. If pads "B", 4. Visually align #2 boom section with base sec-
"F", "G", "J", and "K" are installed, loosen the tion by shimming pad "B" on either side to
capscrews . The retaining bolts and eccentrics bring the #2 section into alignment. Check the
at pads "A", "E", and "I" are to be backed off to alignment of the #2 section by running a string
enable aligning the boom sections later. along the top of the base and #2 section as
shown below. Shim and install the other pad
"B" to a 1/32 inch clearance between the pad
surface and the #2 boom section.
CHECKING FOR PROPER ALIGNMENT
II
TOP BOOM PLATE

STRING
6-9

5. Align the #3 boom section with the #2 boom

section in the same manner as step 4 by shim-
ming and installing pads "F".
PAD ADJUSTMENT
6. Align #4 (tip) boom section with the #3 boom BASE
section in the same manner as step 4 by shim-
ming and installing pads "J".
7. Shim and tighten pads "C", "G", and "K" to

1 /32 inch clearance between the pad surface
and the boom section on each side.'
8. Grease the boom ahead of wear pads.
9. Retract the boom, checking that no excessive

binding occurs.
10. Adjust the brackets on pads "A", "E", and "I"

so the pads contact the base boom section. BOOM TOP PLATE
Then "back off' until there is 1/32 inch clear-
ance between the pad adjustment base and
the pad. This must be done for the left and
right pad for each section. This will maintain 11. A final check of boom alignment should be
a total clearance of 1/16 inch. Tighten the made by "stringing" as described earlier and
lock bolts. also by a visual inspection with the boom ful-
ly extended and at maximum angle.
6 - 10

BOOM CHAIN ADJUSTMENT

- 4 SECTION BOOM -
BOOM CHAIN ADJUSTMENT: For proper opera- 5. If the gap is more than .38 inch, loosen
tion and boom life the extend and retract chains adjustment A and tighten adjustment B until
must be adjusted properly. To adjust these chains the gap is within specifications.
use the following procedure.
6. Fully retract the boom and recheck the gap.
THIRD SECTION EXTEND AND RETRACT
Repeat step 3 through 5 if necessary.
CHAINS (4 SECTION BOOMS):
7. Fully extend the boom horizontal.

1. Fully retract the boom.
8. Through the first hole in the side plate of the
2. Measure the gap between the front of second
second boom section (the hole closer to the
section and the back of the third section. This
base section), measure the sag of the retract
gap should be .25 inch to .38 inch.
chain. This measurement must be taken from
the bottom of the second section to the bot-
3. If adjustment is required, extend the boom
tom of the chain. This dimension should be
approximately 1/2 way.
2.25 inches to 2.50 inches.
NOTE: Before attempting to tum one of the adjust-
9. If the dimension is greater than 2.50 inches,
ing nuts, extend or retract the boom slightly
loosen adjustments A and B equal amounts
to relieve the tension on that nut. After
until the measurement is within specifica-
extending the boom, adjustment A will be
tions.
under tension and B will be free. After
retracting the boom, adjustment B will be
10. If the dimension is less than 2.25 inches,
under tension and A will be free.
tighten adjustments A and B equal amounts
until the measurement is within specifica-
4. If the gap is less than .25 inch, loosen adjust-
tions.
ment B and tighten adjustment A until the
gap is within specifications.
A
~~~~~~I~~t~~~~~~~~~~=~~=:::~~==:=:=:: :-.._. . .
_. ._. _. . . . . .__. . . _._. _. _. _. _.Jl·
o 0 0 0 0 0 0 0 0 0 0 0 •
GAP

BOOM CHAIN ADJUSTMENT

- 4 SECTION BOOM -
FOURTH SECTION EXTEND AND RETRACT 6. Fully retract the boom and recheck the gap.
CHAINS (4 SECTION BOOMS): Repeat step 3 through 5 if necessary.
1. Fully retract the boom. 7. Fully extend the boom horizontal.
2. Measure the gap between the front of third 8. Through the first hole in the side plate of the
section and the back of the tip section. This third boom section (the hole closer to the sec-
gap should be .25 inch to .38 inch. ond section), measure the sag of the retract
chain. This measurement must be taken from
3. If adjustment is required, extend the boom the bottom of the third section to the bottom
approximately 1/2 way. of the chain. This dimension should be 2.75
inches to 3.00 inches.
NOTE: Before attempting to turn one of the adjust-
ing nuts, extend or retract the boom slightly 9. If the dimension is greater than 3.00 inches,
to relieve the tension on that nut. After loosen adjustments C and D equal amounts
extending the boom, adjustment C will be until the measurement is within specifica-
under tension and D will be free. After tions.
retracting the boom, adjustment D will be
under tension and C will befree. 10. If the dimension is less than 2.75 inches,
tighten adjustments C and D equal amounts
4. If the gap is less than .25 inch, loosen adjust- until the measurement is within specifica-
ment D and tighten adjustment C until the tions.
gap is within specifications.
11. Under the same condition, the maximum sag
5. If the gap is more than .38 inch, loosen in the extend chain should be 7.00 inches to
adjustment C and tighten adjustment D until 7.50 inches. This measurement is from the
the gap is within specifications. bottom of the third boom section to the top of
the extend chain.
GAP

AXLE LOCKOUT SYSTEM
AXLE LOCKOUT
LOW POINT
VALVE
ON MANIFOLD
AXLE LOCKOUT SYSTEM OPERATION CHECK
For safe operation of the crane when operating on

rubber, the axle lockout valve should be checked
daily as follows:
Air in the axle lock circuit de-
creases stability. Bleed the sys- 1. Place boom in travel position.
tem immediately whenever this
occurs. 2. Drive one tire of the rear (oscillating) axle up
on an eight inch block.
If the axle does not hold in the blocked position or
oscillates when the upper structure is swung 20 3. Swing the retracted unloaded boom approxi-
degrees from the travel position, bleed the system. mately 20 degrees from the center position.
Swing the retracted unloaded boom into the travel 4. Drive the crane off the block. If the tire re-
position so that the lock valve will open. With the mains in the up position proceed with step (5).
engine running at an idle, loosen the bleeder If the tire does not remain in the up position
screw. When a steady flow of oil is running from readjust or replace lockout valve.
the bleed screw, retighten the bleeder screw.
5. Allow crane to set for three to five minutes.
ADJUSTMENT
6. Observe the tire, it should remain in the up
With the cam plunger fully retracted, adjust valve position.
position for .005-.010 inches gap between the cam
roller and the cam travel area on the manifold. Do 7. Swing the crane back to the center position,
not measure at the low point on the manifold. the tire should return to its original position.
If not readjust or replace the lockout valve and
Tighten and secure with nuts, washers, and cap- repeat this procedure.
screws.
6 - 13

CONTROL LINKAGE ADJUSTMENTS
FIGURE 1
a
Console Frame
Bumper
/
~I 1
'n J
---_ ...... _.... Adjust this
end of the
Swing Brake Pedal In The cable first.
First Click Position
:pi/ I
Swing Brake Pedal In The ~-
Seventh Click Position
~ ~ Adjust this end of the

~ I I cable if necessary.
~ S";og B..ke G,bI.
Swing Speed Reducer
Swing Brake Control Adjustment:
(a) During normal operation, the swing brake

pedal should be operating in the 4 to 5 click
range if the swing brake pedal is properly The cables used on this machine
adjusted. If the swing brake pedal is operating are sealed. Never adjust a cable
in the 6 or 7 click range during normal opera- to the point that the threads on
tion, the swing brake cable will need to be the rod end are pulled into the
adjusted. seal.
CLICK DESCRIPTION
Note: If the machine is not equipped with a
1 Bumper should rest against the pedal. swing brake pedal bwnper on the console
2 Brake disks should begin to engage. frame, skip step "b".
3
4 Brake discs should be fully engaged (b) Refer to figure 1. Release the swing brake and
move the swing brake pedal to the first click
5 and should hold at full engine RPM. position. Adjust the bumper to rest against
6 Swing brake cable should be adjusted the swing brake pedal.
7 and/ or brake pads may need replacing.

CONTROL LINKAGE ADJUSTMENTS
Anchor
Swing speed reducer
FIGURE 2
(c) Adjust the pedal end of the swing brake cable (e) If the swing brake fails to prevent the boom
by increasing the thread length as indicated from rotating or if the swing brake pedal con-
in Figure 1 until the swing brake pedal is tinues to operate in the 6 or 7 click range, the
operating in the 4 to 5 click range. Mter the swing brake cable and/or the brake discs
adjustments are made, sufficient thread must may need to be replaced.
remain so that all the threads of the jam nuts
are engaged.
Note: Any adjustment required on the swing

speed reducer end ojthe swing brake cable
will require that the swing brake cable is
disconnected from the swing brake pedal.
(d) Set the swing brake and begin to attempt to

swing the machine against the swing brake.
You should exercise caution in doing this
until you know that the swing brake is in good
working order and will hold against the swing
pressure. Once you have verified that the
swing brake is holding, the engine RPM
should be brought up to full governed speed
slowly.

SWING BEARING
40
~H"!lS3-
4
22
RING GEAR BOLTING SEQUENCE
MAINTENANCE CHECK
It is very important to perform periodic ring gear A number of causes can reduce tension in the
bolt checks. The bolts MUST BE KEPT TORQUE bolts when torquing and after use. These include
TIGHTENED to a rating of 600 Ft. Lbs. (813 NM). rust on the threads, damaged or rough threads
Mter the initial 40 hours of machine operation, on bolts and nuts, shanks of blots which hang up
check and tighten the bolts. If additional torque is on holes, etc. All of these causes have a tendency
required after the first 40 hours, then recheck to absorb the torque when bolts are being tight-
each 40 hours until all bolts are found properly ened.
torqued. Thereafter, checks should be performed
QUARTERLY. It is important to make periodic checks of the ring
rear bolts. The bolts Must be kept torque tight-
RING GEAR TORQUING ened.
The gear and bearing assembly consists of an Torque the inner race first, then the outer race as
inner race and ring gear, an outer race, bearing shown in the bolting sequence. Torque the 7/8
rollers, spacer and a seal ring. The inner race is inch, Grade 8, bolts to 600 Ft. Lbs. (813 NM)
bolted to the carrier; the outer race to the turnta-
ble.

TORQUE WRENCH EXTENSIONS
,I
1~4~ _________A __________ ~~~~.- _____________

VB .1
In some applications, a standard torque wrench

and socket cannot be fitted to the bolt (s) to be FORMULA
tightened because of restricted access. In other
instances, the torque value specified cannot be orque wrench (600 ft. lb.) times ("B")
obtained because sufficient force cannot be etting (1WS) ("B") plus ("A")
applied to the standard length wrench. Both of
these problems may be solved by the use of = lpq -Plw
appropriate torque wrench extensions - either
commercially made or fabricated by the user.
When using an extension, it must be remembered EXAMPLE

that the wrench torque (the actual torque reading
or setting of the wrench) and the wrench force = 10.25"
(the force applied to the wrench) must be
adjusted to compensate for the added length and
produce the desired bolt torque. S (600 FT.LB.) X 43
42 + 10.25
Refer to the illustration and formula below when
calculating the proper adjusted values for wrench 2580
torque, wrench force and bolt torque. 53.25
NOTE: Torque wrench setting at length "B" would = 485 FT. LB.
be 600 ft. lb. (813 NM) for capscrews not
requiring us of adapter.

WELDING INSTRUCTIONS
Before welding on the unit. contact the factory

service department for approval.
When doing repair welding on your unit take pre- Always have a fire extinguisher on hand in case of
caution attaching your ground to the component fire. Adequate ventilation and dry area are neces-
being repaired. This will reduce the chance of arc- sary. Protective clothing should be used and all
ing through a bearing, cylinder, etc., damaging persons in the welding area should have protec-
the component. Paint should be removed from tion for their eyes. Follow instructions for welding
the surface to be used as the "ground" (earth). and cutting on paint.
AWS CLASS E7018 Low hydrogen rod for normal

repairs on low alloy to medium carbon steel. All
position welding, good penetration, and crack
resisting up to 80,000 yield. Also suitable for
Use necessary precaution when welding around repair of previous intershield welds.
fuel tanks, oil reservoir, batteries, tubing and
pressure systems. AWS CLASS EII018G Low hydrogen rod for
repair on high strength alloy steel such as T -1,
80,000 to 100,000 yield. All position welding,
good penetration, and high tensile strength up to
110,000.
When welding close to glass, cylinder rods, or any Note: Low hydrogen rod E7018 must be used
polished surface, provide adequate protection within four (4) hours upon removal from a
from splatter. freshly opened container or from a storage
oven.
Low hydrogen rod Ell 018G must be used

within 1/2 hour upon removal from its con-
tainer or from a storage oven.
Never weld when the engine is running. Always
disconnect the battery cables and applicable
grounds before welding.
All welding procedures and welding operator

qualifications shall be in accordance with ANSI/
Do not weld on wet surfaces since this will cause AWS D14.3 when welding on load sustaining
hydrogen embrittlement of the weld. members (ANSI/ASME B30.5)

WELDING & CUTTING ON

PAINTED SURFACES
When welding or cutting steel coated with a certain paint

systems. the worker is exposed to decomposition prod-
ucts (metal fumes. gases or vapors. particulate) which
vary depending on the type of process being used to weld
or cut. the nature of the base metal, and the type of
coating system. The following control procedures should
be utilized when one is welding or cutting coated steel:
• Use a power brush or grinding wheel to strip the coat-

ing from the steel in the vicinity where the cut or weld
is to be made. Remove the paint far enough from the
weld to prevent any remaining paint from becoming
heated and bubbling. If this happens. continue to
brush or grind the paint away.
• A toxic dust respirator and eye protection should be

used while stripping the paint.
• Welder should be outfitted with a fresh air supplied

respirator and other personal protective equipment
required for welding.
• Other employees should be removed from the area or

told to stand back a minimum of 10 feet from the
welder. Do not be in direct line with the weld fumes.
• Use a local exhaust hood to remove fumes during the

welding or cutting operation if one is available.

HYDRAULIC CYLINDERS
HEAD GLAND
SPACER "0" RING
PISTON BACK-UP
"0" RING RING "U" CUP WIPER
PISTON
SHAFT
""
'I
HOLD VALVE
4000 PSI PRESET
SET SCREW BUTTRESS DO NOT CHANGE
NUT RETRACT PORT EXTEND PORT
EXTEND CYLINDER
SEAL THREAD RING & BOLT

JOINTS WITH "SILASTICO'
THRUST ROD AFTER ASSEMBLY.
HEAD GLAND
/
PLATE
"0" RING
& BACK·UP
'X"3!.-_--WIPER
TORQUE PISTON TO 400 FT. LBS.

THEN TIGHTEN SETSCREW.
LIFT CYLINDER

HYDRAULIC CYLINDERS MAINTENANCE
HYDRAULIC CYLINDER DISASSEMBLY
GENERAL
Do not disassemble a cylinder unless no other Failure to remove the locking capscrew may
maintenance procedure can correct the problem. result in serious thread damage.
All overhaul or new cylinder installations should
be done in a cleaen, dust-free atmosphere with all Note: One turn off, back 1/3 turn alternately.
ports plugged until hose connections are made.
2. Remove the head gland, shaft, and piston
BOOM EXTEND CYLINDERS from the case.
The outer case is the "moving" member of the cyl- 3. Remove piston and gland by removing set-
inder. The hollow shaft is "stationary". The hollow screws in retaining collar removing retaining
shaft ports the piston and case end to retract the nut. Remove piston and gland from rod.
cylinder while a tube within the "shaft" ports the Access to all seal units is now possible.
piston and head gland to extend the cylinder.
HYDRAULIC CYLINDER INSPECTION
Disassemble the boom extend cylinders by the
following procedure: Wash the cylinder bore and all the components
with solvent and make the following inspection:
1. Using an adjustable spanner wrench, remove
head gland of cylinder. As head gland is loos- CYLINDER BORE
ened, it may be necessary to begin to move
rod out of cylinder tube. For signs of scoring and deep scratches. In the
event of any defects, reassemble the entire cylin-
2. With head gland fully disengaged, remove as der and contact your distributor.
an assembly, piston rod, head gland, and pis-
ton assembly. CYLINDER SHAFT
3. To remove piston, remove the setscrews which For dents, deep scratches, or damaged chrome
secure the piston retaining ring to piston rod. plating. File any sharp edges on ends of shaft to
protect the seals upon reassembly. Always pro-
Note: There are two types of ctlinders used on the tect the shaft finish when clamping in a vice or
machine. Both cylinders have setscrews when welding against weld splatter.
located under the wear ring to retain the pis-
ton to the rod. PISTON RINGS
Note: After rerrwving the piston, the retainer can be For cracks or other damage. Particularly check
rerrwved to reseal the inner tube. the interlocking ends that they are not missing or
broken.
BOOM LIFT CYLINDER
PISTON SEALS
Disassemble the boom lift cylinder by the follow-
ing procedure: For signs of severe damage. Do not remove unless
replacement is necessary.
1. Remove the locking socket head cap screw
from the draw ring. With an adjustable span-
ner wrench, remove the draw ring and head
gland.

HYDRAULIC CYLINDERS MAINTENANCE
PISTON & HEAD GLAND BOOM EXTENDED CYLINDERS
It is not normally necessary to replace the piston, With the piston, piston rod, head gland, and
piston rings, or head gland. retaining ring assembled as a unit, slide the pis-
ton into the cylinder bore. Next, insert the head
HYDRAULIC CYLINDER REASSEMBLY gland. It may be necessary to tap the gland into
place using a wood block and hammer. In this
GENERAL event, cover the rod with rags or a rubber tube to
prevent damage from a glancing hammer blow.
As cylinder components are reassembled, be cer- The head gland is then spun in and tightened.
tain all rings, seals, spcaers, and setscrews
required in one step are in place before proceed- Note: Apply Loctite Gr. 242 to piston retaining rings
ing to the next step. See Group 39 of the Parts at assembly. Also apply to locking set-
Manual for a complete listing of cylinder parts. screws.
