Operator's Manual

Crane Serial Number

The crane serial number is written on the Crane Rating In the event the serial number can not be found on the
Manual located in the lower right interior of the opera­ Crane Rating Manual, the number is stamped on the
tor's cab. The crane serial number should always be top right side of the carrier frame and on the right side of
furnished when ordering parts for the crane, or when the upper frame just below the boom hoist cylinder lug.
corresponding with the distributor or factory regarding This number can then be used to identify the crane.
the crane. The serial number is the only method the
distributor or factory has of ensuring that the correct
parts will be furnished.

BOOK981 J7101122 Preface

Operator's Manual

WARNING
CONSTRUCTION EQUIPMENT CAN BE DANGEROUS
IF IMPROPERLY OPERATED OR MAINTAINED. THIS
CRANE SHOULD BE OPERATED AND MAINTAINED
ONLY BY TRAINED AND EXPERIENCED PEOPLE WHO
HAVE READ, UNDERSTOOD, AND COMPLY WITH THE
OPERATOR'S & MAINTENANCE MANUAL.

The productive life of construction equipment depends that may occur. Any questions pertaining to the care
largely on the care and consideration given to it. This and upkeep of this crane which are not covered in this
especially holds true for hydraulic cranes. This Opera­ manual should be directed to your nearest distributor.
tor's & Maintenance Manual was compiled to explain In addition to this Operator's & Maintenance Manual, a
the procedures and adjustments necessary for proper Parts Manual, Crane Rating Manual, and Safety Manu­
operation of this crane. al are supplied with the crane. Read and understand
A study of this manual will acquaint the operator and all safety guidelines before operating the crane. Addi­
service personnel with the construction of this crane. It tional copies of all manuals are available through your
will enable them to identify and remedy most problems distributor.

Preface
 Operator's Manual
Throughout this manual, reference is made to the left, right, front, and rear pertaining to direction and locations.
These reference directions are relative to the operator, sitting in the operator's seat with the upper directly over the
front of the carrier (single axle to the front), unless otherwise stated.

Danger, warning, and caution captions as well as special notes are used throughout this manual and on the crane to
emphasize important and critical instructions. Labels, plates, decals, etc. should be periodically inspected and
cleaned as necessary to maintain good legibility for safe viewing. If any instruction, caution, warning, or danger
labels, decals, or plates become lost, damaged, or unreadable, they must be replaced. Information contained
on such labels, decals, and plates is important and failure to follow the information they contain could result in an
accident. Replacement labels, decals, and plates can be ordered through your distributor. For the purpose of this
manual, and the labels which are placed on the crane, danger, warning, and caution captions and notes are defined
as follows:

DANGER
An operating procedure, practice, etc. which,
if not correctly followed, will result in severe
personal injury, dismemberment, or loss of
life.

WARNING
An operating procedure, practice, etc. which,
if not correctly followed, may result in
personal injury and may result in damage to or
destruction of equipment or property.

CAUTION
An operating procedure, practice, etc. which,
if not correctly followed, may result in damage
to or destruction of equipment or property.

NOTE
Note: An operating procedure step, condition,
etc. which is essential in order for the process to
be completed properly.

Preface
Operator's Manual
General Index
A detailed table of contents for each section of this manual is included at the
beginning of each section. The following is a description of each section:

Section 1 - Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 1-1 Thru 1-114

Section 1 includes the necessary information for safe, productive crane operation. It includes the nomenclature and
operation of all control switches, levers, pedals, and instrumentation of the crane.

Section 2 - Lubrication And Preventive Maintenance . . . . . . . . . . . . . . . .Pages 2-1 Thru 2-30

Section 2 includes the necessary information for proper lubrication and preventive maintenance for daily opera­
tions. It includes the check/change intervals and procedures for maximizing the service life of the crane under nor­
mal working conditions. It also includes lubrication types and specifications approved for use in the crane.

Section 3 - Periodic Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 3-1 Thru 3-18

Section 3 includes the adjustments which must be made periodically to keep the crane in proper, safe working order.
It includes the procedures and necessary information for adjusting the brakes, mechanical linkages, and hydraulic
pressures on the crane.

Section 4 - Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 4-1 Thru 4-22

Section 4 includes the use and operation of the crane attachments. It includes the necessary information for installa­
tion, erection, storage, and removal of the auxiliary lifting sheave and lattice fly section.

Section 5 - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 5-1 Thru 5-20

Section 5 includes general information on the Crane Rating Manual and serial number as well as wire rope specifica­
tions, inspection, replacement, connections, and reeving. General specifications for the crane are also included.

Section 6 - Fundamental Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pages 6-1 Thru 6-10

Section 6 includes a list of terms which are used to refer to crane functions, assembly, operation, and maintenance.
These terms are defined as to how they are used in this manual.

Preface
 Operator's Manual
Table Of Contents
Crane Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

On Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Operator Awareness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Electrical Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Radio Frequency Or Electro Magnetic Interference (RFI Or EMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Signalmen And Bystanders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Crane Inspections And Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Crane And Area Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Weights, Lengths, And Radii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

Leaving The Operator's Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20

Personnel Handling Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Authorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Maintenance, Lubrication, And Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Inspection And Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

Crane Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Operation And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Additional Requirements For Offshore Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

Cab Control And Gauge Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

Gauge Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

Shifter Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30

Rated Capacity Limiter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32

Steering Column And Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

Transmission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

Section 1 - Operating Instructions i

Operator's Manual
Operating The Transmission Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

Combination Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Conventional Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Rear Wheel Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

6‐Wheel Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Crab Steer Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Changing Steering Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

Travel Pump Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

Diagnostic Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

Diagnostic Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

Top Hatch Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

Battery Disconnect Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

Power Panel Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

Operator's Cab Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

Operator's Cab Interior Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

Outrigger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

To Extend Outrigger Beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

To Extend Outrigger Jacks - Raise The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

To Retract Outrigger Jacks - Lower The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

To Retract Outrigger Beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Outrigger Removal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Outrigger Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46

Outrigger Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

Crane System Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

Engine Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

Swing Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

Swing Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

Travel Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50

ii Section 1 - Operating Instructions

 Operator's Manual
Swing Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

360° Swing Lock (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

Wire Rope Winch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52

Front Winch Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

Rear Winch Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

Winch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

Warm‐up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

To Lift A Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

To Hold A Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

To Lower A Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

Winch Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

High Speed Hoist Or Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

To Return To Standard Winch Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-53

Winch Disable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

Drum Rotation Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

Boom Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

Boom Telescope System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-54

Boom Telescope Control Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

Boom Telescope Override Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-55

Fine Metering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57

Crane Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58

Anti‐Two Block Warning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58

Lockout Pin And Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-59

MicroGuard 434 Rated Capacity Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-60

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61

Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62

To Perform System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62

System Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63

System Inoperative Or Malfunctioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63

Configuration Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64

To Select Rigging/Travel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69

Section 1 - Operating Instructions iii

Operator's Manual
To Cancel Audible Alarm And Reset Function Limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69

Operator Settable Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-69

Setting Length/Angle/Height/Swing Operator Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-70

To Set Operator Defined Area Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-72

MicroGuard 534 Rated Capacity Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75

Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-75

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78

System Self‐Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78

System Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78

System Inoperative Or Malfunctioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78

Configuration Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79

To Select Rigging/Travel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85

Cancel Audible Alarm And Reset Function Limiters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85

Operator Settable Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85

Angle, Length, And Height Operator Settable Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86

Swing Operator Settable Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87

Operator Defined Area Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87

System Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-90

Entering And Exiting The Operator's Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-92

Break‐In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93

Before Starting Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93

Engine Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94

Engine Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94

Jump Starting The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-95

Electric Engine Block Preheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-96

Ether Start (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-97

Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98

Air Conditioning (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99

Crane Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100

During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101

iv Section 1 - Operating Instructions

 Operator's Manual
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-102

Counterweight Removal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103

Counterweight Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-103

Counterweight Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-105

Pick And Carry Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-106

Traveling The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-106

Job Site Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-106

Highway Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-107

Towing The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-108

Caging The Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110

Uncaging The Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-110

Transporting The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111

Suspension Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112

Lifting The Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-113

Crane Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-113

Short Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-113

Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-113

Section 1 - Operating Instructions v

Operator's Manual
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112

vi Section 1 - Operating Instructions

 Operator's Manual
3 2 1

4 5 6 9 10
1. Front Winch 4. Rear Outrigger 7. Boom Hoist Cylinder 9. Hook Block
2. Rear Winch 5. Turntable Bearing 8. Boom 10. Hook Ball
3. Counterweight 6. Front Outrigger

Figure 1-1
Crane Nomenclature

On Delivery
WARNING
When a new crane is delivered, follow the instructions Do not lift, suspend, swing or lower
loads or attachments over anyone.
outlined in the latest version of Technical Bulletin Gen­ Do not allow anyone to ride on any
eral Series #213. part of load or attachment.

Operating Safety SAFETY INSTRUCTIONS

Construction equipment can be dangerous if
Remember SAFETY every day. Someone's LIFE may improperly operated or maintained. This
depend on it, MAYBE YOUR OWN. crane should be operated and maintained
only by trained and experienced people
Safe operations of a hydraulic crane requires a well who have read, understood, and complied
with the Operator's Manual.
trained, qualified operator. Crane operation is more in­ Before leaving operator's position, lower
volved than it may appear, and operation by a careless load to the ground.
Do not use swing brake for swing lock.
or unqualified person can result in a serious accident. When facing over rear some functions
will be reversed relative to operator.
When a hydraulic crane is maintained and used prop­ Raise the crane on outriggers, or block the
erly it can be a safe, highly productive piece of equip­ wheels before working on the crane. Replace
all guards or panels before operating the crane.
ment, but if not used properly, it can be dangerous.
Think Safety - You, the operator, are in charge of an
important piece of equipment. It is very important that
you know what it can do. It is also important that you Do not deface or remove this label from the crane.

know what it should not do. No set of instructions can

anticipate all of the situations you will encounter. The
rules given here cover the general usage, and some of
the more common specific cases. If conditions arise Figure 1-2
not covered by these rules, consult your nearest dis­ Read and understand all points covered in the
tributor. A phone call could save someone's life. Operator's Manual before operating the crane.

Section 1 - Operating Instructions 1-1

Operator's Manual

Diesel exhaust fumes can be

harmful. Start and operate engine in Keep clear of
a well ventilated area. If it is
necessary to operate in an enclosed
moving parts to
area, vent the exhaust to the outside. prevent serious
Properly maintain the exhaust bodily injury.
system to its original design.

Figure 1-3 Figure 1-4

Diesel exhaust fumes can be harmful. Keep hands and tools clear of moving parts.

General Safety Rules 7. Keep all walking surfaces (steps, ladders, plat­
forms, etc.) and non‐skid materials on the crane
The following is a list of safety rules which should be fol­ clean. Non‐skid materials are placed on the crane
lowed during all crane operations. to assist operators and service personnel with safe
access/egress to/from the crane and to/from ad­
Operator Awareness justment and inspection areas. Do not allow non‐
1. Read this operator's manual and heed it. The man­ skid materials to become contaminated with mud,
ual contains important information. snow, ice, oil, paint, wax, etc. Any contamination
2. An operator must not eat, read, or otherwise divert can cause the non‐skid materials to become slick,
his attention while operating a crane. Remem­ reducing their effectiveness for safety while walk­
ber-operating is a full‐time job. ing on the crane. If any non‐skid materials become
3. Don't smoke when fueling, or fuel up near an open ineffective due to wear, age, or destroyed in any
flame. Keep the nozzle in contact with the filler way, they must be replaced.
neck to prevent static electric sparks. Shutdown 8. To prevent movement of individual boom sections,
the engine when fueling. shutdown the engine and ensure that the operator
4. Start and operate the engine in a well ventilated has properly vacated the operator's cab before
area. Diesel exhaust fumes can be harmful. If it is putting hands or tools inside the boom. Unexpec­
necessary to operate in an enclosed area, vent the ted movement of the boom sections could sever
exhaust to the outside. Properly maintain the ex­ fingers, hands, arms, etc.
haust system to its original design. 9. The operator, supervisor, or person in charge of the
5. Keep fingers, feet, and clothing away from load must observe the following rules:
sheaves, drums, and ropes unless the crane is a. Loads must be well secured before lifting. Be
shutdown and everyone knows what you are do­ sure that the rigging cannot slip off or pull away
ing. Do not place a hand on wire ropes when from the load, or get out of position on the load.
climbing on the crane. A sudden movement could Be sure the load is rigged so it will not turn over.
pull you into the drums or sheaves. b. Chains and slings must be of adequate size, in
6. Keep your shoes clean. Before entering the opera­ good condition, and not twisted around each
tor's cab, wipe clean any mud, gravel, snow, ice, other.
moisture, or grease from your shoes. Slippery
shoes could cause momentary loss of control of
crucial foot operated controls.

1-2 Section 1 - Operating Instructions

 Operator's Manual

Right
Wrong

A 3 Degree Side Tilt Can Grade Ground Level

Reduce Capacities Or Block Under Crane.
By Over 50%. The Load Should Hang
Parallel With The Boom.

Figure 1-5
Level the crane.

c. The load must not catch on an obstruction f. Avoid sudden starts and stops. Lift carefully,
when lifting or swinging. Be sure the load, fall swing gently, brake smoothly, lower and set
lines, or any other parts of the crane do not loads carefully. Jerking the load, swinging and
snag or strike any obstruction. engaging swing brake roughly, and lowering
d. Do not allow the load to rotate out of control. the load rapidly and slamming on brakes, will
Personal injury to ground personnel, load put shock loadings and possible side loadings
damage, crane damage, or damage to anti‐ on the boom. Unnecessary abuse labels the
two block system may occur. operator as a beginner. Be a professional.
e. When hoisting with single part line, especially g. Do not wrap the winch rope around the load.
in long falls applications, the design of wire Do not use discarded, worn, or damaged wire
rope and hookball is crucial to minimize the po­ ropes for slings. They may fail and drop the
tential for uncontrolled rope and/or load rota­ load.
tion. Rotation‐resistant wire rope is recom­ h. The crane must be level on a firm supporting
mended for single part of line applications. surface before making a lift. Use the bubble
See Wire Rope Capacity Chart in the Crane level to level the crane. Check its accuracy fre­
Rating Manual for the specific types of rotation quently with a carpenter's level. Remember, a
resistant wire rope recommended for your three degree side tilt can reduce capacities by
crane. 50% or more.

Section 1 - Operating Instructions 1-3

Operator's Manual

Wrong

Just A Little Bump Can Cause This!

Like This ...........

Figure 1-6
Do not let the load hit the boom or fly.

or any other object. A dent or other damage could

result, which will weaken the boom or attachment. If
the damage is severe, the attachment could col­
Wrong lapse. If a lattice or diagonal bracing member on the
fly is broken, cracked, or bent, contact your local dis­
tributor for repair procedures. If the boom or fly is
struck, or damaged by anything, STOP. The loading
on a boom or attachments increases as they are low­
ered, therefore their suspension systems could col­
lapse during lowering. Use another crane to lower a
damaged boom or attachment.
12. Watch the load or a signalman at all times. A sus­
pended load must have your undivided attention.
13. Don't pull sideways on the boom or fly, not even a
little. Lift straight up on every load. Moving trucks,
rail cars, barges, or anything else pulling sideways
on the winch rope could buckle the boom or fly. It
could also damage the swing mechanism. Pulling
sideways on a boom or fly can overturn the crane.
14. Heat from the sun only on one side of the boom
may cause a temperature differential between the
Figure 1-7 sides of the boom. The thermal effects may cause
Do not use the boom to pull sideways. boom distortion (the boom to “deflect” to one side)
creating a side load on the boom and/or fly. Side
10. Operate the crane from the operator's seat only. loading is dangerous and shall be avoided.
Operating the crane from any other position, such as 15. Do not “two block” (pull the hook block into the
reaching in a window, constitutes a safety hazard. head machinery) as this can cause winch rope and
11. Don't let the load or bucket hit the boom or fly. Don't sheave breakage resulting in an accident.
let the boom or attachment rest on, or hit, a building

1-4 Section 1 - Operating Instructions

 Operator's Manual
16. After slack winch rope operation, make sure the
winch rope is properly seated in sheaves and on
drums before continuing to operate. Use a stick or
mallet to set the winch rope, not your hands.
Right
17. Do not lower the load beyond the point where less
than three full wraps of winch rope are left on the
drum. This condition could occur when lowering a
load beyond ground level. If all the winch rope runs
off the drum, the load will jerk which could break
the winch rope.
18. Make sure there is a safety latch on the hook, and
that it works properly. Without a latch, it is possible
for slings or chains to come off the hook, allowing
the load to fall.
19. Don't alter any part of the crane. Additions to or
changes in any part of the equipment can create
loadings for which the crane was not designed.
Such changes may seriously affect the usable ca­
pacities and make the entire Crane Rating Manual
invalid. Alterations can dangerously overload or
Figure 1-8
weaken critical parts and may cause disastrous
Crane level, all beams extended equally (all
failure.
fully extended, intermediate extended or fully
20. Do not exceed the rated capacities of the crane un­
retracted) and tires clear of the ground.
der any circumstances. While a crane has more
stability when lifting over a corner (as compared to
straight over the side) the crane capacity is not in­ When blocking or matting under pontoons, be
creased. Anytime the load exceeds the rated ca­ sure that each pontoon is supported fully - no un­
pacities listed in the Crane Rating Manual, the supported pontoon area is permissible. Be sure
crane is overloaded. Overloads can damage the pontoons are on a smooth surface. Rough sur­
crane and such damage could cause failure and face, rocks, etc., under pontoons will cause un­
accidents. equal loadings, and can puncture them, causing
21. When operating on outriggers, all beams must be them to collapse.
equally extended; all fully retracted, all intermedi­ Capacities are based on all outriggers being equal­
ate extended or all fully extended. All jacks must be ly extended: all fully retracted, all intermediate ex­
extended so all tires are clear of the ground, and tended, or all fully extended. Working on outrig­
the crane must be level. Be sure that pontoons are gers that are not equally extended will reduce ca­
set on firm surface, adequate to support the block­ pacities and crane stability considerably and could
ing, pontoon, crane and load without settling, slip­ cause an accident. Do not make any lifts while on
ping or collapsing. Blocking or matting under pon­ outriggers without the outrigger beams equally ex­
toons must form a smooth level surface under the tended.
entire pontoon. Do not block under outrigger
beams inside the pontoons as this reduces stabil­
ity. Blocking must be under pontoons only. Re­
member-there are tremendous loadings on pon­
toons and blocking - the weight of the entire crane
plus any load.

Section 1 - Operating Instructions 1-5

Operator's Manual
1

Wrong

2
3

6
4

1. Head Sheave
2. Main Chord
3. Lattices
4. Picture Frame
5. Connecting Lugs 5
6. Head Machinery Cross Shaft

Figure 1-9 Figure 1-10

Watch that carrier! Fly Section Nomenclature

22. Cold weather operation requires some special at­ f. Use caution when lifting any load during freez­
tention by the operator to allow for changes in eve­ ing weather, as it may be frozen to the ground
ryday routines: or the supporting surface. The added tension,
a. Clean the crane, especially the boom, of accu­ to break the load free, could cause an unsus­
mulated amounts of ice or snow. Operating pected overload situation. Also, when the load
the crane with an ice covered boom is danger­ does finally break loose it could create an er­
ous. The added weight of the ice or snow can ratic motion causing damage or injury.
drastically reduce the capacity of the crane. g. At the end of the work shift, park the crane where
Also, falling ice may pose danger for ground it will not freeze to the ground. Major damage to
personel. the drive mechanism could occur while trying to
b. Clean all snow and ice from steps, ladders, free the crane from a frozen surface.
platforms, etc. to eliminate slippery walking 23. Before attempting to move the carrier, make sure
surfaces. there is enough oil pressure to operate the brakes.
c. If cold weather starting aids are provided on Always check the brake operation before traveling
the crane, use them. The use of aerosol start­ the crane.
ing sprays can be dangerous if the manufac­ 24. Brake firmly in one application. Avoid fanning the
turer's directions are not closely followed. brakes. This could exhaust oil pressure so fast that
d. Pay close attention to the gauges in the opera­ the pump may not supply enough oil.
tor's cab when starting the engine. Normal 25. Do not coast downhill with the transmission shifter
“warm up” times will be longer. Be sure pres­ in neutral. It makes control of the crane more diffi­
sures and temperatures are within normal cult and dangerous.
ranges before beginning operations. 26. Position the transmission shifter to neutral before
e. Always handle flammable materials according operating the crane. When parking, shift to neutral
to the manufacturer's instructions. Propane, and engage the park brake. Block wheels if on an
diesel, or other fuel for auxiliary heaters can be unlevel surface.
dangerous if not properly handled. Do not 27. When operating with the boom at a high angle, use
store such fuels on the crane. care not to let the load hit the carrier.

1-6 Section 1 - Operating Instructions

 Operator's Manual
1
Right
Wrong

3
1
1

1. Use The Connecting Lugs And/Or Head Machinery Cross Shafts As 3. Do Not Attach Slings To Lattices, They Will Bend.
Lifting Points.
2. Use The Main Chords As Lifting Points With Nylon Straps Only

Figure 1-11
Handling The Fly Section.

28. Use care handling the fly when loading, transport­ the fly to protect it from damage. Do not over­
ing, and unloading. Damage that occurs during tighten the tie downs or the fly may be damaged.
these operations can go undetected and could re­ Do not use chain tie downs, as they may dent and
sult in failure of these components, once subjected damage the fly section.
to loading. Do not attach slings to the lattices when 30. Thoroughly inspect all the elements of the fly sec­
lifting the fly, as they will bend. Use the connecting tion before installing it on the crane. Check each
lugs and/or head machinery cross shaft as the lift­ main chord, picture frame, diagonal, lattice, and
ing points. However, it is permissible to attach ny­ connecting lug for bends, dents, and cracked or
lon straps around all four main chords. corroded welds. Picture frames must be square.
29. Block under and between the fly sections when Do not use any fly or jib section that is even slightly
loading them on a transport vehicle. When secur­ damaged. Consult your local distributor for the
ing the fly to a transport vehicle, it is best to use syn­ proper repair procedures.
thetic webs or slings. If using wire rope slings, pad

Section 1 - Operating Instructions 1-7

Operator's Manual

Wrong
Stay away from crane
if close to power lines.
Crane, load, and
ground can become
electrified and deadly.
Consult Operator's
Manual for minimum
required clearance.

ELECTROCUTION HAZARD.
Keep all parts of crane and
load at least 15 ft (4.57m)
from electrical lines or as
stated in local code. Consult
Operator's Manual for
minimum required
clearances.

Figure 1-12
Stay Away From Power Lines.

Electrical Dangers Minimum Required Clearance For Normal

1. All Electrical Power Lines Are Dangerous. Contact Voltage In Operation Near High Voltage Power
with them, whether insulated or not, can cause Lines And Operation In Transit With No Load
death or injury. When operating near power lines, And Boom Or Mast Lowered.
the best rule is to have the power company turn off Minimum Required
Normal Voltage, kV
the power and ground the lines. However, in some Clearance, ft (m)
(Phase to Phase
cases, the operator may be unable to have the See Note 1
power turned off. Follow these rules whether the Operation Near High Voltage Power Lines
power is turned off or not. To 200 15 (4.57)
a. Be alert. You are working around conditions
which can cause death. Over 200 To 350 20 (6.10)
b. Keep all parts of the crane, fall lines, hook Over 350 To 500 25 (7.62)
block, and load, at least 15 ft (4.57m) away Over 500 To 750 35 (10.67)
from the electrical lines or as specified in the Over 750 To 1000 45 (13.72)
“High Voltage Power Line Clearance Chart” or
Operation in Transit with no Load and Boom or
other distance specified by applicable codes.
Mast Lowered
Slow down crane operation.
To 345 15 (4.57)
Over 345 To 750 16 (4.87)
Over 750 To 1000 20 (6.10)
Note 1: Environmental conditions such as fog,
smoke, or precipitation may require increased
clearances.
High Voltage Power Line Clearance Chart

1-8 Section 1 - Operating Instructions

 Operator's Manual

Wrong Wrong

Shaded area shows “sensitivity zone” with full boom length

Shaded area shows “sensitivity zone” with the probe near the
sensor used, and adjusted for 15 ft. (4.57m) clearance. Contact
boom peak and adjusted for 15 ft. (4.57m) clearance. Contact
can be made outside this zone by the fall lines, winch rope, cab,
can be made outside this zone by the fall lines, winch rope, cab,
etc. In such cases, the alarm will not sound, but the crane will be
etc. In such cases, the alarm will not sound, but the crane will be
electrified and deadly.
electrified and deadly.
Figure 1-13 Figure 1-14
Crane equipped with proximity warning device Crane equipped with proximity warning device
on the entire boom. on boom tip.

c. Assume that every line is “Hot”. g. Grounding the crane can increase the danger.
d. Appoint a reliable person equipped with a loud Poor grounding such as a pipe driven into the
signal (whistle or horn) to warn the operator ground, will give little or no protection. In addi­
when any part of the crane is working around tion, a grounded crane may strike an arc so
the power line. This person should have no heavy that a live line may be burned down.
other duties while the crane is working around This could cause the crane and the area
the power line. around it to be electrified.
e. Warn all personnel of the potential danger. h. When operating near radio or T.V. transmitting
Don't allow unnecessary persons in the area. stations, high voltage can be induced in metal
Don't allow anyone to lean against or touch the parts of the crane, or in the load. This can oc­
crane. Don't allow ground workers to hold cur even if the crane is some distance from the
load lines, or rigging gear unless absolutely transmitter or antenna. Painful, dangerous
necessary. In these cases use dry plastic shocks could occur. Consult trained electronic
ropes as tether lines. Make certain everyone personnel before operating the crane to deter­
stays at least 15 ft (4.57m) away from the load, mine how to avoid electrical hazards.
or as specified in the “High Voltage Power Line 2. What do you do if a power line is touched by a
Clearance Chart” or such distance as required crane or load?
by applicable codes. a. Remain calm - think - a mistake can kill
f. The use of boom point guards, proximity de­ someone.
vices, insulated hooks or swing limit stops do b. Warn all personnel to keep clear.
not assure safety. Even if codes or regulations c. If crane will still operate, try to move it away
require the use of such devices, you must fol­ from contact. You, the operator are reasonably
low rules listed here. If you do not follow them, safe in the cab unless the crane is on fire or an
the result could be serious injury or death. arc is cutting through the cab.

Section 1 - Operating Instructions 1-9

Operator's Manual

Wrong

Wrong

1
1

This Man Is Not Protected 1. Insulated Link

1. Insulated Link
Figure 1-16
Figure 1-15 Crane equipped with insulated link and boom
Crane equipped with insulated link. point guard.

d. Move away from contact in the reverse direc­

tion to that which caused the contact. Exam­
ple: If you swing left to the wire, swing to the
right to break contact. Remember - once an
arc has been struck, it will stretch out much far­
ther than you think before it breaks. Keep mov­
ing until the arc has been broken.
e. When the arc breaks, continue moving away
until you are at least 15 ft (4.57m) away (or as
specified in the “High Voltage Power Line
Clearance Chart” or as specified by local
codes). Stop the crane. Make a thorough in­
spection for crane damage before further use.
f. If you cannot disengage from the electrical
line, and the crane is not on fire or no arc is cut­
ting through the cab, stay in your seat until
power line can be turned off.
g. If you must leave the crane, don't step off.
Leap from the crane as far as you can, landing
with feet together, then hop away from the
crane with feet together, or shuffle feet to keep Figure 1-17
them close together. This could help prevent If you must leave the crane, do not step off.
personal injury. Leap as far as you can with feet together and
3. When using a magnet: hop or shuffle away from the crane.
a. Lifting magnet generators produce voltage in
excess of 200 volts and present an electrical c. Do not let workmen get between magnet and a
shock hazard. Only trained personnel should metal object.
work on the magnet, controller, or wiring. d. If necessary to position a load, use a dry,
Don't open the controller door with the genera­ wooden stick.
tor running. e. Open magnet disconnect switch at magnet
b. Do not let workmen touch magnet or load. control panel before connecting or discon­
necting leads.

1-10 Section 1 - Operating Instructions

 Operator's Manual

Wrong

Wrong

Figure 1-19
Use a signalman, back safely.
Figure 1-18
No hook riders!
6. Do not tamper with safety devices. Keep them in
Radio Frequency Or Electro Magnetic good repair and properly adjusted. They were put
Interference (RFI Or EMI) on the crane for your protection.
Certain areas may contain high Radio Frequency Or 7. When operating a crane equipped with any form
Electro Magnetic Interference (RFI or EMI). In these of load indicating mechanism, overload warning
areas the boom can act like an antenna and produce an system, or any automatic safety device, remem­
electrical current that may cause electrical shocks and/or ber that such devices cannot replace the skill and
the crane to malfunction. If operating in an area where judgment of a good operator. For instance, such
these conditions may exist, test the crane or have the devices cannot tell when a crane is located on a
area tested for the magnitude of this interference before supporting surface that will give away, that too
operating the crane. Operation may not be possible or few parts of line are being used to lift a load, can­
boom length may be limited. Comply with all local, state, not correct for the effects of wind, warn that the de­
and federal laws when operating in high RFI/EMI areas. vice may be improperly adjusted, correct for side
pulls on the boom, or for many conditions which
Protective Equipment could occur and create hazards. It requires all the
1. Always replace protective guards and panels be­ skill, experience, judgment, and safety conscious­
fore operating the crane. ness that a good operator can develop to attain safe
2. Always wear hard hats, safety glasses, steel toe operation. Many safety devices can assist the op­
shoes, hearing protection, and any other safety erator in performing his duties, but he should not
equipment required by local job conditions, rely on them to keep him out of trouble.
OSHA, or regulations.
3. Always wear safety glasses when drilling, grinding
Signalmen And Bystanders
1. Don't allow crane boom or loads to pass over peo­
or hammering. Flying chips could injure the eyes.
ple, or endanger their safety. Remove all loose ob­
4. Always wear a mask to prevent breathing any dust,
jects from load. All unnecessary personnel should
smoke, fumes, etc. while cleaning, drilling, weld­
leave the immediate area when crane is operating.
ing, grinding, sanding, etc. on any part of the
2. Do not allow anyone to ride on the hook ball, hook
crane. Breathing dust, smoke, fumes, etc. can be
block or any part of the load or attachment for
very hazardous.
construction work or recreational activities. (This ap­
5. The crane is equipped with a fire extinguisher in the
plies to recreational activities such as “bungee jump­
operator's cab. Make sure all personnel know that
ing” or “bungee cord jumping”). Cranes are intended
one is available and where it is located. It must be
to lift objects, not people. They are not elevators.
kept in the crane at all times (except when need­
3. Do not carry passengers! There is only one seat
ed). Instruct all operating and maintenance per­
and it is for the operator. Do not allow personnel to
sonnel in proper use of the extinguisher. Check pe­
ride on the carrier deck during operation or while
riodically to make sure it is fully charged and in
traveling the crane. A fall from the crane can cause
working order. Replace immediately if required.
death or serious injury.

Section 1 - Operating Instructions 1-11

Operator's Manual
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ DANGER

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
OUT OF SERVICE
Do not operate the crane or start the engine without

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
first notifying this mechanic. Personnel within the
crane could be hurt or killed. Crane damage may

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
also result from premature operation of systems

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
which are under repair.

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
Signed:

Figure 1-20 Figure 1-21

Remove the keys from the ignition and post a Allow engine to cool before removing radiator cap.
sign to make others aware of repair activity.
4. Always look before you back up, or better yet, post a. Fully retract the boom. Lower the boom to the
a signalman to guide you. Make sure the back up limit of the boom hoist cylinder. Be sure boom
alarm is working properly. Use the horn as a signal. or cylinder does not hit the carrier.
Use a code such as one beep - stop, two beeps - b. Shutdown the engine, but leave the key in the
forward, and three beeps - backward. Make sure “ON” position, disengage the main pump, and
everyone on the job site knows the code. work all control levers back and forth to relieve
5. Do not make a lift which is not in plain sight without pressure and relax the attachment.
a signalman. This can lead to an accident or crane c. If the above instructions cannot be followed,
damage. block securely under the attachment so it can­
not move.
Crane Inspections And Adjustments d. Bleed any precharge off the hydraulic reservoir
1. Inspect crane daily. Do not operate a damaged or
before opening it or disconnecting a line.
poorly maintained crane. Pay particular attention
e. Hydraulic oil becomes hot during operation. In
to the clutches, brakes, attachments, and wire
some cases it becomes hot enough to cause
ropes. If a component is worn or damaged, re­
severe burns. Be careful not to let hydraulic oil
place it before operating.
come in contact with skin.
2. Labels, plates, decals, etc. should be periodically
f. Disconnect battery cables and remove ignition
inspected and cleaned as necessary to maintain
key so crane can't be started. Post warning
good legibility for safe viewing. If any instruction,
signs in cab so no one will try to start the en­
caution, warning, or danger labels, decals, or
gine. Never adjust, maintain or repair a crane
plates become lost, damaged, or unreadable, they
while it is in operation.
must be replaced.
5. When making repairs, which require welding, use
3. When performing repetitive lift applications, espe­
proper welding procedures. Also the following
cially at or near maximum strength limited capaci­
precautions must be taken:
ties, an inspection of the major structural areas of
a. All paint in the area should be removed to pre­
the crane, for cracks or other damage, should be
vent burning the paint. The smoke and fumes
conducted on a regular basis. (A non‐destructive
from the burning paint can be very hazardous.
test such as magnetic particle or dye penetrant
b. Turn the battery disconnect switches to the
may even be considered.) Along with inspection
“OFF” position to protect any electronic equip­
for cracks and damage, frequently check the criti­
ment on the crane which may be affected by
cally loaded fasteners, such as the turntable bear­
electric arc welding.
ing mounting capscrews, to ensure they have not
c. The welding ground cable should be attached
been stretched. Not only does frequent inspection
to the portion of the crane being welded. If
promote safety, but it is also much easier and less
welding on the upper, ground on the upper. If
expensive to perform a repair when a crack is
welding on the carrier, ground on the carrier.
small, before it has a chance to traverse through a
Failure to take this precaution may result in
structural member. Any sign of cracks or damage
electrical arcs in the turntable bearing.
must be repaired before continuing operations.
d. The welding ground cable should always be
Consult your distributor for repairs.
connected as close as possible to the area be­
4. When performing maintenance on the crane, do
ing welded. This minimizes the distance that
the following:
electricity must travel.

1-12 Section 1 - Operating Instructions

 Operator's Manual
Right

Figure 1-22 Wrong

Use a guard when inflating tires.

e. Disconnect computers and other electronic Figure 1-23

equipment (such as rated capacity limiters and Do not use an open flame near the battery.
engine computers) to prevent damage. Con­
tact the distributor for proper procedures.
f. Remove all flammables from the proximity of
the welding area.
6. Use extreme caution when removing radiator WARNING
caps, hydraulic pressure caps, etc. They can fly off Battery posts, terminals, and related accesso­
and hit you, or you could be burned by hot oil, ries contain lead and lead compounds. Wash
water, or steam. hands after handling.
7. Keep the crane clean, in good repair, and in proper
adjustment. Oil or grease on the decks may cause 11. When using jumper cables to start an engine, be
falls. Improper adjustments can lead to crane sure to connect negative post to a ground stud,
damage, load dropping, or other malfunctions. and positive post to positive post. Any spark could
8. Keep all walking surfaces (steps, ladders, plat­ cause the battery to explode. Refer to “Jump Start­
forms, etc.) and non‐skid materials on the crane ing the Crane” found later in this section of the Op­
clean. Non‐skid materials are placed on the crane erator's Manual for the proper procedure.
to assist operators and service personnel with safe 12. Test the automatic winch brake by raising the load
access/egress to/from the crane and to/from ad­ a few inches and holding. It should hold without
justment and inspection areas. Do not allow non‐ slipping. It takes more braking power to hold a load
skid materials to become contaminated with mud, in the air when the drum is full of rope than when it
snow, ice, oil, paint, wax, etc. Any contamination is a few inches above the ground with only a few
can cause the non‐skid materials to become slick, wraps on the drum.
reducing their effectiveness for safety while walk­ 13. Always reduce pressure in hydraulic system to
ing on the crane. If any non‐skid materials become zero before working on any part of the system.
ineffective due to wear, age, or destroyed in any 14. Use extreme care when working with circuits with
way, they must be replaced. accumulators. Check that hydraulic pressure is re­
9. Check tires daily for correct pressure. Do not stand lieved before opening the circuit for repairs.
in front of a tire when inflating it. The lock ring can 15. When setting pressures, never exceed the manufac­
fly off and injure you. Use a clip‐on inflator, and turer's ratings. Always follow instructions exactly.
stand aside. Use a guard in front of the tire. Over pressurization can cause hydraulic component
10. When checking battery fluid level, use a flashlight, damage or failure of mechanical parts on the crane.
not an open flame. If the battery explodes, you can Any of the above can lead to an accident.
get acid in your eyes, which could cause blind­
ness. Don't check battery charge by shorting
across posts. The resulting spark could cause the
battery to explode. Check with a tester or hy­
drometer. Don't smoke near batteries.

Section 1 - Operating Instructions 1-13

Operator's Manual
Ball Usage With Rotation Resistant Rope” found in
Thursday. . . . .
Section 5 of this Operator's Manual.
Wrong
4. Do not handle wire rope with bare hands. Always
use gloves to prevent possible injury from frayed or
damaged spots in the rope.
“I thought I could save 5. Inspect head machinery and hook block often as
money by running this damaged or deteriorating sheaves can cause
rope until Friday”. undo wear of the wire rope.
6. A swivel hook ball may be used with rotation resist­
ant rope only if certain criteria are met . Refer to
“Hook Ball Usage With Rotation Resistant Rope”
found in section 5 of this Operator's Manual.
7. When reeving wire rope on the crane, do not stand,
walk, or climb on the boom or attachment. Use a
ladder or similar device to reach necessary areas.

Crane And Area Clearance

1. Know your job site conditions. Familiarize yourself
with work site obstructions and other potential haz­
ards in the area which might lead to mishaps.
Make any necessary arrangements to eliminate
Figure 1-24 any potential hazards, if possible.
Do not operate the crane with worn or 2. Erect barricades around the immediate work area
damaged wire rope. to prevent unauthorized personnel from wander­
ing onto the job site.
3. Be sure the work area is clear. Make sure to have
Wire Rope proper clearance for the crane, boom, and load.
1. Inspect all wire rope thoroughly. OSHA (Occupa­ Don't swing, travel, lift, or lower loads, raise or
tional Safety And Health Act) regulations state “a lower jacks, without first making sure no one is in
the way. If your vision is obscured, locate a signal­
thorough inspection of all ropes shall be made
man so you can see him, and he can see all areas
once a month and a full written, dated, and signed
you can't. Follow his signals. Be sure you and the
report of the rope condition be kept on file where
signalman understand each other's signals. See
readily available.” A visual inspection must also be
hand signal chart Figure 1-99. Use the horn to
performed daily. Replace any worn or damaged
signal or warn. Make sure everyone on the job site
rope. Pay particular attention to winch ropes.
understands signals before starting operations.
Check end connections (pins, sockets, wedges,
4. When working inside a building, check overhead
etc.) for wear or damage.
clearance to avoid a collision. Check load limits on
2. Use at least the number or parts of winch line floors or ramps so as not to crash through.
specified on the Wire Rope Capacity chart located 5. Don't operate close to an overhang or deep ditch.
in the Crane Rating Manual to handle the load. Lo­ Avoid falling rocks, slides, etc. Don't park crane
cal codes may require more parts of line than is where a bank can fall on it, or it can fall in an exca­
shown. Check code requirements and use them vation. Don't park where rain can wash out footing.
where applicable. 6. Watch the tail swing of the upper revolving frame
3. Non‐rotating, rotation‐resistant, or spin‐resistant wire and counterweight. Even though the original set‐
ropes are recommended for single part of line ap­ up may have been clear, situations change.
plications. This is of utmost importance for long fall 7. Do not store material under or near electrical
hoist line applications. Only if certain criteria are met power sources. Make material handlers aware of
may a swivel hook ball be used with rotation resistant the dangers involved with storing material under
rope. Refer to “Single Part Line Hoisting' and “Hook power lines or in the vicinity of any other hazards.

1-14 Section 1 - Operating Instructions

 Operator's Manual

Wrong

“It looks like Wrong

about 15 tons”

Figure 1-26
Do not lift two loads at the same time.

is a matter of judgment and experience. Some fac­

Figure 1-25 tors which may require reduction of capacities are:
Know your load. a. Soft or unpredictable supporting surfaces.
b. Wind.
c. Hazardous surroundings.
Weights, Lengths, And Radii d. Inexperienced personnel.
1. Know your load. Don't try to guess or estimate the e. Poor visibility.
load. Use a scale or a load indicating system to de­ f. Fragile loads.
termine exact weight. Remember the weight being g. Crane in poor condition.
lifted includes the weight of any lifting slings or gear, h. Condition and inflation of tires.
the hook block, and any other weight on the hook. If
When in doubt, do not take a chance. Reduce rat­
lifting off the boom with the fly erected, the weight of
ings more than you think you need. Avoid working
the fly must also be considered as part of the load.
a crane in high winds. If you must work in a wind,
(The Rated Capacity Limiter will automatically de­
reduce capacities as shown on the “Wind Speed
duct the weight of the stowed fly to obtain the total
Restrictions” chart in the Crane Rating Manual.
allowable load.) The total load weight must never
Wind blowing against the load and the boom pro­
exceed the rated capacity of the crane, as listed in
duces a side load on the boom and reduces its ca­
the Crane Rating Manual, for the position, boom
pacity.
length, load radius, and condition of operation be­
ing used. Remember - capacities in the Crane Rat­ When lifting loads, in a wind, which have large sur­
ing Manual are based on ideal conditions: face areas, such as building panels, the movement
a. Standing on firm, level surface. of the load may pose a danger to workmen or
b. Calm wind. building structures. Out swing of a load will in­
c. No side loads or out swing of load. crease the load radius, and may overload the
d. Good visibility. crane. This could lead to boom failure or the crane
e. Crane in top condition and equipped as when tipping.
leaving the factory. 2. Do not lift two loads at the same time, even if the
When such conditions cannot be attained, loads total load weight is within crane capacity. Loads on
being handled must be reduced to compensate. the boom and fly at the same time, stress the boom
The amount loads are reduced depends upon how and drastically reduce its ability to handle loads.
good or how poor actual operating conditions are. It Your full attention cannot be given to both loads,
creating a dangerous situation.

Section 1 - Operating Instructions 1-15

Operator's Manual

Operation under conditions which

exceed listed capacities may result in
overturning.
Wrong
Swinging, extending or lowering boom
to radii where no capacities are listed
Figure 1-27 may result in overturning even without
Do not push with the boom. a load.
Figure 1-28
3. Lifts where two or more cranes work together can Safety Instruction Label
be hazardous and should be avoided. Such lifts
should be made only under the direction of a quali­
fied engineer. If a multiple crane lift is unavoidable, 6. Some capacities on hydraulic cranes are based on
observe the following rules: strength of materials. In these cases, overloads
a. The cranes must be level and located on firm will cause something on the crane to break, before
surfaces. it will tip. Do not use signs of tipping as a warning of
b. The cranes should be the same size and ca­ overload.
pacity, use the same boom length and be 7. Don't lash a crane down. Lashing a crane down
reeved similarly. encourages overloading. Crane damage or injury
c. Cranes must be positioned so that each boom could result.
point is directly over its load attaching point. 8. Do not shock load and/or overload the crane at
The winch lines must be vertical during all anytime. Shock loading or overloading the crane
phases of the lift. will reduce the fatigue life of crane components
d. The rigging must be placed so each crane lifts and could result in component failure.
a share of the load well within the crane's ca­ 9. When performing repetitive lift applications, espe­
pacity. cially at or near maximum strength limited capaci­
e. Be sure that during handling more load is not ties, be aware that these applications may reduce
transferred to any crane than it can handle. component life. These applications include re­
f. Don't attempt to travel when making multiple peated lifting (or lifting and swinging) of near 100%
crane lifts. strength limited capacities and repeated lifting
g. Coordinate plans with the other operator be­ maximum moment loads. These applications may
fore beginning to lift. fatigue the major structural portions of the crane.
h. Use only one signalman. Although the crane may not break during these ap­
i. Use of an operable load and angle indicating plications, they can reduce the fatigue life and
system is desirable. shorten the service life of the crane. To improve the
4. When operating off the main boom with the fly service life, while performing repetitive lift applica­
erected, deductions must be made for the fly tions, consider reducing the capacities to 70% of
weight. (The Rated Capacity Limiter will automati­ maximum strength limited capacities to reduce fa­
cally deduct the weight of the stowed fly to obtain tigue cracking. Frequently perform a thorough in­
the total allowable load.) The weight of the fly, etc., spection of all the structural areas of the crane.
must be subtracted to obtain a “NET” capacity. Any sign of cracks or damage must be repaired be­
Failure to do so could result in an overloading con­ fore continuing operations. Consult your distribu­
dition and cause boom failure. Refer to the Crane tor for repairs.
Rating Manual for amounts to be deducted. 10. Always refer to the Crane Rating Manual after
5. When operating off the main boom with the auxil­ changing the arrangement of the attachments for
iary lifting sheave installed, the weight of the auxil­ the correct lifting capacities.
iary lifting sheave must be deducted. Refer to the 11. The boom must be extended in the correct manner
Crane Rating Manual for amount to be deducted. before making a lift. The capacities listed in the Crane
Rating Manual for this crane are based on the boom
sections being extended in accordance with boom
mode “AMax1”, “AMax2”, or “Standard”.