A teflon ring must be installed before the piston On cylinder, preset nylon plug with a 25 ft lb
ring or wear ring is installed since the teflon ring torque, using a Grade 8 cap screw, and install
must first be "walked" into the piston ring groove setscrew and setscrew and torque to 15 ft lbs,
and then into its own groove. Warm the teflon three (3) places.
ring until reasonably flexible and oil the piston
ring or wear ring to aid in the installation. HYDRAULIC CYLINDER OPERATION
Most piston ring breakage is due to careless or As soon as the cylinder is ready to be placed in
hasty assembly at this point. operation, it should be slowly cycled under no
load conditions for several minutes in order to
BOOM LIFT CYLINDERS allow the entrapped air within the cylinder to
escape to the reservoir and, also facilitate the
With the piston, piston rod, head gland, retaining reforming of the seals which may have tempo-
ring, and rod eye reassembled as a unit, slide the rarily deformed during shipping, storage, or reas-
piston into the cylinder bore. Next, insert and sembly.
seat the head gland. It may be necessary to drive
the head gland into place using a wood block and New cylinders may show a slight "drifting" ten-
hammer. In this event, cover the rod with rags or dency when first used. This is natural, due to one
a rubber tube to prevent damage from a glancing or both of the following causes:
hammer blow. The retaining ring is then spun in
and tightened to secure the head gland. Install 1. Air entrapped in the oil.
socket head cap screws. The retaining ring
should be secured with Loctitie Grade 242. Coat 2. Seals not yet fully reformed or seated.
both grooves around the thred ring as well as the
bolt heads with a "silstic" type silicon sealant to "Drifting" should decrease with operation as piS-
keep moisture out. ton rings and seals "break in" to provide better
sealing and the eventual escaping of the trapped
Note: When installing the piston ring nut on the air in the oil.
piston rod, torque to 400 jt lbs and then
secure with setscrew lock. Use Loctite Grade
242 on ring nut and setscrews.

WINCH MOTOR
_.
.
_. ,
...,
I
I
i
i
i
j
-' -' -' -' -'- ..J
-' -'-' -' -' ......... $S .......1'-·· ... -1

l
.-'-' -' -- -' -' ~~
~ O(Q ~
........•
Q
................-
i
,-.-
I
i
- ~ ... '...-
.....,-J
_.-....-'-
~
....-.-'-'
_.-'
-,-' -.-
.-.-'-'-'

WINCH MOTOR
Attention!
Observe the following notices when carrying out repair
work at hydraulic aggregates!
Close all ports of the hydraulic aggregates.
Replace all seals.

Use only original HYDROMATIK spare parts.
Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.
Fill up hydraulic aggregates with medium

before start-up

WINCH MOTOR
Seal kit for drive shaft.
.' .
External seal kit.
\
Housing.
Complete rotary group

Pos.2 Note: Pas. 1 - For port plate with differential piston
Pas. 2 - For port plate with synchronizing piston
Pos.1
Port plate with control piston

Pos.1 Pos.2
Note: Pas. 1 - For port plate with differential piston
Pas. 2 - For port plate with synchronizing piston

WINCH MOTOR
Proportional Solenoid
Solenoid
Cover with * throttle pin.

* Throttle pin "as to order requirement".
'.'---------------'
Cover with flushing and boost pressure valve and *
throttle pin.
Throttle pin "as to order requirement".

WINCH MOTOR
z.B.HA HD DA
HA2
"as to order requirement".

WINCH MOTOR
z. B. HZ3 / EZ3
~ ~,
,,
,
/
,,,
,
,,
,,,
,,
,,,
,
,,
,,
....................
"'-'~:~--------------------------'~
Q~
'G~
HA3/ HA3U
.~
l~O~, ~
r---------·
I
~ -----------------------:~~)
ti!!t ' I
I
~!f!!!!3
/~
I
I
filii , ~ " .,'~
,i /1
I ~ I
I
I
I
8 !a
-'.
/ I
,, ,/ ,,,
", ,/'/. t... ......... - ......
,

WINCH MOTOR
Replace seal nut.

First measure and record setting height.
When tightening, counterhold setting screw, then

check setting height.

WINCH MOTOR
12
Protecting the drive shaft.

Remove retaining ring and shim.
Screw in sheet metal screw into the holes
~
fitted with rubber.
Pull out seal with pliers.
?~'
'.
,
/
.
\,\'."..
"'.
".
\\IY )
Press in shaft seal ring and shim with bush to stop.

~ Take note of press-in depth!
i l l Install mark for press-in depth of sfaety ring.
*

WINCH MOTOR
- '
: /-
~ Attentionl
Spring load
16
Inspect
Drilling in housing, O-ring, groove.
A Do not remove adjustment screw.

Inspect
O-ring, O-ring groove, housing
Assembly aid
Insert pin with grease.

WINCH MOTOR
20
Example: A6VM ... HD control

Disassembly position:
Remove cover pos. I
2
l. O-ring
2. Input flow of oil control
3. Throttle pin
"'" Installation position differs according to the
i l l control components
1. Input flow of oil control

2. High pressure / low pressure
3. High pressure / low pressure
3 4. Leckage oil
5. Control piston
___ 0 0 I
~-~-::::L= 4

WINCH MOTOR
24
Example: A6VM ... control - differential piston

Disassembly position: Remove cover pos. 2.
~ Attention! Spring load.
i l l Dimension x: Note dimension (begin of regulation).
1. Check O-ring
1. High pressure - small control piston side

2. Control pressure
3. High pressure - check valve
4. High pressure - check valve
4 -11--#"-'''\
"__ 0 0
LV~-~I
WINCH MOTOR
Differential piston:
Note dimension x
For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.
Remove Qrnin-screw.
Swivel rotary group to 0°.

WINCH MOTOR
Synchronizing position:
Note dimension x
a....-screw For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.
Remove Qrnin-screw and plug.
Swivel rotary group to zero position

with screw Qrnin.

WINCH MOTOR
Port plate
Mark position. Loosen screws.
Removal
Check O-ring.
Stick new O-ring with some grease.
"'" Do not swivel rotary group.
i l l Piston rings to hang out from the cylinder boring.
~ Stick control lens in sliding surface with grease.

Assembly in reversal order.
Mount port plate.
~ Rotary group vertical.

WINCH MOTOR
Differential piston Synchronizing

piston
Loosen fixing screw.

Use only socket wrench.

WINCH MOTOR
Remove piston with piston ring.
Differential piston
Warm up fixation screw for positioning

plug via boring (screw glued - to turn out).
.& Use new screw.

Precote coating.
• Note tightening torque!
Synchronizing piston
Remove screw.
Remove piston .
.& Note installation position.

WINCH MOTOR
36
Screw in threaded pin into center pin.
t Fix the cylinder with disc and locknut.

Remove Qrnax-stop screw.
Size 28: M4x58mm

55: M5x71mm
80: M6x82mm
107: M6x92mm
140: M8x 105mm
160: M8x 105mm
200: M8x 109mm
. Press out rotary group!

'" If the bearings are used again
.ill do not hit on the drive shaft

WINCH MOTOR
Or press-out with extraction device.

WINCH MOTOR
pressedin ~
Complete rotary group
.&. Setting of hydraulic part

necessary. 40
Rotary group
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part: Lh. Adjustment necessary 41
.. ' .~~~ ..
* .--- ~\)
:.--- .
--~-.- .
~~
--~
Rotary group: All parts
.. Setting
Setting value, torque see service information. 42

WINCH MOTOR
Remove fIxing screw (cylinder).

Remove cylinder.
Disassemble retaining plate.

"'" Screws are glued.
i l l Use Torx-tools.

WINCH MOTOR
Free of corrosion, erosion or fretting; no damage

to splines or keyways.
Pistons
No scoring and no pittings.
1 Center pin
2
No scoring and no pittings.
Retaining plate
No scoring and no evidence of wear.
Cylinder block / control lens

1 Bores free of scoring, no evidence of wear.
2 Faces smooth and even, free of cracks and scoring.

WINCH MOTOR
Control housing
Sliding surface and side guides free of scoring
.L
---- .J
and no wear.
l .1. ~..j
.L
Visual check:
Bearing areas free of scoring and no evidence of wear.

WINCH MOTOR
Rotary group: mechanical part
Adjustment dimension *
and bearing torque
see selVice infoprmation.
Press on bearing.
Do not exeed bearing torque
during press-on.
Preload bearing with assembly sleeve

and steady control of the torque.
I ~
.~
. ) \
~. . '
) ,
I
/
.•
-'

WINCH MOTOR
Rotary group: mechanical part
Assemble safety ring.

Determine dimension for
adjustment disc with final
dimensions (crossover).
Install adjustment disc.

Assemble safety ring.
Drive shaft ready for assembly.

WINCH MOTOR
---
52
Insert retaining plate with piston and center pin.

Use screw with Precote-coating.
Make sure all parts are fitted in correctly.
Swivel cylinder block to max. and fix the cylinder.

WINCH MOTOR
Rotary group completely assembled

ready for assembly.
t Place assembly sleeve.
Warm up housing to 176°F.

WINCH MOTOR
Insert rotary group into housing

to seat position.
2 1
t 2
Fix zero position of cylinder

with Qrnax-screw.
1. Disassemble cylinder
fixing screw.
2. Insert O-ring.

WINCH MOTOR
Determine cylinder swivel range to max.

angle with screw.
* Disc
*
Place centering disc.
Mount measuring device.
Check dimension X.

WINCH MOTOR
1. Assemble port plate with

&. differential piston.
Take care of assembly designl
&. TlQhten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set amln -screw to
dimension* .
4. Assemble plug.
5. Remove assembly sleeve.
Assemble cover.
Assemble control components.

WINCH MOTOR
1. Assemble port plate with

A. synchronizing piston.
Lh Take care of assembly designl
+ Tighten fixing screws
~ with torque.
2. Swivel rotary group to "starting
position".
3. Set aRlin -screw to
dimension* .
4. Assemble plug.
5. Remove assembly sleeve.
Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve .
.& Take care of press-in depth.

WINCH MOTOR
Tightening torques for shaft bolts

(Metric ISO Standard Thread)
strength Classes
The va__ for tighIening_
1lIread 8.8 I 10.9 I 12.9
_inlhll
___ ....... validonlylor
mebiclSO-_ size Teghtening Torque (lb.lt)
M3 0.8 1,2 1.4
_and_~ ..' -
_ i n _ _ DlN M4 2.1 3.0 3.6
912, DIN 931 and OIN 933. Theaa M5 4.4 6,3 7.4
vaI_ ... _ valid only lor IigN or M6 7,4 10.3 12,5
unoiIed._1Od ... - .. _ .. M8 18,4 25.8 30,2
for .... only _1DfqUe-indicati Ml0 36,1 50,9 61,2
_ a n d Ion:elirnlting_. M12 63,4 88.4 106.9
M14 99,S lAO,O 169,5
M16 154.8 211',4 281.6
M18 213.7 288,S 357.4
M20 302,2 427,5 508,5
M22 405.4 514,9 685,4
M24 523,5 737,0 884.4
M27 773,9 1105,5 1328,6
MOO 1088.7 1474.0 1788.8
Tightening torques for locking screws VSTI

(Metric ISO fine thread)
Threadaize DesIgnation TIghtening lIxquea (1b.1t)
M8xl VSTl8xl -EOISA .. 4
M 10xl VSTI10xl -ED .7
M12xl,5 VSTl12 x 1,5 -ED .15
M 14x 1,5 VSTl14xt,5 -ED -22
M16xl,5 VSTl16xl.5 -EDISA -22
M18xl,5 VSTl18x 1.5 -~ISA .29
M20xl,5 VSTl20xl.5 -EDISA =37
M22xl,5 VSTl 22 x 1,5 -ED .. 44
M28xl,5 VSTl16xl,5 ·EDISA =51
M27x2 VSTl27x2 -ED ,,68
M30xl,5 VSTl30xl,5 -EDISA .74
M33x2 VSTI33x2 -EDISA .88
M42x2 VSTl42x2 -EDISA .147
M48x2 VSTl 48 x2 ·ED .220
T.ghtening torques for seal-lock nuts

(MetrIc ISo-standard Thread)
Strength Classes
The values for 1IghIening_ Thread 8.8 10.9 12.9
shown in the ....... valid only lor aile Tlghten1f19 torque (1b.1t)
0801_ nu\II of 1he RWIgIh cI_ 8.8 M6 7,4
\\
andwtlh_I~_.
M8 16,2
Ml0 29,5
M12 50,9
M14 81,1
M16 125,3
TIghtening torques for _&-Slotted lens head screws

. DlN7985
(Metric ISO- Standard Thread)
StrengIhtA811&e8
The _Iortighlanlng_
_ _ _ _ DIN Thread 8.8 110.8 I 12.9
shown in 1he table ... valid only lor
size 11ghtenlfl9torques (1b.1t)
M3 0,8
\\
7985 oI1he -..gth _ 8.8 and WiIh
M4 2,1
mebiclso-ndard Ih_.
M5 4,4
M6 7,4
M8 18,4
Ml0 36,1

WIRE ROPE AND REEVING
MAINTENANCE
All wire ropes in active service should be

inspected daily along with spooling, sheaves, The use of non-rotating 18 :x: 7 class wire rope
wedge sockets, and any other wire rope fittings is not recommended in multiple reeving appli-
for damage. Once weekly a thorough wire rope cations and, if used for applications involving
inspection should be made by a competent single part line, must not be used with loads
inspector. A record should be kept of the inspec- exceeding one fifth (1/5) the rated breaking
tion on the form provide in section 4. strength. The inner wires are generally the
first to fail on this class of rope making it very
Refer to ANSI Standard B30.5 for guidlines cover- difficult to inspect as broken wires cannot be
ing the inspection, maintenance, repair, and seen. Refer to ANSI B30.5, Section 5-2.4 for
replacement of wire rope. Worn, kinked, bird- the necessary inspection procedure and
caged, fatigued, or otherwise damaged wire rope replacement criterion.
must be removed immediately. Wire rope, when
properly installed, lubricated, and employed, will If non-rotating or spin resistant rope is used on
give many hours of satisfactory use. Whereas, a this crane, the rope must be replaced if two or
new piece of wire rope can be immediately ruined more wires are found broken in one lay of the
if misused. Replace any wire rope found to be in rope.
unsatisfactory condition.
CABLE REEVING
In addition to damage such as kinking, crushing
and broken wires, factors such as corrosion, When reeving the machine for any job, remember
abraSion, pitting, peening, and scrubbing of out- that hoisting and lowering speeds decrease as the
side tires, reduction of rope diameter, the condi- number of pacts of line increases. For the most
tion of other components, and proper lubrication efficient use of the machine, it is desireable to use
are considered. Refer to section 4 for wire rope the minimum number of required pacts for lifting
lubricating procedures. the anticipated loads.
Before installing a new or replacement rope,

make certain the rope to be used is the proper
type and size. The wrong rope will not function
properly and may even be dangerous. Never use less than the number of parts called
for by the load rating chart. The minimum
Refer to Section 9 for instructions on inspecting required number of parts is determined by
and replacing sheaves. referring to the load rating chart.
WIRE ROPE SPECIFICATIONS This machine incorporates a "Quick Reeving"
boom head and block which do not require
MAIN & AUXILIARY WINCH removal of the wedge and socket from the rope in
order to change the reeving. Removal of two pins
5/8" (16 mm) dia. 6 x 19 and 6 x 37 IWRC IPS in the boom head and three in the hook block will
right regular lay, preformed, 450 ft. (137.2 m) allow the wedge and socket to pass through.
Minimum Breaking Strength 17.9 Tons (16.2 MT)
MAIN & AUXILIARY WINCH

OPTIONAL HOIST LINE
5/8" (16 mm) rotation resistant If a socket is changed or replaced, or if you are
compacted strand 18 x 19 or 19 x 19 changing hook block weights; it is important
Minimum Breaking Strength 22.6 Tons (20.6 MT) to use the correct socket.

SPOOLING WIRE ROPE ON DRUMS
Care must be exercised when installing wire rope Apply breaking force to the reel flange in order to
on the winch drum. Improper spooling can result prevent overrun as the rope is being drawn off.
in winch damage through crushing, kinking, Loops formed by overrun can cause kinks and
doglegs, abrasion, and cutting. Poorly installed doglegs in the rope, resulting in damage and pre-
wire rope will also adversely affect the operating mature rope failure. A timber or block forced
characteristics of the machine by causing against the shipping reel flange can be used to
uneven application of force and motion. This can provide the required braking force.
cause premature fatiguing and failure of the
rope. Install cable on the winch drum in accordance
with the following procedure.
Thoroughly inspect and clean the winch before
proceeding with the installation. CHeck the lag- 1. Position the cable over the boom nose sheave
ging and drum flanges for cracks, breaks, and and route back to the winch drum.
excessive wear. Deformed or outsized drum and
excessive undercutting at the base of the flange 2. Position the winch drum with the cable
also indicate the repair or replacement of the anchor slot on top.
drum is necessary.
3. Insert cable through slot and position around
Check the bearings for excessive wear or play. the cable wedge.
Mter correcting any defects revealed by the 4. Position the anchor wedge in the drum slot;
inspection and determining that the winch is in pull firmly on the free end of the cable to
good operating condition, spool the wire rope as secure the wedge.
follows:
5. Slowly rotate the drum, ensuring the first
Mount the cable shipping reel vertically on jacks layer of cable is evenly wound onto the drum.
or a suitable supporting structure, with a pipe or
bar through the reel center. The cable should be 6. Install the remainder of cable, as applicable.
drawn from the top of the reel, as shown, in
order to avoid reverse bending as it is spooled The end of the cable should be even with the bot-
onto the winch drum. tom of the anchor wedge.
If cable is wound from the storage reel onto the

drum, the reel should be rotated in the same Note: If the wedge does not seat securely in the
direction as the hoist. slot, carefully tap the top of the wedge with
a mallet.
RIGHT
WRONG

CABLE SOCKETS
2. Insert the wedge and allow the rope strands

to adjust around it.
The wrong cable wedge could permit the wire

rope to work loose and detach itself from the
drum, possibly causing property damage or
c.~ .
personal injury.
Tension the wire rope by braking the shipping

reel and slowly operate the winch in the raise is
mode to wind the cable onto the winch drum. As
the spooling proceeds, make sure that adjacent
turns are tight against one another. A lead or
brass hammer may be used to tap the rope over
against preceding turns. Tight winding on the 3. Seat the wedge and loop just tightly enough
drum is absolutely essential. to allow handling by attaching the socket to a
strong support and engaging the winch to
take a strain on the rope.
4. Final seating of the wedge is accomplished by

Never use a steel hammer or punch bar to making lifts of gradually increasing loads.
move the rope on the drum. These tools can Avoid imposing shock loading on the rope
easily damage the rope. until the wedge is firmly in place.
Mter the wire rope is wound onto the winch

drum, reeve the cable as desired.
Use only factory supplied sockets, wedges, and

pins of the proper size; make no substitutions. WORKING E.ND
Follow the procedure below when installing wedge

type sockets on wire rope. Be certain the correct
socket and wedge are used. 5. Mter the wedge has been firmly seated, a
short length (6 inches) of the cable should be
1. Lead the rope through the socket, form a large secured to the free end of the wire rope to act
loop and draw the rope end back through the as a stop as shown. Do not clamp the free end
socket. A length of rope equal to at least one to the load supporting end as this will weaken
rope lay should be drawn back through. the rope.

CABLE SOCKETS
ROPE SIZE PART NO. & DESCRIPTION WHERE USED

~
518"
G- 123~ ~234-43
USED ON FREE END OF
WIRE ROPE
(PIN 1234-18)
E ~
2165~
USED IN WINCH DRUM WEDGE POCKET

MACHINE STORAGE
INDEX
SECTION 7
SUBJECT PAGE
SHORT TERM STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
ENGINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
RESTORING ENGINE TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
TRANSMISSION STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
RESTORING TRANSMISSION TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
RESTORATION TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
CHROME CYLINDER ROD STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 6
Revised: May 2002

MACHINE STORAGE
Machines being placed in storage must be ade- 2. Drain and refill the swing reducer, winch(es),
quately protected from deterioration during the axle differentials, planetary hubs and the hy-
period of idleness. This will ensure that they can draulic reservoir. Refer to page 4-19 when servic-
be restored to active service with a minimum ef- ing the reservoir.
fort.
3. Distribute the new hydraulic fluid to all parts
Before removing this hydraulic crane from ser- of the system by operating all function.
vice for extended periods, it should be prepared
for storage as prescribed in the following para- 4. Clean and tape the battery cables after remov-
graphs. In general, three (3) major components ing and storing the battery.
must undergo preparation. These are the Ma-
chine Proper, the Engine and the Transmission. 5. Coat the external ring gear of the swing bearing
The specific procedure to be followed depends with oper gear lubricant.
upon the expected period of storage.
6. Fill the hydraulic reservoir to the top AFTER
THE MACHINE IS PARKED IN ITS STORAGE SPOT.
SHORT TERM STORAGE - 30 DAYS OR LESS 7. Coat wire rope with lubricant.
Short term storage requires minimal preparation.
8. Coat exposed cylinder rods with grease.
The MACHINE should be thoroughly cleaned, lu-
bricated in accordance with Section 4, and paint- The ENGINE should be prepared as prescribed
ed surfaces retouched where the paint has on page 7-2, the topic "Engine Storage".
deteriorated. exposed portions of all hydraulic
cylinders should be coated with multipurpose The TRANSMISSION should be prepared as
grease. Coat unpainted metal surfaces with mul- prescribed on page 7-4, the topic "Transmis-
tipurpose grease after removing any rust accu- sion Storage."
mulations.
The ENGINE should be prepared as prescribed

on page 7-2, the topic "Engine Storage". ENGINE STORAGE
The TRANSMISSION should be prepared as pre-

scribed on page 7-4, the topic "Transmission
Storage". PREPARING ENGINE FOR STORAGE - When an
engine is to be stored or removed from operation
for a period of time, special precautions should
be taken to protect the interior and exterior of the
WNG TERM STORAGE - 30 DAYS OR MORE engine, transmission, and other parts from rust
accumulation and corrosion. The parts requiring
Long term storage requires greater preparation attention and the recommended preparations are
than short term storage and must be undertaked given below.
with greater care.
It will be necessary to remove all rust or corrosion
The MACHINE should be prepared as follows: completely from any exposed part before applying
a rust preventive compound. Therefore, it is rec-
1. Perform the short term machine storage prep- ommended that the engine be processed for stor-
aration, making certain that All points with age as soon as possible after removal from
grease fittings are liberally lubricated. operation.
7 - 1 Issued: May 1998

MACHINE STORAGE
The engine should be stored in a building which EXTENDED STORAGE (30 DAYS OR MORE)
is dry and can be heated during the winter When An Engine Is To Be Removed From Opera-
months. Moisture absorbing chemicals are avail- tion For An Extended Period Of Time, prepare It
able commercially for use when excessive damp- as follows:
ness prevails in the storage area.
1. Drain and thoroughly flush the cooling sys-
temwith clean, soft water
TEMPORARY STORAGE (30 DAYS OR LESS)
To protect an engine for a temporary period of 2. Refill the cooling system with clean, soft water.
time proceed as follows:
3. Add a rust inhibitor to the cooling system (re
1. Drain the engine crankcase. fer to page 4-7, "Corrsion Inhibitor).
2. Fill the crankcase to the proper level with the 4. Remove, check and reconditon the injectors, if
recommended viscosity and grade of oil. necessary, to make sure they will be readyt to op-
erate when the engine is restored to service.
3. Fill the fuel tank with the recommended grade
of fuel oil. Operate the engine for two minutes at 5. Reinstall the injectors in the engine, time
1200 rpm and no load. them, and adjust the valve clearance.
NOTE: Do not drain the fuel system or the crank- 6. Circulate the coolant through the entire sys-
case after this run. tem by operating the engine until normal operat-
ing temperature is reached (160°F. to 185°F).
4. Check the air cleaner and service it, if neces-
sary as outlined under Air System. 7. Stop the engine.
5. If freezing weather is expected furing the stor- 8. Remove the drain plug and completely drain
age period, add a high boiling point type anti- the engine crankcase. Reinstall and tighten the
freeze solution in accordance with the drain plug. Install new lubricating oil filter ele-
manufacturer's recommendations. Drain the ments and gaskets.
raw water system and leave the drain cocks open.
9. Fill the crankcase to the proper level with a
6. Clean the entire exterior of the engine (except 30-weight preservative lubricating oil MIL-L-
the electrical system) with fuel oil and dry it with 21260, Grade 2 (PlO), or equivalent.
air.
10. Drain the engine fuel tank.
7. Seal all of the engine openings. The material
used for this purpose must be waterproof, vapor- 11. Refill the fuel tank with enough rust preven-
proof and possess sufficient physical stength to tive fuel oil such as Americal Oil Diesel Run-In
resist puncture and damage fro m the expansion Fuel (LH 4089), Mobil4Yl7, or equivalent, to en-
of entrapped air. able the engine to operate 10 minutes.
An engine prepared in this manner can be re- 12. Drain the fuel filter and strainer. Remove the
turned to service in a short time by removing the retaining bolts, shells and elements. Discard the
seals at the engine openings, checking the engine used elements and gaskets. Wash the shells in
coolant, fuel oil, lubricating oil, transmission, clean fuel oil and insert new elements. Fill the
and priming the raw water pump, if used. cavity between the element and shell about two-
thirds full of the same rust preventive compound
as used in the fuel tank and reinstall the shell.
7-2 Issued: May 1998

MACHINE STORAGE
13. Operate the engine for 5 minutes to circulate 20. Remove and clean the battery and battery ca-
the rust preventive throughout the engine. bles with a baking soda solution and rinse them
with fresh water. Store the battery in a cool (nev-
14. Refer to page 4-6 and service the air cleaner. er below 32°F.) dry place. Keep the battery fully
charged.
15. With an all-purpose grease such as Shell Al-
vania No.2, or equivalent, lubricate the clutch 21. Insert heavy paper strips between the pulleys
throwout bearing, clutch pilot bearing, drive and belts to prevent sticking.
shaft main bearing, clutch release shaft, and the
outboard bearings (if so equipped). 22. Seal all of the openings in the engine, includ-
ing the exhaust outlet, with moisture resistant
16. Remove the inspection hole cover on the tape. Use cardboard, plywood or metal covers
clutch housing and lubricate the clutch release where practical.
lever and link pins with a hand oiler. Avoid get-
ting oil on the clutch facing. 23. Clean and dry the exterior painted surfaces of
the engine. Spray the surfaces with a suitable liq-
17. Apply a non-jriction rust preventive com- uid automobile body wax, a synthetic resin var-
pound, to all exposed parts. If it is convenient, nish or a rust preventive compound.
apply the rust preventive compound to the engine
flywheel. If not, disengage the clutch mechanism 24. Cover the engine with a good weather-resis-
to prevent the clutch disc from sticking to the fly- tant tarpaulin or other cover if it must be stored
wheel. outdoors. A clear plastic cover is recommended
for indoor storage.
The stored engine should be inspected periodical-

ly. If there are any indications of rust or corro-
Do not apply oil, grease or any wax base com- sion, corrective steps must be taken to prevent
pound to the flywheel. The cast iron will absorb damage to the engine parts. Perform a complete
these substances which can "sweat" out during inspection at the end of one year and apply addi-
operation and cause the clutch to slip. tional treatment as required.
18. Drain the engine cooling system (tag cap).
19. The oil may be drained from the engine

crankcase if so desired. If the oil is drained, rein-
stall and tighten the drain plug (tag cap).

MACHINE STORAGE
13. Remove the inspection hole cover and inspect

the clutch release lever and link pins and the
RESTORING ENGINE TO SERVICE bearing ends of the clutch reliease shaft. Apply
engine oil sparingly, if necessary to these areas.
1. Remove the valve rocker cover(s) and pour at 14. After all of the preparations have been com-
least one-half gallon of oil, of the same grade as pleted, start the engine. The small amount of
used in the crankcase, over the rocker arms and rust preventive compound which remains in the
push rods. fuel system will cause a smoky exhaust for a few
minutes.
2. Reinstall the valve rocker cover(s).
NOTE: Before subjecting the engine to a load or
3. Remove the covers and tape from all of the high speed, it is advisable to check the engine
openings of the engine, fuel tank, and electrical tune-up.
equipment. Do not overlook the exhaust outlet.
4. Wash the exterior of the engine with fuel oil to TRANSMISSION STORAGE
remove the rust preventive.
5. Remove the rust preventive from the flywheel.

PRESERVATIVE SELECTION When transmis-
6. Remove the paper strips from between the pul- sions are to be stored or remain inactive for ex-
leys and the belts. tended periods of time, specific preservative
methods are recommended to prevent rust and
7. Check the crankcase oil level. Fill the crank- corrosion damage. The length of storage will usu-
case to the proper level with the heavy-duty lubri- ally determine the preservative method to be
cating oil recommended under Lubricating Oil used. Various methods are described below.
SpecifICations.
8. Fill the fuel tank with the fuel specified under STORAGE NEW UNITS
Diesel Fuel Oil Specifications. New units contain preservative oil when shipped
for Funk and can be safely stored for 6 weeks
9. Close all of the drain cocks and fill the engine without further treatment. Refer to the Funk
cooling system with clean soft water and a rust Transmission manual for additional information.
inhibitor. If the engine is to be exposed to freezing
temperatures, add a high boiling point type anti-
freeze solution to the cooling system (the anti- STORAGE, 30 DAYS TO 1 YEAR - WITHOUT
freeze contains a rust inhibitor). OIL
10 Install and connect the battery. 1. Drain Oil.
11. Service the air cleaner as outlined under Air 2. Seal all openings and breathers, except oil
System. drain hole, with mOisture-proof cover or tape.
12. Prepare the generator for starting. 3. Coat all exposed, unpainted surfaces with Nox
Rust X-I 10.

MACHINE STORAGE
4. Atomize or spray 4 ounces of Nox Rust VCI No.

10 oil, or equivalent, into the transmission RESTORATION TO SERVICE
through the oil drain hole. Install the drain plug.
5. If additional storage time is required, (3) and Refer to page 7-4, "RestOring Engine to Service",
(4) above should be repeated at yearly intervals. and page 7-5 and 7-6, "RestOring Transmission
to Service", for the procedures required to restore
these components to service.
*Nox Rust is a preservative additive manufac-
tured by the Daubert Chemical Company. Chi- Remove the MACHINE from storage via the fol-
cage. Illinois. Motorstor is covered by US lowing procedure:
Military Specifications MIL-L-46002 (ORD)
and MIL-1-23310 (WEP). 1. Remove preservative lubricants from all sur-
faces.
I RESTORING TRANSMISSION TO SERVICE 2. Check all fluid levels, adding or draining as re-
quired.
1. IfNox Rust, or equivalent, was used in prepar- 3. Lubricate the machine according to Section 9,
ing the transmission for storage, use the follow- making certain that all points with grease fittings
ing procedures to restore the unit to service. are lubricated.
2. Remove the tape from openings and breather. 4. Make a thorough visual inspection of the entire
machine, placing special emphasis on the condi-
3. Wash off all the external grease with solvent. tion of all hydraulic hoses.
4. Add hydraulic transmission fluid, type C3 to

proper level.
NOTE: It is not necessary to drain C3 oil and Nox

Rust mixture from the transmission.
5. If Nox Rust or equivalent, was not used in pre-

paring the transmission for storage, use the fol-
lowing procedures to restore the unit to service.
6. Remove the tape from openings and breathers.
7. Wash off all the external grease with solvent.
8. Drain oil.
9. Install a new oil filter element(s).
10. Refill transmission with hydraulic transmis-

sion fluid, type C3 to proper level.
7-5 Revised: November 2000

MACHINE STORAGE
CHROME CYLINDER ROD STORAGE 4. Inspect the cylinder rod surfaces and reapply
at three to six month intervals.
5. If the equipment is to be moved and then

Hard chrome plating is primarily applied to steel stored again for an extended period of time
cylinder rods for its wear resistant properties, al- or if the cylinder is cycled, steps 1 thru 4
though it does provide considerable corrosion re- should be repeated for all cylinder rods that
sistance as well. Once the chrome-plated rod is were exposed.
assembled into a cylinder and put into service,
the hydraulic fluid on the surface of the rod pro-
vides all the corrosion resistance required for the *Ferro-Kote 5856-BF is a product of Quaker
rod during its life cycle. As a cylinder cycles, hy- Chemical Company, Conshohocken, PA
draulic fluid is driven into any surface cracks 19428
that exist in the chrome plate. When these
cracks are filled with hydraulic fluid, moisture or For the protection of Older EqUipment that is to
corrosive fluids can not penetrate the cracks. be stored, the procedure outlined above can be
However, some machining and cleaning opera- used, but greater attention to cleaning the ex-
tions can negatively impact the future corrosion posed portions of each cylinder rod is required.
resistan~~ of chrome-plated. shafting. For exam- Solvent applied with plastic or copper wool can
ple, addItives such as chlonne, sulfur, and sodi- be used, but abrasives such as sandpaper
um found in Extreme Pressure (EP) coolants and should never be used to clean the exposed sur-
some washing solutions are known rust acceler- faces of the cylinder rod. If surface damage to
ates and can strip chrome plating from the base the chrome plate is discovered, the frequency of
metal. Cleaning processes, such as phosphate corrosion barrier applications should be in-
washing are also known to be detrimental to the creased.
corrosion resistance of hard chrome plated
shafting. Note: Caution must be used when cleaning
equipment in service with high pressure
If the rod is not periodically cycled and is subject washes. Soaps or chemicals containing
to a corrosive environment, moisture and oxygen chlorines or other corrosive elements
can work its way down through the chrome layer should be avoided. Cylinders should be
and begin to corrode the base metal. Brand new cleaned in a retracted position as not to
equipment may be stored outside for a consider- expose rods to the chemicals. Cylinders
able period of time at the equipment dealership should be cycled immediately folloWing
before it is sold. During these times, a protective the wash. .if rods are to be stored in the
barrier must be applied to the exposed cylinder extended position, refer to steps 1-4
rod. This protective barrier will preserve the in- above.
tegrity of the chrome plating by preventing the
elements of corrosion from getting to the metal
substrate.
Cylinders should be stored in the retracted posi-

tion, if at all possible. The steps outline below
cover the procedures to be followed for protect-
ing New Equipment from corrosion if it must be
stored in the extended position:
1. Position the equipment as it will be stored

and identify all the exposed portions of the
chrome plated cylinder rods.
2. Clean any dirt and dust from the exposed

portions of the cylinder rods using a dry
cloth or a cloth which has been dampened
with an appropriate solvent. Do not use
caustics or acids.
3. Apply a thin coating of "Ferro-Kote 5856-BF"

to the exposed surfaces of the chrome plated
cylinder rods. The ferro-Cote may be
thinned using a 40% Kerosene or no. 1 fuel
oil mixture.