1-16 Section 1 - Operating Instructions

 Operator's Manual
12. Do not use the boom to push or pull. It is not de­
signed for this purpose. Such action can damage DANGER
the boom and lead to an accident.
13. Know the load radius. Don't guess at it. Determine
the load radius by using the boom angle indicator,
the boom length indicator, and the Crane Rating
Manual, or measure it with a steel tape. Remember
- Radius is the horizontal distance from the center­
line of rotation of the upper to the center of gravity
of the load, when the load is hanging free.
14. Do not operate a hydraulic crane at radii or boom
lengths where the capacity charts in the Crane Rat­
ing Manual show no capacity. Don't use a fly not
designed with or for your crane. Either of the above
can tip the crane over or cause attachment failure.
In some cases, the crane can tip over with no load
on the hook, forward or backward! Also, if the Figure 1-29
boom is fully extended at a low angle, the crane Pinch Point Label
may tip until the boom touches the ground. In any
of these cases, injury or crane damage could re­ 17. Know the boom length. Don't guess. Use of an in­
sult. correct boom length can cause an accident.
15. When lifting a load with any crane, the load may 18. When lowering or retracting the boom, the load will
swing out, or sideways. The load radius will in­ lower. To compensate for this, the operator must
crease. Due to the design of hydraulic crane hoist up on the winch rope. Otherwise, movement
booms, (cantilever boom, supported by cylinders of the load may cause an accident. When extend­
and overlapping sections) this increase is much ing the boom, the load will raise. The operator
more pronounced. The increase or out swing of must hoist down the winch rope to keep the load in
the load can overload the boom, and lead to boom place. Extending the boom without winching
failure or tipping. Also, movement of the load can down, can lead to “two blocking”. This is when the
cause it to hit something. Make sure the load being hook block or the hook ball contacts the head ma­
lifted will remain within capacity as it is lifted and the chinery. Two blocking can lead to sheave or wire
boom deflects. rope damage.
16. When extending or lowering a boom with a load, 19. Pinch points, which result from relative motion be­
the load radius increases. As the load radius in­ tween mechanical parts, can cause injury. Keep
creases, capacity decreases. If capacity is ex­ clear of the rotating upper or moving parts.
ceeded, the boom may bend or the crane may tip 20. Lifting heavy loads can cause the crane to tilt or
over. Sometimes at low angles, a hydraulic crane lean toward the load. When swinging a load from
boom can be extended with a load, but cannot be over the end to over the side, the tilt of the crane will
retracted. This is because more power is available increase. Since tilt acts to increase load radius, it
in the boom telescoping cylinders to extend than to must be compensated for when swinging the load.
retract. If an operator extends the boom under Swing slowly. Change boom angle (raise the
load, he may not be able to retract the boom and boom) while swinging, to maintain a constant ra­
may get into a dangerous situation. dius, and prevent in swing or out swing of load. If
not, a dangerous condition could result.

Section 1 - Operating Instructions 1-17

Operator's Manual

Wrong

A little side
tilt while
working over
the end......

Wrong
1

1. Load Radius at Rest

....Increases load 2. Load Radius Increases Due To Centrifugal Force
radius when swung
over the side Figure 1-31
Watch that centrifugal force!

22. Watch out for centrifugal force when swinging a

load. Swing gently. Centrifugal force tends to in­
crease load radius. This increase in radius could
overload the crane and cause crane damage or tip­
ping. When stopping the swing, over swing of the
load can side load the boom.
23. Keep the winch ropes as short as possible to pre­
vent excessive swinging. Always use the shortest
boom length which will do the job. Remember -
Figure 1-30 the shorter the boom, the better the capacity.
Watch that side tilt!
24. Due to inertia (weight), a load will momentarily tend
to stay in position when the crane starts to move.
21. The winch rope must be vertical when starting to For this reason do not back the crane away from a
lift. If not, the load will swing in, out, or sideways suspended load when handling near capacity
when lifted from the ground. The crane will lean to­ loads. The inertia effect will tend to increase load
ward the load when lifting heavy loads. This is radius and decrease stability. Use hand lines as re­
caused by elasticity of the crane and the boom. quired to control the load.
This lean will increase operating radius so the load 25. Don't increase the counterweight. Don't add any­
will swing outward when it clears the ground. This thing to the crane that will act as additional counter­
out swing is dangerous to anything in the path of weight. Remember that anything which has
the load, and because of the increase in load ra­ weight, if carried behind the crane's center of grav­
dius may overload the crane. To overcome this out ity, acts as counterweight. Adding counterweight
swing, boom up as the load is lifted so winch ropes affects backward stability of the crane, particularly
remain vertical. When setting the load on the when working over the side. It also encourages
ground, lower boom after the load touches down to overloading of the crane.
avoid hook block swing when it is unhooked from 26. Working areas for cranes are defined per the working
load. areas chart in the Crane Rating Manual. Permissible
loads, per the Crane Rating Manual, will vary from lift­
ing quadrant to lifting quadrant. The operator must

1-18 Section 1 - Operating Instructions

 Operator's Manual
make sure capacity ratings are not exceeded regard­ 2. When traveling on the highway, road the crane
less of which quadrant he is operating in, or when safely. Watch for narrow bridges and low clear­
swinging from one quadrant to another. ances. Check load limits, heights, width and
27. When working on tires, the tires must be inflated to length restrictions in the area you are traveling.
pressures shown on the Tire Inflation label located Make sure your crane complies with all regula­
on the left rear fender of the carrier. tions.
28. Prior to lifting any loads, inspect the boom or boom 3. When roading the crane, note the following:
and fly combination to ensure they are straight. The a. Operate with lights on. Use proper warning
heat from the sun may distort the boom due to tem­ signs, flags and other devices. Use an escort
perature differential on the sides of the boom. Re­ service if required.
position the boom to allow the thermal effects from b. Engage travel swing lock. Release the swing
the sun to equalize the temperatures of the side walls park brake and 360_ swing lock (if equipped).
of the boom to eliminate the distortion before lifting a c. Lash down or otherwise restrain the hook
load. Refer to “Boom Distortion Due To Thermal Ef­ block.
fects Of The Sun“ found in Section 1 of this Operat­ d. Check for maximum allowable travel speed
or's Manual for additional information. and any other travel limitations. Don't exceed
these maximums. Crane damage or an acci­
Traveling dent could result.
1. Traveling with a suspended load should be e. Inflate tires as listed on the Tire Inflation Label
avoided if possible. It is especially hazardous located on the left rear fender of the carrier.
when terrain is rough or irregular, on a side slope, f. Fully retract all outriggers.
or in a hilly area. When traveling with a load, ob­ g. Remove all pontoons from the outrigger jacks
serve the following rules: and store them properly.
a. Use a hand line to control the load and reduce 4. If the crane must be towed, refer to “Towing The
load swing. Crane” found later in this Section of the Operator's
b. Travel by the smoothest, most level route. If a Manual for specific instructions.
smooth, level route is not available, don't travel
with a suspended load. Grade the route to pro­
vide a smooth, level path. If it is not possible to
grade the route, move the load by stepping.
Level the crane on outriggers, lift the load and
set it down ahead of the crane. Travel the un­
loaded crane beyond the load, level the crane
on outriggers, lift the load, swing and set it
down farther along the route. Continue this
procedure until the load is at its destination.
c. Carry loads as close to the ground as possible.
d. Do not allow side swing of the load.
e. Don't attempt to carry loads which exceed the
crane's rating.
f. Don't travel with a load on soft ground. If the
crane sinks into ground, stability can be af­
fected to the point of tipping the crane.
g. Keep all personnel clear of crane and load. Be
prepared to set load down quickly at any time.
h. Fully extend outrigger beams. Extend or re­
tract jacks until pontoons just clear the ground.
i. Check clearance for the extra width of the
crane with the outriggers extended. Outrigger
beams or pontoons must not hang on any ob­
struction.
j. When making lifts on tires, inflate tires as
shown on the Tire Inflation label located on the
left rear fender of the carrier.

Section 1 - Operating Instructions 1-19

Operator's Manual
Leaving The Operator's Cab
1. Do not get on or off a crane in motion. Use the grab
Wrong handles and ladders when climbing on or off the
crane. Remain in three point contact with the crane
at all times (two hands and one foot or two feet and
one hand).
2. Whenever an operator leaves the control station for
any reason, the following must be done:
a. Lower the load to the ground.
b. Engage swing lock. Engage the park brake.
Shutdown the engine and remove the keys.
c. Do not depend on a brake to suspend a load
unless the operator is at the controls, alert and
ready to handle the load. Brake slippage, van­
dalism, or mechanical malfunctions could
cause the load to drop.
3. Do not leave crane unattended with engine running.
4. When changing work shifts be sure to notify the next
operator of any changes or problems with the
crane.
5. Hydraulic cylinders, left extended under load, often­
Figure 1-32
Do not leave crane while a load is suspended. times have a tendency to drift in (retract) due to in­
ternal fluid passage in the cylinders and/or control
valves. Do not shutdown the crane and leave it unat­
tended for extended periods of time, i.e. overnight,
with the boom positioned over anything or the crane
itself that the boom could damage if it should lower.
For instance the boom hoist cylinder may drift allow­
ing the boom to lower and damage the engine
hood. Position the boom over the front to avoid the
engine hood on the rear of the crane.

1-20 Section 1 - Operating Instructions

 Operator's Manual
Personnel Handling Guidelines pertaining to both cranes and personnel work plat­
forms. Job site management must ensure all re­
Introduction quirements listed in these resource documents are
The following information is intended to provide Link‐ followed for all personnel handling operations.
Belt's recommended minimum requirements that S American National Standards Institute Reference -
must be followed when handling personnel with a ANSI Standards A10.28, A92.2, A92.3, B30.5, and
personnel basket or work platform (hereafter referred B30.23.
to as a work platform) suspended by wire rope from S Power Crane and Shovel Association (PCSA) Bureau
the boom of Link‐Belt cranes. These requirements of the Association of Equipment Manufacturers
are based upon several sources and are put forth in (AEM) Reference - PCSA Standard No. 4.
recognition of current industry practices. However, S American Petroleum Institute (A.P.I.) Specification
safety, when handling personnel, remains the full re­ 2C.
sponsibility of job site management and is depend­ S OSHA Part 29, CFR 1926.550 Cranes and Derricks.
ent upon the responsible action of every person on
the job involved in the related work. Authorization
This information is intended to supplement and not Authorized use of a work platform may be permitted
to supersede or replace any more restrictive federal, only after the following on‐site procedures have been
state, or local regulations, safety codes, or insurance performed:
requirements. It is intended to serve users of per­ 1. A competent person on the job site (job site man­
sonnel work platforms in achieving the following ob­ ager) specifically responsible for the overall work
jectives. function to be performed has determined that
1. Reduce risk of personal injuries to users and the there is no practical alternative means to perform
public. the needed work and has authorized a personnel
2. Inform users of their respective responsibilities. lifting operation.
3. Provide standards of equipment requirements. 2. For each instance of such lifting, a competent per­
4. Provide standards for tests and inspections. son responsible for the task has attested to the
5. Provide standards of operation to promote safety. need for the operation by issuing a written state­
ment describing the operation and its time frame
Link‐Belt cranes are designed and intended for
and itemizing that each of the on-site authoriza­
handling material. They are not normally equipped
tion requirements has been met. The written state­
with secondary systems or other devices required by
ment, after being approved by a qualified person,
personnel lift or elevator standards and are not inten­
shall be retained at the job site. (Refer to Personnel
ded for handling personnel for construction or
Handling Pre-Lift Check List For Link‐Belt Cranes
amusement purposes. Use of cranes for these pur­
found later in this Section for a sample check list.)
poses is hazardous and is not recommended by
3. Review of crane inspection records has been con­
Link‐Belt. However, Link‐Belt understands that cir­
ducted to ensure the crane being used meets ap­
cumstances may occur (in construction work) when
plicable provisions in ANSI B30.5 and B30.23.
lifting or lowering personnel on a materials handling
4. Review of the work platform inspection records
crane load line is the only or the least hazardous
and specifications has been conducted to ensure it
method available to position personnel. In fact, Oc­
meets applicable design standards (refer to ANSI
cupational Safety and Health Administration (OSHA)
A10-28).
Part 29 CFR 1926.550(g) states “The use of a crane
5. Review of the personnel lifting operation practices
or derrick to hoist employees on a personnel work
specified in these instructions have been conduc­
platform is prohibited, except when the erection, use,
ted with job site managers and crane operator(s),
and dismantling of conventional means of reaching
foreman, designated signal person, personnel to
the work site, such as personnel hoist, ladder, stair­
be lifted, safety supervisor, and any other per­
way, aerial lift, elevating work platform, or scaffold
son(s) who has jurisdiction over the operation to
would be more hazardous or is not possible because
ensure that they are aware of the hazards of the op­
of structural design or work site conditions.”
eration and they are aware of provisions of these
Much corollary and supplementary information is instructions that must be adhered to before and
contained within the following resource documents during the personnel lifting operation.

Section 1 - Operating Instructions 1-21

Operator's Manual
Equipment Their arrangement shall comply with the following
1. The crane system shall be equipped with the fol­ as a minimum:
lowing: a. The work platform harness must be of suffi­
a. A fully functional working operational aid such cient length to prevent any portion of the work
as a Rated Capacity Limiter (RCL) system - A platform or the harness from coming in contact
system consisting of devices that sense crane with the boom at any working boom angle.
loading, boom length (extendable booms b. Audible and visual alert systems shall be
only), boom angle, and also automatically provided to the personnel in the work platform
provide an audible/visual signal when the to signal for assistance in the event of an emer­
loading conditions approach, reach, and/or gency.
exceed the rated capacity values. When the c. Hooks on hook ball assemblies, hook block
Actual Load exceeds the Rated Capacity, the assemblies, or other assemblies, shall be of a
system supplies a signal to a function cutout type that can be closed and locked, (with a
system. The operational aid shall be equipped working safety latch) eliminating the hook
with these additional devices: throat opening, and shall be full load-bearing,
1. Anti-two block device to prevent damage and contain a manual trigger release.
to the hoist rope, other crane components, 3. No unauthorized alterations or modifications shall
or attachments, and subsequent endan­ be made to the basic crane.
germent of personnel.
Maintenance, Lubrication, And Adjustments
S It is required that the anti-two block 1. The crane operator must have a complete under­
device warn both audibly and visually as standing of the crane's maintenance, lubrication,
well as have the capability to cutout the and adjustment instructions as outlined in the
controls/functions that may cause a two Operator's Manual.
block condition. 2. The crane shall be maintained, lubricated, and ad­
2. Boom angle indicator. justed, by a designated person, as specified in the
S Cranes with extendable booms must Operator's Manual.
utilize a boom angle indicator having 3. The crane and work platform decals must be un­
“high and low” set points and audible/ derstood and maintained.
visual alarm(s) capable of activating 4. All decal precautions and instructions shall be
function cutouts. strictly observed.
b. Boom hoist and load line shall have power
lowering and raising and shall have an auto­ Inspection And Rigging
matic brake which is applied when the applic­ 1. The lift crane and work platform shall be inspected
able control is in neutral, or when the anti-two immediately prior to commencement of operation.
block device is actuated. (Refer to the Crane Operator's Manual and ANSI
c. If the crane is equipped with a “free‐fall“ hoist, B30.5, Section 5, Section 5-2.1.2 and 5.2.4, and
steps shall be taken to ensure its use is not ANSI B30.23 for the required inspection proced­
possible during the use of the work platform. ures for the crane. Refer to ANSI A10-28 for in­
(Note: A.P.I. applications do not permit the spection procedures required for the work plat­
crane to be equipped with free‐fall.) form.)
d. Each crane shall have a mechanical swing 2. The inspection shall be performed once daily when
park brake or swing lock capable of being set the crane is being used in work platform service or
at any swing position, and shall have a variable each time the crane is converted from material lift­
swing brake or swing controls capable of stop­ ing to personnel handling operation. In the event
ping the upper swing motion smoothly. The the operator is replaced, a new inspection is re­
swing brake must be properly maintained at all quired. Written documentation of all inspections
times to ensure its holding capability. must be kept on the job site during personnel
handling operations.
Note: All operational aids and equipment 3. Inspect the crane and work platform for any loose,
must be maintained in operable condition. damaged, or missing components.
4. Any structural or functional defect which adversely
2. The work platform shall be designed by a qualified affects the safe operation of the lift crane shall be
engineer competent in structural design. Its main­ corrected before any operation utilizing a work
tenance, and its attachment to the crane load line, platform begins or continues.
is the responsibility of the job site management.

1-22 Section 1 - Operating Instructions

 Operator's Manual
5. The hoist drum shall have at least three wraps of Crane Test Procedures
wire rope remaining on the drum at all times when The test procedures listed below shall be conducted
using a work platform. at the following intervals:
6. Minimum load hoist and boom hoist wire rope S Daily
safety factors for the combined weight of the lift at­ S When an operator is replaced
tachments, work platform personnel, and tools S When, in the judgement of responsible job site man­
shall be 7:1 for manufacturer's specified construc­ agement, there has been a significant change in the
tion wire rope and 10:1 for rotation resistant wire conditions of the personnel lifting operation.
rope. (Note: A.P.I. applications require 10:1 for all
rope construction.) Note: No personnel shall ride the work platform dur­
7. Telescopic Boom Cranes - The work platform ing any of the tests recommended in this Section.
shall be suspended from the main boom head
sheaves only. Lattice Boom Cranes - The work 1. The work platform shall be loaded with ballast at
platform shall be suspended from the main boom two times the intended load. This load shall not ex­
head sheaves only, or on a luffing attachment, the ceed the rated capacity of the work platform. Do
luffing jib head sheaves only. Do not suspend a not exceed the rated lifting capacity of the applic­
work platform from any other lifting sheave(s) on able lift crane capacity chart. (Refer to ANSI
any attachment. A10.28 for suspended work platform testing and
8. Inspect the wire ropes, hoist drum brakes, boom, inspection.)
and other mechanical and rigging equipment vital a. This test load shall be tested for stability.
to the safe operation of the crane. A written record S The operator and signal person shall con­
of this inspection must be maintained on the job duct this test.
site.
S This test shall include movement of the work
9. In addition to other regular inspections, visual in­
platform through its entire intended range of
spection of the crane and work platform shall be
motion, simulating the specific operation to
conducted immediately after testing and prior to
be undertaken.
lifting personnel. The following inspections shall
be conducted on extendable booms prior to lifting S A successful stability test must not produce
personnel: instability of the crane or cause permanent
a. Full power style booms: deformation of any component.
1. Inspection of all extension wire ropes at b. This test load shall be raised and lowered at
the access points in the boom where the maximum power controlled line speed (NOT
end connections are visible - Refer to the FREE‐FALL). The acceleration must be
Operator's Manual for inspection and ad­ smooth and the deceleration capability of the
justment procedures. control/braking system shall be confirmed by
b. Pinning and latching style booms: bringing the work platform to a smooth stop.
1. Inspection of the latching mechanism, (This experience is intended to sharpen the
sensors, and hydraulic/electrical circuit at skill of the operator in handling the work plat­
the access points. form and to give the operator an opportunity to
2. Inspection of all pins and pinning locations evaluate the crane's performance.) The work
in the individual boom sections and at the platform shall then be inspected for any evid­
fully retracted position. ent sign of damage or defect.
3. Verification of the accuracy of the boom 2. All limiting and warning devices shall be tested by
length indicator. Refer to the Operator's activation of each appropriate control function.
Manual for the procedures. 3. With pinning and latching style extendable booms,
10. The following inspections shall be conducted on a visual inspection shall be conducted to verify that
fixed length style booms prior to lifting personnel: the boom extend pins are properly set in the exten­
a. Inspection of all pendants, pendant links, ded boom sections.
pendant spreader bars, and dead end lugs
and links, etc.
b. Inspection of all mechanical linkages, shafts,
drums, etc.
c. Inspection of all chord and lattice members of
all boom sections, luffing jib sections, and live
mast, as equipped.

Section 1 - Operating Instructions 1-23

Operator's Manual
Operation And Safety 10. The combined weight of the work platform, any at­
1. The Operator's Manual for the crane shall be read tachment device, personnel, tools, and other
and fully understood by operating personnel. It equipment shall not exceed 50% of the lifting capa­
shall be available to them at all times. city of the applicable lift crane capacity chart.
2. Safety when handling personnel remains the full (Note: A.P.I. applications require 25% of lifting ca­
responsibility of job site management and is de­ pacity as the limit.)
pendent upon the responsible action of every per­ 11. The following actions and operations are strictly
son on the job involved in the related work. prohibited when working with personnel suspen­
3. Mobile lift cranes shall be erected to obtain maxim­ ded in a work platform:
um crane stability. The crane must be level and on a. Cranes shall not travel while personnel are in
firm ground with the outriggers fully extended and the work platform.
the tires clear of the ground before beginning any b. No lifts shall be made on another of the crane's
operation. load lines with personnel suspended in a work
4. The operator shall not leave the operator's station platform.
when the work platform is occupied. The operator c. No external load shall be lifted by attaching it to
shall remain alert in a position of readiness at the the work platform.
work station with the engine running and the mas­ d. Work platform lifts shall be a single crane oper­
ter clutch engaged, if crane is so equipped. ation. A work platform shall not be lifted using
5. Unauthorized personnel shall not be in the operat­ two cranes.
or's cab on the lift crane, or near the lift crane while e. Hoisting of personnel shall be discontinued
a work platform is suspended from the load line. upon indication of any dangerous weather
6. Any operation in which a work platform is to be sus­ conditions, wind, or other impending danger.
pended from the load line shall be carefully f. The emergency manual mode operation of
planned by the operator, supervisory personnel, pinning and latching style extendable booms
designated signal person, and personnel to be lif­ shall not be utilized.
ted prior to commencement of such operation. g. Free-Fall (if equipped) shall not be used.
They are to be advised: 12. Movement of the work platform with personnel
a. That the crane does not have safety devices shall be done in a slow, controlled, cautious man­
normally used on personnel handling equip­ ner with no sudden movements of the crane or
ment. work platform.
b. That the safety of the operation depends on 13. Clear, unobstructed visibility between personnel
the skill and judgment of the crane operator on the work platform and the crane operator shall
and others present. be maintained at all times except where a desig­
c. Of procedures to enter and leave the work plat­ nated signal person has been assigned and posi­
form and other safety procedures. tioned such that he is visible to both. Such desig­
7. After positioning of the work platform: nated signal person shall have no other duties to
a. All brakes and locks on the lift crane shall be perform when personnel are in the work platform.
set before personnel perform any work. 14. Voice communication between work platform per­
b. With pinning and latching style extendable sonnel, the crane operator, and designated signal
booms, a visual inspection shall be conducted person, if assigned, shall be maintained.
to verify that the boom extend pins are properly 15. If other cranes or equipment may interfere with the
set in the extended boom sections. lifting of personnel, signals or other means of com­
8. Telescope operation is not recommended with any munication between all crane or equipment oper­
extendable boom with personnel in the work plat­ ators shall be maintained to avoid interference with
form. individual operations.
9. A work platform attached to load line of lift cranes 16. If the work platform is not landed, it shall be tied to a
shall not be used for working on any energized structure before personnel mount or dismount the
electric power line, or any energized device or facil­ work platform.
ity used for electric power generation or transmis­ 17. Personnel in the work platform shall wear personal
sion. Minimum working clearance shall be at least fall arrest systems. Anchors used for attachment of
twice that recommended for material handling op­ personal fall arrest equipment shall be independ­
erations in ANSI B30.5b section 503.4.5 and ANSI ent of any anchors being used to support or sus­
B30.23. pend work platforms. Personnel shall keep all
parts of body, tools, and equipment inside work
platform during raising, lowering, and positioning.

1-24 Section 1 - Operating Instructions

 Operator's Manual
18. Personnel shall always stand firmly on the floor of Additional Requirements For Offshore Cranes
the work platform and shall not sit or climb on the 1. Link‐Belt offshore cranes are designed to handle
edge of the work platform or use planks, ladders, materials. However, due to the special conditions
or other devices for attaining a work position. (This commonly existing offshore, the use of cranes to
does not apply to offshore personnel transfer bas­ transfer personnel between vessels or from a ves­
kets. Personnel must ride on the exterior of this sel to a work platform is an established practice.
type of personnel handling device to assure great­ The safety of the personnel, if a materials handling
er safety of the operation.) crane is used in transferring personnel, depends
19. When welding is done by personnel in the work upon the skill and judgment of the crane operator
platform, the electrode holders shall be protected and alertness of the personnel being transferred.
from contact with metal components of the work Sea and weather conditions may create additional
platform. If electrically connected electrode hold­ hazards beyond the skill of persons involved.
ers contact work platform, work platform could be This operation is approved by the American Petro­
dropped due to burning/melting of wire ropes sus­ leum Institute (A.P.I.). By adopting procedures for
pending the work platform. this operation, the institute has determined that the
transfer of personnel may be performed safely un­
der certain offshore conditions. Therefore,
whenever an offshore crane is used to transfer per­
sonnel, all persons involved in the operation must
know and implement the A.P.I. procedures and
verify that sea and weather conditions are within
safe limits for the transfer.
In addition to all previous requirements in these In­
structions, A.P.I. 2C requires the following:
S Boom and load hoists used shall be approved by
the hoist manufacturer for personnel handling
and shall be so indicated on their name plate.
S Refer to A.P.I. 2C Section 6 for further details and
procedures.

Section 1 - Operating Instructions 1-25

Operator's Manual

Personnel Handling
Pre‐Lift Check List for Link‐Belt Cranes

I am the designated person responsible for verifying that all safety requirements are met for this
personnel handling operation;
1
Name: Title:

Signature: Date: / / Initials

2 I have verified that there are no better alternative means to handle personnel for this operation.
I have a written statement authorizing personnel handling from a competent person on the job
3
who accepts full responsibility, or I accept full responsibility for the operation.
The Crane Operator acknowledges that he has read and fully understands the Crane
4 Operator's Manual and Crane Rating Manual. All personnel involved have been informed and
understand the tasks required to complete the personnel lifting operation.
The crane has been maintained, lubricated, and adjusted by a designated person, as
5
specified in the Crane Operator's Manual.
6 The lift crane is equipped, and all devices operate properly as follows:
S Anti-two block device with hydraulic cutouts
S Power load raising and lowering with automatic brakes and function cutouts - Free-Fall (if
equipped) shall not be used
S Boom angle indicator with high and low set points and function cutouts
S Boom length indicator (telescopic booms only) and function cutouts
S Rated Capacity System
S A variable swing brake or swing controls capable of stopping upper swing motion smoothly
S A mechanical swing park brake or swing lock to hold the upper in position while personnel
are working from the work platform
S Hook block or hook ball being used can be closed and locked with a safety latch
7 A working audible and visual alert system is provided to the personnel in the work platform.
8 A mechanical and structural crane inspection has been completed by a designated person.
Test has been completed with twice the total load in the work platform that is expected for the
9
total load during the personnel handling operation.
10 Lifting personnel is allowed from:
S Telescopic Boom Cranes - Main boom head sheaves only
S Lattice Boom Cranes - Main boom head sheaves only or on a luffing attachment, the luffing
jib head sheaves only
11 Crane travel is not allowed with personnel in the work platform.
12 Telescoping the boom is not recommended with personnel in the work platform.
When handling personnel with pinning and latching style booms, it is recommended that the
13 boom be kept in a pinned position. Inspections must be done to ensure that all boom extend
pins are set.
Voice communications between the Crane Operator and the personnel in the work platform
14
are present and operational.
15 Fall arrest systems are present and in use by personnel in the work platform.
16 Weather and wind conditions are acceptable to safely perform the lift.

Note: This checklist is to be used as a supplement to (not a substitute for) the information and procedures
supplied for personnel handling operations.

1-26 Section 1 - Operating Instructions

 Operator's Manual
1 2 3 4 5 6 7 8 9 10 11 12 13

Rear Wheel Combination Range Select Travel Swing Park Brake Fine Metering 3rd Wrap Ind. Boom Floodlight Driving Lights Emergency Flashers A/C Controls
Brakes Offset Steer Park Brake On On On On On

Front
2H 2WD High
Apply Off Off Off Off Off
2L 2WD Low

On Operate On On On High
6L 6WD Low
Rear Med

Off Disable Off Off Off Low

Check Gauges Function Lockout Upper Lights Wiper/Washer Rotating Beacon

22 21 20 19 18 17 16 15 14
1. Engine Speed Warning Light 9. Third Wrap Indicator Switch 16.Upper Lights Switch
2. Service Brake Warning Light 10.Boom Floodlight Switch 17.Function Lockout Switch
3. Rear Wheel Offset Indicator Light 11.Driving Lights Switch 18.Travel Park Brake Switch
4. Combination Steering Switch 12.Emergency Flashers Switch 19.Check Gauges Audio Alarm
5. Range Select Switch 13.Air Conditioner Controls 20.First Layer Warning Light
6. Travel Park Brake Indicator Light 14.Rotating Beacon Switch 21.Third Wrap Warning Light
7. Swing Park Brake Indicator Light 15.Wiper/Washer Switch 22.Case Drain Filter Change Indicator
8. Fine Metering Switch

Figure 1-33
Cab Control Panel

when the rear wheels are out of line with the carrier.
Cab Control And Gauge Panels Refer to “Combination Steering” found later in this
Located throughout the cab are several panels which Section of the Operator's Manual for complete op­
contain the controls, switches, and gauges to operate erating procedures.
and monitor crane operations. The following is a de­
scription of each gauge, switch, or control in each pan­ 4. Combination Steering Switch
el, along with an explanation of their function and/or The crane is equipped with four different modes of
operation. steering in order to provide maximum maneuver­
ability on the job site. Refer to “Combination Steer­
Control Panel ing” found later in this Section of the Operator's
The control panel is located above and to the right of Manual for complete operating procedures.
the operator. It contains the following controls and is
shown in Figure 1-33. 5. Range Select Switch
This switch is used to select either the 2‐Wheel
1. Engine Speed Warning Light High drive mode, 2‐Wheel Low drive mode, or
This light will illuminate along with an alarm buzzer 6‐Wheel Low drive mode. Bring the crane to a
to alert the operator that the engine speed is too complete stop and position the transmission shift­
high. When this light illuminates, decrease engine er to neutral before changing the position of the
speed until light extinguishes. range select switch.

2. Service Brake Warning Light 6. Travel Park Brake Indicator Light

This light will illuminate to warn the operator of an This light will come on anytime the park brake is en­
imminent brake failure. Approximately twelve gaged and the ignition is on.
brake applications can be obtained prior to com­
plete brake system failure. When this light illumi­ 7. Swing Park Brake Indicator Light
nates discontinue operations immediately and cor­ This light will illuminate anytime the swing park
rect the problem before placing the crane back into brake is applied and the ignition is on.
service.
3. Rear Wheel Offset Indicator Light
(If Equipped)
Cranes which are equipped with combination
steering use this indicator light to alert the operator

Section 1 - Operating Instructions 1-27

Operator's Manual
8. Fine Metering Switch operation of these controls. To allow normal
operation of the control levers and boom telescope
This switch is used to activate the fine metering
foot pedal, move function lockout switch to the
system. Refer to “Fine Metering System” found lat­
“OPERATE” position.
er in this Section of the Operator's Manual.
18. Travel Park Brake Switch
9. Third Wrap Indicator Switch (If Equipped)
This switch controls engaging and releasing the
This switch operates the third drum wrap indicator
park brake.
system for the winch drum(s). When this switch is
in the “ON” position, a red warning light will illumi­
nate and a buzzer will sound to alert the operator
when the wire rope is down to the third wrap on the WARNING
winch drum. Do not use the park brake to stop the crane in
motion (as a service brake) except in cases of
10. Boom Floodlight Switch (If Equipped) extreme emergency. Application cannot be
This switch operates the boom floodlight. Flip the controlled.
switch up to turn floodlight on, down to turn it off.

11. Driving Lights Switch To Engage Park Brake

a. Bring the crane to a full stop.
Pull the knob out to illuminate the headlights and b. Position the transmission shifter to neutral.
parking lights. To turn the lights off, push knob in. c. Move park brake switch to “ON” position.
d. Park brake indicator light should illuminate.
12. Emergency Flashers Switch
This switch controls the warning flashers. Flip the To Release Park Brake
switch up to turn flashers on, down to turn them off. a. Apply the carrier service brake.
b. Move park brake switch to the “OFF” position.
13. Air Conditioner Controls (If Equipped) c. The park brake indicator light should go out.
These switches control the air conditioner. Use the 19. Check Gauges Audio Alarm
top toggle switch to turn the unit on and off and the
lower toggle switch to select the desired mode. This buzzer alarm will sound to alert the operator
that a gauge is detecting an abnormal operating
14. Rotating Beacon Switch (If Equipped) range. The check engine or stop engine light will
also illuminate where applicable. The problem
This switch controls the cab rotating beacon. Flip
should be repaired before operating the crane.
the switch up to turn beacon on, down to turn it off.
20. First Layer Warning Light (If Equipped)
15. Wiper/Washer Switch
The crane may be equipped with a first layer warn­
Rotate the wiper/washer knob clockwise to acti­ ing light option. This red warning light will illumi­
vate the windshield wiper. Rotate the knob to the nate to alert the operator that there is one layer of
first detent for low speed wiper, to the second wire rope on the winch drum.
detent for high speed wiper. Rotate the knob
counter‐clockwise to turn wiper off. Push the wip­ 21. Third Wrap Warning Light (If Equipped)
er/washer knob to spray cleaning fluid to wash the The crane may be equipped with the third wrap in­
windshield. dicator option. This red warning light will illuminate
and a buzzer will sound to alert the operator that
16. Upper Lights Switch the wire rope is down to the third wrap on the winch
This switch operates upper lights. Flip switch up to drum.
turn lights on, down to turn them off.
17. Function Lockout Switch
This switch is used to disable hydraulic functions
WARNING
Three (3) full wraps of wire rope must be
which are operated by the control levers and boom
maintained on the winch drum at all times
telescope foot pedal. Move switch to the
during operation. Rope failure may occur.
“DISABLE” position to prevent inadvertent

1-28 Section 1 - Operating Instructions

 Operator's Manual
22. Case Drain Filter Change Indicator Light
This indicator light will illuminate to alert the opera­
tor that the case filter is being by‐passed. If this
light illuminates, change the filter immediately. Re­
fer to “Hydraulic Case Drain Filter Change” found
in Section 2 of this Operator's Manual.

Gauge Panel 9
10 8
The gauge panel is located in the right front corner of 7
the operator's cab. It contains the following gauges
6
and is shown in Figure 1-34.

1. Tachometer
5
The tachometer registers engine speed in revolu­
tions per minute (rpm). Refer to the engine manu­
facturer's manual for suggested operating speeds. 4

2. Engine Oil Pressure Gauge

3
This gauge registers the engine oil pressure. For
proper oil pressure operating range, refer to the
engine manufacturer's manual. If there is no en­ 2
gine oil pressure after 10-15 seconds of running
time, shutdown the engine immediately and repair
1
the problem to avoid engine damage. When the oil
pressure exceeds or drops below normal operat­
ing range, an indicator light within the gauge will il­
luminate and an alarm buzzer will sound.
1. Tachometer 7. Hydraulic Charge Filter Indi­
3. Water Temperature Gauge 2. Engine Oil Pressure Gauge cator Light
3. Water Temperature Gauge 8. Stop Engine Indicator Light
This gauge registers the engine cooling system 4. Fuel Level Gauge 9. Check Engine Indicator
temperature. For proper cooling system operating 5. Battery Gauge Light
temperature range, refer to the engine manufactur­ 6. Hydraulic Oil Temp Gauge 10.Pump CPU Indicator Light
er's manual. If the cooling system overheats, re­ Figure 1-34
duce engine speed until the temperature returns to Gauge Panel
normal operating range. If engine temperature
does not return to normal temperature, refer to en­
gine manufacturer's manual. When the coolant 5. Battery Gauge
temperature exceeds normal operating range an
indicator light within the gauge will illuminate and This gauge registers the charge in the batteries
an alarm buzzer will sound. and the output of the alternator through the regula­
tor. It should read 12 volts with the key on, and 12.5
4. Fuel Level Gauge to 14 volts with the engine running. If the gauge is
not registering within the normal range, an indica­
This gauge registers the level of fuel in the fuel tank. tor light within the gauge will illuminate.
The fuel tank capacity is 95 gal (360L). Refer to the
engine manufacturer's manual for the correct
grade of diesel fuel. When the fuel level reaches an
eighth of a tank, an indicator light within the gauge
will illuminate.

Section 1 - Operating Instructions 1-29

Operator's Manual
6. Hydraulic Oil Temperature Gauge 10. Travel Pump CPU Indicator Light
This gauge registers the hydraulic oil temperature This light will flash to alert the operator that a fault
in the main return line. Normal operating ranges has been detected from the travel pump control
vary with the oils used in different climates. Refer to unit. Refer to “Travel Pump Control Unit” found lat­
Section 2 of this Operator's Manual for proper oil er in this Section of the Operator's Manual. There
viscosities and operating temperature ranges. If is an indicator light on the PCU that will flash the
the hydraulic oil exceeds the maximum operating same codes. The following describes the flash pat­
temperature, an indicator light within the gauge will tern fault code.
illuminate and an alarm buzzer will sound. Shut­ Flashing Pattern:
down the crane immediately and correct the prob­
1 Flash = Loss of engine speed feedback sig­
lem before continuing operations.
nal.
7. Hydraulic Charge Filter Indicator Light 3 Flashes = DC voltage supply to module is less
than 8.5 volts.
This indicator light will illuminate to alert the opera­
tor that the hydraulic charge filter is being by‐ 4 Flashes = Either an electrical short or an open
passed. If this light illuminates, change the filter im­ circuit has occurred.
mediately. Refer to “Hydraulic Charge Flow Filter 5 Flashes = Loss idle validation signal.
Change” found in Section 2 of this Operator's 9 Flashes = Bad learn‐in has occurred
Manual.
Note: The pump CPU light will illuminate mo­
8. Stop Engine Indicator Light mentarily when the ignition is turned on as a
This red indicator light will illuminate along with an means of testing the indicator light. The light
alarm buzzer to make the operator aware of critical should go out after a short period of time.
engine problems. When this light illuminates stop
operations immediately and shutdown the engine. Shifter Console
Consult the engine manufacturer's manual and
The shifter console is located to the right of the opera­
determine the problem before any further opera­
tor. It contains the following controls and is shown in
tion of the engine. This light will also flash when us­
Figure 1-35.
ing the engine diagnostic request switch to retrieve
active engine fault codes stored in the engine con­ 1. Engine Diagnostic Connector
trol module (ECM).
The diagnostic connector provides access to diag­
Note: The stop engine light will illuminate mo­ nostic codes within the engine control module
mentarily when the ignition is turned on as a (ECM). The service technician can plug in a data
means of testing the indicator light. The light reader to retrieve the engine fault codes stored in
should go out after a short period of time. the ECM. Refer to the engine manufacturer's man­
ual for information on engine diagnostics and en­
9. Check Engine Indicator Light gine fault code descriptions.
This amber indicator light will illuminate along with
an alarm buzzer to make the operator aware of 2. Engine Diagnostic Request Button
minor engine problems. When this light illuminates This button is used to activate the stop engine indi­
engine operation may continue. However, consult cator light to flash active engine fault codes. When
the engine manufacturer's manual and determine the engine is not running and with the ignition on,
the problem as soon as possible to avoid prolonged pressing and holding the button will flash out en­
operation of the malfunctioning engine which could gine fault codes through the stop engine indicator
develop into a major problem. This light will also light.
flash when using the engine diagnostic request
switch to retrieve inactive engine fault codes stored Refer to the engine manufacturer's manual for in­
in the engine control module (ECM). formation on engine diagnostics and engine fault
code descriptions.
Note: The check engine light will illuminate mo­
mentarily when the ignition is turned on as a
means of testing the indicator light. The light
should go out after a short period of time.

1-30 Section 1 - Operating Instructions

 Operator's Manual

3 4 5 6 7 8

1. Engine Diagnostic Connector 5. Trans Temperature Gauge

2. Engine Diagnostic Request Button 6. Transmission Shifter
3. 360 Degree Swing Lock 7. 12V DC Accessory Outlet
4. Travel Swing Lock 8. Bubble Level

Figure 1-35
Shifter Console

3. 360 Degree Swing Lock (If Equipped) 6. Transmission Shifter

This lever is used to lock the upper in any position This transmission shifter is used to control the di­
over the carrier. Refer to “Swing System” found lat­ rection of travel. Refer to “Transmission Shifter”
er in this Section of this Operator's Manual for com­ found later in this section of this Operator's Manual.
plete operating procedures.
7. 12V DC Accessory Outlet
4. Travel Swing Lock Use this outlet for electrical accessories.
This knob is used to lock the upper directly over ei­
ther the front or rear of the carrier. Refer to “Swing
System” found later in this Section of this Opera­
CAUTION
tor's Manual for complete operating procedures. Do not connect an accessory to any part of the
crane other than the accessory outlets.
5. Trans Temperature Gauge Damage to the crane's electrical system may
This gauge registers the hydraulic oil temperature result. If it is necessary to do so, contact your
in the wheel motor return line. Normal operating Link‐Belt distributor.
ranges vary with the oils used in different climates.
Refer to Section 2 of this Operator's Manual for
proper oil viscosities and operating temperature
8. Bubble Level
ranges. If the hydraulic oil exceeds normal operat­ The bubble level is provided to assist the operator
ing temperature, an indicator light within the gauge in leveling the crane on outriggers.
will illuminate and an alarm buzzer will sound.
Shutdown the crane immediately and correct the
problem before continuing operations.

Section 1 - Operating Instructions 1-31

Operator's Manual
2. Throttle Indicator Light
1 This light will illuminate when the throttle select
2 switch is in the “Hand” position.
3
3. Hand Throttle Control Knob
The hand throttle gives the operator the ability to
set and hold a specific engine speed. Turning the
4 throttle control knob clockwise increases engine
speed; turning it counter‐clockwise reduces en­
gine speed. The throttle select switch must be in
the “Hand” position to use the hand throttle control
knob. Refer to “Engine Throttle” found later in this
5 Section of the Operator's Manual.
6 4. Rated Capacity Limiter Display
This displays the boom length, boom angle, load
weight, etc. See “Crane Monitoring System” found
later in this Section of the Operator's Manual for
1. Throttle Select Switch 4. RCL Display complete operating instructions.
2. Throttle Indicator Light 5. Heater Switch
3. Hand Throttle Control Knob 6. Heat Control Knob
5. Heater Switch
Figure 1-36 To start the cab heater, move the heater switch to
Rated Capacity Limiter Panel the “LOW” or “HIGH” position. To stop the cab
heater, move the heater switch to the “OFF”
Rated Capacity Limiter Panel position.
The Rated Capacity Limiter panel is located to the low­ 6. Heater Control Knob
er right of the operator. It contains the following and is
shown in Figure 1-36. Turn the heater control knob to adjust the tempera­
ture in the cab.
1. Throttle Select Switch
The throttle select switch allows the operator the
flexibility to choose between “Hand” operated, or
“Foot” operated throttle control.

1-32 Section 1 - Operating Instructions

 Operator's Manual
Steering Column And Wheel
The following is a description of the controls on the
steering column, along with an explanation of their 4
function and/or operation. Refer to Figure 1-37.
5
1. Turn Signal Lever 1
Pull the lever back for left turn signal, push forward
on lever for right turn signal. 2 6

2. Ether Start Button (If Equipped) 7

The ether start system is activated by pressing this
button while cranking the engine. Refer to “Ether
Start” in this Section of the Operator's Manual for
additional details and operating instructions.

3. Column Tilt Pedal

This pedal controls the tilt (angle) function of the
steering column. To change steering column angle:
a. Bring the crane to a complete stop.
b. Position the transmission shifter to neutral and
engage the park brake.
c. Depress the column tilt pedal.
d. Position the steering wheel at the desired an­
gle and release pedal to lock it in place.
e. Check all steering wheel functions before con­
tinuing operation. 3

4. Telescoping Column Knob

This knob controls the telescoping function of the
steering wheel. To change steering wheel height:
1. Turn Signal Lever 4. Telescoping Column Knob
a. Bring the crane to a complete stop. 2. Ether Start Button (If 5. Steering Wheel
b. Position the transmission shifter to neutral and Equipped) 6. Horn
engage the park brake. 3. Column Tilt Pedal 7. Ignition Switch
c. Turn control knob counter‐clockwise. Figure 1-37
d. Position steering column at desired height and Steering Column and Wheel
turn control knob clockwise to lock it in place.
e. Check all steering wheel functions before con­ 6. Horn
tinuing operation.
The button on the right of the steering column acti­
5. Steering Wheel vates the horn. Press the button to sound the horn.
Turn the steering wheel clockwise for right turns
7. Ignition Switch
and counter‐clockwise for left turns.
The ignition switch is the key operated, automotive
Note: Steering function remains the same when type. It controls engine off/run/start and energizes
upper is positioned directly over the rear. the instrument panel gauges in the cab.