GENERAL INFORMATION
INDEX
SECTION 8
SUBJECT PAGE
CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
AVERAGE WEIGHT OF MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 3
SUGGESTED TORQUE RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 4
MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
Revised: February 2001

GENERAL INFORMATION
CONVERSION TABLES
DECIMAL AND METRIC EQUIVALENTS OF FRACTIONS OF AN INCH
Fractions Decimals Milli Fractions Decimals Milli

of an inch of an inch meters of an inch of an inch meters
1/64 .0156 0.397 33/64 .5156 13.097

1/32 .0313 0.794 17/32 .5313 13.494
3/64 .0469 1.191 35/64 .5469 13.891
1/16 .0625 1.588 9/16 .5625 14.287
5/64 .0781 1.985 37/64 .5781 14.684
3/32 .0938 2.381 19/32 .5938 15.081
7/64 .1094 2.778 39/64 .6094 15.478
1/8 .1250 3.175 5/8 .6250 15.875
9/64 .0406 3.572 41/64 .6406 16.272
5/32 .1563 3.969 21/32 .6563 16.688
11/64 .1719 4.366 43/64 .6719 17.085
3/16 .1875 4.762 11/16 .6875 17.462
13/64 .2031 5.159 45/64 .7031 17.859
7/32 .2188 5.556 23/32 .7188 18.256
15/64 .2344 5.953 47/64 .7344 18.653
1/4 .2500 6.350 3/4 .7500 19.050
17/64 .2656 6.747 49/64 .7656 19.447
9/32 .2813 7.144 25/32 .7813 19.843
19/64 .2969 7.541 51/64 .7969 20.240
5/16 .3135 7.937 13/16 .8125 20.637
21/64 .3281 8.334 53/64 .8281 21.034
11/32 .3438 8.731 27/32 .8438 21/430
23/64 .3594 9.128 55/64 .8594 21/827
3/8 .3750 9.525 7/8 .8750 22.224
25/64 .3906 9.922 57/64 .8906 22.621
13/32 .4063 10.319 29/32 .9063 23.018
27/64 .4219 10.716 59/64 .9219 23.415
7/16 .4375 11.12 15/16 .9375 23.812
29/64 .4531 11.509 61/64 .9531 24.209
15/32 .4688 11.906 31/32 .9688 24.606
31/64 .4844 12.303 63/64 .9844 25.003
1/2 .5000 12.700 1 1.0000 25.400
8-1 Issued: December 1999

GENERAL INFORMATION
LIQUID WEIGHTS AND MEASURES METRIC EQUIVALENTS
LIQUID MEASURE LIQUID MEASURE

4 gills equals I pint I litre equals .0353 cu. ft.
2 pints " I quart I litre " .2642 gallon
4 quarts " I gallon I litre " 61.023 cu. in.
7.48 gallons " I cu. ft. I litre " 2.202 Ibs. of
240 gallons of " I Ton water(62°F.)
water I cu. foot " 28.32 litres
340 gallons of " I Ton I gallon " 3.785 litres
gasoline I cu. inch " .0164 litre
MEASURES OF WEIGHTS MEASURE OF WEIGHTS

16 ounces equals 1 pound 1 gram equals .0353 ounce
2000 pounds " 1 short ton 1 kilogram " 2.205Ibs.
2240 pounds " 1 long ton 1 ounce " 28.35 grams
100 cu. feet " 1 register ton 1 pound " .454 kilogram
40 cu. feet " 1 U.S. shipping 1 ton " .907 metric ton
ton
CIRCULAR MEASURE ELECTRICAL UNITS
60 seconds equals I minute I kilowatt equals 1.34 H.P.

60 minutes " I degree I horsepower " 746 watts
90 degrees " 1 quadrant
360 degrees " circumference
SURVEYOR'S MEASURE
7.92 inches equals 1 link

100 links " 66 feet
or 4 rods
or 1 chain
80 chains " 1 mile

GENERAL INFORMATION
AVERAGE WEIGHT OF MATERIALS

Lb. per Cu. Ft.
METALS,ALLOYS,ORES EARTH
Aluminum, Cast-Hammered 165 Clay, Dry 63

Brass, Cast-Rolled 534 Clay, Damp, Plastic 110
Bronze 509 Clay & Gravel, Dry 100
Copper, Cast-Rolled 556 Earth, Dry Loose 76
Gold, Cast-Hammered 1205- Earth, Dry Packed 95
Iron, Gray-Cast 442 Earth, Moist Loose 78
Iron Slag 172 Earth, Moist Packed 96
Lead 710 Earth, Mud Flowing 108
Manganese 475 Earth, Mud Packed 115
Mercury 847 Riprap, Limestone, Sandstone,
Nickel 537 Shale 80-105
Steel 481-489 Sand, Gravel, Dry Loose 90-105
Tin, Cast-Hammered 459 Sand, Gravel, Dry Packed 100-120
Tin, Cast-Hammered 459 Sand, Gravel, Wet 126
Tungsten 1200
Zinc, Cast-Rolled 440
EXCAVATIONS IN WATER
Sand or Gravel 60
MASONRY Sand or Gravel & Clay 65
Clayt 80
Ashlar Masonry * 143-162 River Mud 90
Rubble Masonry * 137-156 Soil 70
Dry Rubble Masonry * 110-130 Stone Riprap 65
*Granite , Syenite, Gneiss, Marble,
Limestone, Snadstone, Bluestone
Brick Masonry 103-128 STONE, QUARRIED, PILED
Concrete Masonry 100-128
Portland Cement 196 Basalt, Granite, Gneiss 96
'Portland Cement, Loose 94 Limestone, Marble, Quartz 95
Lime, Gypsum, Loose 53-64 Sandstone 82
Mortar, Lime, Set 103 Shale 92
Greenstone, Hornblend 107
WOOD
MISCELLANEOUS
Cedar 22
Fir, Douglas 32 Water, 4 0 C. 62.4
Oak 42-54 Water, 1000 C. 59.8
Pine, Oregon 32 Paper 58
Pine, Southern 38-42 Glass, Common 162
Redwood 2 Petroleum 45-54
Spruce 28 Coal, Anthracite 47-5
Black Walnut 37 Coal, Bituminous 40-54
Coal, Coke 23-32

GENERAL INFORMATION
TORQUE RATINGS
ES - 100.0
TORQUE RATINGS
FOR
DRY - UNCOATED FASTENERS
TORQUE VALUES TO BE WITHIN ± 5%

ALL FIGURES IN FOOT POUND
THIS TABLE DOES NOT APPLY TO HY-

DRAULIC CONNECTIONS. WHEN
TORQUING HYDRAULIC CONNEC-
TIONS REFER TO ES-100.1
NOM. DIA. IN. GRADE 2 GRADE 5 GRADE 8
1/4 6 -*4 8 12 BOLT HEAD MARKING

5/16 12 -*7 20 25
3/8 20 - * 12 30 45
7/16
1/2
9/16
5/8
35
50
75
100
- * 20
- * 30
- * 45
- * 60
- * 110
50
80
115
160
75
110
160
225
o GRADE 2
(8
3/4 180 280 400
7/8 175 450 640
1 265 680 970
GRADE 5
1-1/8 375 840 1,380
1-1/4 530 1,200 1,930
2
1-3/8
1-1/2
1-3/4
700
930
1,460
2,200
1,570
2,080
2,090
3,200
2,540
3,380
5,300
7,990
® GRADE 8
2-1/4 3,200 5,350 11,690

2-1/2 4,400 7,300 15,990
The above information was compiled for D.N.C. Threaded Fasteners.
NOTE: * = Torque Values For Bolts And Screws Longer Than 6"
Fasteners as supplied by the vendor are considered not
lubricated.

GENERAL INFORMATION
TORQUE RATINGS
ES - 100.1
TORQUE RATINGS
FOR
LUBRICATED OR PlATED FASTENERS
TORQUE VALUES TO BE WITHIN ± 5%

ALL FIGURES IN FOOT POUND
REFER TO THIS TABLE WHEN TORQU-

ING HYDRAULIC CONNECTIONS (Piping
& Cylinders).
NOM. DIA. IN. GRADE 2 GRADE 5 GRADE 8

BOLT HEAD MARKING
1/4 5 - *3 7 lO
5/16 9 -*5 14 20
o
3/8 16 - *9 25 35
7/16 25 - * 15 40 55
1/2 40 - * 20 60 85
9/16 55 - * 30 85 120 GRADE 2
5/8 75 - * 45 120 170
3/4
7/8
1
135
130
200
- * 80 2lO
340
515
300
485
720
(8GRADE 5
1-1/8 280 635 1,030
1-1/4
1-3/8
1-1/2
1-3/4
400
520
695
1,lOO
890
1,175
1,560
1,825
1,450
1,900
2,530
3,980
® GRADE 8
2 1,650 2,750 6,000

2-1/4 2,400 4,000 8,760
2-1/2 3,300 5,500 12,000
The above information was compiled for V.N.C. Threaded Fasteners.
NOTE: If threads are not lubricated prior to assembly or are not

plated use Torque Spec. ES-JOO.O
* = Torque Values for Bolts and Screws longer than 6"

Fasteners as supplied by the vendor are considered not
lubricated.
TEREX
LIFTING
RT 500 SERIES rough terrain crane
specifications
STANDARD BOOM EQUIPMENT
BOOM
35-110 ft. (10.67-33.53 m), four section full power boom. elevation of -4 to 76 degrees. Maximum tip height 115 ft.
Telescoping is mechanically synchronized with single lever (35.05 m).
control. The synchronization system consists of a single
BOOM HEAD
telescope cylinder and high strength leaf chains to extend
and retract the third section and the tip section. The boom Welded to fourth section of boom. Five or six metallic
is a high-strength four plate design, welded inside and out load sheaves and two idler sheaves mounted on heavy
duty, anti-friction bearings. Quick reeving boom head.
with anti-friction slide pads. Boom side plates are made
with stamped impressions to reduce weight and increase Provision made for side-stow jib mounting.
strength. A single boom hoist cylinder provides for boom
OPTIONAL BOOM EQUIPMENT
JIBS AUXILIARY BOOM HEAD

32 ft. (9.68 m) side stow swing-on one-piece lattice Removable auxiliary boom head has single metallic
type jib. Single metallic sheave mounted on anti-friction sheave mounted on anti-friction bearing. Removable pin-
bearing. Jib is offsettable at 0°, 15°, or 30°. Maximum type rope guard for quick reeving. Installs on main boom
tip height is 146 ft. (44.50 m). peak only. Removal is not required for job use.
HOOK BLOCK
33-57 ft. (10.15-17.30 m) side stow swing-on lattice type
. jib. Single sheave mounted on anti-friction bearing. Jib is Five or six metallic sheaves on anti-friction bearings with
extendible to 57 ft. (17.30 m) by means of a 25 ft. (7.62 m) hook and hook latch. Quick reeving design does not require
manual pull-out tip section, roller supported for ease of removal of wedge and socket from rope.
extension. Jib is offsettable at 0°, 15°, or 30°. Maximum tip HOOK & BALL
height is 170 ft. (51.82 m). 7 ton (6.3 mt) top swivel ball with hook and hook latch.
8-6 Issued: February 2001

STANDARD UPPERSTRUCTURE EQUIPMENT
UPPERSTRUCTUREFRAME optimum visibility of the load open or closed. Acoustical foam
All welded one-piece structure fabricated with high tensile padding insulates against sound and weather. The deluxe six-way
strength alloy steel. Counterweight is bolted to frame. adjustable seat is equipped with a mechanical suspension and
includes head and arm rests.
TURNTABLE CONNECTION
CONTROLS
Swing bearing is a single row, ball-type, with internal teeth. The
swing bearing is bolted to revolving upperstructure and to the All control levers and pedals are pOSitioned for efficient
carrier frame. operation. Hand operated control levers include swing, boom
telescope, boom hoist, winch(s), 360° house lock, shift, and
SWING vernier adjustable hand throttle. Switches include ignition,
A hydraulic motor drives a double planetary reduction gear for engine stop, two-speed winch(s), lights, horn, windshield
precise and smooth swing function. Swing speed (no load) is wipers, defroster, steering mode, parking brake, and outrigger
2.8 rpm. controls. Foot control pedals include swing brake, boom raise,
boom lower, service brakes and accelerator.
SWING BRAKE
Heavy duty multiple disc swing brake is mechanically actuated INSTRUMENTATION AND ACCESSORIES
from operator's cab by foot pedal. Brake may be locked' on or In-cab gauges include air pressure, bubble level, engine oil
used as a momentary brake. A 360° mechanical house lock is pressure, fuel, engine temperature, voltmeter, transmission
standard. temperature, and transmission oil pressure. Indicators include
low air, high water temperature/low oil pressure/high transmis-
RATED CAPACITY INDICATOR sion temperature audio{visual warning, low coolant audio/Visu-
Rated Capacity Indicator with visual and audible warning system al warning, hoist drum rotation indicator(s), and Rated
and automatic function disconnects. Second generation picto- Capacity Indicator. Accessories include fire extinguisher; light
graphic display includes: boom radius, boom angle, boom package including headlights, tail lights, brake lights, direc-
length, allowable load, actual load, and percentage of allowable tional Signals, four-way hazard flashers, dome light, and back-
load registered by bar graph. Operator settable alarms provided up lights with audible back-up alarm; windshield washer/Wiper;
for swing angle, boom length, boom angle, tip height, and work skylight wiper; R.H. and L.H. rear view mirrors; dash lights; and I
area exclusion zone. Anti-two block system includes audio{visual seat belt. Circuit breakers protect electrical circuits.
warning and automatic function disconnects.
HYDRAULIC CONTROL VALVES
OPERATOR'S CAB Valves are mounted on the rear of the upperstructure and are
Environmental cab with all steel construction, optimum visibility, easily accessible. Valves are mechanically operated and
tinted safety glass throughout, and rubber floor matting is include one pressure compensated two spool valve for boom
mounted on vibration absorbing pads. The cab has a sliding door elevation and telescope, one pressure compensated two spool
on the left side, framed sliding window on the right side, hinged valve for main and auxiliary winch, and one single spool valve
tinted all glass skylight and removable front windshield to provide for swing. Quick disconnects are provided for ease of installa-
tion of pressure check gauges.
OPTIONAL EQUIPMENT
Auxiliary Winch • Hydraulically powered Air Conditioner
with or without hydraulic heater • LP or Diesel
Heater/Defroster • Tachometer • Work Lights. Rotating
Beacon • Nylon Sheaves
STANDARD CARRIER EQUIPMENT

CARRIER CHASSIS STEERING
Chassis is Terex designed with four-wheel drive and four-wheel Hydraulic four-wheel full power steering for two-wheel, four-
steer (4x4x4). Has box-type construction with reinforcing cross wheel coordinated, or or four-wheel crab steer is easily con-
members, a precision machined turntable mounting plate and trolled by steering wheel. A rear axle centering light is provid-
integrally welded outrigger boxes. Decking has anti-skid sured.
faces, including between the frame rails lockable front tool
Turning radius to center of outside tire.
storage compartment, and access steps and handles on the
(standard tires) (optional tires)
left and right sides and on all four corners.
Two-wheel 40' 4" (12.3 m) 40' 0" (12.2 m)
AXLES AND SUSPENSION Four-wheel 23' 4" (7.1 m) 23' 0" (7.0 m)
Rear axle is a planetary drive/steer type with 10.5 in (0.26 m) of TRANSMISSION
total oscillation. Automatic oscillation lockouts engage when the
Full power-shift transmission with integral torque converter has
superstructure is swung 10° in either direction. Front axle is a
neutral safety start, 6 speeds forward, and 3 speeds reverse pro-
planetary drive/steer type, rigid mounted to the frame for
vides wide ratio coverage. Automatic pulsating back-up alarm.
increased stability.

STANDARD CARRIER EQUIPMENT (continued)
MULTI-POSITION OUT & DOWN OUTRIGGERS SERVICE BRAKES
Fully independent hydraulic outriggers may be utilized fully extend- Split system air brakes on all four wheels; 201f4' x 4'
ed to 22 ft. (6.71 m) centerline to centerline, in their 1f2 extended (51.43x10.2 cm) wedge type drum brakes.
position, or fully retracted for maximum flexibility. Easily removable
steel floats, each with an area of 254 in2 (1639 cm2), stow on the PARKING BRAKE
outrigger boxes at their point of use. Complete controls and a sight Front and rear axles equipped with spring-set, air-released
leveling bubble are located in the operator's cab. emergencyfparking chambers acting on service brakes.
WHEELS & TIRES

Disc type wheels with full tapered bead seat rim. 150.50 in OPTIONAL EQUIPMENT
(3.82 m) wheelbase. Cold Weather Starting Aid • Immersion Heater. Pintle Hook
• Fuel Water Separator. Clearance Lights. Independent
TIRES Rear or Four Mode Rear Wheel Steer. 20,000 Ib line pull front
Wide earthmover (E3) style tread tires provide life and flotation. mounted winch
26. 50x25 , 26 P.R. - std.
21.00x25, 28 P.R. opt.
HYDRAULIC SYSTEM
HYDRAULIC PUMPS FILTRATION
Three gear type pumps, one single and two in tandem, driven Full flow oil filtration system with bypass protection includes a
off the transmission. Combined system capability is 119 gpm removable 60 mesh (250 micron) suction screen-type filter
(450Ipm). Includes pump disconnect on tandem pump. and 5 micron replaceable return line filter.
Main and Auxiliary Winch Pump HYDRAULIC RESERVOIR
59.5 gpm (225.2 Ipm) @ 3,500 psi (246.1 kgfcm2)
All steel, welded construction with internal baffles and diffuser.
Boom Holst, Telescope Pump Provides easy access to filters and is equipped with an exter-
38.5 gpm (145.7Ipm)@3,500 psi (246.1 kgfcm2) nal sight level gauge. The hydraulic tank is pressurized to aid
Power Steering, Outrigger and Swing Pump in keeping out contaminants and in reducing potential pump
21 gpm (79.5Ipm)@ 2,500 psi (175 kgfcm2) cavitation. Capacity is 112 gal (424 liters). Hydraulic oil cooler
is standard.
MAIN WINCH SPECIFICATIONS OPTIONAL AUX. WINCH

Hydraulic winch with bent axis piston motor and planetary reduction gearing pro- Hydraulic 2-speed winch with bent piston
vides 2-speed operation with equal speeds for power up and down. Winch is motor, equal speed power up and down, plan-
equipped with an integral automatic brake, grooved drum, tapered flanges, stan- etary reduction with integral automatic brake,
dard cable roller on drum, and an electronic drum rotation indicator. grooved with tapered flanges, drum roller, and
rotation indicator.
PERFORMANCE LO-RANGE HI-RANGE Performance
Max. line speed (no load) Max. line speed (no load)
First layer 184 fpm (56.1 mlmin) 369 fpm (112.5 mlmin) Fifth layer 533 fpm (162.5 mlmin)
Fifth layer 266fpm(81.1 m/min) 533 fpm (162.5 mlmin) Max. line pull
Max. line pull-first layer 15,639 Ibs (7093 kg) 7,2981bs (3310 kg) First layer 15,6391bs (7,093 kg)
Max. line pull-first layer 10,827 Ibs (4911 kg) 5,052 Ibs (2291 kg) Drum Dimensions and Capacity
Permissible line pull 11,250 Ibs (5102 kg) (Same as main winch)
DRUM DIMENSIONS DRUM CAPACITY
OPTIONAL HOIST LINE
10.62 in (270 mm) drum diameter Max. Storage: 939 ft (286.2 m)
MAIN WINCH AND OPTIONAL AUXILIARY WINCH
22.42 in (570 mm) length 7th layer not a working layer
-5fo" (16 mm) rotation resistant compacted
20.0 in (508 mm) flange dia. Max. Useable: 772 ft (235.3 m)*
strand 34 x 7. Min. breaking strength 28.21
Cable: 51. in. x 500 ft (16 mm x 152.4 m)
*Based on minimum flange height above tons (25.59 mt).