Section 1 - Operating Instructions 1-33

Operator's Manual
1
2 WARNING
Do not attempt to travel crane up or down a
grade larger than the crane capability in a
particular Range Select. Failure to do this
could result in loss of control and/or crane
damage. Also some crane capabilities such
as 6 WD Low maximum gradeability may not
be usable due to such factors as maximum
engine oil pan angle and crane stability.

Note: Relative direction of the crane is based on the

carrier.

1. Transmission Shifter
1. Transmission Shifter The transmission shifter is used to select forward,
2. Transmission Temperature Gauge reverse, or neutral. To travel forward or reverse, the
release ring under the knob must be pulled up to
Figure 1-38 release the neutral lock. The lever is then pushed
Transmission Shifter
forward to engage forward travel, or backward to
engage reverse travel.

Transmission Controls 2. Trans Temperature Gauge

The transmission is a continuously variable hydrostatic This gauge registers the hydraulic oil temperature
drive. The transmission shifter is located on the shifter in the wheel motor return line. Normal operating
console to the right of the operator. Refer to ranges vary with the oils used in different climates.
Figure 1-38. The transmission shifter has three‐posi­ Refer to Section 2 of this Operator's Manual for
tions (with lock in neutral feature) for forward, neutral, proper oil viscosities and operating temperature
and reverse. When using the range select switch on ranges. If the hydraulic oil exceeds normal operat­
the overhead cab control panel, the crane has 3 for­ ing temperature, an indicator light within the gauge
ward and 3 reverse speeds. See “Traveling The Crane” will illuminate and an alarm buzzer will sound.
found later in this Section of the Operator's Manual for Shutdown the crane immediately and correct the
necessary preparations before traveling the crane. problem before continuing operations. If the crane
is using Grade 100 oil, the indicator light and buzz­
Crane er will activate at 190° F (88° C). If the crane is us­
Max Speed ing Grade 68 oil, the indicator light and buzzer will
Range Capability
Select activate at 170° F (77°C). If the crane is using
Max Grade
mph km/hr Grade 22 oil, the indicator light and buzzer will acti­
Allowed
vate at 110° F (43° C).
6 WD Low 3 4.8 55%
2 WD Low 9 14.5 15%
2 WD High 18.5 29.8 6%

CAUTION
Extended driving in 6 WD Low may damage
the hydraulic system. Limit travel in this mode
to 1/2 hour maximum time period. Select
appropriate travel range based on the grade
of slope.

1-34 Section 1 - Operating Instructions

 Operator's Manual
Transmission Travel Limits
Hydraulic Oil Max Travel System Temperature
Travel Conditions Auxiliary Oil Cooler
Grade °F °C
22 110 43
Heavy Required 68 170 77
100 190 88
22 110 43
Not Required
Moderate 68 170 77
Required 100 190 88
Not Required 22 110 43
Light Not Required 68 170 77
Not Required 100 190 88
Heavy:Extensive 6‐wheel drive (greater than 30% of the time), or grades greater than 10%, or 2‐wheel travel
greater than 5 miles.
Moderate: 6‐wheel drive (5-30% of the time), or grades 5-10%, or 2‐wheel travel 2-5 miles.
Light: 6‐wheel drive (0-5% of the time), or grades 0-5%, or 2‐wheel travel 0-2 miles.

Operating The Transmission Shifter 3. Forward Travel

a. With the transmission shifter in neutral, fully
apply the carrier service brake and release the
CAUTION park brake.
Extended travel may cause the hydraulic oil in b. Move transmission shifter to the “F” position.
the travel circuit to overheat. Crane damage c. Slowly release the service brake while using
may occur if hydraulic oil temperatures are the throttle pedal to increase the engine and
exceeded. Monitor the trans temperature travel speed, allowing the crane to accelerate.
gauge to ensure hydraulic oil temperature 4. Reverse Travel
within the travel circuit is not exceeded. Refer a. With crane at a full stop, apply the carrier ser­
to the Transmission Travel Limits chart for vice brakes, and position the transmission
maximum travel system temperatures. shifter to neutral.
b. Move transmission shift lever to the “R” posi­
1. Engage the park brake and place transmission tion.
shifter in neutral position. Start the engine. (En­
Note: The travel/back‐up alarm will sound
gine will start only when transmission shifter is in
anytime the transmission shifter is in re­
neutral.) Allow the hydraulic oil to circulate for a
verse. It will also sound anytime the trans­
few moments.
mission shifter is moved out of neutral and
2. Engage travel swing lock and release the 360_
the upper is not positioned directly over the
swing lock, if equipped.
front of the carrier.
c. Slowly release the service brake while using
CAUTION the throttle pedal to increase the engine and
Do not leave the 360_ swing lock engaged travel speed, allowing the crane to accelerate.
during pick and carry operations or when
traveling or transporting the crane. Use the
travel swing lock. Failure to release the 360_
swing lock during these operations may result
in damage to the swing gear.

Section 1 - Operating Instructions 1-35

Operator's Manual
Front Front Front Front

Conventional Rear Wheel 6-Wheel Crab

Figure 1-39
Steering Modes

turn in the opposite direction. This results in a greatly

Combination Steering reduced turning radius that allows extra maneuverabil­
The crane is equipped with four different modes of ity in certain job site conditions. Use this steer mode for
steering in order to provide maximum maneuverability job site travel and pick and carry operations only; not
on the job site: conventional, rear wheel, 6‐wheel, and for extended or highway travel.
crab steer. Each steer mode provides slightly different
In six wheel steer mode, holding the steering wheel
maneuverability to meet job site requirements. Refer to
against the stops allows the inside wheels to spin 30%
Figure 1-39 for illustration of the four steer modes.
slower than the outside wheels. This feature provides a
Conventional Steer Mode tighter turn radius.
This steer mode is similar to that of an automobile. In Crab Steer Mode
this steer mode, the front wheels may be turned in
This steer mode allows steering with all six wheels. The
either direction and the rear wheels remain straight.
front and rear wheels turn simultaneously in the same
Use this steer mode for all extended or high speed
direction which moves the crane in a diagonal path of
travel.
travel. This gives the operator another method of ma­
neuvering the crane where job site conditions require
it. Use this steer mode for job site travel only; not for
WARNING extended or highway travel.
Do not use rear wheel, 6‐wheel, or crab steer
mode for extended or high speed travel as Changing Steering Modes
steering behavior may be unfamiliar and a The crane may be equipped with a rear wheel offset in­
loss of crane control could occur. dicator light located on the control panel. It is designed
to assist the operator when changing steering modes,
by determining when the rear wheels are straight. This
Rear Wheel Steer Mode light will come on anytime the rear wheels are not in‐
This steer mode is similar to that of a fork truck. In this line with the carrier. Use the following procedure when
steer mode, the rear wheels may be turned in either di­ changing steering modes:
rection and the front wheels remain straight. Use this 1. Bring the crane to a complete stop.
steer mode for job site travel and pick and carry opera­ 2. If equipped with the rear wheel offset indicator, turn
tions only; not for extended or highway travel. the steering wheel until light goes off.
3. Move steer switch to conventional steering mode.
6‐Wheel Steer Mode 4. Check all wheels for proper alignment by traveling
This steer mode allows steering with all six wheels. The the crane a short distance, straight ahead, to en­
front wheels turn in one direction and the rear wheels sure it tracks straight.
5. Bring the crane to a complete stop and move the
steer mode switch to the desired position.

1-36 Section 1 - Operating Instructions

 Operator's Manual

7 1
6 2

3
5

1. Power 4. Pulse Width Modulation (PWM) Out­ 6. Module Status

2. Status put Driver Status 7. Network Status
3. High Side Output Driver Status 5. Digital Input Status

Figure 1-40
Pump Control Unit

The pump control unit uses light emitting diodes

Travel Pump Control Unit (LED's) to indicate operating conditions and to perform
The travel pump control unit is mounted on the right system diagnostics. The LED's are defined in Table A.
side wall of the operator's cab, just behind the opera­
tor's seat. It is constantly measuring the throttle posi­ Diagnostic Error Codes
tion and engine rpm electronically. The unit receives The status LED, on the pump control unit, will blink si­
input from the throttle (hand or foot pedal), engine multaneously with the “Travel Pump CPU Indicator
speed sensor, transmission shifter, and steer assist Light”, located on the gauge panel, to alert the operator
pressure switches. The control unit logic is as listed be­ that an error has occurred in the system. Either light
low. may be used to define an error message These lights
1. Automotive style driving: crane travel speed in­ are normally off but will illuminate and blink to inform
creases as throttle increases, pump rpm increases the operator of the error condition. Both lights will blink
as throttle increases, pump displacement in­ on for 1/2 second and then blink off for 1/2 second to
creases as throttle increases. indicate one blink. A sequence of blinks will be inter­
2. Horsepower dissipation: the control unit will send rupted by blinking off for 1 1/2 seconds. Count the
a signal to put the pump circuit over relief if the en­ number of blinks between interruptions to determine
gine rpm exceeds throttle position by more than each of the error messages. The error codes are spe­
6% of the mapped throttle position rpm. This fea­ cifically defined in Table B.
ture is important during travel and winch operation
to prevent engine over‐speed. Diagnostic Connector
3. Anti‐stall feature: will reduce pump displacement A diagnostic connector is located in the wire harness,
if engine speed drops below throttle position by below the pump control unit, for initial calibration or ex­
more than 6% of mapped throttle position rpm. tensive troubleshooting. Extensive troubleshooting re­
This reduces load on the engine and prevents the quires a laptop computer, diagnostic software, and a
engine from stalling. factory trained technician. Contact your area distribu­
tor if extensive troubleshooting is required.

Section 1 - Operating Instructions 1-37

Operator's Manual
No. LED Description Qty Color Signal Description
1 Power 1 Green S On: Power On, Normal
S Blinks: Power supply Voltage is > 30Vdc
S Off: Power supply Voltage is < 8Vdc
2 Status 1 Red S Off: Normal
S Blinking: System error, see Table B
3 High Side Output Driver Status 6 Green S On: Corresponding high side output is
activated.
S Blinks once per second: Open circuit
S Blinks 4 times per second: Short Circuit
4 PWM Output Driver Status 3 Red/Yellow/Green This LED displays duty‐cycle status for the
corresponding PWM output. The LED will
A: Left Side Pump change from red, to yellow, to green as the
B: Right Side Pump duty‐cycle changes from 0% to 100%; dis­
C: HP Dissipation playing yellow at 50%.
5 Digital Input Status 8 Green S Turns on when the corresponding input is
activated. Inputs can be programmed as
active high or low.
S Off: Not Used See Table C
6 Module Status 1 Green/Red S Off: No power applied to module
S On Green: Normal
S Blinks Green: Standby
S Blinks Red: Recoverable fault
S On Red: Module has unrecoverable fault
S Blinks Red/Green: Self test Mode
7 Network Status Green/R ed S Off: Device in not on line
S Blinks Green: Device is on line but has
Not Used not established connection
to other nodes
S On Green: Device is on line and has
established connection to
other nodes
S Blinks Red: One or more connections is
in a timed-out state
S On Red: The device has detected an error
that has rendered it incapable of
communicating on the network
Table A
Pump Control Unit Indicator Lights

1-38 Section 1 - Operating Instructions

 Operator's Manual
Blink Code Error Recommended Action
0 Blinks Normal, no errors S No action required
S Check that engine is running
Speed feedback signal from engine has been
1 Blink S Check wiring and connections between
lost
pump control unit and the engine
S Check fuses
3 Blinks Power supply voltage is < 8.5Vdc S Check crane battery for low voltage
S Check circuit wiring and connections
S Check fuses
S Check circuit wiring and connections to pro­
Open or shorted connection to proportional
4 Blinks portional solenoids
valve solenoids
S Confirm working condition of solenoids; re­
pair or replace, as required.
S Check fuses
S Check circuit wiring and connections to
Throttle switch is not closed or not making
5 Blinks throttle pedal switch
contact
S Confirm working condition of throttle pedal
switch; repair or replace, as required.
Bad Learn‐In (calibration) of engine No‐Load
9 Blinks S Contact area distributor
RPM.
Table B
Pump Control Unit Diagnostic Error Codes

Status Connector
Function
Indicator Pin No.
DIG 1 Direction Mode - Forward F3
DIG 2 Direction Mode - Reverse G3
DIG 3 Learn‐In H3
DIG 4 Not Used J1
DIG 5 Not Used J2
DIG 6 Idle Validation/Limit Switch J3
DIG 7 Left Steer Assist Pressure Switch K2
DIG 8 Right Steer Assist Pressure Switch K3
HSOUT 1 Left Propel Pump - Forward B1
HSOUT 2 Left Propel Pump - Reverse B2
HSOUT 3 Right Propel Pump - Forward C1
HSOUT 4 Right Propel Pump - Reverse C2
HSOUT 5 Horsepower Dissipation D1
HSOUT 6 Error Status Light D2
Table C
Digital Input & High Side Output Status Indicators

Section 1 - Operating Instructions 1-39

Operator's Manual
Top Hatch Wiper
The top hatch wiper motor is located in the top right
corner of the cab roof. The switch for the wiper is lo­
cated on the wiper motor. Move the switch to the “ON”
or “OFF” position as desired. Refer to Figure 1-41.

1. Wiper Switch
2. Wiper Motor

Figure 1-41
Top Hatch Wiper

1-40 Section 1 - Operating Instructions

 Operator's Manual

7
5 6
4
3
2
1

1. 15 Amp Circuit Breaker 5. Hour Meter

2. 20 Amp Circuit Breaker 6. Battery Disconnect Switches
3. 30 Amp Circuit Breaker 7. Batteries
4. 30 Amp Circuit Breaker

Figure 1-42
Power Panel, Battery Disconnect Switches, And Hour Meter

Battery Disconnect Switches Power Panel Circuit Breakers

The battery disconnect switches are located in the bat­ The power panel is located on the right front of the up­
tery box on the right front of the upper. Refer to per. Refer to Figure 1-42. The power panel contains
Figure 1-42. reset type circuit breakers which service the crane's
electrical system. Depending upon how the crane is
equipped, the power panel may contain up to four re­
CAUTION set type circuit breakers which service the crane's elec­
Major damage may occur to the electronic trical system as follows:
equipment from welding on the crane prior to 1. 15 Amp Circuit Breaker - Oscillation Relay.
turning disconnect switches to the “OFF” 2. 20 Amp Circuit Breaker - Engine Diagnostic Plug.
position. 3. 30 Amp Circuit Breaker - DDEC Relay.
4. 30 Amp Circuit Breaker - Air Conditioning.
Ignition switch should be shut off at least 30
seconds prior to turning disconnect switches
to the “OFF” position. Hour Meter
The hour meter is located on the left side of the power
Move the disconnect switches to the “Off” position be­ panel box. The hour meter registers engine operating
fore welding on the crane to protect the crane's elec­ hours. It is useful in determining lubrication and main­
tronic components from damage due to an electric arc tenance schedules.
type welder. Ignition switch should be shut off at least
30 seconds prior to turning disconnect switches to the
“OFF” position.

Section 1 - Operating Instructions 1-41

Operator's Manual

9 10
11
12

7 6 5 4 3 8 2

1. Seat Belt 5. Seat & Console Release Lever 9. Outrigger Control Box Storage Location
2. Arm Rest Height Adjustment Knob 6. Seat Release Lever 10.Interior Light
3. Seat Height Adjustment Lever 7. Seat Back Adjustment Lever 11.Interior Light Switch
4. Tool Box 8. Fire Extinguisher 12.Fuse Panel Cover

Figure 1-43
Operator's Cab

1-42 Section 1 - Operating Instructions

 Operator's Manual
Operator's Seat
This 6‐way adjustable seat is controlled by manual
controls. Refer to Figure 1-43.

WARNING
Do not make seat or console adjustments
while operating the crane or while crane is in
motion. Discontinue operations and properly
park crane before making adjustments.

1. Seat Belt
A seat belt is provided and must be worn during all Figure 1-44
operations. To fasten the seat belt pull the belt out Operator's Cab Fuse Panel Identification Label
of the retractor and insert the tongue into the
buckle until you hear a snap and feel the latch en­
gage. Be sure the belt is not twisted and is fitting 7. Seat Back Adjustment Lever
snugly around the hips, not around the waist.
Raise the lever and lean back in the seat to adjust
the seat back to the desired position and release
the lever to lock the seat back in place.
WARNING
Always wear the seat belt while operating the Fire Extinguisher
crane. The seat belt must be snug and low
A fire extinguisher is located in the operator's cab be­
across the hips.
low the left console. Raise the left console to gain ac­
cess to the extinguisher. Refer to Figure 1-43. It is an
2. Arm Rest Height Adjustment Knob A B C type fire extinguisher, meaning it is capable of ex­
tinguishing most types of fires. The operator should be
Loosen the knob on the inside of the arm rest. familiar with its location, the clamp mechanism used to
Position the arm rest as desired and tighten knob. secure it in place, and foremost the operation of the de­
vice. Specific instructions, regarding operation, are
3. Seat Height Adjustment Lever given on the label attached on the fire extinguisher. A
Move the height adjustment lever to the left and charge indicator on the fire extinguisher monitors the
hold. Position the seat as desired and release the pressure within the tank. Check the indicator daily to
lever to lock the seat in place. ensure the fire extinguisher is adequately charged and
ready for use.
4. Tool Box
A tool box is provided under the operator's seat to
Operator's Cab Fuse Panel
store tools and other crane accessories. The fuse panel is located in the upper right rear corner
of the operator's cab. Located on the back of the fuse
5. Seat And Console Release Lever panel cover is a label which designates the electrical
Move the seat and console release lever to the left circuit protected by each fuse. Refer to Figure 1-43
and hold. Position the seat as desired and release and Figure 1-44. Each fuse has a letter designation
the lever to lock the seat in place. which corresponds to the upper electrical system as
shown on the fuse identification label.
6. Seat Release Lever
Move the seat release lever to the left and hold. Po­ Operator's Cab Interior Light
sition the seat as desired and release the lever to
lock the seat in place. The interior light is located above the fuse panel cover.
Use the switch below the light to turn the light on or off.
Refer to Figure 1-43.

Section 1 - Operating Instructions 1-43

Operator's Manual
The hand held, tethered control box stores on the right
side wall of the cab beside the operator's seat. Refer to
1 Figure 1-43 for control box location and Figure 1-45
10 for switch identification. The control box allows the op­
2 erator to remotely control all outrigger functions.

9
3 WARNING
Do not extend or retract an outrigger beam or
jack unless it is in full view of the operator or
4 signalman. Make sure all personnel and
8
obstructions are clear from the path of the
machinery.
5 7
To Extend Outrigger Beams
6 1. Park crane in the desired location. Position the
transmission shifter to neutral, engage the park
1. Beam - Left Front 6. Jack - Left Rear brake, and shutdown engine.
2. Jack - Left Front 7. Jack - Right Rear 2. Remove the pontoons from storage and attach one
3. Extend Mode - Beam/Jack 8. Beam - Right Rear to each outrigger jack.
4. Retract Mode - Beam/Jack 9. Jack - Right Front
5. Beam - Left Rear 10.Beam - Right Front

Figure 1-45 WARNING

Outrigger Switches Pontoons must be attached to outrigger jacks
before crane is set on outriggers. If pontoons
should settle, the jacks could disengage from
Outrigger Operation the pontoons, causing a loss of stability.
The outriggers can be used in any one of three 3. Determine the outrigger position desired. Set the
positions; fully retracted, intermediate extended, or extend position lever as required (Refer to
fully extended. The outriggers are controlled by Figure 1-46).
switches located on a hand held , tethered control box
(Refer to Figure 1-43 and Figure 1-45) and the
extend position levers located on the outrigger boxes WARNING
(Refer to Figure 1-46). Each outrigger switch (Left When making lifts on outriggers, all outrigger
Front, Left Rear, Right Front, Right Rear) controls all beams must be equally extended; all fully
functions of that outrigger beam and jack cylinder. The retracted, all intermediate extended, or all
mode switch controls outrigger cylinder direction, fully extended. Failure to do so will cause a
extend/retract. Each extend position lever controls the loss of stability and possible crane damage
extend length of the beam. It allows for beams to be and/or personal injury.
fully extended, or limits them to intermediate extended
lengths based on the selected position of the extend 4. Start the engine.
position lever. 5. Push an outrigger switch to the “BEAM” position
The outrigger pontoons must set on a smooth, solid and hold.
surface flush with ground with no hills or valleys under 6. Push the mode switch to “EXTEND MODE” posi­
them or they may be damaged or destroyed. If there is tion and hold until the beam reaches the selected
any doubt as to the ground conditions, use mats under position; intermediate extended or fully extended.
the pontoons. Check pontoons before and during op­ 7. When beam reaches selected position, release
erations. If they are allowed to settle, they may lose both switches.
their effectiveness, and make continued operations 8. Repeat steps 5-7, for each outrigger beam, until
unsafe. all the beams are set to the selected position.
9. If the intermediate extended beam position is to be
A bubble level is provided on the shifter console, in op­
used, visually check that all beams are properly
erator's cab, to assist in determining when crane is
positioned in the intermediate extended position.
level.

1-44 Section 1 - Operating Instructions

 Operator's Manual
All beams must be extended until the stop plate
contacts the extend position lever and the arrow is
aligned with the outrigger box collar. Refer to
Figure 1-46.
10. Set the rated capacity limiter to the proper setting Improper extension of outriggers can lead to serious
to match the position of the outrigger beams. personal injury and/or equipment damage. Use only
specified outrigger positions with corresponding
rated capacity limiter settings.
INTERMEDIATE EXTENDED
WARNING OUTRIGGER POSITION

When making lifts with the crane on

outriggers, all outrigger beams must be
equally extended; fully retracted,
intermediate extended, or fully extended.
When making lifts with the outrigger beams in
FULLY EXTENDED
the intermediate extended position, the
OUTRIGGER POSITION
extend position lever must be in the
intermediate extended position. Visually
check that all outrigger beams are extended
until the stop plate contacts the extend
position lever and the arrow is aligned with the
outrigger box collar before beginning
operations. Figure 1-46
Check that the Rated Capacity Limiter is set to Outrigger Extend Position Lever
the correct outrigger position before
beginning operation. 6. Check that all tires are clear of the ground and pon­
Failure to perform any of the above may cause toons are not settling.
crane damage and/or serious personal injury. Note: A bubble level is provided on the shifter
console to assist in determining when the crane
To Extend Outrigger Jacks - Raise is level.
The Crane
1. With the beams extended to the selected position
(fully retracted, intermediate extended, or fully ex­
tended), push an outrigger switch to the “JACK” WARNING
position and hold. All capacities listed in the Crane Rating
Manual, when on outriggers, are based on all
CAUTION tires clear of the ground, all outrigger beams
equally extended (fully retracted,
When the hoist line is tied off to the crane or intermediate extended, or fully extended),
any solid object, the winch system can be using the proper chart for the outrigger
overloaded causing major winch, wire rope, position and the crane setting level on a firm,
or crane damage. Do not extend boom, raise solid surface. Serious reductions in the crane
or lower the boom, or raise the crane on lifting capacity and unsafe operating
outriggers unless wire rope is spooled off the conditions can result if these conditions are
drum to prevent tension on the wire rope. not met.

2. Push the mode switch to “EXTEND MODE” and

hold until the jack cylinder is fully extended. To Retract Outrigger Jacks - Lower
3. Release both switches. The Crane
4. Repeat Steps 1-3 for each outrigger jack. 1. Fully retract the boom. Swing the upper over the
5. Raise or lower jacks as required to level the crane. front of the carrier and engage the travel swing lock.
2. Fully boom down.
Note: As conditions warrant, a proficient crane 3. Push an individual outrigger switch to the “JACK”
operator may operate multiple jack cylinders position and hold.
such as one end or side at the same time.

Section 1 - Operating Instructions 1-45

Operator's Manual
4. Push the center mode switch to “RETRACT hardware in the crane's tool box located under the
MODE” position and hold until the jack cylinder is operator's seat.
fully retracted.
5. Release both switches.
6. Repeat Steps 3-5 for each outrigger jack. WARNING
All outrigger jacks and beams must be fully
Note: As conditions warrant, a proficient crane
retracted before connecting pins are removed
operator may operate multiple jack cylinders
or the hydraulic pin cylinder is retracted.
such as one end or side at the same time. Failure to do so can result in personal injury
and/or crane damage.
To Retract Outrigger Beams 5. Remove the connecting pins or retract hydraulic
1. Push an individual outrigger switch to the “BEAM” pin cylinder.
position and hold. 6. Shutdown engine and relieve hydraulic system
2. Push the center mode switch to the “RETRACT pressure.
MODE” position and hold until the beam is fully re­
tracted.
3. Release both switches.
4. Repeat Steps 1-3 for each beam.
WARNING
Hydraulic oil is under pressure and may be
5. Store all pontoons in the brackets provided. hot. A sudden release of hot oil could cause
burns or other serious injury. Before
Outrigger Removal System removing or installing any outrigger circuit
hydraulic hose, shutdown the engine and
The front and rear outrigger boxes can be removed relieve hydraulic system pressure.
from the carrier to reduce the overall weight of the
crane. Quick disconnect type hydraulic fittings are uti­ 7. Remove hydraulic hoses from their ports on the
lized to reduce the effort of removing the outrigger carrier. Be sure to match up and mate the dust
boxes. The outrigger box assemblies weigh approxi­ caps and plugs from all the quick disconnect fit­
mately 8,000 lb (3 629kg) each. The crane or an auxilia­ tings and keep them clean for future use. Refer to
ry lifting device can be used to remove and install the Figure 1-48.
outrigger boxes. When using the crane boom to re­ 8. Remove the electrical connection from the recep­
move outrigger boxes, always refer to the Crane Rating tacle.
Manual to ensure crane capacities are not exceeded.
The auxiliary lifting device, skids, and any rigging used
must be capable of handling the entire weight of an out­
rigger box assembly.
WARNING
When using the crane's boom or an auxiliary
This crane may be equipped with hydraulic pin cylinder lifting device to handle the outrigger boxes,
system to ease removal of the outrigger boxes from the always ensure lifting capacities are not
carrier frame. exceeded.

Outrigger Box Removal 9. Using the crane's boom or an appropriate auxiliary

1. With crane parked on a firm, level surface, position lifting device, rig a sling to lifting shackles on top of
transmission shifter to neutral and apply park outrigger box.
brake. 10. Lift the outrigger box up and away from the crane.
2. Fully retract all outrigger jacks and beams. 11. Place and secure outrigger box onto a transport
3. Remove the pontoons from each outrigger jack vehicle.
and properly store them on the outrigger box. 12. Repeat procedure for the other outrigger box.
4. Remove the capscrews from the connecting pins. 13. Before transporting the crane be sure all hydraulic
If equipped with hydraulic pin removal, remove the hoses and mounting pins are secure.
pin locks from the hydraulic pin cylinder. Store the

1-46 Section 1 - Operating Instructions

 Operator's Manual

Outrigger pin retention devices must be

in place to prevent accidental removal.
Retention devices must be removed to pull
pins. See Operator's Manual.
STANDARD OUTRIGGER PINS OPTIONAL HYDRAULIC OUTRIGGER PIN REMOVAL

PIN

UNPIN HYDRAULIC OUTRIGGER PIN REMOVAL

Do not activate outrigger pin removal
BOLT 2 REQD PIN 2 REQD PINNING system when crane is on outriggers.
WASHER 4 REQD CLIP 2 REQD SWITCH
NUT 2 REQD VIEW FROM BACK OF OUTRIGGER VIEW FROM UNDER FENDER

OUTRIGGER
HYDRAULIC
AND ELECTRICAL
CONNECTIONS

NOTE: INBOARD
HYDRAULIC HOSE
IS CABLE TIED
TO THE WIRE
HARNESS

6 VIEW FROM UNDER FENDER

5 4

3
2

1
1. Extend Position Lever 5. Hydraulic Hoses
2. Connecting Pins 6. Lifting Shackles
3. Bolt, Washers, And Locknut 7. Mounting Pins
4. Electrical Connection

Figure 1-47
Standard Outrigger Box Assembly

Section 1 - Operating Instructions 1-47

Operator's Manual

Outrigger pin retention devices must be

in place to prevent accidental removal.
Retention devices must be removed to pull
pins. See Operator's Manual.
STANDARD OUTRIGGER PINS OPTIONAL HYDRAULIC OUTRIGGER PIN REMOVAL

PIN

HYDRAULIC OUTRIGGER PIN REMOVAL UNPIN

Do not activate outrigger pin removal PIN 2 REQD

BOLT 2 REQD PINNING
system when crane is on outriggers. WASHER 4 REQD CLIP 2 REQD SWITCH
NUT 2 REQD VIEW FROM BACK OF OUTRIGGER VIEW FROM UNDER FENDER

OUTRIGGER
HYDRAULIC
AND ELECTRICAL
CONNECTIONS

NOTE: INBOARD
HYDRAULIC HOSE
IS CABLE TIED
5
TO THE WIRE
HARNESS

VIEW FROM UNDER FENDER 6

6
5

7
4 3 1
1. Pin Lock 4. Hydraulic Hoses 6. Mounting Pins
2. Extend Position Lever 5. Lifting Shackles 7. Hydraulic Pin Cylinder
3. Electrical Connection

Figure 1-48
Outrigger Box Assembly With Hydraulic Pin Cylinder

1-48 Section 1 - Operating Instructions

 Operator's Manual
Outrigger Box Installation Crane System Controls
1. With crane parked on a firm, level surface, position The following pages, along with Figure 1-50, give de­
transmission shifter to neutral and apply park tailed instructions of individual controls related to crane
brake. operation. It is essential that the operator knows the
2. Rig a sling to the lifting shackles on the top of the function of each control and its duty in the overall op­
outrigger box. Refer to Figure 1-48. eration of the crane.

WARNING WARNING
When using the crane's boom or an auxiliary Read and understand all “Operating Safety”
lifting device to handle the outrigger boxes, procedures as well as all other operating
always ensure lifting capacities are not instructions in this manual before attempting to
exceeded. operate the crane. Operation of the crane by
unqualified personnel may result in an
3. Using the crane's boom or an appropriate lifting accident.
device, lift the outrigger box off the transport ve­
hicle and set it down to the front or rear of the car­
rier, positioning it for installation. Engine Throttle
4. Carefully lift the outrigger box enough to align the Two throttle controls are located in the operator's cab
mounting pins of the box with the mounting lugs of to provide the operator with flexibility of engine throttle
the carrier. Lower the box onto lugs. operation. A foot throttle is located on the cab floor and
5. Shutdown the engine and relieve hydraulic system a hand throttle is mounted above the Rated Capacity
pressure. Limiter display. Refer to Figure 1-50.
Using the hand throttle gives the operator the ability to
WARNING set and hold a specific engine speed. Turning the
throttle control knob clockwise increases engine
Hydraulic oil is under pressure and may be
hot. A sudden release of hot oil could cause speed; counter‐clockwise reduces it. The throttle se­
burns or other serious injury. Before lect switch must be in the “Hand” position to use the
removing or installing any outrigger circuit hand throttle control knob. The throttle indicator light
hydraulic hose, shutdown the engine and will illuminate when the throttle select switch is in the
relieve hydraulic system pressure. “Hand” position. Once the hand throttle is set to a de­
sired engine speed it will remain in that position until
6. Connect hydraulic hoses to the ports on the carrier. manually moved to a new setting. To operate the foot
Install all dust plugs to any open port. Plug the throttle, move the throttle select switch to the “Foot”
electrical connector into the receptacle. position and press down to increase engine speed; re­
7. Install the connecting pins. Install the capscrews, lease to decrease engine speed.
washers, and locknuts to the connecting pins
8. If crane is equipped with the hydraulic pin cylinder,
properly start engine and allow the system pres­
sure to reach normal operating range. Activate the
hydraulic pin cylinder control switch to extend the
cylinder pin through the carrier mounting lug eyes.
Install the pin locks on each end of the hydraulic
pin cylinder and secure with cotter pins.

WARNING
Outrigger pin locks must be installed to the
hydraulic pin cylinders to prevent accidental
pin removal.

Section 1 - Operating Instructions 1-49

Operator's Manual
3. Fully apply the swing brake pedal and release the
swing park brake and/or swing lock(s).
DANGER 4. Release the swing brake pedal and begin to en­
gage the swing control lever.

DANGER
Swing slowly and cautiously. Watch for
centrifugal force. Out swing of a load
increases the load radius and thus decreases
capacity. Load out swing may result in tipping
Keep clear of or damaging the crane.
swing upper to
prevent serious All personnel and equipment must be out of
bodily injury. the path of the rotating upper. Failure to do so
could result in severe personal injury or
equipment damage.
Figure 1-49
Keep Clear of Pinch Points
To Stop Upper Swing
Swing System 1. Ease swing control lever into the neutral position.
2. Apply the swing brake to bring the upper to a com­
Rotation of the upper over the carrier is controlled by plete stop.
the swing system. Use the following controls to operate 3. Engage the swing park brake as required.
the swing function of the crane: 4. Check engagement of the swing park brake by try­
ing to swing right, then left. The upper should not
Swing Brake Pedal
swing.
The swing brake pedal is used to stop rotation of the
upper over the carrier. To apply the swing brake, push Travel Swing Lock
down on the swing brake foot pedal. To release the Use the travel swing lock to lock the upper directly over
swing brake, release the swing brake foot pedal. either the front or rear of the carrier. The travel swing
lock will engage in these two positions only. Use of the
Swing Control Lever travel swing lock is mandatory when traveling or trans­
The control lever, on the left side of the operator's seat, porting the crane and during pick and carry operations.
is used to operate the swing function of the upper.
Move the control lever to the “SWING LEFT” position to To Release The Travel Swing Lock
swing left; move it to the “SWING RIGHT” position to 1. Fully apply the swing brake pedal.
swing right. 2. Press the button in the center of the travel swing
lock knob and pull the knob up.
3. Release the button and knob. The knob should re­
main in the released position.
WARNING
To Engage The Travel Swing Lock
Do not exceed maximum boom 1. Position the upper directly over either the front or
angles listed on the backward rear of the carrier. Apply swing brake pedal and
stability label located in the bring the upper to a complete stop.
operators cab. Crane can tip over 2. Press the button in the center of the travel swing
backwards. lock knob and push the knob down.
Note: In order to engage the travel swing lock, it
To Swing The Upper
may be necessary to swing the upper slightly to
1. Compare the boom configuration and length to the
align the swing lock pin and retaining bracket
capacity chart in the Crane Rating Manual. Posi­
on the carrier deck.
tion the boom safely within the limits specified on
the capacity chart. 3. Check the engagement of the travel swing lock by
2. Ensure that all personnel are out of the swing path. trying to swing the upper right, then left. The upper
Dangerous pinch points are created during swing­ should not swing.
ing.

1-50 Section 1 - Operating Instructions

 Operator's Manual
1

6
7 8
2
9 10
11
12
3
13
4

5
8

21
14
20 15
19
18
17
5 16
22
23

Single Axis Controls

24
18 WARNING
MAXIMUM BOOM ANGLES Do not exceed
25 COUNTERWEIGHT TIRES RETRACTED maximum boom angles.
(LBS) FRT SIDE REAR OUTRIGGERS This crane can tip
24,000 55 47 80 72
over backwards when
on tires or retracted
12,000 68 62 80 80 outriggers.
0 76 71 80 80

1. Hand Throttle 10.Drum Rotation Indicator Switch 18.Swing Park Brake Switch
2. Crane Rating Manual Holder 11.Winch Control Switches 19.Hydraulic Control Lever
3. Carrier Service Brake (Front & Rear Drum) (Swing, Rear Winch)
4. Throttle Pedal 12.Transmission Shifter 20.Swing Brake Pedal
5. Horn Button 13.Pump Control Unit 21.Boom Telescope Pedal
6. 360° Swing Lock (If Equipped) 14.Windshield Washer Fluid Reservoir 22.Hydraulic Control Lever (Boom Hoist)
7. Travel Swing Lock 15.Operator's Manual Holder 23.Hydraulic Control Lever (Front Winch)
8. Drum Rotation Indicator 16.Fire Extinguisher 24.Hydraulic Control Lever (Rear Winch)
9. Hydraulic Control Lever 17.Boom Telescope Override Switches 25.Hydraulic Control Lever (Swing)
(Boom Hoist, Front Winch)
Figure 1-50
Crane Controls

Section 1 - Operating Instructions 1-51

Operator's Manual
Swing Park Brake per is mechanically locked by a manually operated
pawl that engages in the gear teeth of the turntable
The swing park brake is a self contained dry multiple
bearing. Use this swing lock during normal, stationary
disc type brake. It is used for holding the upper in any
crane operations. Engage the travel swing lock and re­
position over the carrier during normal, stationary
lease the 360°swing lock anytime the crane is traveled
crane operations. Engage the travel swing lock and re­
or transported.
lease the swing park brake anytime the crane is trav­
eled or transported. An indicator light on the control
panel will illuminate when the swing park brake is ap­ CAUTION
plied. Do not leave the 360°swing lock engaged
during pick and carry operations or when
Note: The swing park brake is automatically ap­
traveling or transporting the crane. Use the
plied when the left side console is raised.
travel swing lock. Failure to release the 360°
swing lock during these operations may result
in damage to the swing mechanism.
CAUTION
Do not leave the swing park brake applied
To Release The 360°Swing Lock
during pick and carry operations or when
1. Fully apply the swing brake pedal.
traveling or transporting the crane. Use the
2. Move the control lever down to the RELEASED
travel swing lock. Failure to release the swing
position.
park brake during these operations may result
in damage to the swing mechanism. To Engage The 360° Swing Lock
1. Rotate the upper to the desired position over the
carrier. Apply the swing brake pedal to bring the
To Release The Swing Park Brake upper to a complete stop.
1. Fully apply the swing brake pedal.
2. Push the swing park brake switch on the left con­
troller. The indicator light on overhead control pan­ CAUTION
el will go out. Refer to Figure 1-50 for switch loca­
Do not attempt to engage 360°swing lock with
tion. the upper in motion. This practice will result in
To Apply The Swing Park Brake damage to the swing mechanism. Use swing
1. Rotate the upper to the desired position over the brake pedal to stop rotation of the upper.
carrier. Apply the swing brake pedal to bring the
upper to a complete stop. 2. Move the control lever up to the ENGAGED posi­
2. Push the swing park brake switch on the left con­ tion.
troller. Indicator light on overhead control panel will
Note: In order to engage the 360°swing lock, it
illuminate. Refer to Figure 1-50 for switch loca­
may be necessary to swing the upper slightly to
tion.
allow the swing lock pawl to engage in the turn­
table gear teeth.
CAUTION 3. Check engagement of 360°swing lock by trying to
Do not attempt to apply swing park brake with swing upper right, then left. Upper should not
the upper in motion. This practice will result in swing.
damage to the swing mechanism. Use the
swing brake pedal to stop rotation of upper. Wire Rope Winch System
This system controls raising and lowering the winch
3. Check engagement of swing brake by trying to lines. The system is equipped with a two speed motor
swing upper right, then left. Upper should not swing. that, when activated, will approximately double winch
line speed. The controls for the system are shown in
360° Swing Lock (If Equipped) Figure 1-50. Review the following for control descrip­
The 360°swing lock, if equipped, is a positive lock tions and a brief summary of operation.
against rotation of the upper over the carrier. The up­

1-52 Section 1 - Operating Instructions

 Operator's Manual

CAUTION WARNING
When the hoist line is tied off to the crane or
any solid object, the winch system can be Cold weather operation of the winch requires
a warm‐up procedure. Failure to properly
overloaded causing major winch, wire rope,
warm‐up the winch may result in brake
or crane damage. Do not extend boom, raise
slippage. Warm‐up the winch before
or lower the boom, or raise the crane on
beginning crane operations.
outriggers unless wire rope is spooled off the
drum to prevent tension on the wire rope.
Warm‐up Procedure
A warm‐up procedure is recommended at each start‐
up and is essential at ambient temperatures below
WARNING +40°F (+4°C ). Allow the engine to run at idle speed
The weight of the load must be known before with the winch control lever(s) in neutral, for several
making a lift. Compare the load weight to the minutes. Once the hydraulic oil begins to warm, oper­
appropriate capacity chart in the Crane Rating ate the winch at low speed, with no load, lifting and low­
Manual to ensure compliance with capacity ering only the hookblock until warm oil circulates
ratings. Compare the load weight to the Wire throughout the winch.
Rope Capacity chart in the Crane Rating
Manual to determine the number of parts of To Lift A Load
line required to lift the load. Rig and setup the Attach the hook block or ball to the load. Position head
crane to ensure compliance with both the machinery directly above the load, pull the control lever
appropriate crane capacity chart and Wire back, toward the operator.
Rope Capacity chart in the Crane Rating
Manual. Properly set the Rated Capacity To Hold A Load
Limiter to the correct crane configuration. Return the control lever to the neutral position. The
Do not lift a load to the point where the hook automatic brake in the winch system will hold the load
block contacts the head machinery. “Two in position.
blocking” could damage the hook block
To Lower A Load
and/or the head machinery. Always keep load
and hook block a safe distance from the Push the control lever forward. Return the control lever
boom. to neutral to stop the load.

Winch Control Switches

Front Winch Control Lever These switches are used to control engaging/disengag­
This lever controls the front winch drum. Pull control ing the high speed hoist and disabling the front or rear
lever back, toward the operator to lift the load. Push winch.
control lever forward, away from the operator to lower
High Speed Hoist Or Lower
the load. Refer to “Winch Operation” for more specific
instructions. Move the winch control switch to the “High Speed”
position. Move the control lever to the “Up” or “Down”
Rear Winch Control Lever position. The high speed hoist will activate after engag­
This lever controls the rear winch drum, if equipped. ing the control lever. Refer to Figure 1-50.
Pull control lever back, toward the operator to lift the Note: Using the high speed hoist reduces the maxi­
load. Push control lever forward, away from the opera­ mum line pull by approximately one half. The high
tor to lower the load. Refer to “Winch Operation” for speed hoist switch can be activated at anytime dur­
more specific instructions. ing either winch mode. Switching the high speed
hoist switch before engaging the winch control
Winch Operation lever will make the system work smoother.
The following is a brief description of the basic proce­
dure for operating the wire rope winch. Crane opera­
To Return To Standard Winch Mode
tions are to be performed only by a qualified operator
who has read and fully understands the entire content Move winch control switch to the “Low Speed” posi­
of this manual. tion. Winch will immediately return to standard speed.

Section 1 - Operating Instructions 1-53

Operator's Manual
To raise the boom (boom up): Move the right control
2 lever left to the “Up” position.

3
CAUTION
1
4 When the hoist line is tied off to the crane or
any solid object, the winch system can be
overloaded causing major winch, wire rope,
5 or crane damage. Do not extend boom, raise
or lower the boom, or raise the crane on
outriggers unless wire rope is spooled off the
6 drum to prevent tension on the wire rope.

To lower the boom (boom down): Move the right con­

1. Boom Head Machinery 4. Center Section trol lever right to the “Down” position.
2. Tip Section 5. Inner Section
3. Outer Section 6. Base Section
CAUTION
Figure 1-51
Wire rope must be spooled off the winch drum
Boom Nomenclature
as the boom is lowered. Failure to do so may
cause two blocking.
Winch Disable
Move the winch control switch(es) to the “Disable” To stop the boom: Release the right control lever. It is
position to disable the winch(es) to prevent inadvertent spring loaded and should return to neutral and stop the
operation of the winch(es) while using the control le­ boom.
vers to perform other operations.
Boom Telescope System
Drum Rotation Indicators The crane is equipped with a five section full power
This system is used to monitor winch drum speeds boom. The five section boom consists of a base, inner,
through the use of a mechanical signaling device center, outer, and a tip section. Refer to Figure 1-51.
mounted inside each of the winch control levers. To acti­ The telescoping feature of the boom sections is oper­
vate the system, move the drum rotation indicator ated through the use of three hydraulic cylinders and a
switch, on the right seat control panel (Figure 1-50), to cable/sheave mechanism which are an integral part of
the “On” position. Place your thumb over the end of the the boom assembly. The boom can be extended or re­
control lever being used. As the winch drum rotates, a tracted to the desired length using the boom telescope
mechanical signal will be felt with your thumb. The fre­ pedal in the operator's cab. Refer to Figure 1-50. The
quency of the mechanical signal is a direct indication of telescope feature has three modes of operation. Refer
the winch drum speed. Move drum rotation switch to to Figure 1-52.
the “Off” position to deactivate system.
Note: Boom must be fully retracted before chang­
Boom Hoist System ing boom modes.
Raising and lowering the boom is controlled by the
boom hoist control lever located on the right arm rest. Boom Mode “Amax1”: When using boom mode
“Amax1” only the inner and center sections telescope
Refer to Figure 1-50.
simultaneously. This mode offers increased strength
capacities. Select this mode through the rated capac­
ity limiter system.
WARNING
Boom Mode “Amax2”: When using boom mode
Do not exceed maximum boom “Amax2” only the center, outer, and tip sections tele­
angles listed on the backward scope simultaneously. This mode offers increased sta­
stability label located in the bility capacities. Select this mode through the rated ca­
operators cab. Crane can tip over pacity limiter system.
backwards.

1-54 Section 1 - Operating Instructions

 Operator's Manual
Boom Mode “Standard”: When using boom mode 3. Set the rated capacity limiter to the desired tele­
“Standard” all power boom sections extend/retract si­ scope mode.
multaneously. This mode offers full boom extension.
Select this mode through the rated capacity limiter sys­
tem.
CAUTION
When the hoist line is tied off to the crane or
Boom Telescope Control Pedal any solid object, the winch system can be
Figure 1-50 shows the location of the telescope con­ overloaded causing major winch, wire rope,
trol pedal in the operator's cab. Depress the toe of the or crane damage. Do not extend boom, raise
telescope control pedal to extend the boom. Depress or lower the boom, or raise the crane on
the heel of the telescope control pedal to retract the outriggers unless wire rope is spooled off the
boom. Use the telescope mode in conjunction with the drum to prevent tension on the wire rope.
telescope control pedal to extend the boom sections to
the desired length. 4. Depress the toe of the telescope control pedal.

Boom Telescope Override Switches

CAUTION
Three switches are provided to manually override the
telescope system if the boom is not extending/retract­ Wire rope must be spooled off the winch
ing proportionally. There is one switch for the inner, drum(s) as the boom is extended. Failure to
center, and outer sections. For all boom modes, these do so may cause two blocking.
switches will stop their corresponding boom section so
the boom can be extended/retracted proportionally. 5. Stop the boom sections by releasing the telescope
Refer to Figure 1-50 for switch location. control pedal.

To Extend The Boom Sections Note: The telescope control pedal is spring
1. Park the crane on a firm level surface, position the loaded and should return to the neutral position
transmission shifter to neutral, and engage the when released.
park brake.
2. Review the appropriate capacity chart in the Crane To Retract The Boom Sections
Rating Manual to establish boom length, angle, 1. Depress the heel of the telescope control pedal.
and load limitations. 2. Stop the boom sections by releasing the telescope
control pedal.
Note: Boom must be fully retracted before
changing boom modes.

Section 1 - Operating Instructions 1-55

Operator's Manual

Boom Mode “Amax1”

Inner and center sections telescope simultaneously.

Center Inner Base

Telescope Length (Ft.) Boom Length (Ft.)

0 0 40
5.0 5.0 50
10.0 10.0 60
15.0 15.0 70
20.0 20.0 80
25.0 25.0 90
27.5 27.5 95

Boom Mode “Amax2”

Center, outer, and tip sections telescope simultaneously.

Tip Outer Center Base

Telescope Length (Ft.) Boom Length (Ft.)

0 0 0 40
3.33 3.33 3.33 50
6.66 6.66 6.66 60
10.00 10.00 10.00 70
13.33 13.33 13.33 80
16.66 16.66 16.66 90
20.00 20.00 20.00 100
23.33 23.33 23.33 110
27.50 27.50 27.50 122.5

Boom Mode “Standard”

Inner, center, outer, and tip sections telescope simultaneously.

Tip Outer Center Inner Base

Telescope Length (Ft.) Boom Length (Ft.)

0 0 0 0 40
2.5 2.5 2.5 2.5 50
5.0 5.0 5.0 5.0 60
7.5 7.5 7.5 7.5 70
10.0 10.0 10.0 10.0 80
12.5 12.5 12.5 12.5 90
15.0 15.0 15.0 15.0 100
17.5 17.5 17.5 17.5 110
20.0 20.0 20.0 20.0 120
22.5 22.5 22.5 22.5 130
25.0 25.0 25.0 25.0 140
27.5 27.5 27.5 27.5 150

Figure 1-52
Boom Telescope Mode

1-56 Section 1 - Operating Instructions

 Operator's Manual

FINE METERING
VALVE GUIDE

N2 N4 N6 N8

N1 N3 N5 N7

2 4 6 8

1 3 5 7

1. Swing Left 3. Boom Down 5. Front Winch Down 7. Rear Winch Down
2. Swing Right 4. Boom Up 6. Front Winch Up 8. Rear Winch Up

Figure 1-53
Fine Metering Valve

ity with slower speed. Use for jobs where accurate

Fine Metering System positioning is more important that speed. The system
This fine metering system is used to adjust the crane's is activated by the fine metering switch located on the
hydraulic functions to certain job functions or for set­ control panel, above and to the right of the operator.
tings that are comfortable to the operator. The system Refer to Figure 1-33 for switch location.
is for precise controlled operation and heavy lift capac­

Section 1 - Operating Instructions 1-57

Operator's Manual
1 2 6

Lockout Pin Installed

WARNING
MAIN BOOM ATB IS DISABLED
WHEN LOCK OUT PIN IS IN
HOLE. TO OPERATE MAIN BOOM
ATB, REMOVE PIN AND STORE
IN STORAGE HOLE BEHIND
SWITCH. FAILURE TO HAVE

3 FULLY OPERATIONAL ATB SYSTEM

COULD RESULT IN SERIOUS
INJURY OR DEATH.
LOCK OUT PIN HOLE

1. Jumper Assembly 4. Anti‐Two Block Weight

2. Plug Assembly 5. Lockout Pin & Flag
3. Anti‐Two Block Switch 6. Lockout Pin Storage Hole

Figure 1-54
Anti‐Two Block Warning System

Crane Monitoring System CAUTION

Crane monitoring systems are available for monitoring Do not alter any component in the anti‐two
boom length, boom angle, load weight and two block block system. If any components are altered,
situations. Figure 1-55 shows the display units, for the crane may not be protected against a two
the monitoring systems, which may be used on this block condition. Crane damage may occur.
crane model.
Your crane may be equipped with one of the systems Three basic components are used to make up the anti‐
available for this crane. Use Figure 1-55 to determine two block system. The anti‐two block weight, anti‐two
which system you have and where to find the appropri­ block switch with lockout pin, and the display unit in the
ate operating instructions. operator's cab. Refer to Figure 1-54 and
Figure 1-56.
Anti‐Two Block Warning System
Integrated into the Rated Capacity Limiter system is an
anti‐two block warning system. An anti‐two block
CAUTION
warning system is a system designed to alert the op­ Do not allow the load to spin out of control
erator before the hook block or hook ball contacts the when hoisting. The anti‐two block weight may
head machinery of the main boom, auxiliary lifting become entangled with the wire rope and
sheave, or fly. When a two block situation is imminent, could damage the anti‐two block system, wire
an audio/visual alarm is activated to alert the operator rope, or boom. Use rotation resistant rope
of the pending danger. When the alarm activates it is during single part line hoisting applications,
essential that the operator discontinue operations im­ especially when long fall lifts are involved.
mediately, and correct the two block situation.

1-58 Section 1 - Operating Instructions

 Operator's Manual

MicroGuard 434 MicroGuard 534

Refer to Page 1-60 Refer to Page 1-75

Figure 1-55
Crane Monitoring Systems

An anti‐two block weight is suspended from the head boom. It is connected to the jumper assembly on the
machinery switch where lifts are to be made and is attachment when operating from that attachment.
used to hold the switch in the “working” position. Check that all the harness connections between the at­
When the anti‐two block weight is lifted by the hook tachments are properly joined and test the system be­
block, it allows the switch to activate the audio/visual fore beginning operations.
alarm on the display unit in the operator's cab. In addi­
tion to the audio/visual alarm, function limiters will be Lockout Pin And Flag
activated.
The lockout pin is used to hold the main boom anti‐two
The added feature of hydraulic function limiters, pre­ block switch in the “working” position, the same as
vents the operator from continuing crane functions having a two block weight suspended from the switch.
which will cause a two block situation to occur. The
crane functions of winch up, boom down, and boom When operating from the main boom the lockout pin
extend are disabled when the anti‐two block weight is and flag must be in the stored position. When operat­
lifted. These functions will remain disabled until the two ing from an attachment only, the lockout pin must be
block situation is corrected or the “cancel alarm” installed in the main boom head anti‐two block switch.
switch on the display unit is utilized. When both main boom and any other attachment are
The main boom head must always have an anti‐two reeved for operation, lockout pin and flag must be re­
block switch. Each of the added attachments used on moved from switch and properly stored.
the crane must employ a similar head machinery Note: When using main boom and any other attach­
switch as well, in order for that particular attachment to ment, anti‐two block weights must be suspended
be monitored by the system. from each anti‐two block switch.
The plug assembly is connected to the jumper assem­
bly on the boom head when operating from the main

Section 1 - Operating Instructions 1-59

Operator's Manual

16
1
15
2

14 3

13
4

12

5 5

11

10 9 8 7
1. Bar Graph 7. Cancel Alarm Button 12.Load Radius Display
2. Two Block Alarm Indicator 8. Operator Alarms Button 13.Boom Angle Display
3. Maximum Rated Capacity Display 9. Crane Setup Button 14.Boom Length Display
4. Actual Load Display 10.Test Button 15.Pre‐Alarm Indicator
5. Configuration Selection Buttons 11.Crane Setup Screen 16.Overload Indicator
6. Contrast Button

Figure 1-56
Rated Capacity Limiter

MicroGuard 434 Rated Capacity Limiter

The following describes the function and operation of WARNING
the MicroGuard 434 Rated Capacity Limiter. The sys­ Although the system will alert the operator of
tem is intended to aid the operator in the efficient op­ an approaching overload or unsafe condition,
eration of the crane by continually monitoring the load it remains the responsibility of the operator to
and warning of an approach to an overload or unsafe operate the crane safely at all times.
condition. The display is located in the front right cor­
This system must never be substituted for the
ner of the operator's cab.
good judgment of the crane operator using
safe operating procedures. The operator is
solely responsible for safe operation of the
crane.
!!THIS SYSTEM IS AN OPERATOR'S AID -
NOT A SAFETY DEVICE!!

1-60 Section 1 - Operating Instructions

 Operator's Manual
System Description
1 2 3 4
The system monitors crane functions by means of high
accuracy sensors and continuously compares the load
with a copy of the crane capacity chart which is stored
in the computer memory. If an overload is approached,
the system warns by means of audible and visual
alarms and is configured to cause function limitation.
The MicroGuard 434 Rated Capacity Limiter provides
the operator with a continuous display of:
D Rated Capacity
D Actual Load 1 2 3
D Percentage of Rated Capacity
D Radius of the Load
D Angle of the Main Boom
D Crane Configuration 1. Green Light - Percentage 3. Red Light - Overload
D Length of the Main Boom of Rated Load 4. Brightness Control
2. Yellow Light - Approach­
Note: The head height may be displayed by access­ ing Overload
ing the angle/length/height operator settable alarm
Figure 1-57
screen.
Overhead Bar Graph And External Light Bar
Option
An additional feature of the system is the provision of
operator settable alarms. These alarms, when proper­
ly set, provide a method of obstacle avoidance. This is 2. Two Block Alarm Indicator
achieved by means of minimum and maximum boom The Two Block Alarm Indicator illuminates anytime
angle, maximum boom length, maximum height, left a two block situation is imminent. An audible alarm
and right swing, and defined area alarms. These and function limiters will also activate when a two
alarms can be programmed for each job site and set block situation is imminent. Once the two block sit­
rapidly for the prevailing site conditions thereby aiding uation is corrected the system will return to normal
the operator in safe operation of the crane. working mode.

Display Unit 3. Maximum Rated Capacity Display

The following is a description of the control buttons, in­ The Maximum Rated Capacity is a digital display of
dicators, and windows on the display unit. Use them the maximum permitted capacity. It is derived from
along with Figure 1-56. a copy of the crane's capacity chart which is stored
in the computer memory and is the reference ca­
1. Bar Graph pacity for any lifting operation. It is dependent on
The Bar Graph is an analog bar graph which gives the configuration currently selected, which is
a visual indication of how much of the crane's ca­ shown in the crane setup screen, and which deter­
pacity is being used and the rate at which an over­ mines the section of the capacity chart to be used
load is being approached. The 100% RATED CA­ as the rated capacity reference.
PACITY indicator above the bar graph marks the
Note: All maximum rated load data shown is X
point at which 100% of the rated capacity of the
1,000 lb (kg), e.g. 12.6=12,600 lb (kg).
crane has been reached. The leading edge of the
bar graph aligns with three colored bands around 4. Actual Load Display
the bar graph window. Red indicates an overload.
The Actual Load Display is a digital display which
Between the red and yellow is a black notch which
shows total load suspended below the boom or fly
indicates 100% of rated capacity. Yellow indicates
head. It includes the load, any slings, pins or tackle
90-99.9%, and green indicates below 90% rated
used to secure the load and the hook block.
capacity.
Note: System may be equipped with an optional Note: All actual load data shown is X 1,000 lb
overhead bar graph or an external light bar (kg), e.g. 12.6=12,600 lb (kg).
which operates similar to the bar graph on the
display. Refer to Figure 1-57.

Section 1 - Operating Instructions 1-61

Operator's Manual
5. Configuration Selection Buttons 14. Boom Length Display
These buttons are used during the crane configu­ The Boom Length Display gives a continuous indi­
ration selection routine. Refer to “Configuration cation of the boom length in feet (m). It is the dis­
Selection” found later in this section of the Opera­ tance from the centerline of the boom foot pin to
tor's Manual. the center line of the boom head machinery.

6. Contrast Button 15. The Pre‐Alarm indicator

This button is used to adjust the display contrast. The Pre‐Alarm (amber) Indicator illuminates at a
pre‐set value of 90% of Maximum Rated Capacity
7. Cancel Alarm Button and provides a visual indication of an approach to
This button is used to silence the audible alarm an overload. The pre‐alarm indicator will also illu­
when the alarm has occurred as a result of either minate when an operator settable alarm value is
an Overload, a Two Block or an Operator Settable approached.
alarm. It is also used to reset the function limit relay
16. Overload Indicator
when it is necessary to by‐pass function limit which
has occurred as a result of either an Overload or a The Overload Indicator (red) illuminates at a pre‐
Two Block alarm. set value of 100% of Maximum Rated Capacity and
provides a visual indication of Maximum Allowed
8. Operator Alarms Button Load. It will also illuminate whenever a wire rope
limit is exceeded or an operator settable alarm has
This button is used to start the operator settable
been reached or exceeded. Function limiters will
alarms routines. Refer to “Operator Settable
occur simultaneously for an Overload, Wire Rope
Alarms” found later in this Operator's Manual.
Limit or a Two Block condition, but function limiters
9. Crane Setup Button will not occur when exceeding an operator settable
alarm. An audible alarm will sound for all 4 condi­
This button is used to start the configuration selec­
tions.
tion routine. Refer to “Configuration Selection”
found later in this section of the Operator's Manual.
System Operation
10. Test Button The following is a list of procedures which are used to
This button is used to initiate a system self test and operate the multiple features of the Rated Capacity
also used to display fault codes. Refer to “To Per­ Limiter. Use these procedures in conjunction with the
form System Test” found later in this section of the previous display unit control descriptions.
Operator's Manual.
To Perform System Test
11. Crane Setup Screen At start‐up the system automatically performs a self test
The Crane Setup Screen provides the operator after which it goes directly to the normal working
with a graphical representation of the crane's cur­ screen. The self‐test can be initiated anytime during
rent configuration during the normal working normal operation of the system by using the TEST but­
mode. It also provides graphical icons used during ton.
the crane configuration selection routine. One press (press and release) will cause the system to
execute a self test routine during which all lamps,
12 Load Radius Display audible alarms, and digital displays will be functionally
The Radius Display gives a continuous indication tested and all memory areas checked for accuracy. If
of the radius of the load in feet (m). It is the horizon­ faults in the system are detected during a test, the
tal distance from the centerline of rotation to the crane setup screen will show the words FAULT
centerline of the hook. DETECTED. If the words FAULT DETECTED occur,
press and hold the TEST button. This will cause the
13. Boom Angle Display display to change to the FAULT mode. In this mode,
The Boom Angle Display gives a continuous indi­ information about the fault condition will be displayed
cation of the angle of the main boom relative to hor­ in the crane setup screen by means of an error code.
izontal. Contact your local distributor for details of the fault
codes.

1-62 Section 1 - Operating Instructions

 Operator's Manual
System Bypass
In emergency situations, the Rated Capacity Limiter 2 1
computer can be bypassed. The computer is located
on the back of the operator's cab. There is a RCL Sta­
tus keyswitch adjacent to the computer to bypass the
system. Move the key to the “Bypass” position to by­
pass the system. For emergency use while the system
is bypassed, refer to “System Inoperative or Malfunc­
tioning” found in this Operator's Manual.

WARNING
The Microguard 434 is not operational when 3
the computer is bypassed. Bypass the
system in emergency situations only.

System Inoperative Or Malfunctioning

1. RCL Status Keyswitch
When operational aids are inoperative or
2. Operator's Cab
malfunctioning, the following recommendations for 3. Computer
continued use of the crane should be followed or the
crane should be shutdown. Figure 1-58
Rated Capacity Limiter Bypass
1. Steps shall be taken to schedule repairs and recal­
ibration immediately. The operational aids shall be
5. When a boom length indicator is inoperative or
put back into service as soon as replacement
malfunctioning, the designated person responsi­
parts, if required, are available and the repairs and
ble for supervising the lifting operations shall es­
recalibration can be carried out. Every reasonable
tablish the boom length at which the lift will be
effort must be made to expedite the repairs and re­
made by actual measurement or marking on the
calibration.
boom.
2. When the rated capacity limiter is inoperative or
6. When a level indicator is inoperative or malfunc­
malfunctioning, the designated person responsi­
tioning, other means shall be used to level the
ble for supervising the lifting operations shall es­
crane.
tablish procedures for determining load weights
7. In situations where inconsistency exists, verified
and shall ascertain that the weight of the load does
weights, measured radii, boom lengths, and au­
not exceed the crane ratings at the radius where
thorized crane capacities must always take prece­
the load is to be handled.
dence over indicator readings.
3. When a boom angle or radius indicator is inopera­
tive or malfunctioning, the radius or boom angle
shall be determined by measurement.
4. When the anti‐two block warning device is inopera­
tive or malfunctioning, the designated person re­
sponsible for supervising the lifting operations
shall establish procedures, such as assigning an
additional signal person, to furnish equivalent
protection. This does not apply when lifting per­
sonnel in load line supported baskets. Personnel
shall not be lifted in load line supported baskets
when the anti‐two block devices are not function­
ing properly.

Section 1 - Operating Instructions 1-63

Operator's Manual
Configuration Selection configuration selection button to select the desired
In the normal operational mode the system is pro­ erected attachment if required.
grammed to remember the last configuration selected. 6. If an offset fly was previously selected, the crane
Each time the system is powered up it will automatically setup screen will change and graphically display
choose that configuration. Only when the crane is the available offset angles. Press the correspond­
rigged differently must a new configuration be se­ ing configuration selection button to select the de­
lected. Use the following procedure along with sired offset angle if required.
Figure 1-59 to select the crane configuration (the fol­ 7. The crane setup screen will change and graphical­
lowing step numbers correspond with the numbered ly display the front winch lifting point. Press the
screens in Figure 1-59). corresponding configuration selection button to
select the desired front winch lifting point as indi­
Note: When selecting configurations allowed on cated by the flashing arrows. Or press the corre­
outriggers all beams must be equally extended; all sponding configuration selection button to select
fully retracted, intermediate extended or fully ex­
the front winch not in use.
tended.
8. If the crane is equipped with a rear winch, the crane
Depending on how the crane is equipped or which setup screen will change and graphically display
selections have been made, some screens shown the rear winch lifting point. Press the correspond­
in Figure 1-59 may not appear or may not appear ing configuration selection button to select the de­
as illustrated. The system can only be programmed sired rear winch lifting point as indicated by the
for configurations allowed as listed on the “Allow­ flashing arrows. Or press the corresponding con­
able Crane Configuration” chart in the Crane Rating figuration selection button to select the rear winch
Manual. not in use.
9. If the crane is equipped with a fly and was not se­
1. From the normal working screen press the CRANE
lected as an erected attachment, the crane set‐up
SETUP button. The crane setup screen will
screen will change and graphically display the
change and graphically display the carrier options.
stowed deduct. Press the corresponding configu­
Press the corresponding configuration selection
ration selection button to select the desired stowed
button to select the desired carrier configuration.
deduct if required.
10. The crane setup screen will change to the normal
WARNING working screen and graphically display the crane
configuration as previously selected. Press the
The Microguard 434 is not operational when in
corresponding configuration selection button to
the RIGGING/TRAVEL Mode. Return the
select the desired parts‐of‐line for the rear winch.
Microguard 434 to normal operation before
11. If the crane is equipped with a front winch and it
operating the crane.
was selected, press the corresponding configura­
tion selection button to select the front winch.
2. The crane set‐up screen will change and graphi­
Press the corresponding configuration selection
cally display the counterweight options. Press the
corresponding configuration selection button to button to select the desired parts‐of‐line for the
select the desired counterweight. front winch.
3. The crane setup screen will change and graphical­ Note: From the normal working screen, after
ly display the boom mode options. Press the corre­ crane setup has been established, only two
sponding configuration selection button to select selection buttons are active; the winch select
the desired boom mode. button and the parts of line button.
Note: The boom must be fully retracted to To change winches, push the winch select but­
change boom modes. ton to toggle between winches. The winch lift­
4. The crane setup screen will change and graphical­ ing points cannot be changed without going
ly display the auxiliary lifting sheave fitted or not through the crane setup routine.
fitted. Press the corresponding configuration The parts‐of‐line can be changed for the se­
selection button to select the desired auxiliary lift­ lected winch by pressing the parts‐of‐line but­
ing sheave. ton to scroll through the available options for
5. If the crane is equipped with a fly, the crane setup that winch.
screen will change and graphically display an
Refer to Figure 1-60 and Figure 1-61 for ex­
erected attachment. Press the corresponding
amples of some normal working screens.

1-64 Section 1 - Operating Instructions

 Operator's Manual
CRANE SETUP CRANE SETUP CRANE SETUP
NO OBX 0

1 NO OBX 2
12000

2.5 MPH
More...
24000

CRANE SETUP CRANE SETUP

A1

4 3
A2

Standard

CRANE SETUP CRANE SETUP

2 No Fly 70’ Fly

6 5
25 31’ Fly 85’ Fly

45 55’ Fly

CRANE SETUP CRANE SETUP Crane Set Up

None

24’

55’

7 8 9

. 1
55’ Fly
25 _ . 5
55’ Fly
25 _

11 . . 10
24 Std 24 Std

Figure 1-59
Configuration Selection Flow Chart

Section 1 - Operating Instructions 1-65

Operator's Manual

7 5 6

3
5

9
24
A1 4

1 2
8

In this example the crane is setup on intermediate extended outriggers (1),

boom mode Amax1 (2), auxiliary head fitted (3), fly base & tip stowed (4),
the rear winch available with the aux head and the front winch selected (5)
with the winch rope reeved over the main boom (6), with five parts of line
(7), two operator alarms have been set (8), 24,000 lb counterweight (9).

1
55’ Ofst
6
45 _ 5

7
24 Std
2
1

In this example the crane is setup on fully extended outriggers

(1), boom mode Standard (2), 55' offset fly erected with 45° off­
set (3), the front winch available with the main boom and the rear
winch selected (4), with the winch rope reeved over the 55' off­
set fly (5), with one part of line (6), 24,000 lb counterweight (7).
Figure 1-60
Normal Working Screen Examples

1-66 Section 1 - Operating Instructions

 Operator's Manual

5 3 4

6
24 A1

2 1
In this example the crane is setup for stationary on tires (1),
boom mode Amax1 (2), rear winch not in use and the front
winch selected (3), winch rope reeved over the main boom
(4), with three parts of line (5), 24,000 lb counterweight (6).

5 1

4
3

6 0 A2 2

In this example the crane is setup on fully retracted outrig­

gers (1), boom mode Amax2 (2), fly base & tip stowed (3),
rear winch not in use and the front winch selected (4),
with one part of line (5), no counterweight (6).

Figure 1-61
Normal Working Screen Examples

Section 1 - Operating Instructions 1-67

Operator's Manual

6 3 5

7
0 A2
NO OBX

3 2 1
In this example the crane is setup for pick and carry creep speed (1),
no outrigger box installed (2), boom mode Amax2 (3), rear winch not
in use and the front winch selected (4), winch rope reeved over the
main boom (5), with three parts of line (6), and no counterweight (7).

6 3 5

7
12 A2

2.5 MPH
2 3 1
In this example the crane is setup for pick and carry (1), 2.5 mph speed
with outrigger boxes installed (2), boom mode Amax2 (3), rear winch not
in use and the front winch selected (4), winch rope reeved over the main
boom (5), with three parts of line (6), and 12,000 lb counterweight (7).

Figure 1-62
Normal Working Screen Examples

1-68 Section 1 - Operating Instructions

 Operator's Manual
To Select Rigging/Travel Mode
CRANE SETUP
The CRANE SETUP push‐button is also used to select NO OBX
RIGGING/TRAVEL MODE. This mode is used to facili­
tate rigging and travel of the crane by inhibiting func­
tion limiters and the audible alarm while selected. To NO OBX
resume crane operation, select proper outrigger or tire

,
configuration per the proper procedure. 2.5 MPH

WARNING
The Microguard 434 is not operational when in
the RIGGING/TRAVEL Mode. Return the
Microguard 434 to normal operation before
operating the crane.

1. From the normal working screen press the CRANE

SETUP button. The crane setup screen will
change and graphically display the carrier options.
2. Press the corresponding configuration selection
button to select RIGGING/TRAVEL MODE. Refer
to Figure 1-63. Figure 1-63
3. The crane setup screen will change and graphical­ Rigging/Travel Mode Screen
ly display the RIGGING/TRAVEL MODE icon.
The CANCEL ALARM is also used to reset the function
To Cancel Audible Alarm And Reset Function limiters when it is necessary to by‐pass the function lim­
Limiters
iters which has occurred as a result of either an over­
The CANCEL ALARM button is used to cancel the audi­ load, a two block alarm, or a rope limit. Function limit­
ble alarm when the alarm has occurred as a result of ers are reset by first canceling the audible alarm (as de­
either an overload, a two block alarm, or an operator scribed above) and then pressing and holding the
settable alarm. The audible alarm may be canceled by CANCEL ALARM button for about 3 seconds, after
pressing and releasing the CANCEL ALARM button. which the function limiters will be reset to allow normal
The audible alarm remains canceled until the condition operation. However, should another different alarm
which caused the alarm has been removed. For exam­ condition occur when the function limiters had pre­
ple, if the audible alarm was canceled because of an viously been over‐ridden, then the newly occurring
overload condition, it will remain canceled until the alarm condition would cause the function limiters to oc­
overload condition is removed. However, if a different cur again.
alarm, e.g. two block condition, was to occur when the
audible alarm was still canceled for an earlier overload Operator Settable Alarms
condition, the new alarm condition would cause the au­ Some alarms occur automatically as a result of limita­
dible alarm to be re‐started. tions imposed by the capacity chart. The operator has
control over additional alarms which can be set to oper­
ate within the normal chart limitations and which are in
WARNING addition to those already set by the chart.
Once the function limiters have been Operator settable alarms will be stored in the computer
by‐passed, the crane is no longer protected memory, even if the crane is shutdown, until they are
against the condition that initially caused the cleared. Refer to Figure 1-64.
function limiters to occur.
Six alarms are available for operator use.
Minimum Angle Maximum Length
Note: The CANCEL ALARM feature is a temporary Maximum Angle Left and Right Swing
function. The audible alarm or function limit is auto­ Maximum Height Operator Defined Area
matically reset when the condition which caused
the alarm is no longer present.

Section 1 - Operating Instructions 1-69

Operator's Manual

Settable
Alarms
MAX
0 MIN
, Settable
Alarms
MAX
0 MIN

Exit Exit ,

OFF OFF
Exit MAX
OFF
00.0

OFF OFF
MAX MAX

00.0
0 OFF
MIN Exit Menu

Figure 1-64
Operator Settable Alarms

3. Place the crane in the desired position depending

WARNING upon the alarm to be set. The numerical value dis­
played will be the current position of the crane.
The operator settable alarms are a warning
device. All functions remain operational when Note: If an alarm had been previously set, the
entering the operator defined bad area. For numerical value displayed will be the previous­
safe operation, adequate distance must be ly set alarm value. The previous alarm must first
maintained to allow for operator reaction time be cleared, then set the new alarm. Alarms
to avoid entering the bad area. It is the which are not set are indicated by the word OFF.
responsibility of the operator to set points
which ensure that the crane's boom, 4. Press the corresponding selection button to set the
attachment, load, rigging, etc. maintains a alarm value.
safe working distance and complies with local 5. When all alarms are set press the EXIT button to re­
safety regulations. turn to the normal working screen or press the
MENU (Operator Alarm) button to return to the pre­
Setting Length/Angle/Height/Swing Operator Alarms vious menu screen.
6. Test the alarm, with no load, to ensure the alarm
1. From the normal working screen press OPERA­
points have been properly set. When approaching
TOR ALARM button to access the Operator Set­
the alarm set point the pre‐alarm (amber) indicator
table Alarm screen.
lamp will illuminate, the audio will sound intermit­
2. Press the corresponding selection button to select
tently, and a warning message will appear in the
the desired alarm to be set. Crane Setup Screen. When exceeding the alarm
Note: The bottom value displayed in the max set point the red lamp will illuminate, the audible
height alarm box is the current head height. alarm will sound continuously, and a warning mes­
sage will appear in Crane Setup Screen.

Note: An alarm icon will appear on the normal

WARNING working screen to alert the operator that an op­
Avoid positioning the boom, attachment, load, erator alarm has been set. The number of icons
rigging, etc. into the bad area when setting the shown indicate how many operator alarms have
alarm values. been set.
When selecting the alarm values, ensure that 7. Use the following examples to understand the use
the load will maintain a safe distance from the of the procedure.
obstacle.

1-70 Section 1 - Operating Instructions

 Operator's Manual
5. Press the EXIT button to return to the normal work­
ing screen or press the MENU (Operator Alarm)
WARNING button to return to the previous menu screen.
If crane or obstacle is moved or if a different 6. Test the alarm, with no load, to ensure the alarm
size load is lifted, the alarm(s) must be reset. points have been properly set. When approaching
60 degree boom angle the pre‐alarm (amber) indi­
cator lamp will illuminate, the audio will sound inter­
mittently, and “!Maximum Angle” will appear in the
WARNING Crane Setup Screen. The red lamp will illuminate
Check the crane's current configuration, and the audible alarm will sound continuously
capacity chart, and working area chart in the whenever the boom is raised above 60 degrees
Crane Rating Manual to ensure safe, stable and “!Maximum Angle” will appear in Crane Setup
operation under conditions described in the Screen.
following examples.
To Set Maximum Length Alarm
Example: To have an alarm whenever the boom length
To Set Minimum Angle Alarm exceeds 50 feet, use the following
Example: To have an alarm whenever the boom is procedure:
below a 30 degree angle, use the following 1. From the normal working screen press the OPER­
procedure: ATOR ALARM button to access the alarm screen.
1. From the normal working screen Press the OPER­ 2. Press the corresponding button for maximum
ATOR ALARM button to access the alarm screen. length (top right).
2. Press the corresponding button for minimum 3. Extend the boom to 50 feet.
angle (top right). 4. Press the corresponding button (middle left) to en­
3. Move the boom to a 30 degree angle. ter the alarm. The displayed value will be the alarm
4. Press the corresponding button (bottom right) to setting.
enter the alarm. The displayed value will be the 5. Press the EXIT button to return to the normal work­
alarm setting. ing screen or press the MENU (Operator Alarm)
5. Press the EXIT button to return to the normal work­ button to return to the previous menu screen.
ing screen or the MENU (Operator Alarm) button to 6. Test the alarm, with no load, to ensure the alarm
return to the previous menu screen. points have been properly set. When approaching
6. Test the alarm, with no load, to ensure the alarm 50 foot boom length the pre‐alarm (amber) indica­
points have been properly set. When approaching tor lamp will illuminate, the audio will sound inter­
30 degree boom angle the pre‐alarm (amber) indi­ mittently, and “!Maximum Length” will appear in
cator lamp will illuminate, the audio will sound inter­ the Crane Setup Screen. The red lamp will illumi­
mittently, and “!Minimum Angle” will appear in the nate and the audible alarm will sound continuously
Crane Setup Screen. The red lamp will illuminate, whenever the boom is extended beyond 50 feet
the audible alarm will sound continuously, and and “!Maximum Length” will appear in Crane Set­
“!Minimum Angle” will appear in Crane Setup up Screen.
Screen whenever the boom is lowered below 30
degrees. To Set Maximum Height Alarm
Example: To have an alarm whenever the boom tip
To Set Maximum Angle Alarm height exceeds 75 feet, use the following
Example: To have an alarm whenever the boom is procedure:
above a 60 degree angle use the following 1. Press the OPERATOR ALARM button to access the
procedure: alarm screen.
1. From the normal working screen press the OPER­ 2. Press the corresponding button for maximum
ATOR ALARM button to access the alarm screen. height (top right).
2. Press the corresponding button for maximum
angle (top right). Note: The bottom value displayed in the max
3. Move the boom to a 60 degree angle. height alarm box is the current head height.
4. Press the corresponding button (middle right) to
3. Extend the boom and/or adjust the boom angle so
enter the alarm. The displayed value will be the
that the tip height is 75 feet.
alarm setting.

Section 1 - Operating Instructions 1-71

Operator's Manual
4. Press the corresponding button (top right) to enter plane the pre‐alarm (amber) indicator lamp will illumi­
the alarm. The displayed value will be the alarm nate, the audio will sound intermittently, and the mes­
setting. sage “Bad Area” will appear on the Crane Setup
5. Press the EXIT button to return to the normal work­ Screen. When passing the plane the overload (red)
ing screen or press the MENU (Operator Alarm) warning lamp will illuminate, the audio alarm will sound
button to return to the previous menu screen. continuously, and the message “Bad Area” will appear
6. Test the alarm, with no load, to ensure the alarm on the Crane Setup Screen. Use the following proce­
points have been properly set. When approaching dure, Figure 1-65, and Figure 1-66 to set the opera­
75 foot boom tip height the pre‐alarm (amber) indi­ tor defined area alarm:
cator lamp will illuminate, the audio will sound inter­
mittently, and “!Maximum Length” will appear in
the Crane Setup Screen. The red lamp will illumi­ WARNING
nate and the audible alarm will sound continuously
The operator defined area alarm is a warning
whenever the boom tip height exceeds 75 feet and
device. All functions remain operational when
“!Maximum Height” will appear in Crane Setup
entering the operator defined bad area. For
Screen.
safe operation, adequate distance must be
To Set Left & Right Swing Alarms maintained to allow for operator reaction time
to avoid entering the bad area. It is the
Example: To have an alarm whenever the LEFT responsibility of the operator to set points
SWING AND RIGHT SWING exceed which ensure that the crane's boom,
pre‐determined alarm points, use the attachment, load, rigging, etc. maintains a
following procedure: safe working distance and complies with local
1. Press the OPERATOR ALARM button to access the safety regulations.
alarm screen.
2. Press the corresponding button for the swing
alarm (middle right). Setting Operator Defined Area Alarm
3. Swing the boom to the left alarm point. 1. From the normal working screen press the OPER­
4. Press the corresponding button (top left) to enter ATOR ALARM button to access the Operator Alarm
the left alarm point. The displayed value will be the screen.
left alarm setting. 2. Clear any previously set left and right swing alarms
5. Swing the boom to the right alarm point. if required. Refer to “To Clear Operator Settable
6. Press the corresponding button (top right) to enter Alarms” found later in this section of the Operator's
the right alarm point. The displayed value will be Manual.
the right alarm setting. Note: The left and right swing alarms must be
7. Press the EXIT button to return to the normal work­ cleared prior to setting the defined area alarm.
ing screen or the MENU (Operator Alarm) button to
return to the previous menu screen. 3. Press the corresponding button for Area Alarm
8. Test the alarm, with no load, to ensure the alarm (bottom right). Refer to Figure 1-65.
points have been properly set. When approaching
the set alarm point the pre‐alarm (amber) indicator
lamp will illuminate, the audio will sound intermit­ WARNING
tently, and “!Swing Alarm” will appear in the Crane Avoid positioning the boom, attachment, load,
Setup Screen. The red lamp and the audible alarm rigging, etc. into the bad area when setting the
will be activated whenever the swing exceeds the left or right alarm points.
alarm points and “!Swing Alarm” will appear in When selecting the left and right alarm points,
Crane Setup Screen. ensure that the load will maintain a safe
distance from the obstacle. Also ensure that
Note: Both the left and right swing alarms must the two points are set so that the tailswing of
be set for the system to determine the operator the crane will not enter the bad area.
set working area.
4. Position the boom, attachment, load, rigging, etc.
To Set Operator Defined Area Alarm to the left alarm point and press the corresponding
The operator defined area alarm, when set, will define button (bottom left) to enter the left alarm point.
an imaginary vertical plane between two set points to The displayed value will be the left alarm setting.
optimize the working area. When approaching the

1-72 Section 1 - Operating Instructions

 Operator's Manual
5. Position the boom, attachment, load, rigging, etc.
to the right alarm point and press the correspond­ Settable MAX
ing button (top right) to enter the right alarm point. Alarms 0
MIN

The displayed value will be the right alarm setting.

Note: For best results, the two points should be
separated by a minimum of 10 ft (3m) or 30 de­ Exit
grees.
6. When both alarm points are set, press the EXIT
button to return to the normal working screen or
,
the MENU button to return to the previous menu
screen.
7. Test the alarm, with no load, to ensure the alarm
points have been properly set. When approaching
Exit OFF
the plane the pre‐alarm (amber) indicator lamp will
illuminate, the audio will sound intermittently, and
the message “Bad Area” will appear on the Crane
Setup Screen. When passing the plane the over­
load (red) warning lamp will illuminate, the audio
alarm will sound continuously, and the message
“Bad Area” will appear on the Crane Setup Screen.
OFF 00.0

Menu

WARNING Figure 1-65

If crane or obstacle is moved or if a different Operator Defined Area Alarm Screens
size load is lifted, the area alarm must be
reset. To Clear Operator Settable Alarms
1. From the normal working screen press the OPER­
ATOR ALARM button to access the Operator Alarm
screen.
2. Press the corresponding selection button to select
the desired alarm to be cleared.
3. Press the corresponding button for each alarm un­
til the value is replaced with the word OFF.
4. When all alarms are cleared press the EXIT button
to return to the alarm screen or press the MENU
button to return to the previous menu screen.

Section 1 - Operating Instructions 1-73

Operator's Manual

Figure 1-66
Operator Defined Area Alarm

1-74 Section 1 - Operating Instructions

 Operator's Manual
MicroGuard 534 Rated Capacity Limiter
The following describes the function and operation of
the MicroGuard 534 Rated Capacity Limiter. The sys­ 3
tem is intended to aid the operator in the efficient op­ 2
eration of the crane by continually monitoring the load
and warning of an approach to an overload or unsafe
condition.
1
WARNING
Although the system will alert the operator of
an approaching overload or unsafe condition,
it remains the responsibility of the operator to
operate the crane safely at all times.
This system must never be substituted for the
good judgment of the crane operator using safe
operating procedures. The operator is solely
responsible for safe operation of the crane. 1 2 3
!!THIS SYSTEM IS AN OPERATOR'S AID -
NOT A SAFETY DEVICE!!
1. Green Lights - Percent­ 2. Amber Lights - Ap­
age of Rated Load proaching Overload
3. Red Lights - Overload
System Description
The system monitors crane functions by means of high Figure 1-67
accuracy sensors and continuously compares the load Overhead Bar Graph And External Light Bar
with a copy of the crane capacity chart which is stored (If Equipped)
in the computer memory. If an overload is approached,
the system warns by means of audible and visual Display Unit
alarms and is configured to cause function limitation.
The following is a description of the control buttons, in­
The MicroGuard 534 Rated Capacity Limiter provides
dicators, and windows on the display unit. Use them
the operator with a continuous display of: along with Figure 1-68.
D Rated Capacity
D Actual Load 1. Bar‐Graph
D Percentage of Rated Capacity
The Bar‐Graph is a series of twelve colored lights which
D Radius of the Load
gives a visual indication of how much of the crane's ca­
D Angle of the Main Boom
pacity is being used and the rate at which an overload
D Crane Configuration
is being approached. Each green light represents 10%
D Length of the Main Boom
of the crane's rated capacity is being used. Yellow indi­
An additional feature of the system is the provision of cates 90-99.9%, and the red lights indicate an over­
operator settable alarms. These alarms, when proper­ load.
ly set, provide a method of obstacle avoidance. This is
achieved by means of maximum boom angle, maxi­ Note: System may be equipped with an overhead
mum load radius, maximum boom head height, left bar graph or an external light bar which operates
and right swing, and defined area alarms. These similar to the bar graph on the display. Refer to
alarms can be programmed for each job site and set Figure 1-67.
rapidly for the prevailing site conditions thereby aiding
the operator in safe operation of the crane.

Section 1 - Operating Instructions 1-75

Operator's Manual

1 2 3

4
5

17 6
6.5 X 1000 LBS MAX

55’ 0.5 1
45_

16
71.0

15

90.0ft 7

14
110.0ft

13 !! TWO BLOCK !!

12
24000

11 10 9 8

1. Bar‐Graph 7. Configuration Selection Buttons 13. Boom Length Display

2. Pre‐Alarm Indicator 8. Cancel Alarm Button 14. Brightness Buttons
3. Overload Indicator 9. Operator Alarms Button 15. Load Radius Display
4. Maximum Rated Capacity Display 10. Crane Setup Button 16. Boom Angle Display
5. Actual Load Display 11. Display/Select Button 17. Erected Attachment Display
6. Parts‐of‐Line Display 12. Warning Message Area

Figure 1-68
MicroGuard 534 Rated Capacity Limiter

1-76 Section 1 - Operating Instructions

 Operator's Manual
2. Pre‐Alarm indicator 10. Crane Setup Button
The Pre‐Alarm (yellow) Indicator illuminates at a pre‐ This button is used to start the configuration selection
set value of 90% of Maximum Rated Capacity and pro­ routine. Refer to “Configuration Selection” found later
vides a visual indication of an approach to an overload. in this Section of the Operator's Manual.

3. Overload Indicator 11. Display/Select Button

The Overload Indicator (red) illuminates at a pre‐set This button is used to access the Calibration And Diag­
value of 100% of Maximum Rated Capacity and pro­ nostic Screen. Refer to “System Fault Codes” and
vides a visual indication of Maximum Allowed Load. It “Calibration” found later in this Section of the Opera­
will also illuminate whenever a wire rope limit is exceed­ tor's Manual.
ed. Function limiters will occur simultaneously for an
Overload, Wire Rope Limit or a Two Block condition, 12. Warning Message Area
but function limiters will not occur when exceeding an The Warning Message Area displays text messages of
operator settable alarm. An audible alarm will sound various alarms which may occur during normal opera­
and a message will appear in the warning message tion of the system. When an alarm occurs, the rectan­
area for all 4 conditions. gular area fills in red.
4. Maximum Rated Capacity Display 13. Boom Length Display
The Maximum Rated Capacity is a digital display of the The Boom Length Display gives a continuous indica­
maximum permitted capacity. It is derived from a copy tion of the boom length in feet (m). It is the distance
of the crane's capacity chart which is stored in the com­ from the centerline of the boom foot pin to the center
puter memory and is the reference capacity for any lift­ line of the boom head machinery.
ing operation. It is dependent on the configuration cur­
rently selected, which is shown in the crane setup 14. Brightness Buttons
screen, and which determines the section of the ca­
These buttons are used to adjust the display bright­
pacity chart to be used as the rated capacity reference.
ness.
5. Actual Load Display 15. Load Radius Display
The Actual Load Display is a digital display which
The Load Radius Display gives a continuous indication
shows total load suspended below the boom or fly
of the radius of the load in feet (m). It is the horizontal
head. It includes the load, any slings, pins, or tackle
distance from the centerline of rotation to the centerline
used to secure the load and the hook block or ball.
of the hook.
6. Parts‐of‐Line Display 16. Boom Angle Display
Parts‐of‐Line displays the parts of line currently se­
The Boom Angle Display gives a continuous indication
lected for the winch in use.
of the angle of the main boom relative to horizontal.
7. Configuration Selection Buttons 17. Erected Attachment Display
These buttons are used during the crane configuration
The Erected Attachment Display gives a continuous
selection routine. Refer to “Configuration Selection”
display of the erected attachment with the top number
found later in this Section of the Operator's Manual.
indicating the actual fly length and the bottom number
8. Cancel Alarm Button indicating the offset angle if applicable.

This button is used to silence the audible alarm when

the alarm has occurred as a result of either an Over­
load, Wire Rope Limit, a Two Block, or an Operator Set­
table alarm. It is also used to reset the function limit
relay when it is necessary to by‐pass function limit
which has occurred as a result of either an Overload,
Wire Rope Limit, or a Two Block alarm.

9. Operator Alarms Button

This button is used to start the operator settable alarms
routines. Refer to “Operator Settable Alarms” found
later in this Section of the Operator's Manual.

Section 1 - Operating Instructions 1-77

Operator's Manual
“System Inoperative or Malfunctioning” found in this
Operator's Manual.