Cable type: '/. in. (16 mm) 6 x 191WRC,
top layer to comply with ANSI B30.5
XIPS, right regular lay, preformed.
ENGINE SPECIFICATIONS PERFORMANCE (Standard Engine)

Trans- Maximum Grade-
Make and Model Cummins 6BTA5.9 CaterDlllar 3116 DITA mission Forward Maximum Tractive ability
Type 6 cylinder 6 cylinder Gear Drive Speed Effort @Stall
1 4-wheel 2.4 mph 6O.538lbs 127.6%
Bore and Stroke 4.02 x 4.72 in P02x120 mm) 4.12 x5.0 in (105x127 mm) 3.9 km/h 27460 kg
Displacement 359 cu in (5.9 I) 402 cu in (6.6 I) 2 4-wheel 4.2 mph 34,2551bs 48.5%
GrossHP 174 hp (130 kW)@25oorpm 175 hp (130 kw)@24oorpm 6.8 kmJh 15538 kg
Gross Torque 480lboft (651 Nom) @ 1500 rpm 482lboft (654 Nom) @ 1450 rpm 3 4-wheel 5.6 mph 26.061Ibs 34.7%
9.0km/h 11821 kg
Aspiration turbocharged & aftercooled turbocharged & aftercooled 4 2-wheel 9.8 mph 14.765lbs 18.0%
Air Filter dry type dry type 15.8km/h 6697 kg
Electrical System 12 volt 12 volt 5 2·wheel 13.9 mph 10.4101bs 12.0%

22.4kmJh 4722 kg
Alternator 102 amp 115amp 6 2-wheel 24.1 mph 5,960 Ibs 5.9%
Battery (2) 12V-1600CCA (2) 12V-1600CCA 38.8km/h 2700 kg
Fuel Capacity 50 gal (1891) 50 gal (1891) All performance data IS based on a glOSS vehicle weight of 75,000 Ibs
(34 014 kg). 26.5x25 tires, 4x4 drive. Performance may vary due to
engine performance. Gradeability data is theoretical and is limrted by
tire slip, stability, or oil pan design.

GENERAL DIMENSIONS
NOTES:
1. Dimensions given assume the boom is fully retracted in travel position and 26.50x25 tires.
2. Minimum ground clearance under: transmission - 25.25"
axle bowls - 22.25"
tie rods - 25.5"
1------- 31'-2" (9.SOm) - -_ _ _ _ _1--

@
21.00 tires 2S.5tires

A 21° 20°
B 2So 25° t - - - - - . 22'-4" (S.81m) ----+-+-(O.46m)
1'-S.25"
C 7'-9.75" (2.38m) 8'-10" (2.69m)
o 9'-10" (3.00m) 10'-10" (3.30m) t------25'-6.5" (7.79m) _ _ _--.-1
1 - - - - - - - - - - - 44'-2.5" (13.47m) - - - - - - - ' - - - " - - - - 1
UPPER FACING FRONT UPPER FACING FRONT

WEIGHTS & AXLE LOADS
Pintle Hook:
Front + 45 + 60 15 + 20 + 27 7
Rear + 45 25 + 70 + 20 11 + 31
NOTE: Weights are for Terex supplied equipment and are subject to 2% variation due to manufacturing tolerances.
WE RESERVE THE RIGHT TO AMEND THESE SPECIFICATIONS AT ANY TIME WITHOUT NOTICE. THE ONLY WARRANTY APPLICABLE IS OURSTANDARD WRITTEN WAR-
RANTY APPLICABLE TO'THE PARTICULAR PRODUCT AND SALE. WE MAKE NO OTHER WARRANTY, EXPRESSED OR IMPLIED.
~TEREX CRANES
106 12th Street S.E.
Waverly, IA 50677-9466 USA G;vw.tereXlift.cDni:::>
(319) 352-3920· FAX: (319) 352-5727 - -
E-mail: waverly@terexlifling.com
TC-511 C Tarex Cranes, Inc. 2000 Litho in U.SA. 5Ul900T90

WIRE ROPE USER'S MANUAL
INDEX
SECTION 9
SUBJECT PAGE
WIRE ROPE USER'S MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

See Wire Rope User ManuaFile
Greer Company
MICROGUARO@
TEREX RCI500
TELESCOPIC BOOM CRANES
OPERATOR'S MANUAL
n!!O 1o
TEREX CRANES FULL OUTRIGGERS
SWING 360 0
AUX HEAD FITTED
ERECTED
33' TELEJIB, 30 0
REAR WINCH
LIFTING FROM
MAIN BOOM
MAX
I 3lJ.LJI
GREER COMPANY
GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL: (714) 259-9702 FAX: (714) 259-7626
1 of 24 PN W450200 REV A
TEREX RCI 500 RATED CAPACITY INDICATOR
OPERATORS MANUAL
TABLE OF CONTENTS
TEREX RCI 500 TELESCOPIC BOOM CRANES
PAGE
Introduction Outline of operation 3
What Does It Tell You?

Overload, Pre-alarm Indicators 4
Parts of line Indicator 4
Anti two-block Warning 4
Information Screen 4
Length, Radius, Angle Displays 5
Load Displays, Rated and Actual 5
Percentage of Rated Load Bargraph 5
What Must You Tell It ?
Counterweight 6
Outriggers or Tires 6
Stowed and/or Erected Attachments 6
Manual Boom or Boom Mode 6
Auxiliary Head 6
Point of Lift 6
Winch in Use 6
Parts of Line 6
System Set Up
Information Screen 7
Counterweight 8
Outriggers 9
Tires/Rigging Travel Mode 10
Stowed Attachments 11
Erected Attachments 12
Auxiliary Head 13
Choosing the Lifting Point 14
Winch in Use 14
Setting the Parts of Line 14
Cancel Audible Alarm 15
Reset Function Kick-Out 16
Contrast Adjustment (Information Screen) 16
Operator Settable Alarms
Accessing the Alarms 17
Minimum and/or Maximum Boom Angle 18
Maximum Length, Maximum Height 19
Swing Alarms
Access to Swing Alarms 20
Setting Swing Alarms 21
Area Alarms 22
2 of 24 PN W450200 REV A
OPERATORS MANUAL
OUTLINE OF OPERATION
SYSTEM COMPONENTS EXTENSION SENSOR

• MicroGuard Display Unit The extension of the boom is measured by means of
• MicroGuard Computer Unit a potentiometer actuated by a recoil drum. The recoil
• Pressure Transducers drum is attached to the boom head by a cable that
• Reeling drum, with length and angle sensors also carries the A2B signal back through the reeling
• Anti 2-Block switches
drum to the computer.
• Cables
• Installation/Operator Manuals
PRESSURE TRANSDUCERS
The system is intended to aid the crane operator by
The pressure in the boom hoist cylinder is measured
continuously monitoring the load and warning of an
by two pressure transducers. The resultant Total
approach to an overload or two-block condition.
Moment signal is processed to provide a continuous
Crane functions are monitored by means of high
display of the load suspended below the boom head.
accuracy sensors. The system continuously com-
pares the load suspended below the boom head with ANTI TWO BLOCK (A2B)
the crane capacity chart stored in the computer
The approach of the hook block or overhaul ball to
memory. At approach to overload, the system warns
the boom head is monitored by a switch. The switch
by means of audible and visual alarms. The system
is held in the closed position until the hook block or
can be configured to cause function kick-out by
overhaul ball raises a weight that is axially mounted
sending a signal to function disconnect solenoids.
around the hoist rope. When the weight is raised it
DISPLAY causes the magnet to move away from the reed relay
which opens the switch. The resultant signal is sent to
The display contains eight liquid crystal displays
the computer and the A2B alarm operates.
(LCD) each with characters approximately 8.0 mm
high and viewable over a wide angle. The displays FUNCTION KICK-OUT
are backlit and are readable in all lighting conditions.
Electrically operated hydraulic solenoids are used to
The operator is provided with a continuous display of:
cut off the flow of oil to hydraulic functions when an
• Rated Load overload or an A2B condition occurs.
• Actual Load
OPERATOR SETTABLE ALARMS
• Bar graph showing Percentage of Rated Load
These alarms, when properly set by the operator
• Radius of the Load
define the operating range. This is achieved by
• Boom Angle
means of minimum and maximum angle, maximum
• Main Boom Length height and/or maximum length or radius alarms.
• Working Area These alarms can be programmed for each job site
• Crane Configuration and allow the operator to work in a defined area.
On screen messages provide the operator with visual
AREA ALARM
warnings of conditions that occur during operation of
the system. This alarm, when set, permits the operator to define
the operating zone by only two set points. The use of
BOOM ANGLE SENSOR this method of setting results in a greatly enhanced
working area, and also clearly defines the operating
Boom angle is measured by means of a high
zone.
accuracy potentiometer/pendulum assembly that is
damped to prevent over swing.
3 of 24 PN W450200 REV A
OPERATORS MANUAL

SWING 360 0
AUX HEAD FITTED
ERECTED
33' TELEJIB, 30 0
REAR WINCH
LIFTING FROM
MAIN BOOM
MAX
I 30.01
WHAT DOES IT TELL YOU?
1. The OVERLOAD INDICATOR (RED) 3. PARTS OF LINE displays the parts of line
illuminates at a pre-set value of 100% of currently selected.
Maximum Rated Capacity and provides a
4. The ANTI TWO-BLOCK lamp will illuminate
visual indication of Maximum Allowed Load.
when the contacts on the A2B limit switch
2. The PRE-ALARM (AMBER) indicator open, indicating an approach to a two-block
illuminates at a pre-set value of 90% of condition.
Maximum Rated Capacity and provides a
5. The INFORMATION SCREEN contains
visual indication of an approach to an over-
details of the currently selected configuration
load.
and is used to input additional information
about crane set up.
4 of 24 PN W450200 REV A
OPERATORS MANUAL
n!!O ~O
SWING 360 0
AUX HEAD FITTED
ERECTED
33' TELEJIB, 30 0
REAR WINCH
LIFTING FROM
MAIN BOOM
10 7

6. The LENGTH display shows the length of 9. ACTUAL LOAD display shows total load
the Main Boom from the boom foot pin to the suspended below the boom or jib head.
sheave pin of the head machinery.
10. MAXIMUM RATED CAPACITY shows the
7. The RADIUS display gives an indication of RATED CAPACITY of the machine in the
the radius of the load which is the horizontal current configuration.
distance from the center line of rotation to
11. The BARGRAPH gives a quick indication of
the center line of the hook.
the lifted load as a PERCENTAGE OF
8. The ANGLE display gives an indication of RATED LOAD.
the angle, in degrees, of the main boom
relative to horizontal.
5 of 24 PN W450200 REV A
OPERATORS MANUAL
n!!O ~O
FULL OUTRIGGERS
SWING 360 0
AUX HEAD FITTED
ERECTED
33' TELEJIB, 30 0
REAR WINCH
LIFTING FROM
MAIN BOOM
18
WHAT MUST YOU TELL IT ?
17. Are any attachments such as FLYS or JIBS

12. Which COUNTERWEIGHT is fitted
erected?
(if applicable).
18. What is the POINT OF LIFT (e.g. main
13. Whether you are on OUTRIGGERS fully
boom, auxiliary head or jib)?
extended, partly extended, retracted or on
TIRES. 19. Which WINCH will the pick be made with?
14. Which JIBS are stowed on the boom. 20. The number of PARTS OF LINE.
Use these push buttons to input additional
15. Is the MANUAL SECTION extended,
information during set up.
(if applicable)?
16. Is the AUXILIARY HEAD fitted?
6 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O 1o
TEREX CRANES
Set Operator Alarms
Set Jib Selection
Set Swing Alarms
Return To Main Screen
MAX
I 3lIai
USING THE INFORMATION SCREEN (item 5).
• The information screen (item 5) is used in • Press any push-button on the left edge of
conjunction with other push-buttons to set up the screen to access the information screen.
the system.
• The options are:
• There are 4 push-buttons (item 21) on the
"Set Operator Alarms"
left edge of the information screen which are
"Set Jib Selection"
used to access the screen and to make
"Set Swing Alarm"
selections.
"Return to Main Screen"
7 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O ~O
TEREX CRANES
NO COUNTERWEIGHT
3,000# C'TW'T
6,000# C'TW'T
12,000# C'TW'T
MAX
I 3flO I
COUNTERWEIGHT
• On machines which have counterweight • Pressing the push-button (item 21) which is
pointing to the appropriate counterweight will
options the operator must tell the
select that counterweight option.
MicroGuard system which counterweight is
currently fitted. • The information screen will then revert to the
normal working display, the selected
• Start the choice by pressing the counter-
counterweight will be displayed in the work-
weight push-button (item 13). The light in
ing display and the counterweight push-
the center of the counterweight push-button
button will stop flashing and revert to a
will start to flash indicating that a selection is
continuous red light.
available.
• The selections for the machine will appear in • If the counterweight push-button is pressed
on a machine which does not have a
the window of the Information Screen counterweight option the message "no
(item 5). counterweight options" will appear in the
information display. The light in the
counterweight push-button will not illuminate.
GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714) 259-7626
8 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O ~O
SWING 360 0
AUX HEAD FITTED
ERECTED
33' TELEJIB, 30 0
REAR WINCH
LIFTING FROM
MAIN BOOM
MAX
I 3lJ.OI
OUTRIGGERS
• On machines that have multiple outrigger • The information screen (item 5) will
selections, e.g. full outriggers, intermediate indicate full outriggers, half outriggers or
outriggers or retracted outriggers the op- retracted outriggers dependent upon the
erator must select the outrigger push-button selection.
choice which corresponds to the current out-
rigger position. • The light in the center of the outrigger
push-button selected will be illuminated.
• Press the outrigger push-button (item 13)
which corresponds to the outrigger position.
9 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O ~O
TEREX CRANES
STATIONARY, 360 0
RIGG INGITRAVEL
MAX
I :lD.OI
TIRES/RIGGING TRAVEL
• On machines that have more than one tire • Pressing the push-button (item 21) which is
selection, e.g. stationary, pick and carry etc., pointing to the appropriate tire option will
the operator must select the tire select that operating mode.
configuration that corresponds to the current
tire chart. • The information screen will revert to the
normal working display, the selected tire
• Start the choice by pressing the tire push- operating mode will be displayed in the
button (item 13). The light in the center of working display, the tire push-button will stop
the tire push-button will start to flash flashing and revert to a continuous red light.
indicating that a selection is available.
• RIGGINGITRAVEL MODE is selected when
• The selections for the machine, e.g. station- the machine is in the rigging process or, in
ary, pick and carry etc., will appear in the the case of a Rough Terrain machine, is to
window of the information screen (item 5). travel between jobs.
10 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O 1o
33' Offset Jib
33'-58' Tele Jib
MAX
I 3lJ.QI
STOWED ATTACHMENTS
• The attachments available on your machine • Press the push-button (item 21) which points
are selectable via the "INFORMATION to the fly/jib currently installed on your crane.
SCREEN" (item 5) The selected attachment will automatically
be stowed and the flashing red light in the
• To select the current jib press anyone of the "stowed push-button" (item 14) will become
information screen push-buttons (item 21)
continuous indicating a stowed attachment.
• The menu for the information screen will be • If there is no fly/jib, or if the fly/jib is to be
displayed.
removed from the machine, press "No Jib
• Press the button (item 21) which points to Selection". The flashing red light in the
"Set Jib Selection" stowed push-button (item 14) will go out
indicating that there is no stowed
• The available options will appear in the attachment.
window of the Information Screen (item 5),
and the stowed selection push-button (item
14) will flash until the selection is made.
11 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O !o
TEREX CRANES
33' Offset Jib
33'-58' Tele Jib
MAX
I 3lJ.LJI
ERECTED ATTACHMENTS
• To erect any attachment it must first have • If there is a choice of offsets or lengths for
been selected and stowed as detailed on the any given attachment then the light in the
previous page. selected push-button will flash indicating that
the choice must be made in the
• To erect a stowed attachment, press the INFORMATION SCREEN (item 5)
appropriate push-button from fly/jib group
(item 17). • The choice of offset or length will appear in
the INFORMATION SCREEN (item 5).
• The attachment will be selected and the
light in the chosen push-button will become • Press the push-button (item 21) which points
illuminated. to the fly/jib to be chosen The flashing red
light in the erected push-button (item 17) will
• The red light in the "stowed push-button" will become continuous indicating that there is a
be automatically extinguished. selected offset attachment.
• The INFORMATION SCREEN (item 5) will
indicate which erected attachment
has been chosen.
12 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O 1o
EREXCRANES FULL OUTRIGGERS
SWING 360 0
AUX HEAD FITTED
ERECTED
33' TELEJIB, 300
REAR WINCH
LIFTING FROM
MAIN BOOM
MAX
I 3lJ.QI
AUXILIARY HEAD
• On machines fitted with an auxiliary head, FOR MACHINES WHERE THE AUXILIARY
this must be included in the machine set-up. HEAD WAS NOT PART OF ORIGINAL
EQUIPMENT AND IS NOW TO BE FITTED
• To set-up the machine with an auxiliary
head, press the auxiliary head push-button, • If the machine was not equipped for auxiliary
(item 16). head when it was originally calibrated then
the message "No Aux. Head Options" will
• The message AUX HEAD FITTED will
appear in the window of the Information
appear in the window of the INFORMATION
Screen and the red light in the Aux. Head
SCREEN (item 5) and the red light in the
push-button will not be illuminated.
Aux. Head push-button will be illuminated.
• Contact the Terex factory for details of the
• If the machine is not equipped for auxiliary
start-up adjustments that must be made
head then the message "No Aux. Head
before fitting and using an auxiliary head.