2 WARNING
The Microguard 534 is not operational when
the computer is bypassed. Bypass the
system in emergency situations only.
1
System Inoperative Or Malfunctioning
When operational aids are inoperative or malfunction­
ing, the following recommendations for continued use
of the crane should be followed or the crane should be
shutdown.
1. Steps shall be taken to schedule repairs and recal­
ibration immediately. The operational aids shall be
put back into service as soon as replacement
1. RCL Status Keyswitch 2. Computer parts, if required, are available and the repairs and
recalibration can be carried out. Every reasonable
Figure 1-69
effort must be made to expedite the repairs and re­
Rated Capacity Limiter Computer
calibration.
2. When the rated capacity limiter is inoperative or
malfunctioning, the designated person responsi­
System Operation
ble for supervising the lifting operations shall es­
The following is a list of procedures which are used to tablish procedures for determining load weights
operate the multiple features of the Rated Capacity and shall ascertain that the weight of the load does
Limiter. Use these procedures in conjunction with the not exceed the crane ratings at the radius where
previous display unit control descriptions. the load is to be handled.
3. When a boom angle or radius indicator is inopera­
System Self‐Test
tive or malfunctioning, the radius or boom angle
At start‐up the system automatically performs a self test shall be determined by measurement.
after which all lamps, audible alarms, and digital dis­ 4. When the anti‐two block warning device is inopera­
plays will be functionally tested and all memory areas tive or malfunctioning, the designated person re­
checked for accuracy. If faults in the system are de­ sponsible for supervising the lifting operations
tected during a test, the warning message area will shall establish procedures, such as assigning an
show the words SYSTEM FAULT. If the words SYSTEM additional signal person, to furnish equivalent
FAULT occur, press the Display/Select button to dis­ protection. This does not apply when lifting per­
play the diagnostic screen. The diagnostic screen lists sonnel in load line supported baskets. Personnel
information about the fault condition by means of an er­
shall not be lifted in load line supported baskets
ror code. Contact your local distributor for details of the
when the anti‐two block devices are not function­
fault codes.
ing properly.
Note: If the batteries have been disconnected inter­ 5. When a boom length indicator is inoperative or
rupting power to the computer, the start‐up time for malfunctioning, the designated person responsi­
on‐board computer systems will be longer than ble for supervising the lifting operations shall es­
normal. tablish the boom length at which the lift will be
made by actual measurement or markings on the
boom.
System Bypass 6. When a level indicator is inoperative or malfunc­
In emergency situations, the Rated Capacity Limiter tioning, other means shall be used to level the
computer can be bypassed. The computer is located crane.
on the back of the operator's cab. Refer to 7. In situations where inconsistency exists, verified
Figure 1-69. There is a RCL Status keyswitch adja­ weights, measured radii, boom lengths, and au­
cent to the computer to bypass the system. Move the thorized crane capacities must always take prece­
key to the “Bypass” position to bypass the system. For dence over indicator readings.
emergency use while the system is bypassed, refer to

1-78 Section 1 - Operating Instructions

 Operator's Manual
Configuration Selection
In the normal operational mode the system is programmed to remember the last configuration selected. Each time
the system is powered up it will automatically default to that configuration. Only when the crane is rigged differently
must a new configuration be selected. Use the following procedure to select the crane configuration.

Note: When selecting configurations allowed on outriggers, all beams must be equally extended; all fully
retracted, intermediate extended, or fully extended.
Depending on how the crane is equipped or which selections have been made, some screens shown may not
appear or may not appear as illustrated. The system cannot be programmed for configurations not allowed
by the capacity charts listed in the Crane Rating Manual.

, ,
Figure 1-70
Carrier Selection
1. From the normal working screen press the CRANE SETUP button. The normal working screen will change and
graphically display the carrier options. Press the corresponding configuration selection button to select the
desired carrier configuration. Press the “More” button to display additional selections. Press the “More” button
again to return to the first carrier selection screen. If rigging is desired, refer to “To Select Rigging/Travel Mode”
found later in this Section of the Operator's Manual.

WARNING
The Microguard 534 is not operational when in the RIGGING/TRAVEL Mode. Return the Microguard 540
to normal operation before operating the crane.

Section 1 - Operating Instructions 1-79

Operator's Manual

12000

24000

Figure 1-71 Figure 1-73

Counterweight Selection Auxiliary Head Selection

2. The carrier selection screen will change and 4. The boom mode selection screen will change and
graphically display the counterweight options. graphically display the auxiliary lifting sheave fitted
Press the corresponding configuration selection or not fitted. Press the corresponding configura­
button to select the installed counterweight. tion selection button to select the desired auxiliary
lifting sheave configuration.

31'

55'

70'

85'

Figure 1-72 Figure 1-74

Boom Extend Mode Selection Erected Attachment Selection

3. The counterweight selection screen will change 5. If the crane is equipped with a fly, the auxiliary
and graphically display the boom mode options. sheave selection screen will change and graphi­
Press the corresponding configuration selection cally display an erected attachment. Press the cor­
button to select the desired boom mode. responding configuration selection button to se­
lect the installed, erected attachment if required.
Note: Consult the Crane Rating Manual to de­
termine the best boom mode to maximize lift ca­
pacity at working radius. Boom mode options
will only be displayed when the boom is fully re­
tracted.

1-80 Section 1 - Operating Instructions

 Operator's Manual

25

45

Figure 1-75 Figure 1-77

Erected Attachment Offset Selection Front Winch Lifting Point Selection
6. If an offset fly was previously selected, the erected 8. If the crane is equipped with a front winch, the rear
attachment selection screen will change and winch lifting point screen will change and graphical­
graphically display the available offset angles. ly display the front winch lifting point. Press the cor­
Press the corresponding configuration selection responding configuration selection button to select
button to select the installed offset angle if re­ the actual front winch lifting point. Or press the cor­
quired. responding configuration selection button to select
the front winch not in use.

24'

55'

Figure 1-78
Stowed Attachment Selection
Figure 1-76
Rear Winch Lifting Point Selection 9. If the crane is equipped with a fly and was not se­
lected as an erected attachment, the winch lifting
7. The erected attachment or erected attachment off­ point screen will change and graphically display
set selection screen will change and graphically the stowed deduct. Press the corresponding con­
display the rear winch lifting point. Press the corre­ figuration selection button to select the actual
sponding configuration selection button to select stowed attachment.
the actual rear winch lifting point. Or press the cor­
responding configuration selection button to se­
lect the rear winch not in use.

Section 1 - Operating Instructions 1-81

Operator's Manual

Figure 1-79 Figure 1-80

Rear Winch Parts Of Line Selection Front Winch Parts Of Line Selection

10. The crane setup screen will change to the normal 11. If the crane is equipped with a front winch and it
working screen and graphically display the crane was selected, press the corresponding configura­
configuration as previously selected. Press the tion selection button to select the front winch.
corresponding configuration selection button to Press the corresponding configuration selection
select the actual parts of line for the rear winch. button to select the actual parts of line for the front
winch.

Note: From the normal working screen, after

crane setup has been established, only two
selection buttons are active; the winch select
button and the parts of line button.
To change winches, push the winch select but­
ton to toggle between winches. The winch lift­
ing points cannot be changed without going
through the crane setup routine.
The parts of line can be changed for the se­
lected winch by pressing the parts of line button
to scroll through the available options for that
winch.
Refer to Figure 1-81 and Figure 1-82 for ex­
amples of some normal working screens.

1-82 Section 1 - Operating Instructions

 Operator's Manual
7
4

6 5

3
1

In this example the crane is setup on fully extended outriggers (1), boom mode B (2), 24,000 lb
counterweight (3), 55' fly erected at 45 degree offset (4), the rear winch available with the main
boom head and the front winch selected (5), with the winch rope reeved over the fly base (6),
with one part of line (7), and an operator settable alarm enabled (8).

6 5

4
3
1

In this example the crane is setup on intermediate extended outriggers (1),

boom mode Amax2 (2), 24,000 lb counterweight (3) 55' fly stowed (4), the front
winch available with the auxiliary head and the rear winch selected (5), with
the winch rope reeved over the main boom head (6) with three parts of line (7).

Figure 1-81
Normal Working Screen Examples

Section 1 - Operating Instructions 1-83

Operator's Manual

5 4

7 3

1
In this example the crane is setup for stationary on tires (1), boom mode
Amax1 (2), 24,000 lb of counterweight (3), front winch not in use and
the rear winch selected (4), winch rope reeved over the main boom (5),
with three parts of line (6), and the 55' fly stowed (7).

4 6

5
3
1

In this example the crane is setup on fully retracted outriggers (1),

boom mode Amax1 (2), 12,000 lb of counterweight (3), winch rope
reeved over the main boom (4), 55' fly stowed (5), rear winch not
in use and the front winch selected (6), with three parts of line (7).

Figure 1-82
Normal Working Screen Examples

1-84 Section 1 - Operating Instructions

 Operator's Manual
Cancel Audible Alarm And Reset Function Limiters
The CANCEL ALARM button is used to cancel the
audible alarm when the alarm has occurred as a result
of either an Overload, a Two Block alarm, or an Opera­
tor settable alarm. The audible alarm may be canceled
by pressing and releasing the CANCEL ALARM button.
The audible alarm remains canceled until the condition
which caused the alarm has been removed. For exam­
ple, if the audible alarm was canceled because of an
overload condition, it will remain canceled until the
, overload condition is removed. However, if a different
alarm, e.g. two block condition, was to occur when the
audible alarm was still canceled for an earlier overload
condition, the new alarm condition would cause the au­
dible alarm to be re‐started.

WARNING
Once the function limiters have been
by‐passed, the crane is no longer protected
, against the condition that initially caused the
function limiters to occur.

Note: The CANCEL ALARM feature is a temporary

function. The audible alarm or function limit is auto­
matically reset when the condition which caused
Figure 1-83 the alarm is no longer present.
Rigging/Travel Mode Screen
The CANCEL ALARM is also used to reset the function
limiters when it is necessary to by‐pass the function lim­
To Select Rigging/Travel Mode
iters which has occurred as a result of either an over­
The CRANE SETUP push button is also used to select load, a two block alarm, or a rope limit. Function limit­
RIGGING/TRAVEL MODE. This mode is used to facili­ ers are reset by first canceling the audible alarm (as de­
tate rigging and travel of the crane by inhibiting func­ scribed above) and then pressing and holding the
tion limiters and the audible alarm while selected. To CANCEL ALARM button for about 3 seconds, after
resume crane operation, select proper outrigger or tire which the function limiters will be reset to allow normal
configuration per the proper procedure. operation. However, should another different alarm
condition occur when the function limiters had pre­
viously been over‐ridden, then the newly occurring
WARNING alarm condition would cause the function limiters to ac­
The Microguard 534 is not operational when in tivate again.
the RIGGING/TRAVEL Mode. Return the Mi­
croguard 534 to normal operation before op­ Operator Settable Alarms
erating the crane. Some alarms occur automatically as a result of limita­
tions imposed by the capacity chart. The operator has
1. From the normal working screen press the CRANE control over additional alarms which can be set to oper­
SETUP button. The crane setup screen will ate within the normal chart limitations which are in addi­
change and graphically display the carrier options. tion to, those already set by the chart.
2. Press the More button on the carrier options Operator settable alarms will be stored in the computer
screen to display RIGGING and TRAVEL mode memory, even if the crane is shutdown, until they are
selection screen. Refer to Figure 1-83. cleared. Refer to Figure 1-84.
3. Select for stationary rigging or when trav­
eling the crane. Alarms available for operator use are:
Minimum Boom Angle Maximum Boom Length
Note: Boom must be fully retracted to enter rig­ Maximum Boom Angle Left and Right Swing
ging/travel mode. Maximum Tip Height Operator Defined Area

Section 1 - Operating Instructions 1-85

Operator's Manual

EXIT

EXIT 75.0

LENGTH HEIGHT ANGLE

SETTABLE ALARMS 75.0 75.0 60.0

BOOM LIMITS , 75.0

SWING LIMITS 60.0

AREA LIMITS 30.0

Figure 1-84
Boom Limit Alarms

4. Press the corresponding selection button to set the

WARNING desired alarm value as defined below. Press the
button again to turn alarm off.
The operator settable alarms are a warning
device. All functions remain operational when
entering the operator defined bad area. For Maximum Boom Length
safe operation, adequate distance must be
maintained to allow for operator reaction time Maximum Tip Height
to avoid entering the bad area. It is the
responsibility of the operator to set points
which ensure that the crane's boom, Maximum Boom Angle
attachment, load, rigging, etc. maintains a
safe working distance and complies with local Minimum Boom Angle
safety regulations.
5. When all alarm values are set, press the EXIT but­
Angle, Length, And Height Operator Settable Alarms ton to return to the alarm screen. At the Settable
1. From the normal working screen press OPERA­
Alarm screen, press the EXIT button again to return
TOR ALARM button to access the Settable
to the normal working screen.
Alarms screen.
6. Test the alarm, with no load, to ensure the alarm
2. Press the corresponding button for Boom Limits
points have been properly set. When approaching
.
the alarm set point, the audible will sound intermit­
tently and a warning message will appear in the
WARNING warning message area. When exceeding the
alarm set point, the audible alarm will sound con­
Avoid positioning the boom, attachment, load,
tinuously and a warning message will appear in
rigging, etc. into the bad area when setting the
warning message area.
alarm values.
When selecting the alarm values, ensure that Note: An alarm icon will appear on the nor­
the load will maintain a safe distance from the mal working screen to alert the operator that an
obstacle. operator alarm has been set.

3. Position the boom in the desired position depend­

ing upon the alarm to be set. The numerical value
displayed will be the current position of the boom. WARNING
If crane or obstacle is moved or if a different
size load is lifted, the alarm(s) must be reset.

1-86 Section 1 - Operating Instructions

 Operator's Manual

265.0
SET

SWING ANGLE
EXIT
95.0

SETTABLE ALARMS EXIT

BOOM LIMITS 95.0

SET

SWING LIMITS ,
AREA LIMITS

Figure 1-85
Swing Alarm

Swing Operator Settable Alarm Operator Defined Area Alarm

To have an alarm whenever the left swing and right The operator defined area alarm, when set, will define
swing exceed pre‐determined alarm points, use the fol­ an imaginary vertical plane between two set points to
lowing procedure: optimize the working area. When approaching the
1. From the normal working screen press OPERA­ plane, the audible alarm will sound intermittently, and
TOR ALARM button to access the Settable the message “Bad Working Area” will appear in the
Alarms screen. warning message area. When passing the plane, the
2. Press the corresponding button for Swing Limits audible alarm will sound continuously and the mes­
. sage “Bad Working Area” will appear on the warning
3. Swing the boom to the left alarm point . message area. Use the following procedure,
4. Press the corresponding button for Left Swing Figure 1-86, and Figure 1-87 to set the operator de­
to enter the left alarm point. The displayed value fined area alarm.
will be the left alarm setting.
5. Swing the boom to the right alarm point.
6. Press the corresponding button for Right Swing WARNING
to enter the right alarm point. The displayed The operator defined area alarm is a warning
value will be the right alarm setting. device. All functions remain operational when
7. Press the EXIT button to return to the settable entering the operator defined bad area. For
alarm screen. Press the EXIT button on the set­ safe operation, adequate distance must be
table alarms screen to return to the normal working maintained to allow for operator reaction time
screen. to avoid entering the bad area. It is the
8. Test the alarm, with no load, to ensure the alarm responsibility of the operator to set points
points have been properly set. When approaching which ensure that the crane's boom,
the set alarm point, the audible alarm will sound in­ attachment, load, rigging, etc. maintains a
termittently and “Swing Alarm” will appear in the safe working distance and complies with local
warning message area. The audible alarm will acti­ safety regulations.
vate whenever the swing exceeds the alarm points
and “Swing Alarm” will appear in warning message
area.
Note: Both the left and right swing alarms must
be set for the system to determine the operator
set working area.
Note: An alarm icon will appear on the nor­
mal working screen to alert the operator that an
operator alarm has been set.

Section 1 - Operating Instructions 1-87

Operator's Manual

EXIT

SWING ANGLE
EXIT
97.2

SETTABLE ALARMS

BOOM LIMITS

SWING LIMITS

AREA LIMITS ,
Figure 1-86
Operator Defined Area Alarm

Setting Operator Defined Area Alarm button to enter the left alarm point. The dis­
1. From the normal working screen press OPERA­ played value will be the left alarm setting.
TOR ALARM button to access the Settable
Alarms screen. Note: For best results, the two points should be
separated by a minimum of 10 ft (3m) or 30 de­
2. Disable any previously set left and right swing
grees.
alarms if required.
6. When both alarm points are set, press the EXIT
Note: The left and right swing alarms must be
button to return to the settable alarms screen.
cleared prior to setting the defined area alarm.
Press the EXIT button on the settable alarms to re­
3. Press the corresponding button for Area Limit . turn to the normal working screen.
7. Test the alarm, with no load, to ensure the alarm
points have been properly set. When approaching
WARNING the plane, the audible alarm will sound intermittent­
Avoid positioning the boom, attachment, load, ly and the message “Bad Working Area” will ap­
rigging, etc. into the bad area when setting the pear on the warning message area. When passing
left or right alarm points. the plane, the audible alarm will sound continuous­
ly and the message “Bad Working Area” will ap­
When selecting the left and right alarm points,
pear on the warning message area.
ensure that the load will maintain a safe
distance from the obstacle. Also ensure that
the two points are set so that the tailswing of
the crane will not enter the bad area. WARNING
If crane or obstacle is moved or if a different
4. Position the boom, attachment, load, rigging, etc. size load is lifted, the area alarm must be
to the right alarm point and press the correspond­ reset.
ing button to enter the right alarm point. The
displayed value will be the right alarm setting. Note: An alarm icon will appear on the nor­
5. Position the boom, attachment, load, rigging, etc. mal working screen to alert the operator that an
to the left alarm point and press the corresponding operator alarm has been set.

1-88 Section 1 - Operating Instructions

 Operator's Manual

Figure 1-87
Operator Defined Area Alarm

Section 1 - Operating Instructions 1-89

Operator's Manual
CALIBRATION AND DIAGNOSTICS
A00 B0 C00 D00

ERROR CODES

ENTER CALIBRATION

Message Data Count

Figure 1-88
Calibration And Diagnostic Screen

System Fault Codes Calibration

If faults in the system are detected during a test, the If the system requires calibration, contact you distribu­
warning message area will show the words SYSTEM tor for assistance. Calibration must be done by a quali­
FAULT. If the words SYSTEM FAULT occur, press the fied technician. Press the Display/Select button to dis­
Display/Select button to display the Calibration And play the Calibration And Diagnostic screen. On the
Diagnostic screen. On the Calibration And Diagnostic Calibration And Diagnostic screen, press the Enter
screen, press the Error Code button to display error Calibration button. The calibration screen will be dis­
codes in the box at the top of the screen. This informa­ played and prompt a calibration key sequence to begin
tion can then be used to assist the service technician in the calibration routine.
determining the fault. Contact your distributor for as­
sistance with the fault codes.

1-90 Section 1 - Operating Instructions

 Operator's Manual

6 7

1. Offset Lattice Fly Tip Section

2. Fly Extensions
3. Offset Lattice Fly Base Section
4. Auxiliary Lifting Sheave
5. Five Section Boom
6. Front Winch
7. Rear Winch

Figure 1-89
Typical Crane Attachment Setup (Provided For Correct Identification Of Attachments)

Section 1 - Operating Instructions 1-91

Operator's Manual

1. Cab Walk 2
2. Release Handle

Figure 1-90
Cab Walk

the seat allows movement of the seat forward and

backward. This feature also provides operator comfort
WARNING during crane operation. Refer to “Operator's Seat”
To prevent personal injury do not attempt found earlier in this Section of the Operator's Manual
to enter the operator's cab prior to raising for complete seat operating instructions.
the left console stand. Inside the cab two separate features are provided to
prevent accidental operation of the hydraulic controls
while entering or exiting the operator's seat.
Figure 1-91
Left Console Warning Label 1. Function Lockout Switch
This switch is used to disable the hydraulic func­
Entering And Exiting The tions which are operated by the control levers and
boom telescope foot pedal. The switch is located
Operator's Cab on the cab control panel. Refer to Figure 1-33.
Entering or leaving the operator's cab could be hazard­ Move the switch to the “DISABLE” position to pre­
ous if certain aspects are not taken into consideration. vent inadvertent operation of these controls. To al­
The elevation of the carrier deck and operator's cab low normal operation of the control levers and the
alone could cause serious injury if someone was to fall. boom telescope pedal, move the function lockout
For this reason ladders are mounted on each side of switch to the “OPERATE” position. This switch
the carrier to provide easy access to the carrier deck must always be moved to the “DISABLE” position
and operator's cab. A cab walk assembly is mounted before entering or exiting the operator's seat.
under the operator's cab and should be extended
when entering/exiting the cab. Refer to Figure 1-90. 2. Movable Left Side Console
Turn the release handle to extend/retract the cab walk The left side console is hinged at the rear to allow
assembly. Numerous hand grips are also attached to the operator to lift the console up, out of the way
the cab as well as non‐skid safety strips on the surface while entering or exiting the upper cab. A spring
of the carrier deck, to provide safe entry to the cab. Use assists movement of the console.
these features to make climbing on the crane as safe as Lifting the left side console also performs the same
possible. Remain in three point contact with the crane duty as the function lockout switch, described
at all times (two hands and one foot or two feet and one above, disabling all hydraulic functions related to
hand). the control levers and boom telescope foot pedal.
One more feature which is available to ease entry and Lifting the left side console also automatically ap­
exit of the operator's cab, is the adjustable operator's plies the swing park brake. Make sure the side
seat. Move the seat back as required to allow safe en­ console is lifted up, out of the way before attempt­
try. The release lever on the forward left hand side of ing to enter or leave the upper cab.

1-92 Section 1 - Operating Instructions

 Operator's Manual
Break‐In Period Wire Rope And Sheaves
Operate a new crane at half throttle for the first twenty Inspect all wire rope and sheaves for damage or dete­
(20) hours of operation. A break‐in period under mod­ rioration. Replace as necessary. Refer to Section 5 of
erate loads will assist in providing long, trouble‐free this manual for additional information.
performance.
General Inspection
Before Starting Operations Visually inspect the entire crane for loose or missing
cotter pins or bolts, or damaged fly chords or lattices.
Before starting daily operations, make the following Check for oil or fluid leaks. Make repairs as needed.
checks and inspections:
Electrical System
Engine
Check the operation of all lights, windshield wipers,
Check fuel, oil, and cooling systems for proper fluid lev­ horns, turn signals, etc. Repair as needed.
els. Check for leaks. Repair or fill as required. Refer to
engine manufacturer's manual for additional details. Brakes
Gear Cases Start the engine and allow the hydraulic system pres­
sure to reach its normal operating range. Check that
Visually inspect all gear cases for leaks or damage. If the service brake indicator light is not lit. Check the
leaks or damage exists, repair and fill case to proper lu­ park brake and service brake operations. Adjust or re­
brication level. Refer to Section 2 of this manual for ad­ pair as needed.
ditional information.
Controls
Hydraulic System Check all controls for proper operation and adjust­
Check all hoses for chafing, bulging, or other damage. ment. Repair as needed.
Replace as necessary. Inspect hydraulic system for ex­
ternal leaks. Repair as needed. Check hydraulic reser­ Fire Extinguisher
voir oil level. Add oil if necessary.
A fire extinguisher is located in the operator's cab
Lubrication under the left console. Refer to Figure 1-50. Raise the
Lubricate crane as outlined in Section 2 of this manual. left console to gain access to the extinguisher. It is an
ABC type fire extinguisher, meaning it is capable of
Note: Operators may have nothing to do with lubri­ extinguishing most types of fires. The operator should
cation or maintenance of the crane, but it could be be familiar with its location, the clamp mechanism used
advantageous for them to be familiar with it. Knowl­ to secure it in place, and foremost the operation of the
edge of preventive maintenance makes the opera­ device. Specific instructions, regarding operation, are
tor more aware of malfunctions in the crane so re­ given on the label attached on the fire extinguisher. A
pairs can be made with a minimum of downtime. charge indicator on the fire extinguisher monitors the
pressure within the tank. Check the indicator daily to
Tires And Wheels ensure the fire extinguisher is adequately charged and
Check tire inflation. Inflate to pressures per the “Tire ready for use.
Inflation Label” on the left rear fender of the crane or on
the “Tire Inflation Chart” in Crane Rating Manual. Check
wheel lug nut torque, each day, for the first five (5) days of
operation and every 100 hours of operation thereafter.
Refer to Section 3 of this manual for additional informa­
tion.

Section 1 - Operating Instructions 1-93

Operator's Manual
there are no persons under or in close proximity to
Engine Starting Procedure the crane.
5. Turn the ignition switch to the on position to ener­
gize the engine electrical system.
WARNING 6. Turn the ignition switch to the start position. Re­
This manual must be thoroughly read and lease the ignition switch immediately after the en­
understood by the operator before starting gine starts. If the engine fails to start in 30 seconds,
the engine. Crane damage or personal injury release the ignition switch and allow the starter mo­
could result from improper operating tor to cool a few minutes before trying to start
procedures. again. If the engine fails to start after four attempts,
refer to the engine manufacturer's manual for in­
structions.
WARNING 7. Warm Up - Run the engine at low throttle with no
load while engine is warming up. Observe the fol­
Diesel exhaust fumes can be
lowing instruments for proper indications.
harmful. Start and operate
a. Engine Oil Pressure - If there is no oil pressure
engine in a well ventilated area.
after the engine runs 10-15 seconds, shut­
If it is necessary to operate in an
down the engine immediately and repair the
enclosed area, vent the exhaust
problem to avoid major engine damage. Refer
to the outside. Properly
to engine manufacturer's manual for proper oil
maintain the exhaust system to
pressure operating range.
its original design.
b. Battery Gauge - Observe indicator to ensure
battery and electrical system is working prop­
Before attempting to start the engine, the operator erly. The gauge should indicate 12.5 to 14.0
should carefully read and understand the engine start­ volts while engine is running. (It should read
ing instructions in the engine manufacturer's manual 12.0 volts when the key is on, without the en­
and this Operator's Manual. Attempting to start or run gine running.)
the engine before studying these instructions may re­ 8. When the engine has thoroughly warmed up, after
sult in engine damage. The operator should learn and all pressures and temperatures are within operat­
obey all applicable “Rules of the Road” and if not al­ ing ranges, and all daily checks have been made,
ready a competent driver, obtain instructions to attain the crane is ready for operation.
these necessary skills. With the crane fully serviced
and the operator familiar with all gauges, switches,
controls and having read and fully understood this en­
Engine Shutdown Procedure
tire manual, start the engine using the following proce­ 1. Lower any load to the ground and secure it prop­
dures: erly.
2. Engage the travel swing lock.
1. Walk around the crane to verify that there are no
3. Throttle the engine back to idle.
persons under, or in close proximity to the crane.
4. Position the transmission shifter to neutral.
2. Engage the park brake.
5. Turn the ignition switch to the “OFF” position.
3. Position the transmission shifter to neutral. (En­
6. Remove the ignition keys from the cab and lock the
gine will not start unless the transmission is in neu­
doors if the crane is to be left unattended.
tral.)
4. Sound the horn twice in succession, wait 10-15
seconds while making a visual check to verify that

1-94 Section 1 - Operating Instructions

 Operator's Manual
2

+
+

+
- - -

Wrong
1
1. Negative Cable 2. Positive Cable

Figure 1-92 Figure 1-93

Do not use an open flame near the battery. Battery Cable Connections

1. Check all battery terminals and remove any corro­

Jump Starting The Crane sion before attaching jumper cables.
The crane has three (3) 12V batteries. To jump start the 2. Connect one end of the first jumper cable to the
crane a 12V power source and two (2) jumper cables 12V positive (+) terminal of the discharged battery.
are required. Refer to Figure 1-93. 3. Connect the other end of the first cable to the 12V
positive (+) terminal of the 12V power source or
booster battery.
WARNING 4. Connect one end of the second jumper cable to the
To avoid serious personal injury and/or negative (-) terminal of the 12V power source or
equipment damage, follow these procedures booster battery.
in the order they are given. 5. Connect the other end of the second cable to the
ground stud on the upper frame.
Wear protective clothing and shield your face 6. If another vehicle is used to jump start the crane,
and eyes when working around batteries. start the booster vehicle. Run the booster vehicle's
Batteries contain sulfuric acid which burns engine at a moderate speed and allow discharged
skin, eyes, and clothing. batteries to charge for a few minutes prior to at­
Do not jump start a damaged battery. Be sure tempting to start the disabled crane.
vent caps are tight and level. If another 7. Start the disabled crane. After the crane is started,
vehicle is used, be sure booster vehicle and remove jumper cables in reverse order.
crane are not touching. 8. Let the crane's engine run for a few minutes to
charge the discharged batteries.
The gases around the battery can explode if
9. Check the battery gauge in the operator's cab.
exposed to open flames or sparks. An
The gauge reading should be increasing toward
explosion could result in serious personal
14 volts.
injury and/or equipment damage.
Battery posts, terminals, and related accesso­ Note: If the batteries are severely discharged,
ries contain lead and lead compounds. Wash voltage may increase slowly. If voltage does
hands after handling. not increase, replace the batteries and/or check
the electrical system.

Section 1 - Operating Instructions 1-95

Operator's Manual

1 2

1. Preheater Receptacle 2. Counterweight Removal Receptacle

Figure 1-94
Electric Engine Block Preheater

fication label. Plug the other end into a 110V to

Electric Engine Block 120V electrical source.
Preheater
The electric engine block preheater uses electrical
power to heat the coolant and circulate it through the WARNING
engine. The electric engine block preheater receptacle Areas adjacent to the preheater must be clean
is located on the left side of the upper. Refer to and free of oil and debris to avoid possible fire
Figure 1-94. hazard.

To Start The Electric Engine Block Preheater

1. Park crane in suitable area for storage, engage the Note: Unplug the engine block preheater before
park brake, position the transmission shifter to starting the engine.
neutral, and shutdown the engine.
2. Plug an approved extension chord into the recep­
To Stop Electric Engine Block Heater
tacle located on the left side of the upper. Plug the 1. Unplug preheater cord from electrical source.
chord into the receptacle as indicated by the identi­
2. Store the cord

1-96 Section 1 - Operating Instructions

 Operator's Manual

1. Fuel Canister

Figure 1-95
Ether Start System Fuel Canister

Ether Start (If Equipped) To Start The Engine Using Ether Start
1. With the transmission shifter in neutral and the
This system aids engine start‐up by injecting ether into park brake engaged, start cranking the engine.
the air intake while cranking the engine. The system is 2. While the engine is cranking, press the ether start
equipped with an electronic solenoid that prevents in­ (yellow) button, located on the left side of the steer­
jecting ether except when engine is cranking. A ther­ ing column. (Refer to Figure 1-37 for ether start
mostatic switch on the engine prevents ether from be­ button location.) Hold the button for 2 seconds.
ing injected into a hot engine. The ether fuel canister is (Do not hold the button in over 2 seconds.)
located just inside the engine housing door. Refer to 3. Release the ether start button to inject ether into
Figure 1-95. the air intake. Allow 3 seconds for the ether to dis­
charge. If the engine fails to start, repeat Steps
2-3.
WARNING
Use ether start system for starting cold engine
only. Push injector button only while cranking
engine. Use only ether in cold start system.
Do not attempt to use any other type of fuel.
When maintaining or troubleshooting ether
start system, always make sure the area is
well ventilated and away from heat, open
flames or sparks. Wear goggles to avoid eye
injury. When opening ether fuel line or
disconnecting atomizer, make sure it is
pointed away from you. The ethyl ether fuel
used in this system is extremely flammable,
toxic, harmful and can be fatal.

Section 1 - Operating Instructions 1-97

Operator's Manual

1. Cab Heater Control Switch

2
2. Temperature Control Knob

Figure 1-96
Cab Heater Controls

Cab Heater To Stop The Cab Heater

1. Move the heater switch to the “OFF” position.
A cab heater is used to heat the upper cab. Refer to 2. During warm weather conditions or if the heater is
Figure 1-96. The cab heater uses engine coolant cir­ not going to be used for an extended period of
culating through the unit to provide heat. Normally the time, rotate the temperature control knob to the
engine coolant circulates through the heater in the cab coolest setting.
regardless of whether the heater switch is turned on or
not. During warm weather conditions, the operator Cab Heater Shutoff
may wish to shutoff the flow of hot engine coolant to the
heater to reduce the temperature in the carrier cab.
Shutoff valves are located on the engine to perform this
function. Refer to “Cab Heater Shutoff”.
WARNING
Shutdown the engine and allow it to cool
To Start The Cab Heater before operating the heater shutoff valves.
1. With the engine running, move the heater switch to The valves may be hot and could cause
the “LOW” or “HIGH” position. serious burns.
2. Turn the temperature control know to the desired
setting. 1. Shutdown the engine and rotate the handles on
the shutoff valves clockwise to stop the flow of en­
gine coolant to the heater; Counter‐clockwise to
restore it. Refer to Figure 1-97.

1-98 Section 1 - Operating Instructions

 Operator's Manual
1

1
1. Shutoff Valves

Figure 1-97
Cab Heater Shutoff Valves

Air Conditioning
A/C Controls

(If Equipped) On

The operator's cab may be equipped with an air condi­

1
tioning unit. Use the following instructions to operate
Off
the unit. Refer to Figure 1-98.
1. Start the engine and allow all operating tempera­
tures and pressures to reach their normal range. High

2. Move the on/off switch to the “ON” position to acti­

Med
vate the air conditioning unit.
3. Move the fan speed control to the desired position. 2 Low
4. To turn the unit off, move the on/off switch to the
“OFF” position.

Control Panel

1. On/Off Switch
2. Fan Speed Control Switch

Figure 1-98
Air Conditioner

Section 1 - Operating Instructions 1-99

Operator's Manual
c. Lifts while on tires must be from firm level sur­
Crane Operation face. Use mats and/or grade the supporting
Cranes are used primarily for making heavy lifts. In or­ surface as required to ensure safe lift.
der to do this properly, certain procedures must be fol­ 7. Make sure the Rated Capacity Limiter is properly
lowed. The following is a suggested procedure for set to match the crane configuration.
making typical lifts: 8. Raise the boom and swing over the load. Extend
1. Determine the weight to be lifted. Be sure to add the boom to the desired length. Make sure power
the weight of the hook block, slings, rigging, fly, boom sections extend per the selected boom
etc. Determine height to which the load must be mode.
lifted. 9. Lower the hook block and fasten it onto the load.
2. Consult the capacity chart, Working Areas and The following points must be observed:
Working Range charts in the Crane Rating Manual a. The boom peak must be directly above the
located in the operator's cab. Find the shortest load. Booms are made to lift, and should never
boom length and load radius that will accomplish be used to drag a load sideways.
the job. b. Always use chains, wire ropes, or slings of am­
3. Position the crane so a minimum swing is neces­ ple size and make periodic checks of their con­
sary. Do not swing the upper over areas not cov­ dition.
ered on the capacity chart in the Crane Rating c. Always use sufficient parts of line. Consult
Manual, as the crane could tip, even without a load Wire Rope Capacity chart in the Crane Rating
on the hook in these areas. Manual located in the operator's cab for the
4. The crane must be supported by a firm, solid level number of parts of line needed for a given lift.
surface before starting to lift. All capacities in the d. When lifting loads, care should be taken to pre­
Crane Rating Manual are based on the crane being vent sudden loading or unloading of the winch
level in all directions. If the crane is not level, out rope. Ease into the load. Lift the load a few
swing or side swing of the load will greatly reduce inches off ground and hold to check brakes.
lifting capacities and could cause crane damage or 10. Lift the load to the desired height. Boom to the de­
an accident. If the ground is soft, use mats. sired angle. Be careful when booming down or
5. If outriggers are used, the following points must be swinging the load, as these increase the load ra­
observed: dius and result in a decrease in capacity. Make
a. The outrigger beams must all be equally ex­ sure the load being lifted remains within the lifting
tended (all fully retracted, intermediate ex­ capacity of the crane at the boom length and ra­
tended, or fully extended) to lift the loads dius being used.
shown in the Crane Rating Manual. Serious re­ 11. Control the load at all times. Use hand lines to
ductions in lifting capacity will result if beams guide the load. Do not guide loads into place with
are not in the same position and this could lead your hands. Swing slowly and smoothly. Avoid
to serious crane damage or an accident. jerks when starting or stopping swings.
b. Outrigger pontoons must be on solid, smooth 12. If the crane is to travel with a suspended load, refer
footing, flush with the ground (no hills, or val­ to “Pick And Carry Operation” found later in this
leys under pontoons), otherwise pontoons Section of the Operator's Manual for further in­
may be damaged or destroyed. If there is any structions.
doubt, use mats.
c. All capacities listed for the crane on outriggers
are based on the outrigger jacks being used to
raise the crane so that all tires are clear of the
ground and the crane is level. A bubble level is
provided in the operator's cab to assist the op­
erator in leveling the crane.
6. When making lifts on tires, the following points
must be observed:
a. All tires must be inflated to pressures as listed
on the Tire Inflation label located on the left rear
fender of the crane.
b. On tire lifts are to be made from the main boom
only. Do not use the auxiliary lifting sheave, or
fly.

1-100 Section 1 - Operating Instructions

 Operator's Manual
3. Listen for any unusual noises in the hydraulic sys­
During Operation tem, power train, or the speed reducers. If any,
The operator must remain alert to possible malfunc­ correct problem.
tioning of the crane while operating. If the crane does 4. Make sure all controls work freely and easily, with
malfunction, lower the load and shutdown the crane no sticking or binding. Lubricate or adjust as nec­
until the problem is found and corrected. During op­ essary.
eration, the operator must: 5. Watch for oil leaks or any loss of control. If any de­
1. Remain alert to any noise or loss of power, or bad velop, correct before continuing operation.
response to control of the crane. Watch the engine 6. If working on outriggers, periodically check the
oil pressure and water temperature gauges for outriggers to make sure the crane is level and sta­
proper operating ranges. ble. If working on tires, make sure the tires are in­
2. Watch the hydraulic system oil temperature flated to the proper pressure. (Refer to the Tire
gauge. If the temperature exceeds maximum tem­ Inflation label located on the left rear fender of the
perature, shutdown the crane until the problem is crane for proper tire pressure.)
corrected. (Refer to Section 2 of this manual for the 7. Heed all warning and caution labels. Observe
maximum temperature for each viscosity of hy­ good safety practices at all times.
draulic oil.)

Section 1 - Operating Instructions 1-101

Operator's Manual

TRAVEL TRAVEL
HOIST LOWER USE MAIN HOIST (One track) (Both tracks)

USE WHIP LINE RAISE BOOM LOWER BOOM SWING STOP

RAISE THE BOOM AND LOWER THE BOOM AND EXTEND BOOM RETRACT BOOM
MOVE SLOWLY LOWER THE LOAD RAISE THE LOAD (Telescoping booms) (Telescoping booms)

EXTEND BOOM RETRACT BOOM

TRAVEL DOG EVERYTHING EMERGENCY STOP (Telescoping booms) (Telescoping booms)

Extracted from the American National Standard, Crawler, Locomotive and Truck Cranes, ANSI B30.5b-1985, with the
permission of the Publisher the American Society of Mechanical Engineers, 345 E. 47th Street, New York, New York 10017.

Figure 1-99
Hand Signals

These signals should be used at all times unless voice

Hand Signals instructions with a radio or telephone are being used.
Hand Signals are important for communications be­ One person should be designated as a signalman and
tween the designated signalman and the operator. A their signals obeyed by the operator. Obey a stop sig­
hand signal chart, Figure 1-99, is included in this Sec­ nal from anyone.
tion of the Operator's Manual. A copy is also located on
the front outrigger box and on the right side window of
the operator's cab.

1-102 Section 1 - Operating Instructions

 Operator's Manual
9. Remove the lock pins and pins which secure the
Counterweight Removal counterweight to the counterweight removal cylin­
System ders.
10. Push the “Up” button to retract the cylinders away
Access to certain job sites may require the crane to from the counterweight.
be transported on roads with strict vehicle load limita­ 11. Swing the upper over the rear of the carrier. Attach
tions. In order to meet such limitations the crane may a sling to the counterweight using the lifting bars
be equipped with a counterweight removal system cast into the counterweight.
so the counterweight can be removed and trans­ 12. Attach other end of sling to the crane's hook block.
ported separately. Removing the counterweight can
reduce the weight of the crane by as much as 24,000
lb (10 886kg). WARNING
When operating the crane with no
Counterweight Removal counterweight, always refer to the Crane
1. Park the crane on a firm level surface, position the Rating Manual to ensure lifting capacities are
transmission shifter to neutral, and engage the not exceeded.
park brake.
Do not travel or transport the crane with the
2. Properly level the crane on fully extended outrig­
counterweight positioned on the removal
gers with all tires clear of the ground.
brackets. Counterweight may fall causing
3. Fully retract all boom sections. If equipped, prop­
severe personal injury and/or crane damage.
erly store the fly on the boom.
4. Install the counterweight removal brackets to the
13. Lift counterweight off removal brackets and onto
rear outrigger box if required. Refer to
transport vehicle.
Figure 1-100. Removal brackets weigh approxi­
mately 44 lb (20kg) each.
5. Swing the upper over the front of the carrier. En­ CAUTION
gage the travel swing lock.
6. Install the hand held remote control box to the left When swinging over the rear, boom hoist
rear of the upper. Plug the box into the receptacle cylinder may contact counterweight removal
as indicated by the identification label. brackets at low boom angles. When operating
7. Remove the lock pins and pins which secure the at low boom angles, be aware that
counterweight to the upper frame. counterweight removal brackets may be
installed to outrigger box.
Note: Counterweight cylinders may have to be
raised (retracted) to relieve pressure on the 14. Remove the hand held remote control box from the
pins to ease removal. left rear of the upper. Store in crane's tool box lo­
cated under the operator's seat.
8. Push the “Down” button on the remote control box
to lower the counterweight to the counterweight re­
moval brackets.

WARNING
To avoid personal injury, do not stand under
counterweight during lowering or raising of
the counterweights.

Section 1 - Operating Instructions 1-103

Operator's Manual

DANGER
Do not travel or transport
WARNING
crane with the KEEP CLEAR
counterweight positioned
on the removal brackets. OF MOVING
Counterweight may fall COUNTERWEIGHT
causing severe personal
injury and/or crane damage. TO PREVENT
SERIOUS BODILY
Do not deface or remove this label.
INJURY.

DO NOT ALLOW
BOOM TO CONTACT
CTWT BRACKET

3
6

4
5

1. Pin & Lock Pin - Counterweight To Counterweight Removal Cylinder

2. Pin & Lock Pin - Counterweight To Upper Frame
3. Pin & Lock Pin - Counterweight To Counterweight
4. Counterweight Removal Brackets
5. Hand Held Remote Control Box
6. Lifting Bar
Figure 1-100
Counterweight Removal System

1-104 Section 1 - Operating Instructions

 Operator's Manual
Counterweight Installation
1. Park the crane on a firm level surface, position the WARNING
transmission shifter to neutral, and engage the Counterweight must be balanced on the
park brake. removal brackets. Counterweight may fall
2. Properly level the crane on fully extended outrig­ causing personal injury and/or crane
gers with all tires clear of the ground. damage.
3. Install the counterweight removal brackets to the
rear outrigger box if required. Refer to 7. Swing the upper over the front of the carrier and en­
Figure 1-100. Removal brackets weigh approxi­ gage the travel swing lock.
mately 44 lb (20kg) each. 8. Install the hand held remote control box to the left
rear of the upper. Plug the box into the receptacle
as indicated by the identification label.
CAUTION 9. Push the “Down” button on the remote control box
When swinging over the rear, boom hoist to extend the counterweight removal cylinders to
cylinder may contact counterweight removal align connecting lugs on the counterweight.
brackets at low boom angles. When operating 10. Install the pins and lock pins to secure the counter­
at low boom angles, be aware that weight to the counterweight removal cylinders.
counterweight removal brackets may be 11. Push the “Up” button on the remote control box to
installed on outrigger box. retract the cylinders and lift the counterweight.

4. Attach a sling to the counterweight using the lifting

bars cast into the counterweight. WARNING
5. Using the crane, pick the counterweight off the To avoid personal injury, do not stand under
transport vehicle. counterweight during lowering or raising of
the counterweights.

WARNING 12. Continue to lift counterweight until the lugs on the

When operating the crane with no counterweight align with the lugs on the upper
counterweight, always refer to the Crane frame.
Rating Manual to ensure lifting capacities are 13. Install the pins and lock pins that secure the coun­
not exceeded. terweight to the upper frame.
14. Lower (extend) cylinders slightly to transfer the
6. Swing the upper over the rear of the carrier. En­ weight of the counterweight from the cylinders to
gage the travel swing lock. Set the counterweight the upper frame.
on the removal brackets. Make sure counter­ 15. Remove the hand held remote control box and
weight is balanced on the removal brackets. store in the crane's tool box located under the op­
erator's cab seat.