Options" will appear in the window
of the Information Screen and the
red light in the Aux. Head push-button will
not be illuminated.
13 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O ~o
SWING 360 0
AUX HEAD FITTED
ERECTED
33' TELEJIB, 300
REAR WINCH
LIFTING FROM
MAIN BOOM
After configuration has been set, CHOOSING THE LIFTING POINT

operation of the system depends Choose the lifting point from the main boom,
upon only three settings: auxiliary head, or fly/jib by pressing the
appropriate push buttons (item 18).
LIFTING POINT TO BE USED CHOOSING THE WINCH

Choose the winch that you will be using by
WINCH IN USE pressing the appropriate winch push-button
(item 19).
PARTS OF LINE RIGGED SETTING THE PARTS OF LINE

Set the parts-of-line that you will be using by
pressing the parts-of-line push-button (item 20)
until the correct number appears in the screen.
14 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O ~O
TEREX CRANES
FULL OUTRIGGERS
SWING 3600
AUX HEAD FITTED
ERECTED
33' TELEJIB, 30 0
REAR WINCH
LIFTING FROM
MAIN BOOM
MAX
I 3[101
3
CANCEL ALARM PUSH BUTTON
The Cancel Alarm push-button (item 22) is and then recurs, the new alarm condition will
used to silence the audible alarm. Pressing cause the audible alarm to sound again.
this button once will cancel an audible alarm
The CANCEL ALARM push-button is also
which has occurred as a result of either an;
used to reset the function kick-out relay
Overload when it is necessary to by-pass the function
A2B Alarm disconnects.
Operator Settable Alarm Examples of when it may be necessary to
The audible alarm remains canceled until override a function disconnect condition:
the condition that caused the alarm has • If the boom hoist cylinder is fully
been removed. For example, if the audible extended, the pressure in it will rise.
alarm sounded because of an overload con- This will be seen by the system as an
dition it will remain canceled until the over- overload and will not allow the operator
load condition has been removed. If another to boom down. Using the by-pass is
alarm condition that normally causes an necessary in this situation to move away
alarm to sound, such as A2B, occurs while from the fully extended position.
the audible alarm is canceled or if the
previous condition (overload) is removed
GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714)
259-7626
15 of 24 PN W450200 REV A
OPERATORS MANUAL
SYSTEM SET UP
n!!O 1o
TEREX CRANES
FULL OUTRIGGERS
SWING 360 0
AUX HEAD FITTED
ERECTED
33' TELEJIB, 300
REAR WINCH
LIFTING FROM
MAIN BOOM
MAX
I 3[1al
3
CANCEL ALARM (continued)
• When the machine is to be rigged, it is often WHEN THE FUNCTION DISCONNECT RELAY
necessary to put the boom in a position IS RESET BY MEANS OF THE CANCEL
which will cause function disconnect. Using ALARM PUSH-BUTTON, YOU ARE NO
the by-pass is necessary in this situation. LONGER PROTECTED AGAINST THE
CONDITION THAT CAUSED THE FUNCTION
RESET FUNCTION KICK-OUT KICK-OUT.
The relay is re-set by pressing and holding the CONTRAST CONTROL

CANCEL ALARM push-button for approximately
5 seconds until a second beep is heard. When Pressing the Contrast Control push button (item
the condition which caused the alarm is no 23) can increase the contrast in the Information
longer present the function disconnect relay will Screen (item 5). Successive pressing of the
reset to the normal condition. Should a different contrast control push-button will cause the con-
alarm condition occur while the relay is trast of the Information Screen to increase in
over-ridden the new alarm condition will cause fixed steps until reaching maximum. When the
the controls to disconnect again. maximum contrast is reached further pressing of
the push-button will cause the contrast to go to
its lowest level. Continuing to press the push-
button can continue the cycle.
GREER COMPANY 1918 East Glenwood Place, Santa Ana CA 92705 TEL:(714) 259-9702 FAX:(714)
259-7626
16 of 24 PN W450200 REV A
OPERATORS MANUAL
OPERATOR SETTABlE ALARMS
ACCESSING THE OPERATOR ALARMS
FULL OUTRIGGERS
SWING 360 0
AUX HEAD FITTED
Access to the Operator Alarms from the main ERECTED

working screen is obtained by pressing anyone 33' TELEJIB, 30 0
of the push buttons to the left of the 3"x3" REAR WINCH

INFORMATION SCREEN (item 5). LIFTING FROM
MAIN BOOM
Set Operator Alarms

The Information Screen will show the available
choices. Press the push-button pointing to
"Set Operator Alarms" to access the Operator Set Jib Selection
Alarms. If no choice is made, the system will
return to the main screen after 30 seconds or Set Swing Alarms
you can return to the main screen by pressing
the push-button (21). Return to main screen
There are four alarms available:
Minimum Boom Angle [B MIN ANGLE OFF
Maximum Boom Angle

Maximum Boom Length
Maximum Tip Height
[B MAX ANGLE OFF
To exit from the alarm screen, press the

[B MAX LENGTH OFF
Contrast push-button or wait for the 30-second

time-out. [B MAX HEIGHT OFF
Exit
17 of 24 PN W450200 REV A
OPERATORS MANUAL
SETTING MINIMUM BOOM ANGLE ALARM
• Move the boom to the desired minimum

angle, in this example 30 degrees.
[B MIN ANGLE 30 SET
• Access the operator alarm screen.

[B MAX ANGLE OFF
• Press the push-button pointing to

minimum angle. [B MAX LENGTH OFF
• The display will read

MIN ANGLE 30 SET
[B MAX HEIGHT OFF
Exit
~
The red warning light will now flash and the
audible alarm will sound whenever the boom
angle is below 30 degrees.
Pressing the MIN ANGLE push-button again will

cancel the alarm and the display will read MIN
ANGLE OFF.
SETTING MAXIMUM BOOM ANGLE ALARM
• Move the boom to the desired maximum

angle, in this example 65 degrees. MIN ANGLE OFF
• Access the operator alarm screen. MAX ANGLE 65 SET
• Press the push-button pointing to maximum MAX LENGTH OFF

angle.
MAX HEIGHT OFF

• The display will read:
Exit
MAX ANGLE 65 SET.

audible alarm will now sound whenever the
boom angle is above 65 degrees.
Pressing the MAX ANGLE push-button again will

cancel the alarm and the display will read MAX
ANGLE OFF.
18 of 24 PN W450200 REV A
OPERATORS MANUAL

SETTING MAXIMUM BOOM LENGTH ALARM
• Extend the boom to the desired maximum

length, example 65 feet.
[B MIN ANGLE OFF

[B MAX ANGLE OFF
• Press the push-button pointing to maximum

length. [B MAX LENGTH 65 SEl

MAX LENGTH 65 SET
[B MAX HEIGHT OFF
Exit

audible alarm will now sound whenever the ~
boom length is longer than 65 feet.
Pressing the MAX LENGTH push-button again

will cancel the alarm and the display will read:
MAX LENGTH OFF
SETTING MAXIMUM TIP HEIGHT ALARM
• Move the boom tip the desired maximum

height, example 97 feet.
[B MIN ANGLE OFF

[B MAX ANGLE OFF
• Press the push-button pointing to maximum

height. [B MAX LENGTH OFF

MAX HEIGHT 97 SET
[B MAX HEIGHT 97 SET
Exit

audible alarm will now sound whenever the ~
boom tip height is above 97 feet.
Pressing the MAX HEIGHT push-button again

will cancel the alarm and the display will read
MAX HEIGHT OFF
19 of 24 PN W450200 REV A
OPERATORS MANUAL

SETTING SWING ALARMS
NOTE THAT BOTH LEFT AND RIGHT SWING ALARMS MUST BE SET FOR THE SYSTEM TO
OPERATE CORRECTL Y.
FULL OUTRIGGERS
SWING 360 0
ACCESSING THE SWING ALARMS
AUX HEAD FITTED
Access Swing Alarms from the main working
screen by pressing anyone of the push buttons ERECTED
33' TELEJIB, 3cf>
to the left of the 3" x 3" Information Screen.
The Information Screen will show the REAR WINCH
available choices. LIFTING FROM
MAIN BOOM
SELECT SWING ALARMS

Set Operator Alarms
Press the push-button pointing to "Set Swing
Alarms" to access the Swing Alarms. Set Jib Selection
If no choice is made, the system will return to the Set Swing Alarms
main screen after 30 seconds, or you can return
to the main screen by pressing the "RETURN Return to main screen
TO MAIN SCREEN" push button.
20 of 24 PN W450200 REV A
OPERATORS MANUAL
SETTING LEFT SWING ALARM
• Swing the boom to the desired Left Swing

[B LT. SWING OFF
Limit, e.g. 300 degrees.

[B RT. SWING OFF
• Access the operator alarm screen. If the

alarms have not been previously set, the [B
display will read;
LT. SWING OFF [B Exit
RT. SWING OFF

LEFT SWING.
~
LT. SWING 300 SET
(set both alarms)
[B LT SWING 300 SET
(SET BOTH ALARMS)
Both alarms must be set for the system to [B RTSWING OFF

operate correctly.
Pressing the LT. SWING push-button again will

[B
cancel the alarm and the display will read:
LT. SWING OFF
[B Exit
SETTING RIGHT SWING ALARM ~

• Swing the boom to the desired Right Swing
Limit, e.g. 30 degrees.
• Press the push-button pointing to RIGHT

SWING.
• The display will read RIGHT SWING 30 SET
Pressing the RT. SWING push-button again will

cancel the alarm and the display will read
[B LT. SWING 300 SET
RT. SWING OFF

[B RT. SWING 30 SET
The red warning light will flash and the audible

alarm will sound whenever the boom swings [B
past the pre-set limits.
[B Exit
21 of 24 PN W450200 REV A
OPERATORS MANUAL

WORK AREA SELECTION MODE
This alarm, when set, permits the operator to define an Operating Zone by only two set points.
The use of this method of setting results in a greatly enhanced working area and also clearly
defines the Exclusion Zone area more simply. The following diagram illustrates the Operating Zone and
the Exclusion Zone.
Operator Area Alarm and Operating Zones
Operating Zone Operating.Zone

Set Point 2
" " ~Set

.
Point 1
EXCLUSION ZONE.
EXCLUSION ZONE
The operator defined work area alarm, when set, will define an imaginary vertical plane between two set
points to optimize the working area. When passing the plane the red warning lamp will
illuminate, the audio alarm will sound and the message "EXCLUSION ZONE" will flash
on the display.
WARNING
The operator defined work area alarm is a warning device. All functions remain operational when entering
the operator defined Exclusion Zone. "Safe Working Distance" is the time it would take an operator to
react to an alarm and for the machine motion to be halted before entering the Exclusion Zone. It is the
responsibility of the operator to set points that ensure that the cranes boom, attachment, load, rigging etc.
maintains a safe working distance from the obstacle. Avoid positioning the boom, attachment, load, rig-
ging etc. in the Exclusion Zone when setting the left or right alarm points. When selecting the left and right
alarm points ensure that the load will maintain a safe distance from the obstacle. If the crane or obstacle is
moved or if a different size load is lifted the work area alarm must be reset
22 of 24 PN W450200 REV A
OPERATORS MANUAL
WORK AREA SELECTION MODE NOTE: For best results, the Left and Right points
should be separated by a minimum of 10ft or 30
degrees.
ACCESSING WORK ALARMS
• To access the Work Area Alarms from the

main working screen press any push-button
to the left of the 3"x3" INFORMATION
SCREEN (ITEM 5). The Information Screen
will show the available choices.
[B Set Operator Alarms

[B Set Jib Selection
Set Swing/Work Alarms

[B Set Swing/Work Alarms
• If no choice is made the system will return to
the main working screen after 30 seconds or
you can return to the main screen by push-
[B Return to main screen
ing the Return to main screen push-button.
• If the alarms have not been previously set

then the display will read;
Swing Alarms
Swing alarms LT. SWING OFF
LT. SWING OFF
RT. SWING OFF
RT. SWING OFF
Work Area Select Mode
Work Area Sel Mode
LT. POINT OFF
RT. POINT OFF LT. POINT OFF
If no choice is made the system will return to the RT. POINT OFF
main working screen after 30 seconds or you Exit
can return to the main screen by
pushing the Exit push-button.
23 of 24 PN W450200 REV A
TEREX RCI 500 RATED CAPACITY INDICATOR W450200
OPERATORS MANUAL Rev. A

SETTING LEFT AND RIGHT ALARM POINTS
• Move the boom, attachment, load, rigging Swing Alarms

etc. to the desired Left Alarm Point. LT. SWING OFF
• Access the operator alarm screen. RT. SWING OFF

If the alarms have not been previously set, Work Area Sel Mode
the display will read;
LT. POINT OFF
Swing alarms
LT. SWING OFF
RT. SWING OFF RT. POINT OFF
Exit
Work Area Select Mode
LT. POINT OFF
RT. POINT OFF

LT. POINT
The display will read: Swing Alarms
LT. SWING OFF
• LT. POINT SET
(set both alarms)
RT. SWING OFF
Both alarms must be set for the system to Work Area Sel Mode
operate correctly. LT. POINT SET
Set both alarms
Pressing the LT. POINT push-button again will RT. POINT OFF
cancel the alarm and the display will read Exit
LT. POINT OFF
• Move the boom, attachment, load, rigging Swing Alarms

etc. to the desired Right Alarm Point. LT. SWING OFF
• Press the push-button pointing to RT. SWING OFF

RT. POINT Work Area Sel Mode
The display will read:
LT. POINT SET
LT. POINT SET
RT. POINT SET RT. POINT SET
Exit
Pressing the RT. POINT push-button again will
cancel the alarm and the display will read
RT. POINT OFF
24 of 24 PN W450200 REV A
GREER COMPANY
~S~----------------------
MICROGUARD®
TEREX Rei 510
TELESCOPIC BOOM CRANES
QQ
o
o
Q
ORs Full 9.7Klb Ctwt 360 0

ERECTED 60' TELEJIB 17 0 AUXHD ON
PICK FROM MAIN BOOM FRONT WINCH
OPERATOR'S MANUAL
GREER COMPANY 1918 EAST GLENWOOD PLACE, SANTA ANA, CA 92705 PN W450250 Rev A 06/01/00
TEREX RCI510 RATED CAPACITY INDICATOR OPERATOR'S MANUAL TEL:(714) 259-9702 FAX:(714) 259-7626
1 of 35
GREER COMPANY
~S~------------
TABLE OF CONTENTS
Introduction
Outline of Operation ..................................................................................................................... 4
What Does It Tell You?
The Pictograph ............................................................................................................................. 5
Information Screen ...................................................................................................................... 6
Parts-ot-Line Indicator ................................................................................................................. 6
Operator Alarms Indicator ............................................................................................................ 6
Pre-Alarm Indicator ...................................................................................................................... 6
Overload Indicator ....................................................................................................................... 6
Anti Two-Block Indicator .............................................................................................................. 6
Bar Graph for Percentage of Rated Load .................................................................................... 7
Actual Load .................................................................................................................................. 7
Rated Capacity ............................................................................................................................ 7
Radius, Length, Angle ................................................................................................................. 7
What Must You Tell It?
Parts-ot-Line ................................................................................................................................ 8
Point of Lift ................................................................................................................................... 8
Auxiliary Head On or Ott .............................................................................................................. 8
Stowed and/or Erected Attachments ........................................................................................... 8
Manual Section or Boom Mode ................................................................................................... 8
Jib Stowed on Boom .................................................................................................................... 8
Winch ........................................................................................................................................... 8
Counterweight .............................................................................................................................. 8
Tires ............................................................................................................................................. 8
Outriggers .................................................................................................................................... 8
Power Up Self-Test ................................................................................................................................. 9
Start-Up Screen ..................................................................................................................................... 10
Brightness and Contrast Controls ...................................................................................................... 11
System Setup
Counterweight ............................................................................................................................ 12
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Outriggers .................................................................................................................................. 13
Tires/Rigging Travel Mode ......................................................................................................... 14
Stowed Jibs ................................................................................................................................ 15
Erected Jibs ............................................................................................................................... 16
Auxiliary Head ............................................................................................................................ 17
Choosing the Winch ................................................................................................................... 18
Choosing the Point of Lift. .......................................................................................................... 19
Setting the Parts-of-Line ............................................................................................................ 20
Notes .......................................................................................................................................... 21
Cancel Alarm
Push Button to Cancel Audible Alarm ....................................................................................... 22
Reset Function Kick-Out ............................................................................................................ 23
Operator Settable Alarms
Accessing the Operator Alarms ................................................................................................. 24
Setting Minimum and/or Maximum Boom Angle ....................................................................... 25
Setting Maximum Length, Maximum Height.. ............................................................................ 26
Accessing Swing and Work Area Alarms .................................................................................. 27
Swing Alarms ............................................................................................................................. 28
Setting the Left and Right Swing Alarms ................................................................................... 29
Work Area Selection Mode ................................................................................................... 30-31
Glossary ............................................................................................................................................ 32-35
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OUTLINE OF OPERATION
SYSTEM COMPONENTS EXTENSION SENSOR
• MicroGuard® Display Unit The extension sensor provides an increasing voltage
• MicroGuard® Computer Unit proportional to the extension of the boom. A cable
• Pressure Transducers attached to the boom head provides a low current
electrical path for the A2B signal
• Extension Reel with length and angle sensors
• Anti 2-Block (ATB) switches PRESSURE TRANSDUCERS
• Cables Two pressure transducers measure the pressure in

• Installation/Operator Manuals the boom hoist cylinder. The resultant Total Moment
signal is processed to provide a continuous display of
The MicroGuard® TEREX RCI 510 System is intended
the load suspended below the point of lift.
to aid the crane operator by continuously monitoring
the load and warning of an approach to an overload ANTI TWO BLOCK (A2B)
or Two-Block condition. Crane functions are
A switch monitors the approach of the hookblock or
monitored by means of high accuracy sensors. The
overhaul ball to the boom head. The switch is held in
system continuously compares the load suspended
the normal position until the hookblock or overhaul
below the boom head with the crane capacity chart
ball raises a weight that is mounted around the hoist
stored in the computer memory. At approach to
rope. When the weight is raised, it causes the switch
overload, the system warns by means of audible and
to operate. The resultant signal is sent to the
visual alarms. The system can be configured to cause
computer via the extension reel causing the A2B
function kick-out by sending a signal to function
alarm to operate and function kick-out to occur.
disconnect solenoids.
FUNCTION KICK-OUT
DISPLAY
The operator is provided with a continuous display of: Electrically operated solenoids disconnect the control
lever functions for boom hoist lower, telescope out,
• Rated Load
and winch up whenever an overload or an A2B
• Actual Load condition occurs.
• Bar Graph showing Percentage of Rated Load
• Radius of the Load
These alarms, when properly set by the operator,
• Boom Angle
define the operating range. This is achieved by
• Main Boom Length means of minimum and maximum angle, maximum
• Working Area height, and/or maximum length. These alarms can be
• Crane Configuration programmed for each job site and allow the operator
to work in a defined area.
On-screen messages provide the operator with visual
warnings of conditions that occur during operation of AREA ALARM
the system. When set, this alarm permits the operator to define
BOOM ANGLE SENSOR the operating zone by only two set points. The use
Boom angle is measured by means of a high- of this method of setting results in a greatly enhanced
accuracy potentiometer/pendulum assembly that is working area, and also clearly defines the
damped to prevent overswing. It provides a voltage operating zone.
proportional to boom angle. The boom angle sensor is
mounted inside the cable extension reel assembly.
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THE PICTOGRAPH
MANUAL SECTION
/ BOOM MODE STOWED JIB WINCH
JIBS
AUX HEAD
POINT OF LIFT TIRES
OUTRIGGERS
The PICTOGRAPH gives a pictorial representation of the current setup of the system. It does this by means of light
emitting diodes (LEOs). Each shaded area contains a group of one or more LEOs and a push button that is pressed
to change the setup selection. In the groups with more than one choice or option, LED's illuminate one at a time to
indicate the selection. The groups are shown below.
OUTRIGGERS - contain 3 LEOs. These indicate the STOWED JIB - contains 1 LED. This will be
selection of either full outriggers, intermediate, or illuminated when the jib is stowed on the boom.
retracted outriggers.
MANUAL SECTION - contains 1 LED. It is
TIRES - contain 1 LED. When operation on tires is active on cranes that have pinned extensions or
selected, the outrigger LED will turn off and the tire active tip boom options.
LED will illuminate.
JIBS - contain 6 LEOs. These indicate the length
COUNTERWEIGHT - contains 1 LED. It is only active and offset of the jib in use.
on cranes that have counterweight options.
AUX HEAD - contains 1 LED that illuminates
WINCH - contains 2 LEOs. These indicate the when the AUX HEAD is fitted.
selection of FRONT or REAR winch.
POINT OF LIFT - contains 3 LEOs. One will
illuminate to show the point of lift.
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360
AUXHD ON
fRONT WINCH
1. The INfORMATION SCREEN contains 5. The OVERLOAD INDICATOR (RED)

details of the currently selected illuminates at a preset value of 100% of
configuration. Rated Capacity and provides a visual
indication of Maximum Allowed Load.
2. PARTS-Of-LINE displays the parts of line
currently selected. 6. The ANTI TWO-BLOCK lamp illuminates
when the A2B limit switch detects approach
3. The OPERATOR ALARM lamp illuminates
to a Two-Block condition.
when operator alarms have been set.
4. The PRE-ALARM (AMBER) indicator

illuminates at a preset value of 90% of
Rated Capacity and provides a visual
indication of approach to overload.
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ERECTED 6 TELEJ IB 17 0 AUXHD ON
PICK FROM IN BOOM FRONT WINCH
7. The BAR GRAPH indicates the ACTUAL 11. The LENGTH display shows the length of
LOAD as a PERCENTAGE OF RATED the main boom from the boom foot pin to the
CAPACITY. sheave pin of the main boom head
machinery.
8. The ACTUAL LOAD display shows total
load, including load, slings, etc. suspended 12. The ANGLE display indicates, in degrees,
below the lifting point. the angle of the main boom relative to
horizontal.
9. The RATED CAPACITY display shows the
RATED CAPACITY of the crane in the
current configuration.
10. The RADIUS display shows radius of the

load. Radius is the horizontal distance from
the centerline of rotation to the centerline of
the lifting point.
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WHAT MUST YOU TELL IT?
ORs Full
ERECTED 60' TELEJIB
PICK FROM MAIN BOOM
13. The number of PARTS-OF-LiNE. 19. Indicates which WINCH will be used for the
pick.
14. POINT OF LIFT, e.g. main boom, auxiliary
head or jib. 20. Indicates which COUNTERWEIGHT is fitted
(if applicable).
15. AUXILIARY HEAD ON or OFF the crane.
21. TIRES creep, static, 2 1/2 MPH, and
16. Indicates JIB configuration in use.
RIGGINGITRAVEL mode.
17. MANUAL SECTION or ACTIVE TIP
22. OUTRIGGERS full extension, mid
extended (if applicable).
extension, or retracted.
18. JIB STOWED ON BOOM.
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POWER UP SELF-TEST
QQ
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TEREX CD 225
SYSTEM SELF TEST IN PROGRESS
CHART 12262-1205/20W
Immediately following electrical power up or following operation of the TEST switch (item 26), the system
executes a self-test that last for 8 seconds. During this time, the numerical display segments and
bar graph segments are all turned on, the audible alarm will sound, and alarm indicator lights are
illuminated.
The information display shows the crane model and rating chart number.
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START UP SCREEN
READ/UND AND THE

CIMA MANUAL,ASME/ANSI 830.5
OSHA REGS AND OPERATORS MANUAL
PRESS TO CONTINUE>
Immediately following power up self-test, the display indications will show as above. During this time,
crane motions are disabled by the system function kickout. Operation of the bottom right information
display push button (item 27) will acknowledge the information display message and allow the system to
start normal operation.
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BRIGHTNESS AND CONTRAST CONTROLS
LED BRIGHTNESS UP CONTRAST UP
LED BRIGHTNESS DOWN CONTRAST DOWN
Immediately following self-test and the start up screen, the information display will display a 2 second
reminder of the brightness and contrast control functions.
Push buttons to the left of the information display (item 25) allow the brightness of all LED's on the display
panel to be adjusted up or down at any time during operation of the system unless operator alarms are
being set.
Push buttons to the right of the information display (item 27) allow the contrast of the information display
to be adjusted up or down at any time during operation of the system unless operator alarms
are being set.
During adjustment of the contrast or brightness, the information window will automatically display the
reminder window shown.
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SYSTEM SETUP
9,7001b Counterweight
12,OOOlb Counterweight
COUNTERWEIGHT
IF THE COUNTERWEIGHT PUSH BUTTON IS • The available counterweight options will be
PRESSED ON A CRANE THAT DOES NOT displayed in the information screen (1). There
HAVE COUNTERWEIGHT OPTIONS, THE can be four options displayed at a time, one next
MESSAGE "NO OTHER COUNTERWEIGHT to each selection key.
OPTIONS" WILL APPEAR IN THE
)0- If the required option is visible,
INFORMATION DISPLAY. REFER TO YOUR
select the option by pressing the
CRANE RATING MANUAL FOR DETAILS OF
button next to it.
THE OPTIONS ON YOUR CRANE
)0- If more than 4 options are available,
• On cranes that have counterweight options the
a second selection screen can be
operator must tell the MicroGuard® System
viewed by pressing the button next
which counterweight is currently fitted. If there
to the "next" label.
are no options, continue on to selection of
outriggers. )0- If only a single option is available, it
will automatically be selected.
• Start the choice by pressing the counterweight
push button (item 20).
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SYSTEM SETUP
ORs Full 9.7Klb Ctwt

ERECTED 60' TELEJIB 170
PICK FROM MAIN BOOM
OUTRIGGERS
• The operator must tell the system which • The outrigger selection will automatically
outrigger position is in use. move on to the next selection.
EXAMPLE:
• Start the choice by pressing the outrigger
From fully extended to half extended, or
from half-extended to fully retracted and
then back to fully extended with each push
of the button. If no other selections are
available, the message "No other chassis
options" will appear on the information
screen (item 1).
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SYSTEM SETUP
TIRES, 2.5MPH, FRONT RIGGING/TRAVEL
STATIONARY
TIRES/RIGGING TRAVEL
There can be four options displayed at a
IF THE TIRE PUSH BUTTON IS PRESSED ON
time, one next to each selection key.
A CRANE THAT DOES NOT HAVE TIRE
OPTIONS THE MESSAGE "NO OTHER TIRE )0- If the required option is visible,
OPTIONS" WILL APPEAR IN THE select the option by pressing the
INFORMATION DISPLAY. REFER TO YOUR button next to it.
THE OPTIONS ON YOUR CRANE.
• On cranes that have more than one tire viewed by pressing the button next
option, e.g. static, creep etc., the operator to the "next" label.
must select the tire configuration that
)0- If only a single option is available, it
corresponds to the tire chart to be used.
• Start the choice by pressing the tire push
• RIGGINGITRAVEL MODE is selected when
button (item 21).
the crane is in the rigging process or is a
• The available tire selection options will be rough terrain crane traveling between jobs.
displayed in the information screen (item 1).
&. WARNING
DO NOT PERFORM CRANE LIFTING OPERATIONS WHILE
THE RIGGINGITRAVEL MODE IS SELECTED.
ALL CRANE CONTROLS REMAIN ACTIVE WHILE THE

RIGGINGITRAVEL MODE IS SELECTED.
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SYSTEM SETUP
NO STOWED JIB
60' TELEJIB STOWED
STOWED JIBS
IF THE STOWED JIB PUSH BUTTON IS • The available stowed jib options will be
PRESSED ON A CRANE THAT DOES NOT displayed in the information screen (1).
HAVE JIB OPTIONS, THE MESSAGE "NO There can be four options displayed at a
OTHER STOWED OPTIONS" WILL APPEAR time, one next to each selection key.
IN THE INFORMATION DISPLAY. REFER TO
);> If the required option is visible,
YOUR CRANE RATING MANUAL FOR
select the option by pressing the
DETAILS OF THE OPTIONS ON YOUR
button next to it.
CRANE.
);> If more than 4 options are available,
• On cranes that have more than one jib
option (fixed, offset, or telejib etc.), the
viewed by pressing the button next
operator must select the jib to be used.
to the "next" label.
• Start the choice by pressing the stowed jib
);> If only a single option is available, it
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SYSTEM SETUP
38' JIB@2degs 38' JIB@17degs

38' JIB@30degs MORE >
ERECTED JIBS
IF THE ERECTED JIB PUSH BUTTON IS There can be four options displayed at a time,
PRESSED ON A CRANE THAT DOES NOT one next to each selection key.
HAVE JIB OPTIONS, THE MESSAGE "NO )0- If the required option is visible,
OTHER JIB OPTIONS" WILL APPEAR IN THE select the option by pressing the
INFORMATION DISPLAY. REFER TO YOUR button next to it.
THE OPTIONS ON YOUR CRANE.
• To erect a JIB, it must first have been viewed by pressing the button next
selected and stowed as detailed on the to the "next" label.
previous page. )0- If only a single option is available, it
• Start the choice by pressing the erected jib will automatically be selected.
• The available erected jib options will be

displayed in the information screen (item 1).
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SYSTEM SETUP
ORs Full 9.7Klb Ctwt 360

AUXILIARY HEAD
IF THE AUXILIARY HEAD PUSH BUTTON IS An auxiliary head fitted on a crane must be
PRESSED ON A CRANE THAT DOES NOT included in the crane setup.
HAVE AN AUXILIARY HEAD, THE MESSAGE
To set up the crane with an auxiliary head, press
"NO OTHER AUXILIARY HEAD OPTIONS"
the auxiliary head push button, (item 15).
WILL APPEAR IN THE INFORMATION
This will toggle the auxiliary head on and off
SCREEN (ITEM 1).
each time the button is pressed.
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SYSTEM SETUP
QQ
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ERECTED 60 TELEJ IB 17 0
I AUXHD ON
CHOOSING THE WINCH
For cranes with two winches, always select the winch to be used for the lift before selecting the point of lift
and parts of line. The system stores point of lift and parts of line selections for each winch.
• Choose the winch to be used by pressing This toggles between the two available
the winch push button (item 19). winches each time the button is pressed.
If no other winch is available, the message
"No other winch options" will appear for
three seconds on the information screen
(item 1).
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SYSTEM SETUP
gg
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ERECTED 60 TELEJIB 17 0
1
AUXHD ON
CHOOSING THE POINT OF LIFT

Before choosing the point of lift, check that the correct winch has been selected.
Always check the point of lift selection following selection of the winch.
• Choose the point of lift to be either from the );> If an option is not available, it will be
main boom, auxiliary head, or jib by pressing skipped over.
the point of lift push button (item 14).
);> If no other pick point options are
This action moves the selected lifting point
available, the message "No other pick
to the next available lifting point, i.e. from jib
point options" will be displayed on the
to aux head, from aux head to main boom,
information screen (item 1).
and from main boom back to jib again.
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SYSTEM SETUP
99
o
o
9
ORs Full 9.7Klb Ctwt 360

SETTING THE PARTS-Of-LINE
Always check and select parts-of-line following selection of the winch and point of lift.
• Set the PARTS-OF-LiNE for the currently • When another winch is selected, it may be
selected winch by pressing the UP or necessary to reset the parts-at-line tor the
DOWN arrow, as appropriate. (item 13). other winch.
• The number of parts-of-line will appear in • When the number of parts in the parts-ot-
the parts-at-line display (item 13). line on the crane is changed, it will be
necessary to reset the parts-at-line on the
display.
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SYSTEM SETUP
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NOTES
The system has the capability of remembering all of the configuration data
previously set. After removing power to the system and then powering up again,
the settings remain intact until reset by the operator.
• After the configuration has been set, the operation of the System
depends only upon setting which winch is in use. Changing the winch
will automatically change the lifting point and the parts-of-line to the
values previously set for the selected winch. Always check the point of
lift and parts-of-line following selection of the winch.
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CANCEL AUDIBLE ALARM
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9.7Klb Ctwt 360

PUSH BUTTON TO CANCEL AUDIBLE ALARM

The cancel alarm push button (item 23) is (such as overload) is removed and then
used to silence the audible alarm. Pressing this recurs, the new alarm condition will cause
button once will cancel an audible alarm that the audible alarm to sound again.
has occurred as a result of an:
The CANCEL ALARM push button is also used
Overload
to reset the function kick-out relay when it is
A2B Alarm necessary to bypass the function disconnects.
Operator Settable Alarm Examples of when it may be necessary to
override a function disconnect condition are:
The audible alarm remains canceled until the
condition that caused the alarm has been If the boom hoist cylinder is fully extended, the
removed. See page 23. pressure in it will rise. This will be seen by the
system as an overload and will not allow the
EXAMPLES:
operator to boom down. Using the bypass is
AFTER CANCELING AN AUDIBLE ALARM: necessary in this situation to move away from
• If the audible alarm sounded because of an the fully extended boom hoist cylinder position.
overload condition, the alarm will remain
canceled until the condition is corrected.
• If another alarm condition occurs that
normally causes an alarm to sound (such
as A2B) or if a previous condition
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CANCEL AUDIBLE ALARM CONTINUED
gg
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9.7K twt
60' TELEJIB 17 0
RESET FUNCTION KICK-OUT
&.
When the crane is to be rigged, it is often
necessary to put the boom in a position that
could cause function kick-out. Using the bypass WARNING
is necessary in this situation.
Press and release and then press and hold WHEN THE FUNCTION DISCONNECT RELAY
the CANCEL ALARM push button (item 23)
IS RESET BY MEANS OF THE CANCEL
for approximately 5 seconds to reset the
ALARM PUSH BUTTON, THERE IS NO
relay. At this time a second beep is heard
confirming the bypass. When the condition LONGER PROTECTION AGAINST THE
that caused the alarm is no longer present, CONDITION THAT CAUSED THE FUNCTION
the function disconnect relay will reset to the KICK-OUT.
normal condition. Should a different alarm
condition occur while the relay is over-
ridden, the new alarm condition will cause
the controls to disconnect again.
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OFF MAX ANGLE OFF
MAX LENGTH OFF MAX HEIGHT OFF
ACCESSING THE OPERATOR ALARMS
To access the Operator Alarms from the main Each push button operates as a toggle switch
working screen, press the operator alarms push turning the alarm "ON" or "OFF."
button (item 24). The Information Screen will
To activate or deactivate an alarm:
then show the current status of the alarms.
• If the alarm is OFF, press the
The four operator alarms are shown below appropriate push button to turn the
followed by the number identity of the push alarm ON.
button that controls each alarm. These buttons • If the alarm is ON, press the
are called out in the illustration above. appropriate push button to turn the
alarm OFF.
Minimum Boom Angle (item 28)
Maximum Boom Angle (item 29) Refer to page 25 for a discussion on minimum
Maximum Boom Length (item 25) and maximum boom angles and page 26 for
maximum boom length and maximum tip height.
Maximum Tip Height (item 27)
Return to the main screen by pressing the

operator alarm push button (item 24) two
times.
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OPERATOR SETTABLE ALARMS CONTINUED
SETTING MINIMUM BOOM ANGLE ALARM SETTING MAXIMUM BOOM ANGLE ALARM
• Move the boom to the desired minimum angle

(in this example 32°). • Move the boom to the desired maximum
Press the operator alarm push button (item 24) angle (in this example 6]0).
to access the operator alarm screen. • Press the operator alarm push button (item
• Press the push button (item 28) pointing to Min 24) to access the operator alarm screen.
Angle. In this example the display will read • Press the push button (item 29) pointing to
MIN ANGLE 32°. Max Angle. In this example the display will
• The red warning light (item 5) will flash and the read MAX ANGLE 67°.
audible alarm will sound whenever the boom • The red warning light (item 5) will flash and
angle is below 32°. the audible alarm will sound whenever the
Pressing the MIN ANGLE push button again will boom angle is above 67°.
cancel the alarm and the display will read Pressing the MAX ANGLE push button
MIN ANGLE OFF again will cancel the alarm and the display
will read MAX ANGLE OFF.