Section 1 - Operating Instructions 1-105

Operator's Manual
Pick And Carry Operation CAUTION
Travel during pick and carry operations is restricted to
speeds of 2.5 mph (4km/h) or less, and creep, on a Extended travel may cause the hydraulic oil in
firm, level surface. Creep is defined as crane move­ the travel circuit to overheat. Crane damage
ment limited to 200 ft (61m) in a 30 minute period and may occur if hydraulic oil temperatures are
not to exceed 1mph (1.6km/h) maximum speed. Lifts exceeded. Monitor the trans temperature
are to be made off the main boom only, with the crane gauge to ensure hydraulic oil temperature
prepared as follows: within the travel circuit is not exceeded. Refer
1. If equipped, the fly must be secured in the stored to “Transmission Controls” found earlier in
position on boom. this Section for maximum travel system
2. Inflate the tires to the required pressure listed on temperatures.
the Tire Inflation label located on the left rear fend­
11. Carefully travel at no more than creep speed or 2.5
er.
mph (4km/h) depending on which chart was se­
3. Make sure the Rated Capacity Limiter is properly
lected with the Rated Capacity Limiter.
set to the correct pick and carry configuration. Do
12. If outrigger boxes are installed on the crane, take
not exceed Pick And Carry capacities. Refer to
extra care due to the increased overall width
Creep or 2.5 mph (4km/h) capacity charts in the
caused by the extended outrigger beams. The
Crane Rating Manual.
outriggers or pontoons must not be allowed to hit
4. Level the crane on fully extended outriggers (if
any obstructions. Maintain a safe distance from all
installed) with the tires clear of the ground.
personnel and obstructions. Travel only on a firm,
Note: The crane can perform pick and carry op­ level surface.
erations with the outrigger boxes removed. Re­ 13. Once the desired destination is reached, position
fer to the appropriate capacity chart in the the transmission shifter to neutral and apply the
Crane Rating Manual before performing pick park brake.
and carry operations without the outrigger
boxes installed. Traveling The Crane
Certain conditions must be met for safe travel. Refer to
5. Position the upper over the rear of the carrier and
the following outlined procedures before traveling
engage the travel swing lock. Release the swing
crane.
park brake and the 360° swing lock if equipped.

CAUTION WARNING
Do not leave swing park brake applied or 360° Do not use rear wheel, 6‐wheel, or crab steer
swing lock lever in the engaged position mode for extended or high speed travel as
during pick and carry operations. Failure to steering behavior may be unfamiliar and a
release these devices during this operation loss of crane control could occur.
may result in damage to the swing speed Do not travel with upper over the side. Crane
reducer. may tip over causing personal injury and/or
crane damage. Engage the travel swing lock.
6. Boom must be extended in accordance with boom
mode “Amax1”, “Amax2”, or “Standard” as appli­
cable. Job Site Travel
7. Retract all outrigger jacks (if installed) just clear of Job site travel is limited to speeds less than 2.5 mph
the ground but leave the outrigger beams fully ex­ (4km/h). The crane may be traveled on the job site with
tended. no load per the following procedure:
8. Attach as many hand lines as necessary to prevent 1. Inflate the tires to pressure listed on the Tire Infla­
the load from swinging during travel. tion label located on the left rear fender for 2.5 mph
9. Carefully attach the load to the winch rope and lift it (4km/h) maximum speed.
only as high as necessary. 2. Level the crane on fully extended outriggers (if
10. Move the range select switch located on the over­ installed).
head control panel to the 6‐wheel drive mode.

1-106 Section 1 - Operating Instructions

 Operator's Manual
8. Carefully travel at no more than 2.5 mph (4km/h).
CAUTION Maintain a safe distance from all obstructions,
structures, and power lines.
When swinging over the rear, boom hoist
9. Once the desired destination is reached, position
cylinder may contact counterweight removal
the transmission shifter to neutral and apply the
brackets at low boom angles. When operating
park brake.
at low boom angles, be aware that
counterweight removal brackets may be
installed on outrigger box.
Highway Travel
Highway travel is considered to be any travel of the
crane over 2.5 mph (4km/h). The following conditions
Note: The crane can travel with the outrigger and precautions must be met for any highway travel.
boxes removed. 1. If equipped, the fly must be secured in the stored
position on boom.
3. If traveling on a firm, smooth, and level surface,
position the boom between 0° to 45°. Do not move
the boom during travel. Position the upper and at­
tachments in one of the following arrangements:
CAUTION
a. The upper over the front or rear of the carrier. Do not leave the swing park brake applied or
The boom fully retracted. The fly base and tip the 360° swing lock lever in the engaged
stored. position when traveling the crane. Failure to
b. The upper over front or rear of the carrier. The release these devices during this operation
boom fully retracted. The fly base and tip may result in damage to the swing speed
erected and in the 2° offset position. reducer.
4. If traveling on a slope, travel directly up or down the
slope. Position the upper and attachments in the 2. The boom must be over the front of the crane with
following arrangement: the travel swing lock engaged. Release the swing
a. The upper over the front of the carrier. The park brake and the 360° swing lock if equipped.
boom fully retracted at 0°. The fly base and tip 3. All boom sections must be fully retracted with the
stored. boom at 0° angle. Secure the hook block to pre­
vent excessive swinging.

CAUTION
Do not leave the swing park brake applied or DANGER
the 360° swing lock lever in the engaged It is recommended that the boom be
position when traveling the crane. Failure to positioned at 0 degrees when traveling the
release these devices while traveling may crane on the highway. However, it may be
result in damage to swing speed reducer. necessary to raise the boom slightly to
increase right side visibility. If the boom must
5. Engage the travel swing lock. Release the swing be raised, extreme care must be taken to avoid
park brake and the 360° swing lock if equipped. boom contacting any overhead obstacles,
6. Fully retract all outrigger jacks (if installed) and especially power lines.
beams and properly store the pontoons.
7. Secure hook block to prevent excessive swinging. 4. All outriggers must be fully retracted (jacks and
beams) with all pontoons removed from jacks and
stored properly.
CAUTION
Extended travel may cause the hydraulic oil in Note: The crane can travel with the outrigger
the travel circuit to overheat. Crane damage boxes removed.
may occur if hydraulic oil temperatures are
5. The drive train must be set to 2‐Wheel drive and the
exceeded. Monitor the trans temperature
steering selection switch in the conventional
gauge to ensure hydraulic oil temperature
mode.
within the travel circuit is not exceeded. Refer
6. Check all tires for correct pressure, adjust if re­
to “Transmission Controls” found earlier in
quired. Refer to the Tire Inflation label located on
this Section for maximum travel system
the left rear fender of the carrier.
temperatures.

Section 1 - Operating Instructions 1-107

Operator's Manual
connecting points on the crane are the outrigger box
CAUTION mounting lugs. Refer to Figure 1-101. Be sure to use
Extended travel may cause the hydraulic oil in towing equipment of ample size and strength.
the travel circuit to overheat. Crane damage Always exercise safety and follow all local codes when
may occur if hydraulic oil temperatures are towing the crane. Prepare the crane as follows before
exceeded. Monitor the trans temperature towing it.
gauge to ensure hydraulic oil temperature 1. If equipped, store the fly on the boom.
within the travel circuit is not exceeded. Refer
to “Transmission Controls” found earlier in
this Section for maximum travel system CAUTION
temperatures.
Do not leave the swing park brake applied or
the 360° swing lock engaged when towing the
7. During highway travel there must be at least a 30
crane. Failure to release these devices during
minute rest period every 50 miles of driving or 2
this operation may result in damage to the
hours of sustained operation whichever occurs
swing speed reducer.
first and a 60 minute rest period after 4 hours of op­
eration.
2. The boom must be over the front of the crane with
8. Obey all “Rules of the Road” and travel carefully.
the travel swing lock engaged. Release swing park
brake and the 360° swing lock if equipped.
Towing The Crane 3. All boom sections must be fully retracted with the
Always use good judgment and reliable equipment boom at a 0° angle. Secure the hook block to pre­
when towing the crane. Towing the crane should be vent excessive swinging.
done in emergency situations and for short distances 4. All outriggers must be fully retracted (jacks and
only. Use extra caution when towing the crane on the beams) with all pontoons removed from jacks and
highway and in traffic. stored properly.
5. The transmission shifter and all control levers in the
operator's cab must be in the neutral position.
CAUTION 6. Unlock the steering column by turning the ignition
switch to the “ON” position. Turn on the hazard
Do not tow the crane long distances and over
flashers.
1 mph (1.6km/h). Damage to the hydraulic
7. Release the park brake when the crane is attached
travel motors will occur. Tow the crane only
to the towing vehicle and ready to be towed. Re­
for short distances and at low speeds.
leasing the park brake may require the brake to be
manually “caged” to allow the front wheels to ro­
When making connections between the crane and tate. Refer to “Caging The Park Brake” found in
towing vehicle, be sure none of the connections will this Section of the Operator's Manual.
cause damage to either vehicle. The recommended

1-108 Section 1 - Operating Instructions

 Operator's Manual
10'-4”
24' FLY TIP (3.1m)

13'-4” TIP
(4.1m) LUG
FLY
LUG
31' FLY BASE
BOOM (FULLY
BOOM
RETRACTED, 0° 19'-4” FOOT PIN
BOOM ANGLE) (5.9m)

AUXILIARY
WINCH
5'-1”
6'-7” (1.5 m)
(2.0 m)
AUXILIARY
ARM

BOOM HOIST COUNTERWEIGHTS

CYLINDER BOOM 0'-5”
HOIST PIN (.1 m) UPPER SUPERSTRUCTURE

OUTRIGGERS
OF
TOW AND TIE ROTATION
DOWN POINTS
TOW AND TIE
CARRIER DOWN POINTS

TOTAL CRANE OUTRIGGERS

LIFT POINT OF LIFT POINT

63,070 LBS ROTATION 67,060 LBS
(28 610kg) (30,415kg)
Description Weight
Carrier 29,530 lb (13 395kg)
Outriggers 15,960 lb (7 240kg)
Upper Structure 24,050 lb (10 910kg)
Counterweight 24,180 lb (10 965kg)
Boom Hoist Cylinder 4,080 lb (1 850kg)
Boom W/ Foot Pin 25,820 lb (11 710kg)
Auxiliary Winch + Rope 2,560 lb (1 160kg)
Auxiliary Arm 120 lb (55kg)
31.0' Fly Base 1,880 lb (855kg)
24' Fly Tip 790 lb (360kg)
100T Hook Ball & Block 2,470 lb (1 120kg)
Total Crane 131,440 lb (59 620kg)

Figure 1-101
Towing And Lifting The Crane

Section 1 - Operating Instructions 1-109

Operator's Manual

2
1
CAUTION
3 Do not use a pneumatic impact wrench to
install caging bolt. Caging bolt and/or piston
may be damaged. Use only hand tools to
5 install caging bolt.

4 4. Place the washer on the caging bolt and manually

install the caging bolt through the cover plate and
into the piston within the brake.
5. Hand tighten the caging bolt until it bottoms out in
the piston. Do not use a hand or power tool for this
step.
6. Loosen the caging bolt 1/4 turn.
7. While holding the caging bolt with a wrench, manu­
ally turn only the jam nut until it contacts the wash­
er (4) against the cover plate.
8. Continue to hold the caging bolt stationary with
1. Cover Plate 4. Washer one wrench while tightening the jam nut with a sec­
2. Caging Bolt 5. Hub Cover ond wrench. Rotate the jam nut approximately 3/4
3. Jam Nut turn to cage the spring washers and release the
Figure 1-102 park brake.
Caging The Park Brake 9. Confirm that the park brake is released by manual­
ly rotating the hub cover.

Uncaging The Park Brake

Caging The Park Brake 1. While holding the caging bolt stationary with one
If the park brake can not be released to tow the crane, it wrench, loosen the jam nut with a second wrench
may have to be manually “caged” to allow the front by turning it counter‐clockwise. Rotate the jam nut
wheels to rotate. Use the following procedure to cage until the washer is loose; approximately two full
and uncage the park brake. Refer to Figure 1-102. turns.
1. Clean the surface of the cover plate. 2. Remove the caging bolt from the cover plate by
2. Remove the center plug (not shown) from the cov­ turning it counter‐clockwise.
er plate. 3. Apply pipe sealant to the threads of the center plug
3. Install the jam nut on the caging bolt as far as pos­ (not shown) and install it in the cover plate.
sible. 4. Properly store the caging bolt, jam nut, and washer
in the crane's tool box located under the operator's
Note: The caging bolt with jam nut is supplied seat.
with the crane and should be found in the
crane's tool box located under the operator's
seat. If the bolt can not be found, refer to the
crane's Parts Manual for replacement.

1-110 Section 1 - Operating Instructions

 Operator's Manual

Normal Suspension Collapsed Suspension

A 18” (0.46m) Trailer Height 13' 8” (4.17 m) 13' 5” (4.09 m)
A 24” (0.61m) Trailer Height 14' 2” (4.32 m) 13' 11” (4.24 m)

Figure 1-103
Transporting The Crane

Transporting The Crane CAUTION

When transporting the crane, precautions should be
taken in securing the crane to the trailer, barge, or other Do not leave the swing park brake applied or
the 360° swing lock engaged when
means of conveyance. The outrigger box mounting
transporting the crane. Failure to release
lugs are the recommended tie down points.
these devices during this operation may result
If chains are wrapped around the outrigger box collar, in damage to the swing mechanism.
be certain the chains will not damage the hydraulic
lines and fittings. The chains should be wrapped 3. All boom sections must be fully retracted with the
around the outrigger box, not the outrigger beam. boom at a 0° or less. Secure the hook block to pre­
Always exercise safety and follow all local codes when vent excessive swinging.
loading, unloading, or transporting the crane. 4. If outrigger boxes are installed on the crane, all out­
riggers must be fully retracted (jacks and beams)
with all pontoons removed from jacks and stored
properly.
WARNING 5. Position the transmission shifter to neutral and en­
Do not use towing shackles as a means of gage the park brake.
lifting crane. These shackles are not intended 6. If transport height adjustment is required, refer to
to be used to lift the crane and may break if “Suspension Height Adjustment” found later in this
subjected to the entire weight of the crane. Section of the Operator's Manual.
Severe personal injury or extensive 7. All control levers in the operator's cab must be in
equipment damage may result from this the neutral position.
practice. 8. Lock all windows and doors. Remove the keys
from the crane.
9. Depending on the specific situations, further
Prepare crane as follows before transporting it:
preparations may be needed to protect the crane
1. If equipped, store the fly on boom.
from the environment or vandalism. See “Crane
2. The boom must be over the front of the crane with
Storage” for further suggestions.
the travel swing lock engaged. Release the swing
park brake and the 360° swing lock if equipped.

Section 1 - Operating Instructions 1-111

Operator's Manual

SUSPENSION HEIGHT ADJUSTMENT

3

UP

DOWN

1 2

1. Front Wheels Suspension Adjustment Location

2. Left Center And Left Rear Wheel Suspension Adjustment Location
3. Right Center And Right Rear Wheel Suspension Adjustment Location

Figure 1-104
Suspension Height

Suspension Height Adjustment 2. Position the upper directly over the front of the car­
rier, boom fully retracted at 0 degree angle, and the
The oscillation suspension cylinders can be retracted travel swing lock engaged.
to reduce the overall height of the crane during trans­ 3. Select 2‐wheel high drive mode.
port. A hand held electrical control box with 20 ft (6.1m) 4. Move the transmission shifter to forward and apply
of cable is used to adjust the height of the crane. This is the park brake.
the same electrical control box as used on the counter­ 5. Measure the non‐painted rod length for each
weight removal option. Quick connect electrical con­ oscillation cylinder pair (front, right, and left side).
nection is provided under the left front fender for the The sum of the exposed rods should equal 4.25
front wheels. A second quick connect electrical con­ in ± 0.125 in (10.8cm ± 0.3cm). If suspension
nection is provided under the left rear fender for the left cylinders are not within specification proceed
side center and rear wheel . A third quick connect elec­ to the next step.
trical connection is provided under the right rear fender 6. With the crane on a firm, level surface and on tires,
for the right side center and rear wheel. push the UP button to extend the oscillation cylin­
Once the crane reaches the jobsite and is unloaded ders until the measured sum of the exposed rods
from the transport vehicle, the suspension must be equals 4.25 in (10.8cm) for each cylinder pair
properly adjusted to the correct travel height before op­ (front, right, and left side).
erating the crane. Use the following procedures to ad­
just the travel height. Note: Do not retract suspension cylinders to
1. Park the crane on a firm level surface. obtain the measured sum of the exposed rods.

1-112 Section 1 - Operating Instructions

 Operator's Manual
7. Measure the non‐painted rod length on the front 9. Do not allow the hoist lines to contact boom while
oscillation cylinder pair. Measured sum should lifting crane. Damage to the boom may result.
equal approximately 4.25 in ± 0.125 in (10.8cm ±
0.3cm). Crane Storage
8. Measure the non‐painted rod length on the left rear
oscillation cylinder pair. Measured sum should Anytime the crane is going to be left unattended it
equal approximately 4.25 in ± 0.125 in (10.8cm ± should be prepared so that it will not be damaged by
0.3cm). the elements, be an attraction to vandals, or a plaything
9. Measure the non‐painted rod length on the right for children.
rear oscillation cylinder pair. Measured sum
should equal approximately 4.25 in ± 0.125 in Short Term Storage
(10.8cm ± 0.3cm). 1. Do not leave crane where it will be a traffic hazard.
10. Disconnect the control box and store in the crane's 2. Lower all loads to the ground.
tool box located under the operator's seat. 3. The travel swing lock must be engaged.
4. Fully retract the boom. Boom down to 0°. The fly
Lifting The Crane 5.
may be erected if the crane is on outriggers.
Tie off the hook block to the towing shackles.
The entire crane (except the fly) can be lifted or the Winch lines should be snug.
components may be removed from the crane and lifted 6. All control levers must be in the neutral position.
individually. Refer to Figure 1-101 for the center of 7. Position the transmission shifter to neutral, engage
gravities (CG's) and weights for the entire crane and the park brake, and shutdown the engine. Block
the individual components. The following conditions the wheels to prevent the crane from rolling if on
and precautions must be met before lifting the crane or tires.
removing any component. 8. If the crane is on outriggers, the outriggers must be
1. The crane must be parked on a firm level surface properly set and supported so the crane will re­
with the travel swing lock engaged, the swing park main level.
brake released, and if equipped the 360° swing 9. In cold weather, locate the crane where it will not
lock disengaged. freeze to the ground.
2. Use lifting equipment, shackles, slings, etc., of 10. Lock all windows and doors. Remove the keys
suitable size and strength. All lifting equipment from the crane.
must be inspected before lifting the crane. The in­
spection must be recorded and dated in accor­ Long Term Storage
dance with current OSHA regulations. 1. Store the crane inside a building if possible.
3. When lifting the entire crane (without fly), extend 2. Thoroughly clean the crane.
the outrigger beams to the intermediate position 3. Touch up any spots where paint has chipped. This
and install slings around the beams. Protect slings will prevent rusting.
from any sharp edges. 4. Lubricate the entire crane as per the lubrication
4. The weights and locations of all CG's include all chart. Make sure all gear cases are filled to their
possible options (heaviest crane) except the fly. proper oil level.
Use the CG's as a starting point. Center hoist line 5. Inflate tires to proper pressure as shown on the Tire
on the CG, lift a few inches and adjust the hoist line Inflation label located on the left rear fender of the
to keep the crane/components level at all times. crane or the Tire Inflation chart located in the Crane
5. Removal of any components from the crane will Rating Manual. Check tire pressures periodically
shift the CG of the entire crane. Adjust hoist line to during storage to make sure they do not go flat. If
account for the removal of any component. possible block the crane up so the tires are clear of
6. The hook block and ball are assumed to be stored the ground. Make sure the blocking is placed so
in the front carrier storage compartment. the crane cannot fall off it. If this is not possible, set
7. Do not lift crane with fly attached to boom. Dam­ the crane on planks so the tires will not sink in the
age to the fly may result. Remove the fly from the ground. Block tires to prevent crane from rolling.
crane before lifting. Refer to Section 4 of this Oper­ 6. Fully retract all hydraulic cylinders if possible. Fully
ator's Manual for the correct procedures for remov­ retract the boom and store the fly, if equipped.
ing the fly. Cover all cylinder rods and machined and un­
8. Use only properly attached nylon straps to lift fly painted surfaces with a coat of grease.
base or fly tip to prevent damage to the compo­ 7. Leave all control levers in neutral.
nent. Protect the straps from sharp edges.

Section 1 - Operating Instructions 1-113

Operator's Manual
8. Position the transmission shifter to neutral, engage 12. Drain all moisture from the air reservoirs to prevent
the park brake, and shutdown the engine. rust and deterioration.
9. Prepare the engine as per the engine manufactur­ 13. Store the crane so it does not provide a plaything
ers manual. Make sure antifreeze protection is suf­ for children. Such a unit can be an “attractive nui­
ficient to prevent the engine from freezing. If anti­ sance” for children to play on. If they fall off it or get
freeze protection is not adequate, completely drain entangled, serious injury may result.
the engine block. 14. While in storage, the crane should be “exercised”
10. After the engine has cooled, cover all open areas every 60 days to ensure the working condition of
around the engine, cab, etc. to prevent entry of the crane. Remove necessary tarps and covers,
water. Cover the entire engine area with a tarp if start the engine, and operate all switches, control
possible. cables, and hydraulic functions several times to cir­
11. If in a location where vandalism may occur, lock the culate lubricants and to keep all mechanisms and
cab doors. Cover all cab glass with plywood or linkages operative.
boards to prevent glass breakage. Provide a
means of locking the engine access doors, fuel
tank and hydraulic reservoir.

1-114 Section 1 - Operating Instructions

 Operator's Manual
Table Of Contents
General Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Hi Performance Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Disposal Of Used Lubricants, Fluids, Etc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Engine Coolant Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Primary Fuel Filter Water Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Primary Fuel Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Secondary Fuel Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Water Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Hydraulic Reservoir Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Adding Oil To The Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Hydraulic Reservoir Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Hydraulic Reservoir Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Hydraulic Charge Flow Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Hydraulic Pressure Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Hydraulic Case Drain Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Hose Reel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Hydraulic Pump Drive Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Pump Drive Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Pump Drive Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Engine Air System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Changing The Engine Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Cleaning The Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Inspecting The Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Swing Speed Reducer Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Swing Speed Reducer Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

Section 2 - Lubrication And Preventive Maintenance i

Operator's Manual
Swing Speed Reducer Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Swing Brake Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Swing Brake Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Swing Brake Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Winch Drum Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Winch Drum Oil Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Winch Drum Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Boom Lubrication And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Wire Rope Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Lattice Fly Inspection And Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Crane Monitoring Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Display Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Hook Block, Ball, And Swivel Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

Turntable Bearing Capscrew Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Turntable Bearing Capscrew Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Paint Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Regular Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Polishing And Waxing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

ii Section 2 - Lubrication And Preventive Maintenance

 Operator’s Manual
The following procedures are important for proper lu­
General Lubrication brication of the crane:
Information 1. Wipe the grease gun nozzle and grease fittings
clean before lubricating. This will help keep dirt
The crane should be regularly and systematically lubri­ and grit from entering the bushing or bearing.
cated in accordance with the Lubrication Chart shown 2. Keep all grease and oil cans and containers clean.
on the following pages. Refer to Figure 2-1. Another Always replace the lid on containers when finished
copy of the chart is located on the right side of the crane to prevent entry of foreign materials. Wipe off oil
behind the front engine access door. The time intervals can covers before using.
shown on the lubrication chart are intended as a guide 3. Drain oil cases when hot to drain off accumulated
only. Under unusual working conditions, such as work­ sludge.
ing in dry, dusty conditions, in water or mud or around a 4. Watch for signs of incorrect lubrication such as fail­
corrosive atmosphere, more frequent lubrication could ure of clean grease to purge the old grease.
be necessary. In these cases, the oiler must use his 5. Bleed off hydraulic pressure before opening or re­
best judgment and work out his own lubrication sched­ moving a line or fitting.
ule. 6. Replace all guards before starting crane.
In addition to the points on the Lubrication Chart, all 7. Use a clean funnel equipped with a strainer for
movable linkages and control cables should be peri­ pouring lubricants.
odically lubricated to resist wear. 8. Clean the area around check and fill plugs before
removing them to prevent entry of foreign particles.
There are some very practical reasons for lubricating
and lubricant changes. Lubricants serve more than Note: See specific instructions later in this sec­
one purpose. They not only lubricate, but they trans­ tion for lubrication check and change proce­
port chemically reactive additives, wash away minute dures on all gear compartments.
wear particles, serve as a corrosion inhibitor and act as
a heat transfer medium. Draining and refilling any gear
unit with a fresh supply of oil also assists in eliminating
wear particles not trapped by magnetic plugs.

WARNING
Shutdown engine before fueling or lubricating
crane. To avoid a fire hazard, do not smoke or
handle fuel around an open flame. To avoid
crane damage and to prevent serious injury,
do not lubricate gears or any assemblies
while they are in motion.

Keep grease, oil, containers, and guns clean. Wipe all fittings before lubrication. Raise
the crane on outriggers or block the wheels and shutdown the engine before working
on the crane. Replace all guards and panels before operating the crane.

Section 2 - Lubrication And Preventative Maintenance 2-1

Operator’s Manual
7 39 5 4 3 2 35 35 36 34 KEY
1. SYMBOLS:
* Check fluid level and fill as required.
0 Inspect, lubricate, adjust, repair, or
replace as required.
+ Change oil (and filter if applicable).
# Change filter only.
@ Clean filter/strainer as necessary.
X Clean fins if needed.
$ Drain water.
N/A Not applicable.
A,E,H, etc. Lubrication codes. Refer to Lubrication
Code Identification on this chart. Link-Belt
recommends the lubrication types on this
chart. However, if an equivalent is to be
used refer to the Operator’s Manual for
14 32 30 32 detailed specifications to ensure a correct
equivalent is used.
16 13 1 19 2. Refer to engine manufacturer’s manual for proper
maintenance, lubrication, fuel, or coolant grade, and
additional information.
3. Refer to the Operator’s Manual for additional
information.
4. Lubricate the turntable bearing through the grease
fitting on the front of the upper frame. Use a low
pressure handgun and pump grease until clean
grease comes out. Rotate upper a few degrees and
pump grease until clean grease comes out again.
Repeat throughout the 360° cycle.

24 23 25 24 23 24 CAPACITY Lube Lube

Code Code
17 40 20 15 11 12 27 21 41 18 39 6 10 Above Below
Location Gallons Liters −10° F −10° F
Pump Drive 1.3 4.9 TT TT
Hydraulic Reservoir 255.0 965.3 Key 3 Key 3
Hydraulic System 340.0 1 287.0 Key 3 Key 3
Swing Speed Reducer 1.2 4.5 E LL
Winch Drum (Each) 6.0 22.7 HH QQ
22 Fuel Tank 95.0 360.0 Key 2 Key 2
42 Engine Coolant 8.3 31.4 Key 2 Key 2
Engine Oil 7.0 26.5 Key 2 Key 2

LUBRICATION CODE
IDENTIFICATION
Lube
38 37 36 33 9 31 28 8 29 26 Code Recommended Type
A Grease, NLGI Grade No. 2
E Extreme Pressure Gear Lubricant 80W/90
MAINTENANCE Lube Lube H
V
Grease (Summer Grade)
Molybdenum Disulfide Compound Lubricant
Service Code Code HH Gear Lubricant
Ref Interval Above Below KK Grease, NLGI Grade No. 1
LL Extreme Pressure Gear Oil 75W/90
Location No. (Hours) Operation Key −10° F −10° F QQ Synthetic Gear Oil
Surge Tank 1 10 * 1,2 Key 2 Key 2 TT Synthetic Gear Oil GD 220
Radiator 2 10 X 1,2 Key 2 Key 2
Engine 3 10 * 1,2 Key 2 Key 2
Engine Air Cleaner
Pump Drive
4
5
10
10
0
*
1,3
1,3
N/A
TT
N/A
TT
LUBRICATION Lube Lube
2000 + 1,3 TT TT Lube Code Code
Hydraulic Reservoir 6 10 *,$ 1,3 Key 3 Key 3 Reference Number Interval Above Below
500 # 1,3 Key 3 Key 3 Location Number Of Points (Hours) -10°F -10°F
2000 +,@ 1,3 Key 3 Key 3 Bell Cranks 23 4 50 A KK
Charge Flow Filter 7 500 # 1,3 Key 3 Key 3 Steer Linkage 24 16 50 A KK
Pressure Filters 8 500 # 1,3 Key 3 Key 3 Steering Cylinder Ends 25 8 50 A KK
Case Drain Filter 9 500 # 1,3 Key 3 Key 3 Control Arms 26 24 50 A KK
Winch Drum 10 50 * 1,3 HH QQ Travel Swing Lock 27 1 250 A KK
1000 + 1,3 HH QQ 360 Swing Lock 28 4 250 A KK
Swing Speed Reducer 11 50 * 1,3 E LL Oscillation Cylinder Pins 29 12 250 A KK
1000 + 1,3 E LL Turntable Bearing 30 1,Key 4 50 A KK
Swing Brake 12 50 * 1,3 Key 3 Key 3 Turntable Gear Teeth 31 All 50 H H
1000 + 1,3 Key 3 Key 3 Boom Hoist Cylinder Pins 32 2 10 A KK
Battery 13 50 0 1 N/A N/A Boom Sliding Surfaces 33 All Key 3 V,H V,H
Tires 14 10 0 1,3 N/A N/A Auxiliary Lifting Sheave 34 1 50 A KK
Boom 15 10 0 1,3 V,H V,H Fly Sheaves (Base & Tip) 35 4 50 A KK
Fly 16 10 0 1,3 N/A N/A Boom Head Machinery 36 All 50 A KK
Wire Rope 17 10 0 1,3 Key 3 Key 3 Hook Block & Sheaves 37 All 50 A KK
Primary Fuel/Water 18 10 $ 1,3 Key 3 Key 3 Hook Ball 38 1 50 A KK
Separator 500 # 1,3 Key 3 Key 3 Boom Foot Pin 39 2 10 A KK
Secondary Fuel Filter 19 500 # 1,3 Key 3 Key 3 Boom Extend Sheaves 40 2 50 A KK
Boom Extend 20 250 0 1,3 N/A N/A Boom Retract Sheaves 41 2 50 A KK
Wire Rope Anchors Hose Reel Wobble Rollers 42 2 50 A KK
Boom Retract 21 250 0 1,3 N/A N/A
Wire Rope Anchors
Hose Reel 22 250 0 1,3 N/A N/A

Figure 2-1
Lubrication Chart

2-2 Section 2 - Lubrication And Preventative Maintenance

 Operator’s Manual

Lubrication Specifications
The following specifications are approved for use in Link-Belt cranes. The specifications are identified by a code
letter. When a code letter appears on the lubrication or maintenance chart, it is referring to one of the lubricants
as described on the following pages. These lubricants are listed by specifications and by one brand name. Most
reputable oil companies can provide a lubricant to match a particular specification. It may then be used in the
crane no matter what the brand name. When using other brand names, the user assumes all responsibility for
product and patent liability.

Type A Type E
Grease, NLGI Grade No. 2 Extreme Pressure Gear Lubricant, 80W/90
A mineral oil based, multipurpose lithium complex ex­ An extreme pressure gear lubricant containing anti‐
treme pressure (EP) grease. Composed of a lithium foam protection, oxidation stability, anti‐rust, and
complex soap, compounded with highly refined par­ anti‐corrosion qualities. Contains sulfur and phos­
affinic base oils and formulated with a special additive phorus additive materials but no zinc in compliance
package to provide rust and corrosion protection, res­ with Eaton, General Motors, and International Har­
istance to water washout, oxidation stability, and wear vester truck driving axle requirements.
protection under high loads. It meets the require­
ments of ASTM D4950 GC-LB covering wheel bear­ Must meet or exceed military specification MIL-
ing and chassis greases. Recommended for use as a PRF-2105E, and is suitable for API service desig­
multipurpose industrial grease, particularily where nations GL3, GL4, MT-1, and GL5, with a rating of
temperature operation is of concern. 10 as determined in the shock load test
CRC-L-42.
Typical Characteristics:
Used in hoist reducer, swing reducer, driving axles,
Appearance . . . . . . . . . . . . . . . . . . Blue, Tacky and drop transmissions.
Lithium Complex Soap, wt % . . . . . . . . . . . 10
Penetration, D 217, Worked 60 X . . . . . . . 280
Physical Properties:
D 217, Worked 10,000 X % Change . . . 10
Dropping Point, Mettler,_F (_C) 450+ (232+) Appearance . . . . . . . . . . Very Dark Red, Dark
Mineral Oil Viscosity, D 445 Gravity, _API . . . . . . . . . . . . . . . . . . . . . 25.7-27
cSt at 104_F (40_C) . . . . . . . . . . . 150-205 Flash, COC, (Min) (_F) (_C) . . . . . . 375 (191)
cSt at 212_F (100_C) . . . . . . . . . . . 14.5-18 Pour Point, (Max) (_F) (_C) . . . . . . -20 (-29)
Rust Protection, D 1743 . . . . . . . . . . . . . . Pass Viscosity, Max @ 100_F (38_C) SUS . . . . 829
Copper Corrosion, D 4048 . . . . . . . . . . . . . 1B Viscosity, Max @ 210_F (99_C) SUS . . . . 72.5
Timken, OK Load, lbs, D 2509 . . . . . . . . . . 40 Viscosity Index . . . . . . . . . . . . . . . . . . . 95-100
Four-Ball EP, D 2596 Sulfur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37
Load Wear Index, kgf . . . . . . . . . . . . . . . . . . 46 Ash (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . None
Weld Point, kgf . . . . . . . . . . . . . . . . . . . . . . . 250 CU Corr 3 Hours 250_F (121_C) . . . . . . . . 1 b
Four-Ball Wear, mm, D 2266 . . . . . . . . . . . 0.4 Channel Point, Max (_F) (_C) . . . . . . . 0 (-17)
1 hr, 167_F (75_C), 1200 rpm, 40 kg Timken Test Lever Load lb (Min) . . . . . . . . . 50
Water Washout, wt % loss at Phosphorus (%) . . . . . . . . . . . . . . . . . . . . . . . 12
100_F (38_C) D 1264 . . . . . . . . . . . . . . . . . . 4
Grease Mobility, U.S. Steel Method g(l)/min Shell 59210 Spirax HD 80W/90 or Equivalent.
-30_F (34_C) . . . . . . . . . . . . . . . . . . . 0.0 (0)
-20_F (29_C) . . . . . . . . . . . . . . . . . . 0.5(1.9)
0_F (-17_C) . . . . . . . . . . . . . . . . . . 5.5(20.8)
20_F (7_C) . . . . . . . . . . . . . . . . . . . 30(113.6)
Guide to Usable Temperature
Min., _F (_C) . . . . . . . . . . . . . . . . -20 (-29)
Continuous Service, Max, _F (_C) 325 (163)
Short Exposure, Max, _F (_C) . . 450 (232)

Shell Code 70311- ALBIDA LC or Equivalent.

Section 2 - Lubrication And Preventative Maintenance 2-3

Operator’s Manual

Type H Type V
Grease (Summer Grade) Molybdenum Disulfide Compound Lubricant
For open gear applications. Satisfactory down to Recommended use for grease on cut tooth gears.
-40_F (-40_C) on dry gears. Good adhesiveness
on open gears at 73_F (22.7_C) and good reten­ A grease consistency mixture containing purified
tion. The grease with use will become tacky and will molybdenum disulfide powder M0S2. Powder to
resist leaking. Used on cast tooth gears and ring meet or exceed specification MIL-L-7866 (AER)
gear teeth. Extremely resistant to water washing. with max particle size of 40 microns.

Compound to have mineral oil base not to exceed

Physical Properties:
50% by volume containing not less than 40% M0S2.
Mineral Oil Component: Non-melting molybdenum disulfide compound. It
Viscosity at 100_F (38_C) SUS . . . . . . . . 4545 is impervious to water and is not affected by most
Viscosity at 210_F (99_C) SUS . . . . . . . . . 170 acids or alkalis. Helps prevent galling and seizing at
Load Wear Index . . . . . . . . . . . . . . . . . . . . . . 56 bearing pressures well over 100,000 pounds per
Penetration, Worked at 77_F (25_C) square inch. Has excellent lubricating qualities at
(60 Strokes) . . . . . . . . . . . . . . . . . . . . . . . . . 280 sub-zero temperatures and elevated tempera­
Dropping Point, Min (_F) (_C) . . . . . . 222(105) tures up to 750_F (398_C) under certain conditions.
Soap Base - Calcium (%) with 22% graphite Has a high film strength, low coefficient of friction
and 3% Molybdenum Disulfide . . . . . 9.0 and tenacious adherence to metal surfaces. Will
Water (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 prevent corrosion. Excellent lubrication on parts ex­
Recommended Max Temperature posed to water.
(_F) (_C) . . . . . . . . . . . . . . . . . . . . 175 (79)
Consistency . . . . . . . . . . . . . . . Buttery Grease Physical Properties:
Color . . . . . . . . . . . . . . . . . . . . . . . . Black-Gray
M0S2 (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Shell 71228 - Rhodina SDX Grease 2 or Equiva­ Drop Point . . . . . . . . . . . . . . . . . . . . . . . . . . None
lent. Mineral Oil (%) . . . . . . . . . . . . . . . . . . . . . . . . 42
Viscosity, Base Oil @ 100_F (38_C) . . . 2690
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . .NIL
Water (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Alkali (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Fillers (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Consistency . . . . . . . . . . . . . . . . . . . . . Medium
Jelling Agent . . . . . . . . . . . Pyrogenic Silicone

Bel-Ray Co. Molylube Anti-seize or Equivalent

2-4 Section 2 - Lubrication And Preventative Maintenance

 Operator’s Manual

Type HH Type KK
Gear Lubricant Grease NLGI Grade No. 1
This gear lubricant is suitable for use in a wide variety Low temperature, extreme pressure, synthetic all
of mobile equipment gear and brake applications. purpose grease made from a low pour point synthetic
Has good oxidation and thermal stability, is non‐cor­ hydrocarbon lubricant, thickened with lithium or clay.
rosive to most gear and bearing materials, and is in­ The grease is fortified with an extreme pressure addi­
hibited to provide good foam resistance and water tive and a rust inhibitor to provide even better equip­
separation characteristics. Has moderate concentra­ ment protection.
tion of EP additives. A multi‐purpose grease that can be pumped from
normal grease dispensing equipment at tempera­
Must meet performance requirements of AGMA
tures down to a -55_F (-48_C). Good for heavy
Specification 250.04 for extreme pressure lubricants.
duty operation.
Is suitable for API service designations of GL2 and
GL3. Recommended for use in centralized lube systems,
wheel bearings. chassis bearings, universal joints, and
Typical Characteristics: all other applications requiring a grease of this type. Of­
fers full protection regardless of the season. Pumpable
Appearance . . . . . . . . . . . . . . . . . . . Very Dark Red at -55_F (-48_C), even in a hand grease gun. Excel­
Gravity, _API . . . . . . . . . . . . . . . . . . . . . . . . 26.7-29 lent anti‐wear and load carrying ability, stays in place
Flash, COC, Min _F (_C) . . . . . . . . . . . . . 410 (210) better than lighter greases, waterproof to resist wash­
Pour Point, Max _F (_C) . . . . . . . . . . . . -10 (-23) out, good shear stability. Assures good high tempera­
Viscosity cSt @ 104_F (40_C) . . . . . . . . . . . . . . 150 ture performances. Compatibility of this grease with or­
Viscosity cSt @ 212_F (100_C) . . . . . . . . . . . . 14.4 dinary greases presents no problems.
Viscosity SUS @ 100_F (38_C) . . . . . . . . . . . . . 796
Viscosity SUS @ 210_F (99_C) . . . . . . . . . . . . . . 76 Physical Properties:
Viscosity Index . . . . . . . . . . . . . . . . . . . . . . . 95-100 Thickener . . . . . . . . . . . . . . . . . . . . . Lithium or Clay
Sulfur, % . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.66 Penetration worked @ 77_F (25_C) (ASTM D217)
Phosphorous, % . . . . . . . . . . . . . . . . . . . . . . . . 0.03 60 strokes . . . . . . . . . . . . . . . . . . . . . 315-325
Timken OK Load, Lbs (Min) . . . . . . . . . . . . . . . . . 60 Texture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth
AGMA No. EP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dropping Point, (_F) (_C)
(ASTM D2265) Max . . . . . . . . . . . +500 (260)
Viscosity (ASTM D445) cSt
Shell 65104, OMALA 150 or Equivalent. 104_F (40_C) . . . . . . . . . . . . . . . . . . . . 26.2-32
212_F (100_C) . . . . . . . . . . . . . . . . . . 5.08-5.2
Rust Properties (ASTM D1743) . . . . . . . . . . Pass
Four Ball, EP (ASTM D2596)
Wear, mm, Max . . . . . . . . . . . . . . . . . . . . . . . 0.7
Weld, kg, Min . . . . . . . . . . . . . . . . . . . . . . . 250
Color . . . . . . . . . . . . . . . . . . . . . . . . . Red or Brown

Exxon Mobil Mobiltemp SHC 32 or Equivalent.

Section 2 - Lubrication And Preventative Maintenance 2-5

Operator’s Manual

Type LL Type QQ
Extreme Pressure Gear Oil, 75W/90 Synthetic Gear Oil
A synthetic, extreme pressure gear oil designed for A specially formulated lubricant for applications
cold weather operation in hypoid, spiral bevel, and where service conditions are severe because of
planetary gear axles. Must meet the requirements high operating and bulk oil temperatures. Typical
of Military Specification MIL-PRF-2105E. Meets applications are spur, helical, herringbone, bevel,
API GL-5 and MT-1 performance ratings and planetary gears and gear boxes with multiple
disc brakes. Lubricant is derived from synthetic
Physical Properties: based oils that are more resistant to thermal and ox­
idation degradation. Can offer advantages of ex­
Gravity, _API (ASTM D-1298) . . . 25.2-33.3 tension of lubricant life and reduced risk of damage
Kinematic Viscosity, (ASTM D-443) to machine elements.
Min @ 212_F (100_C), cST . . . . . . . . . . . . 15.5
Max @ 104_F (40_C) . . . . . . . . . . . . . . . . . 126 Typical Characteristics:
Apparent Viscosity, (ASTM 2983) (Brookfield)
Max @ -40_F (-40_C), ml . . . . . . . . 150,000 AGMA Grade No. . . . . . . . . . . . . . . . . . . . . 4 EP
Flash Point (ASTM D-92) Gravity, _API . . . . . . . . . . . . . . . . . . . 25.5-34.4
Min _F (_C) . . . . . . . . . . . . . . . . . 400 (204) ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . 150
Pour Point (ASTM D-97) Viscosity, Cst (ASTM D-445)
Max _F (_C) . . . . . . . . . . . . . . . -49 (-45) @104_F (40_C) . . . . . . . . . . . . . . . . . . . 140
Viscosity Index (ASTM D-2270) . . 140-151 @ 212_F (100_C), Cst . . . . . . . . . . . . 14.0
Copper Corrosion, (ASTM D-130) Viscosity, SUS (ASTM D-2161)
3 hrs. @ 250_F (121_C) Max . . . . . . . . . . . . . 3 @ 100_F (38_C) . . . . . . . . . . . . . . . . . . 737
Foaming Characteristics (ASTM D-892) @ 210_F (99_C) . . . . . . . . . . . . . . 75-100
(Foam readings taken immediately Viscosity Index . . . . . . . . . . . . . . . . . . . 96-150
after 5 minutes aeration) Pour Point,
Max @ 75_F (24_C), ml . . . . . . . . . . . . . . . . 20 (ASTM D-97) _F (_C) . . . . . . -23 (-10)
Max @ 200_F (94_C), ml . . . . . . . . . . . . . . . 50 Flash Point, COC, (ASTM D-92)
Storage Stability, % Max _F (_C) . . . . . . . . . . . . . . . . . . . . . 229-460
(FTMS 791B Method 3440) . . . . . . . . . . . . 0.25 Rust Test, Distilled Water,
Compatibility (ASTM D-665) . . . . . . . . . . . . . . . . . . Pass
(FTMS 791B Method 3430) . . . . . . . . . . Note 1 Copper Corrosion Test
24 hr. -30 hr. @ 212_F (100_C) . . . . . 1b
Timken Extreme Pressure Test
The latest revision of all referenced specifications (ASTM D-2782) Pass Value (lbs) . . . . 60
and test methods shall be used. FZG Test, Stages, Pass . . . . . . . . . . . . . . . . . 12
FTMS= Federal Test Method Standard. Phosphorus, Wt. % . . . . . . . . . . . . 0.005-0.03

Note 1: Use approved per Eaton PS-163 and Mobil SHC 629 or Equivalent.
Mack GO-J Plus.

Mobil Oil Molilube SHC 75W/90, Code No.

51100‐6 or Equivalent.

2-6 Section 2 - Lubrication And Preventative Maintenance

 Operator’s Manual

Type TT
Synthetic Gear Oil
A specially formulated lubricant for applications
where service conditions are severe because of
high operating and bulk oil temperatures. The high
viscosity index allows the oil to flow at low tempera­
tures and maintain viscosity at high temperatures.
Typical applications are spur, helical, herringbone,
bevel, planetary gears, and gear boxes with multi­
ple disc brakes. This lubricant is derived from syn­
thetic based oils that are more resistant to thermal
and oxidative degradation. It can offer advantages
of extension of lubricant life and reduced risk of
damage to machine elements.

Physical Properties:

Gravity, _API . . . . . . . . . . . . . . . . . . . . . . 31.6-32.4

ISO Viscosity Grade . . . . . . . . . . . . . . . . . . . . . . 220
Viscosity, cSt (ASTM D-445)
@ 104_F (40_C) . . . . . . . . . . . . . . . . 217-228
@ 212_F (100_C) . . . . . . . . . . . . . . 25.2-28.8
Viscosity Index (ASTM D-2270) . . . . . . 146-165
Pour Point (ASTM D-97)
(_F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . -35-49
(_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . -37-45
Flash Point, COC (ASTM D-92)
(_F) . . . . . . . . . . . . . . . . . . . . . . . . . . . 482-510
(_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 250-266
Rust Test, Distilled Water (ASTM D-665) . . Pass

Mobil Oil Company - Mobilgear SHC 220 -

or Equivalent.

Section 2 - Lubrication And Preventative Maintenance 2-7

Operator’s Manual

Hi Performance Hydraulic Oil

Important
Use only pre‐filtered hydraulic oil. Warranty is void if incorrect oil is used.
Incorrect oil may result in damage to hydraulic components. Hi Performance
Hydraulic Oil is available through your distributor in the following grades and
quantities.
Temperature Range Container Capacity
Oil Grades Ambient Maximum Hydraulic Part Number
Gallons Liters
Temperature Use System Temperature

-45°F to 80°F 150°F 5 18.9 830666001

Grade 22
-43°C to 27°C 65°C 55 208.0 830666002

10°F to 100°F 200°F 5 18.9 830667001

Grade 68
-12°C to 38°C 93°C 55 208.0 830667002

40°F to 110°F 200°F 5 18.9 830664001

Grade 100
4°C to 43°C 93°C 55 208.0 830664002

Disposal Of Used
Lubricants, Fluids, Etc.
Properly dispose of used lubricants and filters. Every
drop of misplaced oil damages the environment. Each
year literally thousands of gallons of used oil is dumped
into our fields and streams or buried in community
landfills. These methods of disposal permanently
damage the world around us. You can see that the oil
you use is properly disposed of by sending it to a recy­
cling center. Most local automobile service stations are
happy to receive used oil and will see to it that the oil is
recycled. Refer to the latest EPA, state, and local regu­
lations regarding proper disposal.

2-8 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual
Engine Coolant Check
Check the coolant level in surge tank every 10 hours of
operation. Refer to the engine manufacturer's manual
for draining and refilling of the engine cooling system.
1. Park the crane on a firm level surface, apply the
park brake, position the transmission shifter to
neutral, and shutdown the engine.
2. Check that the coolant level in the surge tank is at
or above the minimum level line on the side of the
tank.

1 2 3
WARNING
Engine cooling system is pressurized. Do not
remove vent cap from a hot engine. Heated
coolant spray or steam can cause personal
injury. Wait until the coolant temperature is
below 122°F (50°C ) before removing vent
cap.

3. If coolant must be added, allow the engine to cool

until the the coolant temperature is below 122°F
(50°C ). Then slowly open the vent cap to relieve
the pressure in the system. 1. Vent Cap
2. Fill Cap

CAUTION 3. Minimum Fill Line

Figure 2-2
Avoid prolonged and repeated skin contact
Engine Coolant Surge Tank
with antifreeze. Such prolonged, repeated
contact can cause skin disorders or other
bodily injury. Keep out of reach of children.
Do not add cold coolant to a hot engine.
Engine castings can be damaged. Allow the
engine to cool until the coolant temperature is
below 122°F (50°C ) before adding coolant.

4. Once the system pressure has been relieved, re­

move the fill cap and add coolant as required to fill
the tank to the minimum level line. Refer to the en­
gine manufacturer's manual for the correct type of
coolant.
5. Replace fill cap. Start the engine and let it run until
it reached normal operating temperature. Shut­
down the engine and repeat Step 2.

Section 2 - Lubrication And Preventative Maintenance 2-9

Operator's Manual

3
1
2
1. Fuel Tank
2. Primary Fuel Filter
3. Secondary Fuel Filter

Figure 2-3
Fuel Filters

Fuel Filters
1
4 Two spin‐on type filters are used, a primary filter/water
separator and a secondary fuel filter. The function of
the filters is to remove water and contaminants from the
fuel before they enter the fuel system. Removal of wa­
ter and contaminants is important for trouble‐free op­
eration and long life of the fuel system. Water should
2 be drained daily before start‐up. Change the filters ev­
ery 500 hours of operation. Use the following proce­
dures along with Figure 2-4.

3 5 Primary Fuel Filter Water Drain

1. Park crane on a firm level surface, engage park
brake, shift transmission to neutral, and shutdown
the engine.
1. Priming Pump 4. Vent Plug
2. Fuel Filter
3. Collection Bowl
5. Drain Valve
CAUTION
The engine must be shutdown when draining
Figure 2-4 water from the fuel filter to prevent water from
Primary Fuel Filter
being drawn into the fuel system.

2-10 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual
2. Place a suitable container under the drain valve.
Open the drain valve and operate the priming
pump.

Note: A 0.312” (0.8cm) I.D. hose may be con­

nected to the fitting on the drain valve if a con­
tainer can not be placed directly under the filter.

3. Continue draining until clear fuel is visible.

CAUTION
Do not over‐tighten the valve. Over‐tightening
1
the drain valve can damage the threads.

4. Close the drain valve.

5. Properly dispose of contaminated fuel.

Primary Fuel Filter Change 1. Secondary Fuel Filter

1. Park crane on a firm level surface, engage park
brake, shift transmission to neutral, and shutdown Figure 2-5
Secondary Fuel Filter
the engine.
2. Clean the area around the filter head.
3. Place a suitable container under the drain valve. Secondary Fuel Filter Change
Loosen the vent plug and open the drain valve.
1. Park crane on a firm level surface, engage park
Drain all fuel from filter.
brake, shift transmission to neutral, and shutdown
Note: A 0.312” (0.8cm) I.D. hose may be con­ the engine.
nected to the fitting on the drain valve if a con­ 2. Clean the area around the filter head.
tainer can not be placed directly under the filter. 3. Turn the shutoff valve to the “Closed” position (per­
pendicular to the valve).
4. Remove the filter and collection bowl together. Re­ 4. Remove the filter from head and discard.
move the filter from the collection bowl and proper­ 5. Fill the new filter with clean fuel and lubricate the o‐
ly discard. ring with clean engine oil.
5. Lubricate the new o‐ring and filter seal with clean 6. Install new filter on filter head and tighten by hand.
engine oil. Install the bowl onto the new filter and
then install them both onto the filter head by hand.
CAUTION
To prevent fuel leaks, make sure the filter is
CAUTION installed tightly but do not over‐tighten.
To prevent fuel leaks, make sure the filter is Mechanical tightening will damage the filter.
installed tightly but do not over‐tighten.
Mechanical tightening will damage the filter. 7. Turn the shutoff valve to the “Open” position (in line
with the valve).
6. Fill the filter with clean fuel. With the vent plug still 8. Start the engine and check for leaks.
loosened, operate the priming pump until fuel
purges at the vent plug. Close the vent plug. Note: If the crane is hard to start, it may be nec­
7. Start the engine and check for leaks. essary to prime the fuel system. Refer to engine
manufacturer's manual for correct procedure.
Note: If the crane is hard to start, it may be neces­
sary to prime the fuel system. Refer to engine 9. Properly dispose of contaminated filter.
manufacturer's manual for correct procedure.
8. Properly dispose of contaminated fuel and filter.

Section 2 - Lubrication And Preventative Maintenance 2-11

Operator's Manual

OIL LEVEL

FULL

ADD

INFORMATION
Check level when oil is cold (approx.
62°F) or (17°C) with engine off,
machine level, and all cylinders fully
retracted. Oil level must be
maintained between “FULL” and
“ADD” marks at all times. Operation of 2
machine with oil level below “ADD” will
contribute to pump failure. Do not
overfill.

8 7 6 5
1. Filter Housing 3. Sight Gauge 5. Water Drain Plug 7. Bottom Access Panels
2. Filler Breather Cap 4. Hydraulic Reservoir 6. System Drain Plug 8. Pressure Filters

Figure 2-6
Hydraulic Reservoir

2-12 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual
marks. Use only Hi Performance Hydraulic Oil or
Hydraulic Reservoir an approved substitute. Do Not Overfill.
The hydraulic reservoir is used to supply and store hy­
draulic oil needed to operate all hydraulic functions of Adding Oil To The Hydraulic Reservoir
the crane. The hydraulic reservoir, as shown in 1. Park the crane on a firm level surface, position the
Figure 2-6, is equipped with a sight gauge for check­ transmission shifter to neutral, engage the park
ing the oil level. brake, and shutdown the engine.
A filter housing is mounted on the top of the tank with a 2. Relieve any trapped hydraulic system pressure by
built in pressure gauge. When the pressure gauge loosening the filler/breather cap, located on the hy­
reads 25 psi (172kPa), the filter is being bypassed. draulic reservoir, 1/4 turn until pressure is fully re­
Drain any water from the hydraulic reservoir, check the lieved. Refer to Figure 2-6.
oil level, and inspect the contamination indicator daily.
Operating the crane with the oil level below the full mark
or with the filter element bypassed can lead to hydrau­ WARNING
lic component failure. Refer to the following proce­ All trapped hydraulic pressure must be
dures when servicing the hydraulic reservoir. exhausted from the system before removing
any plug or cover. A sudden release of hot oil
Water Drain could cause burns or other serious injury.
Drain the water from the hydraulic reservoir daily before
start‐up. Contaminated oil will damage the systems 3. Clean the top of the hydraulic reservoir, the filter
hydraulic components. housing, and filler breather cap to prevent foreign
1. Relieve any trapped hydraulic system pressure by material from entering the hydraulic system.
loosening the filler breather cap, located on the hy­ 4. Remove the filler breather cap.
draulic reservoir, 1/4 turn until pressure is fully re­ 5. Add oil as required. Check the oil level.
lieved. Refer to Figure 2-6. 6. Install filler breather cap.

Hydraulic Reservoir Oil Change

WARNING The hydraulic reservoir oil should be changed every
All trapped hydraulic pressure must be 2,000 hours of operation or seasonally, whichever oc­
exhausted from the system before removing curs first. Change the hydraulic reservoir oil at the end
any plug or cover. A sudden release of hot oil of a working day when any foreign particles will be sus­
could cause burns or other serious injury. pended in the warm oil. If this is not possible, cycle the
crane until the oil is warm and proceed as follows:
2. Loosen the water drain plug and allow the water to 1. With all hydraulic cylinders fully retracted, park the
drain into a suitable container. The water drain crane on a firm level surface. Position the transmis­
plug is slotted and need not be completely re­ sion shifter to neutral, engage the park brake, and
moved to drain the water. shutdown the engine.
3. When a clean flow of hydraulic oil begins to drain 2. Relieve any trapped hydraulic system pressure by
from the water drain plug, tighten the plug. loosening the filler/breather cap, located on the hy­
4. Check the oil level in the hydraulic reservoir before draulic reservoir, 1/4 turn until pressure is fully re­
beginning operation of the crane. Add oil if neces­ lieved. Refer to Figure 2-6.
sary. Properly dispose of the contaminated water.

Hydraulic Reservoir Oil Level Check

1. With all hydraulic cylinders fully retracted, park the
WARNING
All trapped hydraulic pressure must be
crane on a firm level surface. Position the transmis­
exhausted from the system before removing
sion shifter to neutral, engage the park brake, and
any plug or cover. A sudden release of hot oil
shutdown the engine.
could cause burns or other serious injury.
2. With the hydraulic oil cold (approximately 62_F
17_C), check its level through the sight gauge lo­
3. Thoroughly clean the exterior surface of the hy­
cated on the front of the hydraulic reservoir. Refer
draulic reservoir to prevent foreign materials from
to Figure 2-6. The proper level must be main­
entering the system, once the access panels and
tained at all times. Add hydraulic oil as necessary
filter housing are opened.
to bring the oil level between the “FULL” and “ADD”

Section 2 - Lubrication And Preventative Maintenance 2-13

Operator's Manual
oughly drained. Inspect the interior of the hydrau­
1 lic reservoir for foreign material and wipe clean.
10. Clean and install the system and water drain plugs.
11. Clean the filter housing. Install oil diffuser in the
bottom of filter housing. Install a new filter element.
2 12. Install the access panels, using new gaskets.
13. Using clean, uncontaminated oil, fill the reservoir
through the filter element until it reaches the full
mark by the sight plugs.
14. Install the filter housing cover.
15. Start the engine. Allow the engine to idle several
minutes to ensure oil is being cycled properly.
Check for any leaks.
3 16. Check the oil level in the hydraulic reservoir for
proper level. Add oil if necessary. Properly dis­
pose of the used oil.
1. Pressure Gauge
2. Element Note: In case of hydraulic system component
3. Strainer failure, a more thorough oil change procedure
is required. Consult your distributor for this
Figure 2-7
Hydraulic Reservoir Filter procedure.

4. Remove the filler breather and pump the hydraulic

Hydraulic Reservoir Filter Change
oil into suitable containers. Refer to the Lubrication Change hydraulic reservoir filter element after the initial
Chart to determine the volume of oil to be removed. 50 hours of operation and every 500 hours of operation
thereafter. Change the filter element immediately if the
Note: If a pump is not available to remove the oil pressure gauge reads 20 psi (138kPa).
from the reservoir, place a suitable container 1. Park the crane on a firm level surface, position the
under the water drain plug. Open the plug and transmission shifter to neutral, engage the park
drain one container full at a time, until the oil has brake, and shutdown the engine.
thoroughly drained from the reservoir. Do not 2. Relieve any trapped hydraulic system pressure by
remove bottom access panel to drain reservoir. loosening the filler breather cap, located on the hy­
draulic reservoir, 1/4 turn until pressure is fully re­
lieved. Refer to Figure 2-6.
WARNING
Do not remove the bottom access panel
before the hydraulic reservoir has completely
drained. A large volume of hot oil may
WARNING
All trapped hydraulic pressure must be
suddenly be released resulting in personal
exhausted from the system before removing
injury and/or property damage. Drain the oil
any plug or cover. A sudden release of hot oil
from the hydraulic reservoir before removing
could cause burns or other serious injury.
the bottom access panel.
3. Clean the top of the hydraulic reservoir, the filter
5. Remove the bottom access panel and the filter ele­
housing, and filter housing cover to prevent foreign
ment. Properly dispose of the filter element.
material from entering the hydraulic system.
6. Clean any old gasket material off the access pan­
4. Remove the filter housing cover.
els and hydraulic reservoir.
5. Remove the filter element and inspect it for con­
7. Remove and clean the oil strainer in the bottom of
tamination. Any dirt or foreign particles on the filter
the filter housing.
element may indicate excessive system contami­
8. Clean the interior of the hydraulic reservoir with
nation or imminent system component failure.
clean diesel fuel or kerosene.
Once the filter has been thoroughly inspected, dis­
9. Allow the diesel fuel or kerosene to drain into a suit­
pose of it properly.
able container until the hydraulic reservoir is thor­
6. Install new filter element and filter housing cover.

2-14 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual

1. Hydraulic Charge Flow Filter

Figure 2-8
Hydraulic Charge Flow Filter

7. Start engine and check the filter housing for leaks.

8. Check the hydraulic reservoir oil level. Add oil if
necessary.
WARNING
All trapped hydraulic pressure must be
Hydraulic Charge Flow Filter exhausted from the system before removing
any plug or cover. A sudden release of hot oil
Change could cause burns or other serious injury.
Change hydraulic charge flow filter element after the
initial 50 hours of operation and every 500 hours of op­ 3. Remove the filter element and inspect it for con­
eration thereafter. Change the filter element immedi­ tamination. Any dirt or foreign particles on the filter
ately if the charge filter indicator light on the gauge pan­ element may indicate excessive system contami­
el illuminates. nation or imminent system component failure.
1. Park the crane on a firm level surface, position the Once the filter has been thoroughly inspected, dis­
transmission shifter to neutral, engage the park pose of it properly.
brake, and shutdown the engine. 4. Install new filter element.
2. Relieve any trapped hydraulic system pressure by 5. Start engine and check the filter housing for leaks.
loosening the filler/breather cap, located on the hy­ 6. Check the hydraulic reservoir oil level. Add oil if
draulic reservoir, 1/4 turn until pressure is fully re­ necessary.
lieved. Refer to Figure 2-6.

Section 2 - Lubrication And Preventative Maintenance 2-15

Operator's Manual

Figure 2-10
Hydraulic Case Drain Filter
1. Visual Dirt Indicator 2. Pressure Filters
7. Start the engine and check the filter housing for
Figure 2-9
leaks.
Hydraulic Pressure Filter
8. Check the hydraulic reservoir oil level. Add oil if
necessary.
Hydraulic Pressure Filter Change
Change hydraulic pressure filter elements after the ini­ Hydraulic Case Drain Filter Change
tial 50 hours of operation and every 500 hours of opera­ Change the hydraulic case drain filter element after the
tion thereafter. Change the filter element immediately if initial 50 hours of operation and every 500 hours of op­
the visual dirt indicator is in the “change” or “by‐pass” eration thereafter. Change the filter element immedi­
position after the oil has reached operating tempera­ ately if the case filter indicator light on the cab control
ture. panel illuminates after the oil has reached operating
1. Park the crane on a firm level surface, position the temperature. Locate the case drain filter from the un­
transmission shifter to neutral, engage the park derside of the carrier and behind the front wheels.
brake, and shutdown the engine. 1. Park the crane on a firm level surface, position the
2. Relieve any trapped hydraulic system pressure by transmission shifter to neutral, engage the park
loosening the filler/breather cap, located on the hy­ brake, and shutdown the engine.
draulic reservoir, 1/4 turn until pressure is fully re­ 2. Relieve any trapped hydraulic system pressure by
lieved. Refer to Figure 2-6. loosening the filler/breather cap, located on the hy­
draulic reservoir, 1/4 turn until pressure is fully re­
lieved. Refer to Figure 2-6.
WARNING
All trapped hydraulic pressure must be
exhausted from the system before removing WARNING
any plug or cover. A sudden release of hot oil All trapped hydraulic pressure must be
could cause burns or other serious injury. exhausted from the system before removing
any plug or cover. A sudden release of hot oil
3. Thoroughly clean the exterior surface of the filter could cause burns or other serious injury.
housing to prevent foreign materials from entering
the system. 3. Remove the filter element and inspect it for con­
4. Remove the filter housing. tamination. Any dirt or foreign particles on the filter
5. Remove the filter element and inspect it for con­ element may indicate excessive system contami­
tamination. Any dirt or foreign particles on the filter nation or imminent system component failure.
element may indicate excessive system contami­ Once the filter has been thoroughly inspected, dis­
nation or imminent system component failure. pose of it properly.
Once the filter has been thoroughly inspected, dis­ 4. Install new filter element.
pose of it properly. 5. Start engine and check the filter housing for leaks.
6. Install the new filter element and the filter housing 6. Check the hydraulic reservoir oil level. Add oil if
cover. Manually reset the dirt indicator. necessary.

2-16 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual

2 3 1
3
1

6
4 4
1. Hose Reel 4. Broken Spring Indicator
2. Spring Motor Assembly 5. Broken Spring Indicator - IN (Spring OK)
3. Wobble Roller 6. Broken Spring Indicator - OUT (Spring Broken)

Figure 2-11
Hose Reel

and observing the broken spring indicators on the

Hose Reel Inspection side of the canisters.
This crane is equipped with two hose reels to take‐up
or spool off the boom extend/retract hoses. The hose
reels must be periodically inspected to ensure proper WARNING
operation. Use the following procedure to inspect the Do not attempt to disassemble or remove the
hose reels. spring from the spring motor housing.
1. Park the crane on a firm level surface, position the Removal of the spring could result in personal
transmission shifter to neutral, and engage the injury. Clock type springs can be dangerous
park brake to handle and internal replacement parts are
2. Level the crane on fully extended outriggers. not available. Replace the spring motor as an
3. Raise the boom to 45° angle. Swing the upper di­ entire unit only.
rectly over the side of the carrier.
4. Locate the hose reels under the rear of the upper. 7. If the broken spring indicator is protruding out, the
5. Periodically inspect hose for wear and check spring motor assembly must be replaced. Refer to
mounting hardware for tightness. the crane's Service Manual for the correct proce­
6. Check for broken springs by extending the boom dure.
until approximately 2/3 of the hose is off the reel

Section 2 - Lubrication And Preventative Maintenance 2-17

Operator's Manual

1 2

1. Dipstick
2. Breather 3
3. Drain Plug

Figure 2-12
Hydraulic Pump Drive

6. Add oil as required through the dipstick filler tube.

Hydraulic Pump Drive Use only the oil type specified on the Lubrication
Lubrication Chart. Do not overfill.
7. Once the proper oil level is obtained, install the dip­
For maximum operating efficiency and service life of stick in the filler tube and turn the dipstick clock­
the pump drive, check oil level after every 50 hours of wise until tight.
operation and visually check for leaks. The oil, in a new
or rebuilt pump drive, should be changed after the ini­ Pump Drive Oil Change
tial 200 hours of operation. Thereafter, change oil with 1. Park the crane on a firm level surface, position the
each 2,000 hours of operation or annually, whichever transmission shifter to neutral, and engage park
occurs first. At each oil change, check all seals and brake.
thread joints for leaks and tighten as necessary. Refer 2. Cycle pump for several minutes, without a load, to
to the Lubrication Chart for the correct lubricant type. agitate and warm the oil within pump drive.
Refer to Figure 2-12. 3. Engage the travel swing lock and shutdown the en­
gine. Thoroughly clean the exterior surface of the
Pump Drive Oil Level Check pump drive around the dipstick and drain plug to
1. Park the crane on a firm level surface, position the prevent contamination from entering the unit. Re­
transmission shifter to neutral, engage the park fer to Figure 2-12.
brake, and shutdown the engine. 4. Remove drain plug and allow the oil to drain in a
2. Locate the pump drive dipstick on the right side of suitable container
the engine. Refer to Figure 2-12. 5. After the oil has thoroughly drained, remove the
3. Wipe the dipstick area clean. Rotate the dipstick dipstick.
counter‐clockwise and remove the dipstick from 6. Clean and install the drain plug.
the filler tube. 7. Fill the unit with oil until oil is to the full mark on the
4. Wipe all the oil from the dipstick and place it back dipstick. Refer to Figure 2-12. For the correct
into the filler tube but do not rotate it in. grade and quantity of oil, refer to the Lubrication
5. Remove again and read the oil level on the dipstick. Chart.
The oil level should be to the full mark on the dip­ 8. Clean and install the dipstick. Properly dispose of
stick. the used oil.

2-18 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual
2 3
1

ÄÄÄÄÄÄÄ
ÄÄÄÄÄÄÄ
ÄÄÄÄÄÄÄ
ÄÄÄÄÄÄÄ
4

ÄÄÄÄÄÄÄ
5

1. Service Indicator (Mounted Inside En­ 2. Air Inlet Hood 4. Primary Element
gine Hood) 3. Air Cleaner Body 5. Thumb Screw

Figure 2-13
Engine Air Cleaner

Refer to Figure 2-13. Anytime the red band shows in

Engine Air System the indicator, service the air cleaner immediately.
Inspection Clean or replace the air cleaner element as often as re­
quired. Replace the air cleaner element after it has
In addition to servicing the air cleaner, it is also recom­ been cleaned six times or annually, whichever occurs
mended that the engine air system be inspected every first. Service the engine air cleaner as follows:
250 hours or 6 months. Inspect the air system pipes,
hoses, air compressor and turbocharger systems, as Changing The Engine Air Cleaner
equipped. (Be sure to inspect all the pipes and hoses Element
associated with the air compressor, turbocharger, air
1. Park the crane on a firm level surface, engage the
cleaner, and air intake.) Check for any cracks, corro­
park brake, position the transmission shifter to
sion, loose clamps, wear points, leaks, or punctures
neutral, and shutdown the engine.
which can allow contaminants to enter the system and
2. Inspect the service indicator to see if the red band
damage air system components and/or the engine. All
is showing. If the red band is visible, proceed with
hoses should be kept free of oil contaminants, both in­
the following steps. If the red band is not visible,
ternally and externally. Disassemble and clean as re­
there is no reason to service the air cleaner. Over
quired. Tighten or replace parts as necessary to en­
servicing the air cleaner will shorten the life of the
sure that the air system does not leak.
element and unnecessarily increase downtime.
3. Remove the thumb screws to remove the cover.
Engine Air Cleaner Remove the element from the air cleaner body.
Variations in job site conditions prevent establishing a 4. Wipe the inside of the air cleaner body clean using
set interval for air cleaner servicing. For this reason a a damp cloth.
vacuum operated service indicator is mounted on an 5. Clean or replace the element as required.
air tube, inside the engine hood, to assist in determin­ 6. Slide the element into the air cleaner body.
ing the condition of the primary air cleaner element. 7. Install the cover.
8. Reset the service indicator by pressing the button
on top of it.

Section 2 - Lubrication And Preventative Maintenance 2-19

Operator's Manual

Figure 2-14
Cleaning the primary air cleaner element with Figure 2-16
compressed air. Inspecting the air cleaner element.

Compressed Air
Hold an air hose nozzle at least 1 inch (25mm) away
from the air cleaner element. Spray air through the ele­
ment in the direction opposite to normal air flow. Move
the nozzle up and down while rotating the element.
Use air pressure of less than 100 psi (690kPa) to pre­
vent damage to the filter paper within the element.
Thoroughly inspect the element after cleaning. Refer
to Figure 2-14.

Washing
Soak the air cleaner element for 15 minutes or more, in
a solution of water and Donaldson D-1400 detergent,
or equivalent. Refer to Figure 2-15. Thoroughly rinse
Figure 2-15
the element by spraying it with a hose in the direction
Cleaning the primary air cleaner element by
opposite the air flow. Use water pressure of less than
soaking.
40 psi (276kPa) to prevent damage to the filter paper
within the element. Rinse until the water is clear; air dry.
Do not attempt to dry the element using compressed
Cleaning The Air Cleaner Element air or light bulbs. This may ruin the element. Thorough­
The primary air cleaner element can be cleaned by ly inspect the element after cleaning.
washing or using compressed air. Compressed air is
recommended when the element is to be reused im­ Inspecting The Air Cleaner Element
mediately. A washed element must dry before reuse, Place a bright light inside the air cleaner element and
however the washing method does a better job and rotate the element. Inspect the element from the out­
must be used when exhaust soot has lodged in the fine side looking for ruptures, tears and holes. If any dam­
pores of the filter media. Use one of the following pro­ age is discovered, replace the element. Refer to
cedures to clean the air cleaner element: Figure 2-16.

2-20 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual
Swing Speed Reducer
Lubrication 4
Check the oil level in the swing speed reducer after ev­
3
ery 50 hours of operation. The oil in a new swing speed
reducer should be changed after the initial 200 hours of 2 5
operation. Thereafter, change the oil with each 1,000 1
hours of operation or seasonally, whichever occurs 6
first. It is also recommended that every 2,000 hours of
1
operation, the unit be disassembled and thoroughly in­
spected for damaged or worn parts. Replace dam­
aged or worn parts as required.

Swing Speed Reducer Oil Level Check

1. Park the crane on a firm level surface position the
transmission shifter to neutral, and engage the
park brake.
2. Engage travel swing lock and shutdown engine.
3. Clean the speed reducer around the check/fill plug
to prevent contamination from entering the sys­
tem. Remove the plug. Refer to Figure 2-17.
4. Oil should come to within 0.5 inch (12.7mm) of the 7
bottom of the fill port. Add oil as required to bring
the oil to the proper level. Refer to the Lubrication
Chart for the correct grade of oil.
5. Clean and install the check/fill plug.
1. Swing Unit Check/Fill Plug
2. Swing Brake Drain Plug 5. Swing Brake Fill Plug
Swing Speed Reducer Oil Change 3. Swing Brake Vent/Check Plug 6. Service Brake Bleeder
1. Park the crane on a firm level surface position the 4. Park Brake Bleeder 7. Swing Unit Drain Plug
transmission shifter to neutral, and engage the
Figure 2-17
park brake. Swing Speed Reducer
2. Level the crane on fully extended outriggers and
swing the upper for several minutes, to agitate and
warm the oil within the swing speed reducer.
3. Engage the travel swing lock, fully lower the boom,
Swing Brake Lubrication
and shutdown the engine. Some cranes are equipped with a swing brake that re­
4. Thoroughly clean the exterior surface of the swing quires that the oil level be checked every 50 hours of
speed reducer around the check/fill and drain operation. Change the oil with each 1,000 hours of op­
plugs to prevent contamination from entering the eration or seasonally, whichever occurs first.
unit. Refer to Figure 2-17.
5. Remove check/fill and drain plugs and allow the oil Swing Brake Oil Level Check
to drain into a suitable container. The drain plug is 1. Park the crane on a firm, level surface. Shift the
magnetic and should be inspected for large quan­ transmission to neutral, and engage the park
tities of metal particles. After the initial oil change, brake.
this is a sign of damage or extreme wear within the 2. Engage the travel swing lock and shutdown the en­
unit, and a complete internal inspection may be gine. Refer to Figure 2-17.
necessary. 3. Clean the brake around the brake vent/check and
6. After the oil has thoroughly drained, clean and brake fill plugs to prevent contamination from en­
install the drain plug. tering the system. Remove the ventcheck/plug.
7. Fill the unit with oil through the check/fill hole. Oil 4. Oil should be within 1 in (25.4mm) from the top of
should come to within 0.5 inch (12.7mm) of the bot­ the brake housing. Add hydraulic oil through the
tom of the hole. Refer to the Lubrication Chart for brake fill port as required to bring the oil to the
the correct grade and quantity of oil. proper level. Refer to the Hi Performance Hydraulic
8. Clean and install the check/fill plug. Properly dis­ Oil Chart for the correct grade of oil.
5. Clean and install the vent/check and fill plugs.
pose of the used oil.

Section 2 - Lubrication And Preventative Maintenance 2-21

Operator's Manual
Winch Drum Lubrication
1 2 3
For maximum operating efficiency and service life of
the winch drum, check oil level after every 50 hours of
operation. The oil, in a new or rebuilt winch drum,
should be changed after the initial 100 hours of opera­
tion. Thereafter, change oil with each 1,000 hours of
operation or seasonally, whichever occurs first.
It is also recommended that every 2,000 hours of op­
eration, the winch should be disassembled and thor­
oughly inspected for damaged or worn parts. Replace
damaged or worn parts as required.

Winch Drum Oil Level Check

1. Park the crane on a firm level surface, position the
transmission shifter to neutral, engage the park
brake, and shutdown the engine.
2. Oil should be visible in the sight gauge.
1. Alignment Hole - Drain Plug
2. Vent Plug
3. If necessary add oil as required, until it reaches the
3. Sight Gauge proper level. Refer to the Lubrication Chart for the
correct grade of oil.
4. Clean and install the check plug.
Figure 2-18
Winch Drum
Winch Drum Oil Change
1. Park the crane on a firm level surface, position the
transmission shifter to neutral, engage the park
Swing Brake Oil Change brake, and shutdown the engine.
1. Park the crane on a firm, level surface. Shift the
2. Cycle winch for several minutes, without a load to
transmission to neutral, and engage the park
agitate and warm the oil within winch drum.
brake.
3. Rotate winch drum until the drain plug is aligned
2. Engage the travel swing lock and shutdown the en­
with the alignment hole in the side support.
gine. Refer to Figure 2-17.
4. Thoroughly clean the exterior surface of the winch
3. Clean the brake around the swing brake vent/
check and fill plugs to prevent contamination from drum around the vent and drain plugs to prevent
entering the system. Remove the brake fill and contamination from entering the unit. Refer to
vent/check plugs. Figure 2-18.
4. Position a suitable container under the swing 5. Remove the drain plug.
brake drain plug. Remove the drain plug and allow 6. Rotate the drum until the drain hole is at the vertical
the oil to drain in the container. bottom position. Allow the oil to drain in a suitable
5. After the oil has thoroughly drained, clean and container.
install the swing brake drain plug. 7. After the oil has thoroughly drained, rotate the
6. Using clean, uncontaminated hydraulic oil, fill the drum until drain hole is aligned with the alignment
swing brake through the brake fill port as required hole in the side support.
to bring the oil within 1 in (25.4mm) from the top of 8. Fill the unit with oil through the hole, until oil is vis­
the brake housing. Refer to the Hi Performance ible within the sight gauge. Refer to Figure 2-18.
Hydraulic Oil Chart for the correct grade of oil. For the correct grade and quantity of oil, refer to the
7. Clean and install the brake vent/check and fill Lubrication Chart.
plugs. 9. Clean and install the drain plug.
10. Clean and install the vent plug. Properly dispose of
the used oil.

2-22 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual

1
2

1. Telescope Cylinder Wear Shoes - 3 Places

2. Rear Top Wear Shoes - Inside Corners, 8 Places
3. Rear Bottom Wear Shoes - Inside Flats Effected, 8 Places
4. Front Bottom Wear Shoes - All Outside Flats, 8 Places

Figure 2-19 Figure 2-20

Wear Shoe Contact Surfaces Lubrication Do not climb on boom or attachments.

Boom Lubrication And Boom wear shoe locations are shown in Figure 2-21.
Inspection Rear top wear shoes (7, 9, 11, and 13 ) have grease fit­
tings in them and can be accessed by aligning them
Boom lubrication is important to extend wear shoe life
with the hole in the top and sides of adjacent boom sec­
and to aid in smooth performance of the boom. Lu­
brication involves covering most boom sliding surfaces tion. Front top wear shoes (3, 4, and 5), or their sliding
with a film of grease. This is accomplished by applying surfaces, do not require greasing.
grease directly to boom surfaces and the wear shoes Inspect the boom daily for adequate lubrication and
that slide on the boom. Refer to Figure 2-19 for sliding grease it as necessary. Visually inspect all boom sec­
surfaces to be greased. Surfaces which are internal to tions daily for damaged or cracked members or welds.
the boom are lubricated through the access holes on If any dents, bends, cracked welds, etc. are found, do
the sides of each boom section. Generously lubricate not use the crane. Contact your nearest distributor for
the internal surfaces within reach of the access holes. repair procedures. Also check for damaged or leaking
Normal operation of the boom will then distribute the hoses, fittings, valves, cylinders etc. Repair as neces­
grease along the internal sliding surfaces. sary. At 250 hour intervals, check all boom wear shoes
for proper adjustment. See “Boom Wear Shoe Inspec­
tion And Adjustment” in Section 3 of this Operator's
WARNING Manual for further details.
To avoid personal injury, do not climb, stand, Grease boom extend and retract sheaves at 50 hour in­
or walk on the boom or fly. Use a ladder or tervals. It is also recommended that every 4,000 hours
similar device to reach necessary areas. of operation the boom should be disassembled and
To prevent movement of individual boom the extend and retract wire ropes inspected, lubri­
sections, shutdown the engine and ensure cated, and/or replaced as required. See “Boom Ex­
that the operator has properly vacated the tend And Retract Wire Rope Inspection And Adjust­
operators cab before putting hands or tools ment” in Section 3 of this Operator's Manual, “Wire
inside the boom. Unsuspected movement of Rope Lubrication” found later in this Section, and “Wire
the boom sections could sever fingers, Rope Inspection And Replacement Recommenda­
hands, arms, etc. tions” in Section 5 of this Operator's Manual.
Do not use a crane that has a damaged boom.
The structural integrity of the boom is lost and
could collapse with any load. Use the crane
only after the boom has passed a thorough
inspection. Contact your distributor for the
proper inspection procedures.

Section 2 - Lubrication And Preventative Maintenance 2-23

Operator's Manual

H
A B C

H G F
E
D

B 2 G F E
D
C
3

5
6
6
9
7 6
11 6 13

8 12 14
Section D-D Section E-E 10 Section F-F Section G-G
1. Front Bottom Wear Shoe - Base, Inner, Center, Outer (8 Places) 8. Rear Bottom Wear Shoe - Inner (2 Places)
2. Retract Sheave Grease Fitting 9. Rear Top Wear Shoe - Center (2 Places)
3. Front Top Wear Shoe - Outer (2 Places) 10. Rear Bottom Wear Shoe - Center (2 Places)
4. Front Top Wear Shoe -Center (2 Places) 11. Rear Top Wear Shoe - Outer (2 Places)
5. Front Top Wear Shoe -Base & Inner (4 Places) 12. Rear Bottom Wear Shoe - Outer (2 Places)
6. Grease Fitting (8 Places) 13. Rear Top Wear Shoe - Tip (2 Places)
7. Rear Top Wear Shoe - Inner (2 Places) 14. Rear Bottom Wear Shoe - Tip (2 Places)

Figure 2-21
Boom Lubrication And Inspection

2-24 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual
Wire Rope Lubrication Application Of Wire Rope Lubricant
Wire rope is like a machine in that it has moving parts Wire ropes that have been in service should be cleaned
which require lubrication. Each time a wire rope bends before re‐lubricating them. Use a wire brush and
over a sheave or straightens from a slack position compressed air to clean the rope. All possible foreign
many wires move against each other. Lubrication is material and old lubricant should be removed from the
necessary to help prevent wear caused by this move­ rope before re‐lubricating it. Use one of the following
ment. Lubrication also helps prevent deterioration of methods to apply the lubricant.
wire rope due to rust and corrosion.
1. Continuous Bath
Run the rope through a container filled with lubri­
WARNING cant. A sheave mounted in the center of the con­
tainer will hold the rope submerged as it passes
Rusty rope is dangerous since there is no way
through the container. Use swabbing to remove
to determine its remaining strength.
excess lubricant as the rope leaves the container.

Most wire ropes are lubricated during manufacture, but 2. Dripping

the lubricant does not last the life of the rope. The lubri­
Place a container above a sheave so a spigot can
cant is squeezed out of the rope as it runs over sheaves
be opened to drip oil on the wire rope as it passes
under tension, or washed off by rain.
through the sheave groove.
For the above reasons, wire rope MUST BE periodically
lubricated. Crude or used oils and grease should not 3. Swabbing And Painting
be used as lubricants because they may be grit or acid Two fast methods are swabbing the lubricant on
laden. Either of these conditions can cause damage to with rags or painting it on with a brush.
the rope.
No set rule can be given for lubrication frequency. This 4. Spraying
will depend on the type of conditions under which the Light lubricants may be applied with a spray gun.
rope is used. Aerosol cans of lubricant are also available.
A rope used in wet conditions would need to be lubri­
cated more often than one used in dry conditions, to Lattice Fly Inspection And
prevent rust and corrosion.
Lubricants used for wire rope lubrication should have
Lubrication
the following properties: Inspect all parts of the lattice fly daily. Lubricate head
1. They must have enough adhesive strength to stay machinery as required. Pay particular attention to the
on the rope. chords and lattice. If any dents, bends, cracked welds,
2. They must be able to penetrate between the wires etc. are found, do not use the lattice fly. Contact your
and strands. nearest distributor for repair procedures.
3. They must have high film strength.
4. They must resist oxidation.
5. They must remain soft and pliable.
WARNING
Do not use a fly which has been damaged.
The structural integrity of the fly is lost and the
attachment could collapse with any load. Use
the fly only after it has passed a thorough
inspection.

Section 2 - Lubrication And Preventative Maintenance 2-25

Operator's Manual
4. If a known test weight is available, check that the
displayed weight agrees with the test load. The
displayed load includes the hookblock and any lift­
ing attachments such as slings, pins, and
shackles.
5. If the capacity chart is rated for specific areas e.g.
side, front or rear, the system should be checked
by swinging the boom into the permitted areas and
checking that the Rated Capacity reading agrees
with the crane Capacity Chart.

WARNING
Any unusual or erratic system operation must
be investigated and corrected immediately. If
any problem is found with any of the above
inspection steps, the problem must be
corrected/repaired as soon as possible
before continuing operation. If necessary to
Figure 2-22 continue operations, refer to “System
Display Cleaning Inoperative Or Malfunctioning” in Section 1 of
this Operator's Manual.

Crane Monitoring Systems

Display Cleaning
Maintenance of the Rated Capacity Limiter and anti‐
two block system consists of the following daily inspec­ The Rated Capacity Limiter display is not field service­
tion prior to the first operation: able and should not be disassembled by anyone other
1. Check that the system is operating normally as than an authorized service repair facility. However, the
described in Section 1 of this Operator's Manual. screen can be sufficiently cleaned without unit disas­
2. Check the electrical cables connecting the various sembly.
parts of the system. Compressed air used for cleaning electronic equip­
3. Check the insulation on the boom reeling drum ment can be obtained at any major electronic or office
cable. supply store. DO NOT USE COMPRESSED AIR from
4. Check the boom reeling drum cable for proper an air compressor. Kensington Dust Blaster has been
tension. used with good results.
5. Check the anti‐two block boom switches for
freedom of movement. After removing the display from the crane console, lo­
6. Check that the anti‐two block weights are installed cate the rectangular ventilation hole on the side of the
and working properly with the anti‐two block display. This is the area of access for cleaning the dis­
play.
switches.
7. Inspect the pressure transducer connecting hoses Insert the nozzle of the compressed air just to the edge
for oil leaks. of the LCD display at the air gap, and angled toward the
8. Test that the function limiters activate properly by display screen cover. Activate the air container and
two blocking the crane. (Do this by manually lifting slide from end to end of the display. Only a few seconds
the anti‐two block weight.) of application should be required to sufficiently clean
Check the following every 30 days. the display unit. If the unit cannot be adequately
1. Check that the displayed boom angle agrees with cleaned using this process, it must be returned to a fac­
the measured angle. tory authorized repair facility.
2. Check that the displayed radius agrees with the
measured operating radius.
3. Check that the displayed boom length agrees with
the actual boom length.

2-26 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual
Hook Balls: Check pin, nut, and washer to ensure
Hook Block, Ball, And ball halves are held securely together. Check lo­
Swivel Inspection And cating pin for excessive wear. Inspect swivel parts
as specified previously. Check that hook latch is
Maintenance operative.
1. All nuts, setscrews, pins, bolts and retainers 3. If a swivel is constantly overloaded, it will cause
should be checked for tightness every 14 to 30 damage to the unit. The first sign of damage is
days, depending on the operating conditions and often bearing brinelling (dimpling of the bearing
the product involved. races). This condition is determined by spinning
2. Inspect the components carefully at least once a the swivel by hand. If the motion is rough, or has a
month. ratchet‐like effect, the bearing has been damaged
Swivels: Check for excessive gap distance be­ and should be replaced.
tween the rotating parts. Check threaded parts 4. The distance between the swivel barrel and shank
that are installed together to see that they are se­ or rotating members are pre‐set with a factory
cure and tight. Check all setscrews to see that they clearance of .020-.050 inches (0.5-1.2mm). If
are tight and staked. this distance increases more than .060 inch
(1.5mm) over the above distance, it is a good indi­
Hook Blocks: Check all pins and bolts for tight­
cation of bearing fatigue and the unit should be re­
ness, spreading of side plates, weld cracks,
moved from service.
sheave wear, bearing wear, spreading of hook, set­
screws that are tight and staked. Check that hook
latch is operative.

Under Intermittent Under Continuous

Item
Operating Conditions Operating Conditions
Swivels, Swivel Overhaul Balls, Swivel Balls 14 days 24 hours
Blocks with Bronze Bushed Sheaves 14 days 8 hours
Blocks with Roller Bearing Sheaves 14 days 24 hours
Chart A - Hook Block, Ball, & Swivel Lubrication Frequency

Item Frequency What to Check For Appropriate Action

End play or gap of more than .06 inch
Remove from service immediately.
(1.5mm) along the axis.
14 days under continuous operation
Swivels Defective bearing. Remove from ser­
30 days under intermittent operation Rough turning.
vice immediately.
Elongated eye holes, bent clevis pins. Indicates overload. Remove for repairs.
Indicates severe bearing wear. Remove
Misalignment, as evidenced by wobble from service.
14 days under continuous operation or uneven groove flange wear. Check for wear in bronze spacers
Sheaves where used.
30 days under intermittent operation
Striations or corrugations in sheave
Result of rope wear. If serious, replace.
groove.
Missing, off center, bent, broken spring,
Hook Latch When Used Replace immediately.
missing, or defective.
An indication of overload. If serious, re­
place.
Permanent deformation or stretching. Any suspicion of fractures calls for an
immediate investigation and, if neces­
sary, replacement of part.
Hooks Daily or When Used
Hooks should be tested at least once a
year by magnafluxing, x‐ray, or other
Crack or other defects. qualified method. Intermittent tests can
be conducted by a less accurate oil
stain method.
Chart B - Hook Block, Ball & Swivel Inspection Frequency

Section 2 - Lubrication And Preventative Maintenance 2-27

Operator's Manual
Turntable Bearing Turntable Bearing Capscrew Inspection
Schedule
Capscrew Torque Capscrews should be inspected and/or torqued after
Maintaining the proper torque on turntable bearing the initial 250 hours of operation of any new crane or if
mounting capscrews is critical. If the bearing has been the crane has been undecked for any reason.
replaced or the crane undecked for any reason, Inspect and/or torque capscrews per the Turntable
capscrews should be replaced. Reuse of turntable Bearing Capscrew Torque Inspection Schedule,
bearing mounting capscrews is not recommended. thereafter. Torque capscrews to 2,120-2,335 ft lb
(2 875-3 166Nm).
CAUTION
All turntable bearing capscrews use Loctite®
571 Pipe Sealant, or equivalent, with excep­
tion given to capscrews coated with Xylan®.
The sealant or coating is used to protect the
threads of the capscrews from rust and corro­
sion. Unprotected capscrews will not main­
tain the proper torque. Always use sealant or
coating when installing turntable bearing
capscrews.