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OFF MAX ANGLE OFF
58.0 MAX HEIGHT 78.0
SETTING MAXIMUM BOOM LENGTH ALARM SETTING MAXIMUM TIP HEIGHT ALARM
• Move the boom to the desired maximum • Move the boom to the desired maximum
length, in this example 58 ft. height, in this example 78 ft.
• Press the operator alarm push button (item • Press the operator alarm push button (item
24) to access the operator alarm screen. 24) to access the operator alarm screen.
• Press the push button (item 25) pointing to • Press the push button (item 27) pointing to
Max Length. In this example the display will Max Height. In this example the display will
read MAX LENGTH 58 FT. read MAX HEIGHT 78 FT.
• The red warning light (item 5) will flash and • The red warning light (item 5) will flash and
the audible alarm will sound whenever the the audible alarm will sound whenever the
boom length exceeds 58 ft. boom tip height exceeds 78 ft.
Pressing the MAX LENGTH push button again
Pressing the MAX HEIGHT push button again
MAX LENGTH OFF.
MAX HEIGHT OFF.
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LEFT SWING OFF RIGHT SWING OFF
LEFT POINT OFF RIGHT POINT OFF
ACCESSING SWING AND

WORK AREA ALARMS Each push button operates as a toggle switch. If
To access the SWING AND WORK AREA the alarm to be set is OFF, pressing the push
ALARMS from the main working screen, press button will turn the alarm ON. If the alarm to be
the OPERATOR ALARM push button (item 24) set is ON pressing the push button will turn the
2 times. alarm OFF.
The Information Screen will show the current When Operator Alarms are set, the light in the
status of the Swing and Work Area Alarms. push button (item 24) will be illuminated.
There are 4 separate operator alarms, all Return to the main screen by pressing the
controlled by push buttons (items 25, 27, 28, OPERATOR ALARM push button (24).
and 29). Each one of these push buttons relates
to the alarm to which it points.
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SWING ALARMS
These alarms, when set, permit the operator to define a Working Arc and an Exclusion Zone by two set
points. The following diagram illustrates the Working Arc and Exclusion Zone.
WORKING ARC AND EXCLUSION ZONE
Right Swing
A left swing alarm is activated when

, WORKING ARC
swinging to the left.
Left Swing'
A right swing alarm is activated when
swinging to the right
EXCLUSION ZONE
In this example, the working arc is the
smaller piece of the pie.
WORKING ARC AND EXCLUSION ZONE

A left swing alarm is activated when
Left Swing
swinging to the left.
A right swing alarm is activated when

Right Swing swinging to the right
In this example, the working arc is the larger

WORKING ARC
piece of the pie.
&. WARNING
THE OPERATOR DEFINED SWING ALARM IS A WARNING DEVICE. ALL FUNCTIONS REMAIN OPERA-
TIONAL WHEN ENTERING THE OPERATOR DEFINED EXCLUSION ZONE. IT IS THE RESPONSIBILITY OF
THE OPERATOR TO SET SWING ALARMS THAT ENSURE THAT THE CRANES BOOM, ATTACHMENT,
LOAD, AND RIGGING ETC. MAINTAINS A SAFE WORKING DISTANCE FROM THE OBSTACLE. AVOID POSI-
TIONING THE BOOM, ATTACHMENT, LOAD, AND RIGGING ETC. IN THE EXCLUSION ZONE WHEN MOVING
TO THE LEFT AND RIGHT SWING POINTS. WHEN SELECTING LEFT AND RIGHT SWING POINTS ENSURE
THAT THE LOAD WILL MAINTAIN A SAFE DISTANCE FROM THE OBSTACLE. IF THE CRANE OR OBSTACLE
IS MOVED OR IF A DIFFERENT SIZE LOAD IS LIFTED THE SWING ALARMS MUST BE RESET.
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LEFT SWING 325 RIGHT SWING
LEFT POINT OFF RIGHT POINT OFF
SETTING LEFT SWING ALARM SETTING RIGHT SWING ALARM
• Swing the boom to the desired Left Swing • Move the boom to the desired Right Swing
Limit, e.g. 325°. Limit, e.g. 35°.
Press the operator alarm push button (item
• Press the Right Swing push button (item
24) 2 times to access the swing alarm
29). The information screen (item 1) will
screen.
read RIGHT SWING 35°.
• Press the push button (item 28) pointing to
The red warning light (item 5) will flash and the
Left Swing. The information screen (item 1)
audible alarm will sound whenever the boom
will read LEFT SWING 325°.
swings past the preset limits.
Both Left and Right Swing Alarms must be set
Pressing the LEFT SWING and RIGHT SWING
for the system to operate correctly. The red
push buttons again will cancel the alarm and the
warning light (item 5) will flash and the audible
information screen (item 1) will read:
alarm will sound whenever only one of the
LEFT SWING OFF RIGHT SWING OFF.
left/right swing limits is set.
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This alarm, when set, permits the operator to define an Operating Zone by only two set points. The use of
this method results in a greatly enhanced work area and also clearly and simply defines the Exclusion
Zone area. The following diagram illustrates the Operating Zone and the Exclusion Zone.
Operator Area Alarm and Operating Zones
Operating Zone Operating Zone

Set Point 2
" " ~Set

. Point 1
EXCLUSION ZONE.
EXCLUSION ZONE
The operator defined work area alarm, when set, will define an imaginary vertical plane between two set
points to optimize the working area. When passing the plane, the red warning lamp will illuminate, the
audio alarm will sound, and the message "EXCLUSION ZONE" will flash on the display.
&. WARNING
THE OPERATOR DEFINED WORK AREA ALARM IS A WARNING DEVICE. ALL FUNCTIONS REMAIN OPERATIONAL WHEN
ENTERING THE OPERATOR DEFINED EXCLUSION ZONE. "SAFE WORKING DISTANCE" IS THE TIME IT WOULD TAKE AN
OPERATOR TO REACT TO AN ALARM AND FOR THE CRANE MOTION TO BE HALTED BEFORE ENTERING THE EXCLU-
SION ZONE. IT IS THE RESPONSIBILITY OF THE OPERATOR TO SET POINTS THAT ENSURE THAT THE CRANE BOOM,
ATTACHMENT, LOAD, RIGGING, ETC. MAINTAINS A SAFE WORKING DISTANCE FROM THE OBSTACLE. AVOID
POSITIONING THE BOOM, ATTACHMENT, LOAD, RIGGING, ETC. IN THE EXCLUSION ZONE WHEN MOVING TO SET
POINTS 1 AND 2. WHEN SELECTING SET POINTS 1 AND 2, ENSURE THAT THE LOAD WILL MAINTAIN A SAFE DISTANCE
FROM THE OBSTACLE. IF THE CRANE OR OBSTACLE IS MOVED, OR IF A DIFFERENT SIZE LOAD IS LIFTED, THE WORK
AREA ALARM MUST BE RESET.
30 of 35
GREER COMPANY
~S~------------
o
g
LEFT POINT SET RIGHT POINT SET
• Press the operator alarm push button (item • Move the boom, attachment, load, rigging
24) two times to access the Work Area etc. to the desired RIGHT SET POINT.
alarm screen.
• Press the push button (27) pointing to Right
SETTING POINTS 1 AND 2 Point. The information screen (item 1) will
read RIGHT POINT SET.
• Move the boom, attachment, load, rigging
etc. to the desired LEFT SET POINT. The red warning light (item 5) will flash and the
audible alarm will sound whenever the boom tip
• Press the push button (item 25) pointing to
penetrates the exclusion zone.
Left Point. The information screen (item 1)
will read LEFT POINT SET. Pressing the LEFT POINT and RIGHT POINT
push buttons (25 & 27) again will cancel the
Both Left and Right Points must be set for the
alarm and the information screen (item 1)
system to operate correctly. The red warning
will read
light (item 5) will flash and the audible alarm will
sound whenever only one of the left/right swing LEFT POINT OFF RIGHT POINT OFF
limits is set.
31 of 35
GREER COMPANY
~S~------------
GLOSSARY OF TERMS
ACTUAL LOAD The load suspended below the lifting point.
ALARM A signal that warns or alerts, such as a flashing light or loud noise.
ANGLE SENSOR A device that measures the inclination of a boom.
ANTI TWO-BLOCK A device that, when activated, prevents movement that causes two-
blocking.
AUDIBLE ALARM A signal that alerts by means of noise.
AUXILIARY HEAD A short jib fitted at the main boom head that is used to provide
(AUXHD) separation of the main and auxiliary ropes when both are reeved over the
main boom head.
AUXILIARY HOIST A separate hoist rope system other than the main hoist.
(AUX HOIST)
BARGRAPH A pictorial device used to illustrate quantitative relationships.
BOOM A member hinged to the upperstructure that supports the hoisting tackle.
BOOM ANGLE The angle of the longitudinal axis of the boom relative to horizontal.
BOOM HOIST A device for controlling the boom angle.
BOOM LENGTH The length of the boom along its longitudinal axis from the foot pin to the
axle of the head machinery.
BOOM MOMENT The turning moment around the boom pivot caused by the moment of the
unladen boom.
CAPACITY CHART A table showing the rating of a crane.
CENTER LINE OF The vertical axis around which the crane upperstructure rotates.
ROTATION
CENTER OF GRAVITY The point at which the entire weight of a body may be considered as con-
centrated so that if supported at this point the body would remain in equilib-
rium in any position.
COMMISSIONING Preparing to be put into service.
CONFIGURATION An arrangement of the lifting elements of a crane.

32 of 35
GREER COMPANY
~S~------------
COUNTERWEIGHT A weight used to supplement the weight of the crane to provide
(CTWT) stability for lifting.
CURSOR A pointer on a display that indicates the position where data is to be

entered.
DEDUCT A reduction in rated capacity for an unused stowed or erected

attachment.
DIRECTION The direction of rotation of the superstructure.
DUTY A working configuration on a crane usually contained in a single column of a

capacity chart.
ERECTED ATT ACH- An attachment on the main boom fitted in its working position.
MENT
EXTENSION SENSOR A device that measures the extension of the telescoping sections of a boom.
FUNCTION KICK-OUT A device that disengages certain crane functions whose movement could
cause overload or two-blocking.
HEIGHT The vertical distance from the ground to the tip of the boom or attachment.
HORIZONTAL Parallel to the horizon.
INFORMATION SCREEN A display that gives information supplemental to the information on the
pictograph.
INTEGRATED CIRCUITS A tiny complex of electronic components and connections on a small slice of
material (such as silicon).
JIB Something attached such as a lattice fly or jib on a crane boom.
MANUAL SECTION The tip section of the main boom that can be telescoped independently of
the other sections.
MICROPROCESSOR A computer processor contained on an integrated chip.
MOMENT The product of force and distance to a particular axis or point.
OPERATOR ALARMS Alarms that can be set by the operator, which provide working limits
additional to the chart limits.
OUT OF DUTY A point which is either longer than the longest permitted radius or lower than
the lowest permitted angle on a capacity chart
33 of 35
GREER COMPANY
~S~------------
OUTRIGGER (ORs) A support projecting from a main structure used to provide additional
stability.
OVERLOAD The point at which the actual load exceeds the rated capacity of the crane.
PARTS OF LINE The number of parts of hoist rope between the upper and lower blocks.
PICTOGRAPH A pictorial representation of the crane.
POINT OF LIFT The location of the hoist rope for the current lift e.g. main boom, auxiliary
head or jib.
PRE-ALARM The point at which the actual load is 90% of the rated capacity of the crane.
PRESSURE Hydraulic pressure in the boom hoist cylinder
RADIUS The horizontal distance from the centerline of rotation to the center of the
hook.
RATED CAPACITY The lifting capacity of a crane, as determined by the published capacity
chart.
RATED CAPACITY The load that a crane can safely handle based on factors such as strength,
stability, and rating.
RATING A factor determined by legislation that limits the proportion of the

capability of the cranes that may be utilized in a lifting operation.
Usually expressed as a percentage of strength or stability.
REEVING A rope system in which the rope travels around drums and sheaves.
ROPE LIMIT The maximum permitted single line pull determined by the construction and
diameter of a wire rope.
ROPE LIMIT A condition that occurs when the type of rope and the parts-ofline in use
restrict the capacity of the crane.
SENSOR A device that responds to physical stimulus and transmits a resulting

impulse.
SHEAVE A grooved wheel or pulley.
SLEW OFFSET The horizontal distance from the boom pivot to the center of rotation
STOWED ATTACHMENT An attachment usually stowed on the main boom when not in use.
UPPERSTRUCTURE The structural part of a crane above the carrier, usually rotating.
34 of 35
GREER COMPANY
~S~------------
SWING The rotation of a crane upper around its center line.
SWING ALARMS Audible alarms occurring when the upper structure swings into areas
defined by the operator with the use of Operator Alarms.
SWL (%SWL) Percentage of safe working load. The proportion of the crane capacity which
is being utilized at anyone time expressed as a percentage of rated
capacity
TRANSDUCER A device that is actuated by energy from one system and converts this to
another form for use by a different system (as a loudspeaker, that is,
actuated by electrical signals and supplies acoustic power).
TWO-BLOCKING The condition when the lower load block or hook assembly comes in contact
with the upper load block or boom point.
UNLADEN A boom that has no additional stowed or erected attachments and that is not
supporting a load.
WINCH A hoist drum used in conjunction with a rope for raising and lowering loads.
WORK AREA ALARM Permits the operator to define an operating zone by the means of only two
set points.
35 of 35
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth defects,
and other reproductive harm.
WARNING: Battery posts, terminals, and

related accesories contain lead and lead
compounds, chemicals known to the
State of California to cause cancer and
reproductive harm. Wash hands after
handling.
_DE_T_R_O_IT_D_IE_S_E_L_ _
CORPORATION
@\..\....~
CALIFORNIA PROPOSITION 65 INFORMATION

TO CALIFORNIA CUSTOMERS AND
TO COSTOMERS SELLING DIESEL ENGINE EQUIPMENT
INTO OR FOR USE IN CALIFORNIA
Proposition 65, a California law, requires warnings on products which expose individuals
in California to chemicals listed under the law, including certain chemicals in diesel
engine exhaust.
Obligations of Manufacturers of Diesel-Powered Off-Road Equipment. The California
Superior Court has approved either of the following two methods of compliance with
Proposition 65 requirements by manufactures of off-road equipment containing diesel
engines. (The court order containing these provisions may be furnished on request.)
1. On-Equipment Warning. Place the warning pictured in attachment 1 on all equipment
shipped by you into or for sale in California after January 1, 1996. The warning
must be in a location where it is easily visible to the operator of the equipment when
(s}he is operating the equipment. The warning must be secured to the equipment. If
warnings or operating instructions are provided through a digital display, you may
use that method of providing the warning.
2. Operator Manual Warning. When the operator manual is next revised or by
December 31, 1995, whichever is earlier, place the warning in attachment 2 in the
operator manual. The warning may be either printed in the manual or a sticker.
The warning must appear in one of the following locations.
* Inside the front cover
* Inside the back cover
* Outside the front cover
* Outside the back cover
* As the first page of text
Under either alternative, the warning must appear in the same size, print and format as
the attachment selected or be of equally conspicuous size and format. If the warning
is provided in an on-screen display, the warning must contain the language in the attach-
ment and must be provided at the time of or in connection with ignition in the same man-
ner as other safety warnings electronically communicated on screen.
Obligation of Resellers of Diesel Engines. This letter must accompany any loose diesel
engine sold in California.
Should you have any questions, please call Detroit Diesel Corporation, Mr. John F.
Farmer on (313) 592-7111, Fax (313) 592-5014.

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TEREX~CRANES

OPERATOR AND MAINTENANCE

Revised: May 2002 12261-235

When operating a hydraulic crane, the operator should realize that

Therefore, THE OPERATOR MUST BE GUIDED SOLELY BY THE AP-

Issued: August 2000

OVERALL HEADITAILIBRAKE LIGHTS

HYDRAULIC SYSTEM HORN

AIR SYSTEM CABLE SPOOLING

AXLE LOCKOUT AXLE FLUID

TRANSMISSION SWING REDUCER

ENGINE CRANKCASE DRIVE SHAFTS

FUEL TANK TIRE & WHEEL CONDITION &

MACHINE AIR CLEANER

ATTACHMENT CLUTCH & BRAKE

MUFFLER/EXHAUST WHEEL LUG

ALL CONTROL FAN BELT

INSTRUMENT STRUCTURAL MEMBERS &

CLUTCHES BOOM INSPECTION

WIRE ROPE, SHEAVES BATTERIES &

TWO BLOCK DAMAGE ALCOHOL

LOAD SUPPORTING SWING BEARING

FIRE EXTINGUISHER MACHINERY

BACKUP ALARM LOAD CHART &

INSPECTION CODE INTERVALS NOTES:

Revised: December 2002

ITEM REQUIREMENT DATE

Issued: August 2000

1.UPPERSTRUCTURE The upperstructure weldment, swing mecha-

2. BOOM ATfACHMENT The telescopic crane boom with hydraulic winch,

3. CARRIER The chassis complete, power unit, swing bearing,

4. OUTRIGGERS The beams, cylinders, floats, boxes, hydraulic

Issued: August 2000

Issued: August 2000

Training and Knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 3

Signal Person's Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 5

Responsibilities of All Crew Members . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 6

Planning The Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7

Operator's Safety Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 8

Operator Aids Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 8

Operation Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 9

Power Line Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 10

Slip and Fall Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 - 11

Issued: August 2000

Owners, Users, and Operators:

1. Comply with OSHA, Federal, State, and Local Regulations.

2. Read, Understand, and Follow the instructions in this and other

3. Use Good, Safe Work Practices in a common sense way.

4. Only have trained operators - directed by informed and knowl-

NOTE: OSHA prohibits the alteration or modification of this crane without

THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED!

A READ, UNDERSTAND, AND FOLLOW ALL DANGER,

Issued: August 2000 Page 1-1

DANGER Indicates an imminently

WARNING Indicates a potentially

CAUTION Indicates a potentially

ATTENTION - Indicates a situation which, if