Turntable Bearing Capscrew Torque Inspection Schedule

Schedule Interval Requirements
S Perform an initial torque of the capscrews after the first 250 hours of operation of a new
crane, or if the crane has been undecked for any reason, to establish capscrew torque
baseline.
Note: Use the minimum applicable torque value when checking.
S After the next 500 hours of operation, if any of the capscrew torques have degraded,
tighten capscrews to the proper torque.
A 500 Hrs Note: Use the minimum applicable torque value when checking.
S If the crane is utilized for duty cycle work, Schedule A must be continuously maintained
during duty cycle applications.
S Inspection Schedule A must be maintained until such a time that no capscrews require
tightening after 500 hours of operation. Schedule B can then be followed.
S The minimum applicable torque value is acceptable for the turntable bearing capscrew
torque inspection.
S If the capscrew torque has degraded at any annual check, Torque Inspection Schedule
A must be followed until such time that no loss of capscrew torque is observed.
B Annually
S The minimum applicable torque value is acceptable for the turntable bearing capscrew
torque inspection.

2-28 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual
Paint Maintenance Polishing And Waxing Procedure
1. Clean surface thoroughly by hand washing or
Knowledgeable equipment owners realize the value of power washing with a mild detergent. Rinse thor­
periodic preventative maintenance and responsible oughly with water before buffing.
care. A regular surface care program should be fol­ 2. Apply a polishing compound, such as Meguiar's
lowed to protect the equipment's paint finish and main­ M8432, or equivalent, to a surface area approxi­
tain a like‐new appearance. There is no one correct/ul­ mately two feet by two feet at a time. Make sure the
timate procedure since the uniqueness of every ma­ cleaner is applied liberally to entire area and work
chine's operating environment and owner/operator on only that area with the buffing wheel.
maintenance habits differ. However, it is important to 3. Buff surface with an electric or air buffer at 1000
remove surface contaminants before they have time to rpm using a 3M Superbuff polishing pad, or equiv­
bond or etch into the paint finish. alent, with light to medium pressure until a uniform
high gloss is obtained. Hand wipe with a clean
Regular Preventative Maintenance cloth.
1. Regular washing is the best way to remove surface 4. After surface has been buffed, apply a quality auto­
contaminants. motive wax such a Meguiar's M-26 Hi-Tech Yel­
2. Always use mild cleaners and soaps, and rinse low Wax, or equivalent, and hand buff until the
thoroughly after washing. Do not use harsh deter­ cloth moves freely. The original luster of coating
gents, such as household laundry detergents, or should be restored.
cleaners that contain phosphates, as they will
“burn” the paint, strip off protective coating, dimin­
ish the gloss and accelerate the contamination
process.
3. Periodic waxing will enhance the luster and protect
the paint surface.
If environmental damage to the paint finish is detected
(loss of some of its luster due to lack of or inability to
maintain as recommended) the paint finish can be re­
stored to near‐new appearance by following a simple
polishing and waxing procedure.

Section 2 - Lubrication And Preventative Maintenance 2-29

Operator's Manual

2-30 Section 2 - Lubrication And Preventative Maintenance

 Operator's Manual
Table Of Contents
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Tire And Rim Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Tire And Rim Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Swing Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Travel Swing Lock Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

360 Degree Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

360 Degree Swing Lock Inspection And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Bubble Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Crane Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Hydraulic System Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Preparing the Crane For Checking Relief Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Relief Valve Pressure Checking Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Accumulator Check/Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Boom Wear Shoe Inspection And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Boom Extend And Retract Wire Rope Inspection And Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Extend/Retract Wire Rope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Extend/Retract Wire Rope Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Boom Tip Section Anti‐Rotation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Boom Angle Indicator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Section 2 - Lubrication And Preventive Maintenance i

Operator's Manual
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112

ii Section 2 - Lubrication And Preventive Maintenance

 Operator's Manual

Right
Wrong

3
1

1. Tire And Rim Assembly

2. Rim Cage
3. Air Hose With Clip-On Chuck

Figure 3-1
Use a Rim Cage When Inflating Tires

Tire Inspection
DANGER
Inspect the tire treads daily and remove any debris that may
be wedged in the tire grooves. Check for nails, screws, Use a rim cage when inflating tires. Lock ring or
glass, or anything that may penetrate the tire and permit air side flange may explode if damaged or
to leak from the tires. Check the side walls and treads for improperly assembled. Always use a rim cage
cuts, bulges, and other damage. If internal damage to any and stand clear of the tire while inflating it.
tire is suspected, have it demounted and checked. Make
all necessary repairs or replace as required. Two categories of inflation pressures are listed on the
When replacing tires, all tires should be of the same man­ Tire Inflation label, “Maximum Lifts On Rubber” and
ufacturer, size, type, load rating, and construction. Refer “Maximum Speed”. While the crane is at the job site,
to the tire manufacturer and follow all recommendations the tires should be inflated to the pressure listed under
regarding tire inspection and replacement. “Maximum Lifts On Rubber” as all job site travel is lim­
ited to speeds less than 2.5 mph (4km/h). The crane
should not be road driven with the tires inflated to “Max­
Tire Inflation imum Lifts On Rubber” pressures.
Check the tire inflation pressures daily when the tires “Maximum Speed” pressures are for highway travel
are cold. Use the Tire Inflation label, located on the car­ only. Even with the tires inflated to the “Maximum
rier or the Tire Inflation chart located in the Crane Rat­ Speed” pressures, speed is limited to 25 mph (40km/h)
ing Manual, to determine the correct tire pressure for with a 30 minute rest period after each 50 miles (80km)
the type of operation being performed. This label con­ of driving or 2 hours of sustained operation, whichever
tains recommended tire pressures for different operat­ comes first. One hour minimum stop should be ob­
ing conditions. A rim cage should be used when inflat­ served after each four hours of operation.
ing tires to protect the mechanic and any bystanders
Inspect the wheel rims, clamps, nuts, studs, etc., on a
from the danger of “rim explosion”. Improperly assem­
weekly basis. If any damage is apparent, repair or re­
bled or damaged rim components are subject to ex­
place before operating the crane.
plode when tires are inflated. Refer to Figure 3-1.

Section 3 - Periodic Adjustments 3-1

Operator's Manual

2
7

1. Tire 5. O‐Ring
2. Bead Seat 6. Valve Stem
3. Lock Ring 7. Flange
4. Rim

Figure 3-2
Typical Tire And Rim Assembly

not clogged and the tire is completely deflated. Ice

DANGER may form as the air leaves the tire or foreign mate­
rial may clog the stem.
Servicing the tire and rim assemblies can be 4. Do not reinflate a tire that has been run flat or ex­
extremely dangerous. For your protection, tremely under inflated. Demount the tire and in­
read and understand all safety instructions spect it, the rim components, and wheel end for
before removing or installing a tire and rim damage. These components may have been
assembly. damaged or dislocated during the time the tire was
under inflated.
5. Clean and inspect parts prior to assembly. Do not
Tire And Rim Safety use bent, worn, damaged, or rusted parts.
6. When assembling the tire and rim assembly, use
Instructions only parts of the same type, manufacturer, and cor­
1. Always remove the valve cores and exhaust all air rect size. Mismatched parts may appear to fit but
pressure from the tire, prior to removing it. Rim when the tire is inflated they may fly apart with ex­
components are under extreme pressure and plosive force.
could fly off. 7. Always double check to be sure rim components
2. Use a rim cage and stand clear when deflating and are properly installed before inflating the tire.
inflating tires. A damaged or misassembled rim as­ Misassembled parts could fly off during inflation.
sembly may burst. The operator should stand well 8. When inflating an tire, use a air hose with a clip‐on
away from the potentially explosive force. chuck and in‐line pressure gauge. Be sure the air
3. After deflating the tire, check the valve stem by run­ hose is long enough, to permit the person inflating
ning a piece of wire through the stem, to ensure it is the tire, to stand clear of the rim cage.

3-2 Section 3 - Periodic Adjustments

 Operator's Manual
9. Inflate the tire to 10 psi (68kPa), and check the rim Refer to Figure 3-2.
components for proper fit, before completely inflat­ 3. Carefully remove the valve core from the valve
ing. If the assembly is not correct, completely de­ stem (6). Allow the air pressure to exhaust from the
flate the tire and correct the problem. Do not ham­ tire (1). Install the valve core back in the valve stem
mer on an inflated tire and rim assembly. Properly (6). Remove the rim cage.
matched and assembled rim components will seat 4. Remove all but four of the lug nuts from the mount­
without tapping. ing studs. The four remaining lug nuts should be
10. Once it is determined that the tire and rim are prop­ equally spaced around the rim (4).
erly assembled, inflate the tire to the pressure 5. Properly support the tire and rim assembly with an
listed on the Tire Inflation label located on the left appropriate lifting device.
rear fender or Tire Inflation chart located in the 6. Remove the remaining lug nuts from the mounting
Crane Rating Manual. Do not over inflate the tire. studs.
11. Always check rims and wheel ends for damage 7. Carefully remove the tire and rim assembly from
during normal tire inspection. Early detection of the axle.
potential component failure may prevent serious
injury. Installation
12. Do not attempt to rework, weld, heat, or braze any
Correct installation and tightening of the lug nuts on a
damaged rim components. Heating may weaken
tire and rim assembly is one of the most important op­
the part and result in complete failure of the com­
erations in tire and rim maintenance. When tire or rim
ponent and possible personal injury.
problems occur, incorrect installation and lug nut tight­
ening procedures are usually found to be the cause of
Tire And Rim Removal And the problem. The following procedures must be care­
fully followed to ensure safe and dependable service.
Installation Refer to Figure 3-2.
Carefully read and understand the Tire And Rim Safety 1. Check the tire (1) to ensure it is completely de­
Instructions given earlier in this Section of the Opera­ flated. Inspect the flanges (7), bead seat (2), o‐ring
tor's Manual before servicing the tire and rim assem­ (5), lock ring (3), and rim (4) for damage and
blies. proper assembly.

DANGER DANGER
Servicing the tire and rim assemblies can be All air pressure must be exhausted from the
extremely dangerous. For your protection, tire before installing it. An inflated tire may
read and understand all Tire And Rim Safety cause improperly assembled rim
Instructions before removing or installing a components to fly off. Failure to deflate the
tire and rim assembly. tire could result in a fatal accident.

2. Thoroughly clean the mounting surfaces of the rim

Removal (4) and axle. Remove any dirt, rust, excess paint,
1. Properly park the crane and engage the park or other foreign materials. Also clean, but do not
brake. Level the crane on outriggers with all tires lubricate, the lug nuts and mounting studs.
clear of the ground. Shutdown the engine. 3. Properly support the tire and rim assembly with an
2. Position a rim cage in front of the tire and rim assem­ appropriate lifting device. Lift the tire and rim as­
bly before deflating the tire. Refer to Figure 3-1. sembly and carefully position it on the axle.
4. Install the lug nuts on the mounting studs. Tighten
the lug nuts evenly to ensure the rim (4) is properly
DANGER seated on the axle.
Exhaust all air pressure from the tire before
removing it. Use a rim cage and stand clear
when deflating a tire. Rim components are
under extreme pressure and may fly off.
Failure to exhaust air pressure, or use a rim
cage, could result in a fatal accident.

Section 3 - Periodic Adjustments 3-3

Operator's Manual
1
9 11 1
2
4 6

12 8

2 3

7 10
5 2
1. Wheel End
2. Lug Nut

Figure 3-3 1. Park Brake Bleeder Plug

Lug Nut Torquing Sequence for a Twelve Stud 2. Service Brake Bleeder Plug
Wheel End.
Figure 3-4
5. Tighten the lug nuts to 225 ft lb (305Nm). See Swing Unit
Figure 3-3 for the proper torquing sequence.
6. Repeat the proper torquing sequence and tighten Swing Brake Bleeding
the lug nuts to their final recommended torque Bleed the swing brake whenever a hydraulic line is re­
value of 450-500 ft lb (610-678Nm). moved from the swing unit to remove any air that may
have been trapped in the circuit. Use the following pro­
cedure to bleed the swing brake.
CAUTION 1. Park the crane on a firm, level surface. Shift the
Using improper torque values or torque transmission to neutral and engage the park
procedure can cause distortion, slippage, or brake.
misalignment of the tire and rim assembly. 2. Engage travel swing lock and shutdown engine.
3. Position a suitable container under bleeder plugs.
7. Properly position a rim cage in front of the tire and 4. Loosen the park brake bleeder plug. Refer to
rim assembly. Figure 3-4. Turn the key switch to the “ON” posi­
tion but do not start the engine.
5. Operate the swing park brake control switch. Al­
DANGER low the fluid to discharge into the container until no
Use a rim cage and stand clear when inflating air is present. Tighten the park brake bleeder plug.
tires. Rim components are under extreme 6. Turn the key switch to the “OFF” position.
pressure and may fly off. Failure to use a rim 7. Loosen the service brake bleeder plug. Push the
cage could result in a fatal accident. swing brake pedal and allow the fluid to discharge
into the container until no air is present. Tighten
8. Inflate the tire to the pressure specified on the Tire
the service brake bleeder plug.
Inflation label located on the left rear fender. 8. Check the hydraulic oil level. Refer to “Hydraulic
9. Start the engine, fully retract the outrigger jacks Reservoir Oil Level Check” found in Section 2 of
and beams, and drive the crane approximately 1 this Operator's Manual.
mile (1.6km). Tighten the lug nuts again using the 9. Check the swing brake oil level. Refer to “Swing
proper torquing sequence (Figure 3-3). Brake Lubrication” found in Section 2 of this Opera­
Note: Each time a tire and rim assembly is in­ tor's Manual.
stalled the lug nuts should be retightened to the 10. Test all swing brake functions before operating the
recommended torque value after each 10 hours crane.
of operation for the first 50 hours of operation. 11. Properly dispose of used oil.
Check the lug nut torque every 50 hours of op­
eration thereafter.

3-4 Section 3 - Periodic Adjustments

 Operator's Manual

1
2

2
3

5
6

4
3
1. Cable Adjusting Nuts 4. Grease Fitting
1. Cable Adjusting Nuts 3. Swing Gear
2. Swing Lock Pin 5. Retainer
2. Control Cable 4. Swing Lock Pawl
3. Pin Guide Tube 6. Carrier Deck

Figure 3-5 Figure 3-6

Travel Swing Lock Adjustment 360 Degree Swing Lock Adjustment

Travel Swing Lock 360 Degree Swing Lock

Adjustment The 360 degree swing lock, if equipped, functions to
prevent rotation of the upper over the carrier by engag­
The travel swing lock is a two position, positive lock of ing a pawl in the external swing gear teeth. For the
the upper over the carrier to prevent swinging of the up­ swing lock to operate properly it must be adjusted cor­
per. The travel swing lock must be kept in adjustment. rectly.
1. Park the crane on a firm level surface, position
transmission shifter to neutral, and engage the 360 Degree Swing Lock Inspection
park brake. Level the crane on outriggers. And Adjustment
2. Check that the travel swing lock is engaged and 1. Park the crane on a firm level surface, position
shutdown engine. Refer to Figure 3-5. transmission shifter to neutral, and engage the
Note: The travel swing lock control cable park brake. Level the crane on outriggers.
should only operate after the release button in 2. Engage the travel and 360° swing locks. Shut­
the center of the control knob is depressed. Re­ down the engine.
place the control cable if the release button 3. Visually inspect the 360_ swing lock pawl. The
does not operate properly. pawl should be fully engaged with the linkage just
over center. Refer to Figure 3-6.
3. Check the engagement of the swing lock pin in the 4. If the pawl is not fully engaged and the linkage is
retainer on the carrier deck. The pin should extend not just over center, use the cable adjusting nuts to
completely in the retainer plate. correctly position it.
4. Adjust the stroke of the swing lock as required by 5. Tighten the adjusting nuts and test the 360_ swing
using the cable adjusting nuts. lock before operating the crane.
5. Test the swing lock in each working position before
operating the crane.

Section 3 - Periodic Adjustments 3-5

Operator's Manual
gage the travel swing lock. Fully retract the power
sections of the boom. Boom down to 0_ angle.
3. Verify the crane is level by placing a carpenter's
level across the carrier deck. Check that the crane
is level side to side and front to rear. Check level­
2 ness with the upper over the rear and over the side
of the crane. Adjust the outriggers as necessary.
1 4. Rotate the adjustment nuts as required until the
bubble inside each of the glass vials is centered
within the vial. Both bubbles must be centered si­
multaneously. Refer to Figure 3-7.

Note: Do not flatten out the springs under the

bubble level. Loosen rather that overtighten the
adjustment nuts to gain the necessary adjust­
ment.

1. Adjusting Nut
2. Glass Vial Crane Monitoring System
Figure 3-7 A properly calibrated Rated Capacity Limiter is critical
Bubble Level Adjustment for safe crane operation. The boom angle and length
are crucial factors in determining crane capacities. The
Rated Capacity Limiter must be checked for accuracy
Bubble Level Adjustment on a daily basis and calibrated as needed. Refer to
“Crane Monitoring System” found in Section 2 of this
A bubble level, for leveling the crane on outriggers, is Operator's Manual for the daily check list for the sys­
mounted in the upper cab on the right side console. It tem.
should be checked periodically to ensure proper ad­
justment. The Rated Capacity Limiter should be calibrated by a
qualified technician only. Contact your local distributor
1. Park the crane on a firm level surface, position to arrange for a qualified technician to perform the cal­
transmission shifter to neutral, and engage the ibration procedures.
park brake.
2. Level the crane on fully extended outriggers. Posi­
tion the upper over the front of the carrier and en­

3-6 Section 3 - Periodic Adjustments

 Operator's Manual
Hydraulic System Relief Relief Valve Pressure Checking
Instructions
Valve Adjustment
Refer To Figure 3-8 and Figure 3-9 for relief valve and
The following instructions pertain to checking and set­ quick disconnect fitting locations.
ting all relief valve pressures in the hydraulic system.
1. Use a gauge of known accuracy. Have the gauge
All cranes are tested and properly adjusted before leav­
calibrated if necessary. Use a snubber or gate
ing the factory and should not need checking when first
valve to reduce shock loading in the gauge.
put into operation. Each 250 hours of operation, the re­
2. Turn the key to the “ON” position but do not start
lief valve pressure settings should be checked. A drop
the engine and work the control or switch, for the
in relief valve pressure setting may be noticed the first
circuit being checked, back and forth to relieve any
time checked. This is normal and is probably due to
trapped hydraulic pressure.
lessening of spring tension or stress relief in relief valve
parts.
If a new or rebuilt pump is installed, all relief valve pres­
sures must be backed off and reset, as outlined in this
WARNING
Section before putting the crane in operation. The pur­ All trapped hydraulic pressure must be
pose of this is to avoid the possibility of damaging the exhausted from the system before installing a
new pump from over pressurization, if relief valves are gauge in any quick disconnect. A sudden
set incorrectly. Do not operate the crane over relief release of hot oil could cause burns or other
pressures for extended periods of time to avoid over­ serious injury.
heating of hydraulic oil.
3. Install the pressure gauge on the quick disconnect
fitting.
CAUTION 4. Refer to the “Hydraulic Pressure Setting” chart to
Relief valves are provided to protect the determine the correct pressure setting for the cir­
hydraulic system. Do not increase relief valve cuit being checked. Also, review the procedure for
pressures above specifications or hydraulic checking that particular circuit outlined in the
system damage may occur. chart.
5. Start the engine.
6. If applicable, fully engage the control for the circuit
Preparing the Crane For Checking being checked and hold it in that position.
Relief Pressures 7. With the engine running at the speed specified in
the “Hydraulic Pressure Settings” chart, check the
1. Park the crane on firm level surface, position trans­
gauge for the correct reading, adjust as required.
mission shifter to neutral, and engage the park
brake. Note: Obtain each final pressure by bringing
2. Level the crane on outriggers and operate the hy­ the pressure up to the proper setting, not by
draulic functions as required to bring the hydraulic backing down to it.
oil temperature to its normal operating range. Re­
fer to Section 2 of this Operator's Manual for oil op­ 8. Allow the engine to return to idle before shutting it
erating temperature ranges. down.
3. Engage the travel swing lock with the upper di­ 9. Turn the key to the “ON” position but do not start
rectly over the front of the carrier. the engine and work the control or switch, for the
4. Fully retract and lower the boom. Shutdown the circuit being checked, back and forth to relieve any
engine. trapped hydraulic pressure before removing pres­
sure gauge from the quick disconnect fitting.
Note: Checking relief valve pressures is simpli­
fied by using two persons, one in the operator's
cab to operate the controls and one to check
and adjust the relief valves.

Section 3 - Periodic Adjustments 3-7

Operator's Manual
Hydraulic Pressure Settings
Relief Hydraulic Quick Disconnect & Relief Valve
Procedure For Setting The Relief Valve
Valve Circuit Adjustment Location Setting*
Using Gauge Port “A”, Adjust Pressure Compensated
Pump Relief to 3,300‐3,400 psi (22 753-23 443kPa) at “B1”.
Outrigger
Fully Retract An Outrigger Beam & Hold.
Counter­ Figure 3-9 3,200 psi
1 Engine At Idle.
weight Re­ A&B (22 064kPa) Set Relief Valve at (B) to 3,200 psi (22 064kPa).
moval Reset Pressure Compensated Pump Relief to 3,000 psi
±50 psi (20 685kPa ±344kPa).
575 psi
Figure 3-9 (3 965kPa)
2 Pilot Control Engine At Idle.
C&D ±25 psi
(±172kPa)
350 psi
Figure 3-9 (2 413kPa)
3 Park Brake Engine At Idle.
E&F ±25 psi
(±172kPa)
325 psi
Carrier Figure 3-9 (2 241kPa)
4 Charge Cir­ Engine At Idle.
cuit G&H ±25 psi
(±172kPa)
Crane on Fully Extended Outriggers.
Travel Swing Lock Engaged.
Boom Fully Retracted & Over Front.
Travel/Winch With Engine At Idle, Fully Boom Down & Hold. Set Pres­
sure Reducing Valve (5a) to 625-650 psi
Pump Figure 3-9 550 psi (4 309-4 481Pa) at I1 Using Gauge Port “J”
5
Charge I&J (3 792kPa) Increase Engine To Full Throttle.
Circuit Fully Boom Down & Hold.
Set Relief Valve at (I) to 550 ±50 psi (3 792 ± 344kPa).
Reset Pressure Reducing Valve (5a) to 380 ±10 psi
(2 620 ±69kPa) With Engine At Idle.
Crane on Fully Extended Outriggers.
Boom Hoist Travel Swing Lock Engaged.
Figure 3-9 4,400 psi
Telescope Boom Fully Retracted & Over Front.
K&L (30 338kPa)
Retract Fully Boom Down & Hold.
Engine At Full Throttle.

6 Boom
Crane on Fully Extended Outriggers.
Telescope Figure 3-9
Travel Swing Lock Engaged with Boom Over Front.
Extend 3,000 psi Remove Specific Telescope Line. Plug Line & Work Port.
Inner K&M (20 685kPa) Using Specific Telescope Override Switch, Fully Extend
Center K&N Telescope Cylinder & Hold.
Engine At Full Throttle.
Outer/Tip K&O
Crane on Fully Extended Outriggers.
Figure 3-9 3,000 psi Steer Full Right & Hold.
Steering Steer Full Left & Hold.
P&Q (20 685kPa)
Engine Full Throttle.
7 Crane on Fully Extended Outriggers.
Figure 3-9 2,000 psi Travel Swing Lock Engaged.
Swing Swing Left & Right & Hold.
P&R (13 790kPa)
Engine Full Throttle.
*Adjust All Pressures to Within ±50 psi (344kPa) Except Where Noted.
Figure 3-8
Relief Valves Pressures & Adjusting Procedures

3-8 Section 3 - Periodic Adjustments

 Operator's Manual
Upper Relief Valve Locations
5 1a
5a

7 26 1
Carrier Relief Valve Locations (Bottom VIew)

3
4

1 B 1a 2 C
D

A
Note: Screw in to increase.
Approximately 800 psi (5516kPa)
per one revolution.
B1
3 4 G 5 J 5a
H

I1
E F I
6 7 R
R
O
N
M Q P
K L
Figure 3-9
Relief Valves

Section 3 - Periodic Adjustments 3-9

Operator's Manual

3 4
5
2
6

Ä 10

1. Accumulator 5. Regulator Assy 8. Chuck

2. Regulator Valve 6. Dry Nitrogen Tank 9. Adaptor *
3. Regulator Gauge 7. Cap 10. Charging Valve
4. Supply Gauge
* An Adaptor May Be Required To Connect Chuck To Valve.

Figure 3-10
Typical Accumulator Charging Regulator Arrangement

c.Engage the swing park brake and/or travel

Accumulator swing lock, as required.
Check/Charging d. Level the crane on fully extended outriggers.
e. Fully retract and lower the boom, as required.
The crane may be equipped with up to four accumula­ 3. Shutdown the engine and disengage the main
tors. These accumulators are pressurized to 1,400 psi hydraulic pump.
(9 653kPa) with dry nitrogen. The accumulator pres­
sure should be checked at 250 hour intervals to ensure
the accumulator is properly pressurized. WARNING
There are three bladder type accumulators located on Solvents and cleaning solutions can be
the upper behind the operator's cab. hazardous. Serious personal injury may
result from misuse of these products. Read
The accumulators may be checked and/or charged
and follow all the manufacturer's
with the unit installed or removed from the crane. If unit
recommendations concerning solvents and
must be removed from the crane, refer to the Shop
cleaning solutions.
Manual for the correct procedure. Use the following
procedure to check and/or charge the accumulators.
4. Thoroughly clean area to be disassembled with an
1. Lower, detach, and secure load, as required.
approved cleaning solvent to prevent
2. Stabilize the crane for service as follows:
contamination from entering the hydraulic oil
a. Park the crane out of the way on a firm and level
circuits. Allow the area to air dry.
surface.
b. Engage the park brake and/or properly block
the tires.

3-10 Section 3 - Periodic Adjustments

 Operator's Manual
11. Note the reading on the supply gauge (4). The dry
nitrogen tank must contain sufficient volume and
WARNING pressure to charge the accumulator.
Hydraulic oil is under pressure and may be 12. Connect chuck (8) to the charging valve (10) and
hot. A sudden release of hot oil could cause turn the t‐handle clockwise to open the charging
burns or other serious injury. Shutdown the valve (10).
engine and exhaust all trapped hydraulic 13. When charging a new accumulator (1), open the
pressure from the system before removing regulator valve (2) slowly until the regulator gauge
any line or component. (3) reads 5 psi (34kPa).
14. Slowly open the regulator valve (2) until the
5. To relieve hydraulic system pressure: regulator gauge (2) reaches 1,400 psi (9 653kPa).
a. Turn the ignition switch to “ON”, but DO NOT 15. Close the valve on the dry nitrogen tank (6) and
START THE ENGINE. Move the function lock­ turn the t‐handle of the chuck (8) counterclockwise
out switch to the “OPERATE” position. to close the charging valve (10).
b. Work the crane control levers and outrigger 16. Remove the chuck (8) from the charging valve (10)
switches back and forth several times. and inspect the charging valve (10) for leaks.
c. Rotate the steering wheel back and forth There will be a slight discharge of nitrogen when
repeatedly until steering becomes hard. (On the chuck (8) is removed.
cranes equipped with emergency steering
system, it will take several rotations of steering Note: Allow accumulator to rest 10-15 minutes
wheel before steering becomes hard.) after charging. This will allow gas temperature
d. Turn ignition switch to the “OFF” position. to adjust and equalize. Recheck gas pressure
6. Check that all control levers are in the neutral and adjust as necessary.
position and move the function lockout switch to
the “DISABLE” position. 17. Check the charging valve (10) for leaks with soapy
7. Remove cap (7) from the accumulator. Refer to water. If leaks are present, repair as required.
Figure 3-10. 18. If no leaks are present, install the cap (7) on the
8. Close the regulator valve (2) and the valve on the accumulator (1).
dry nitrogen tank (6). 19. Check hydraulic reservoir oil level. Add oil as
9. Connect the regulator assembly (5) to the dry required. Refer to Section 2 of this Operator's
nitrogen tank (6). Manual for correct type and procedure.
10. Open the valve on the dry nitrogen tank (6). The 20. Start the engine and let idle for five minutes.
regulator gauge (3) should read 0 psi (0kPa). If Inspect the connections on the hydraulic lines for
required, close the regulator valve (2) to achieve leaks. Repair if needed.
the zero pressure at the regulator gauge (3). 21. Test all hydraulic functions of the crane for proper
operation before placing the crane into service.

Section 3 - Periodic Adjustments 3-11

Operator's Manual
4 1 2 3

2
1
4 15/16 in
(125.4mm)
Minimum

4 5 6* 7 8
1. Outer Most Section 5. Jam Nut
1. Keeper Plate 3. Washer 2. Backing Plate 6. Shims*
2. Rear Top Wear Shoe 4. Capscrew 3. Wear Shoe 7. Inner Most Section
4. Adjustment Setscrews 8. Shims
Figure 3-11 * Shims used for inner and center sections only.
Keeper Plate - Rear Top Wear Shoe Note: Portions of the boom sections and wear shoe keeper
plate have been removed for clarity.

Boom Wear Shoe Inspection Figure 3-12

Rear Top Wear Shoe Adjustment
And Adjustment
Boom wear shoes are provided as a means of keeping 2. Adjust the following wear shoes to ensure the
the boom working smoothly. They must be inspected boom is straight and each boom section is cen­
tered within the next. Refer to Figure 3-13.
and adjusted periodically to prevent excessive deflec­
a. Front Top Wear Shoes (2, 3, 4)
tion of the boom sections.
1. The front top wear shoes are adjustable in
1. Level the crane on fully extended outriggers with all both horizontal and vertical directions.
tires clear of the ground. If not already installed, Vertical adjustment is used to hold the
install the 24,000 lb (10 886kg) counterweight. wear shoe down against the top of the in­
Swing the upper over the front of the carrier and en­ side boom section. Adjust these so that
gage the travel swing lock. Lower the boom and there is no clearance between wear pads
extend each boom section as required to gain ac­ and boom section. No clearance between
cess to each wear shoe. wear pad and boom section is required.
2. The horizontal adjustment is used to cen­
ter one boom section inside the other.
WARNING Measure the clearance between sections
on each side and space them equally. The
To avoid personal injury, do not climb, stand, wear pads should contact the inside sec­
or walk on the boom. Use a ladder or similar tion on both sides. No clearance between
device to reach necessary areas. wear pad and boom section is required.
To prevent movement of individual boom 3. Replace these wear shoes when adjust­
sections, shutdown the engine and ensure ment is used up.
that the operator has properly vacated the b. Rear Top Wear Shoes (5, 7, 9, 11)
operators cab before putting hands or tools 1. Adjustment of these wear shoes is accom­
inside the boom. Unsuspected movement of plished through holes in the side and top
the boom sections could sever fingers, of the adjacent boom section. Extend only
the boom sections required, and just far
hands, arms, etc.
enough, until the rear top wear shoe ad­
justment setscrews are accessible
through the hole in the top of the adjacent
section. Leave the other inner sections ful­
ly retracted at this point.

3-12 Section 3 - Periodic Adjustments

 Operator's Manual
2. For proper inspection, the rear top wear 7. Extend the inner boom sections to redis­
shoes must be removed and measured. tribute the weight of the boom so that the
Access through the sides of the boom and wear shoes being adjusted will fully seat in
remove the capscrews and washers which the top, inside corner of the outer adjacent
secure the rear top wear shoes keeper boom section.
plates. Remove the keeper plates. Refer 8. Use the adjustment setscrews to horizon­
to Figure 3-11. tally position the boom section so that it is
3. Loosen the jam nuts on the adjustment parallel with, and centered within, the out­
setscrews and back off the adjustment er adjacent boom section. Refer to
setscrews from the backing plate. Refer to Figure 3-12.
Figure 3-12. If shims (6) are employed: Install as
4. Remove and inspect the height of the rear many shims as possible between the
top wear shoes. Minimum wear shoe backing plate and adjustment setscrew
height is 4 15/16 in (125.4mm). Wear mounting plate on both sides of the boom.
shoes worn to less than this dimension Back off the adjustment setscrews one
must be replaced. complete turn and torque the jam nuts to
Note: It may be necessary to lift the ex­ 150-175 ft lb (204-237Nm).
tended boom sections, with an ap­ If shims (6) are not used: Torque the jam
propriate auxiliary lifting device, in or­ nuts to 150-175 ft lb (204-237Nm).
der to relieve pressure on the wear shoe 9. Apply Loctite® 242 to the capscrews used
for removal. to secure the keeper plates. Refer to
5. Install the rear top wear shoes back into Figure 3-11.
their proper location. If new wear shoes 10. Install the keeper plates and secure them
are being installed, the adjustment set­ with the capscrews and washers.
screws may need to be loosened further c. Rear Bottom Wear Shoes (6, 8, 10, 12) Refer to
and/or shims removed to allow room for Figure 3-13.
the larger new shoes. 1. The rear bottom wear shoes are not adjus­
table. For inspection, access to the retain­
Note: Shims (6) are only utilized on the
ing plates for these wear shoes is gained
inner and center sections. The outer
through holes in the sides of the external
and tip section do not require these
boom section when the boom is extended.
shims.
2. Minimum wear shoe thickness is 1.25 in
6. Horizontal adjustment of the rear top wear (3.2cm) for the tip and outer section shoes,
shoes is accomplished with the adjust­ and 1.50 in (3.8cm) for the center and in­
ment setscrews. This adjustment is used ner section shoes. Wear shoes worn to
to align one section inside another. The less than this dimension must be re­
straightness of the boom is dependent on placed.
this adjustment. It is best to check align­ 3. Check the thickness of the front bottom wear
ment using a string line or laser light to es­ shoes (1). The wear shoes and spacers are to be
tablish the straightness of one section to replaced when the bottom most wear pads reach a
another as these wear shoes are adjusted. minimum thickness of 1/2 in (1.3cm). To replace
Note: The rear top wear shoes (5, 7, 9, 11), these shoes, remove the front top wear shoes, lift
for all sections, must be squarely seated up on the inside section, and remove and replace
against the shims and fully seated in the the shoes. Reinstall and adjust the front top wear
corner of the adjacent section before turn- shoes.
ing the adjustment setscrews. Refer to 4. After adjusting the boom wear shoes, boom up to a
Figure 3-13. To accomplish this, extend 60° angle and fully extend the boom. Make sure
other outer boom section(s) until the inner that the boom is straight and the sections are cen­
section(s) rocks forward and wear shoes tered within each other. Thoroughly lubricate
being adjusted raise up and become fully boom wear shoes and their sliding surfaces as out­
seated into the top, inside corner of the ad- lined in Section 2 of this Operator's Manual.
jacent section.

Section 3 - Periodic Adjustments 3-13

Operator's Manual
A
B C D

H G
F
A E

H
B C G F
E
D

2 3
4

7
5
9 11

6 10 12
Section E-E Section F-F 8 Section G-G Section H-H

1. Front Bottom Wear Shoe - (8 Places) 7. Rear Top Wear Shoe - Center (2 Places)
2. Front Top Wear Shoe - Outer (2 Places) 8. Rear Bottom Wear Shoe - Center (2 Places)
3. Front Top Wear Shoe -Center (2 Places) 9. Rear Top Wear Shoe - Outer (2 Places)
4. Front Top Wear Shoe -Base & Inner (2 Places Each) 10. Rear Bottom Wear Shoe - Outer (2 Places)
5. Rear Top Wear Shoe - Inner (2 Places) 11. Rear Top Wear Shoe - Tip (2 Places)
6. Rear Bottom Wear Shoe - Inner (2 Places) 12. Rear Bottom Wear Shoe - Tip (2 Places)

Figure 3-13
Boom Wear Shoe Inspection And Adjustment

3-14 Section 3 - Periodic Adjustments

 Operator's Manual
Boom Extend Wire Rope Anchors Boom Retract Wire Rope Anchor

1 2

1. Extend Rope Anchors (Both Sides)

2. Jam Nut
3. Retract Rope Anchor (Both Sides) 2 3

Figure 3-14
Boom Extend And Retract Wire Rope Anchors

mendations” in Section 5 of this Operator's Manu­

Boom Extend And Retract al.
Wire Rope Inspection And 6. Lubricate the extend/retract wire ropes. Refer to
“Wire Rope Lubrication” in Section 2 of this Opera­
Adjustment tor's Manual.

The boom extend and retract wire ropes must be in­ Extend/Retract Wire Rope Adjustment
spected and the rope anchors torqued periodically to 1. Level the crane of fully extended outriggers with all
compensate for stretching of the wire rope. Refer to tires clear of the ground. Swing the upper over the
Figure 3-14. front of the carrier and engage travel swing lock.
2. Extend the boom in mode “Amax1” until the retract
cable adjustment nuts are visible in the hole in the
WARNING side of the base.
To avoid personal injury, do not climb, stand, 3. Tighten the retract cable until the tip section fully
or walk on the boom. Use a ladder or similar contacts the outer section at the boom head end.
device to reach necessary areas. 4. Fully retract boom and extend again in “Amax2”
mode. Then retract approximately 1 ft (0.3m).
5. Tighten the extend cables at the top front of the
Extend/Retract Wire Rope Inspection center section until there is 1-2 in (2.5-5.1cm) of
1. Level the crane on fully extended outriggers with all sag at the center of the rope and equal sag be­
tires clear of the ground. Swing the upper over the tween the left and right ropes.
front of the carrier and engage travel swing lock. 6. Fully retract boom and verify that the tip section is
2. Fully extend the boom in “Amax2” mode. Retract still contacting the outer section.
the sections approximately 1 ft (304mm) to remove 7. If the tip section does not contact the outer section,
the load from the extend wire ropes and allow them then loosen the extend cables slightly and repeat
to sag the process of tightening the retract cable and then
3. If the extend wire ropes sag more than 4 in the extend cables until the tip section contacts the
(10.2cm) or if there is a difference of more than ½ in outer section when fully retraced and the sag in the
(1.27cm) between the left and the right, wire ropes extend cables is acceptable.
must be adjusted. Refer to “Extend And Retract
Note: A special wrench is provided to aid in the
Wire Rope Adjustment”.
adjustment of the extend cable nuts.
4. Fully retract the boom. All sections must be fully re­
tracted and touching at the boom head end.
5. Inspect extend/retract wire rope for wear. Refer to
“Wire Rope Inspection And Replacement Recom­

Section 3 - Periodic Adjustments 3-15

Operator's Manual
Boom Tip Section
Anti‐Rotation Adjustment
1 Due to the shape of the boom, the boom tip section
2 may have a tendency to rotate during fly erection and
storage. To compensate, an anti‐rotation adjustment
2 may be required to maintain the tip section in a vertical
1 position. Use the following procedure to periodically
check and adjust the boom tip section.
1. Park the crane on a firm level surface, position
transmission shifter to neutral, and engage the
park brake.
2. Fully retract the boom and place it at 0 degrees.
3. Use shims as required to maintain the tip section in
a vertical position. Refer to Figure 3-15.

1. Capscrew
2. Shims

Figure 3-15
Boom Tip Section Anti‐Rotation Adjustment

3-16 Section 3 - Periodic Adjustments

 Operator's Manual

1. Carpenter's Level
2. Screw
3. Boom Angle Indicator

Figure 3-16
Boom Angle Indicator

gage the travel swing lock. Fully retract the boom.

Boom Angle Indicator Boom down to 0_ angle.
Adjustment 3. Verify the crane is level by placing a carpenter's
level across the front of upper frame. Check level­
A bubble type boom angle indicator is mounted on the ness with the upper over the rear and over the side
base section of the boom to the right of the operator's of the crane. Adjust the outriggers as necessary.
cab. Refer to Figure 3-16. It must be adjusted properly 4. Once the crane is level, verify that the boom is at 0
and the crane must be level for the unit to accurately indi­ degrees by placing carpenter's level on top of the
cate boom angles. Check the adjustment of the boom boom. Refer to Figure 3-16. Adjust the boom as
angle indicator daily to ensure its accuracy. necessary.
1. Park the crane on a firm level surface, shift the 5. If necessary, loosen the screw and adjust the angle
transmission to neutral, and engage the park indicator until the bubble within the vial is located
brake. under the 0 mark. Tighten screw.
2. Level the crane on fully extended outriggers. Posi­
tion the upper over the front of the carrier and en­

Section 3 - Periodic Adjustments 3-17

Operator's Manual

3-18 Section 3 - Periodic Adjustments

 Operator's Manual
Table Of Contents
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Auxiliary Lifting Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Installation Of Auxiliary Lifting Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Removal Of Auxiliary Lifting Sheave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Offset Lattice Fly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Offset Lattice Fly Sections Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Offset Lattice Fly Sections Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Storage Of The Fly Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Storage Of The Fly Base And Tip Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Erection Of The Fly Base Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Erection Of The Fly Base And Tip Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Changing The Fly Offset Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Fly Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Adding Fly Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Removing Fly Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Section 2 - Lubrication And Preventive Maintenance i

Operator's Manual
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-112

ii Section 2 - Lubrication And Preventive Maintenance

 Operator's Manual

3
1

1. Boom Head Machinery 4. Center Section

2. Tip Section 5. Inner Section
3. Outer Section 6. Base Section

Figure 4-1
Boom Nomenclature

The telescoping feature of the boom sections is oper­

Boom ated through the use of three hydraulic cylinders and a
The crane is equipped with a five section boom. Refer cable sheave mechanism which are an integral part of
to Figure 4-1. It consists of five basic parts: a base the boom assembly. The inner, center, outer, and tip
section, an inner section, a center section, an outer sections of the boom are “power sections”. Power sec­
section, and a tip section. The base section is con­ tions can be extended or retracted to any desired
nected to the upper revolving frame. It is raised and length using the boom telescope control in the opera­
lowered by the boom hoist cylinder. tor's cab. Refer to Section 1 of the Operator's Manual
for complete operating instructions.

Section 4 - Attachments 4-1

Operator's Manual
12 A

1
10
2
11

4
Lockout Pin Installed
6 A (Switch Inactive)

9 10 WARNING
MAIN BOOM ATB IS DISABLED
WHEN LOCK OUT PIN IS IN
HOLE. TO OPERATE MAIN BOOM
ATB, REMOVE PIN AND STORE
IN STORAGE HOLE BEHIND
SWITCH. FAILURE TO HAVE
FULLY OPERATIONAL ATB SYSTEM
8 COULD RESULT IN SERIOUS
INJURY OR DEATH.
LOCK OUT PIN HOLE

1. Jumper Assembly 7. Auxiliary Lifting Sheave Anti‐Two Block Switch

2. Plug Assembly 8. Anti‐Two Block Weight
3. Main Boom Head 9. Capscrew, Locknut, & Washer
4. Auxiliary Lifting Sheave 10. Main Boom Anti‐Two Block Switch
5. Auxiliary Arm Connector 11. Lockout Pin & Flag (Installed)
6. Auxiliary Lifting Sheave Rope Guard 12. Lockout Pin Storage Hole

Figure 4-2
Auxiliary Lifting Sheave

Auxiliary Lifting Sheave

The auxiliary lifting sheave connects to the boom head
WARNING
The auxiliary lifting sheave adds weight to the
machinery. It is used for reeving winch rope for the sec­
boom which must be considered in lifting
ond winch drum. Once installed, it may be left in place
capacities. When making lifts from the main
without interfering with installation, erection, or storage
boom or fly, refer to Crane Rating Manual for
of other boom attachments.
the appropriate deductions from lifting
capacities.

4-2 Section 4 - Attachments

 Operator's Manual
Installation Of Auxiliary Lifting Sheave Removal Of Auxiliary Lifting Sheave
1. Park crane on a firm level surface, position transmis­ 1. Park crane on a firm level surface, position trans­
sion shifter to neutral, and engage the park brake. mission shifter to neutral, and engage the park
2. Fully retract the boom and position the upper over brake.
the front of the carrier. Engage the travel swing lock. 2. Fully retract the boom and position the upper over
3. Boom down and/or extend the boom as required, the front of the carrier. Engage travel swing lock.
to ease access to the head machinery. 3. Boom down and/or extend the boom as required to
4. Adequately support the auxiliary lifting sheave with ease access to the head machinery.
an appropriate lifting device. It weighs approxi­
mately 120 lb (54kg). Position the auxiliary lifting
sheave frame under the boom head cross shaft. WARNING
Align the holes in the auxiliary lifting sheave frame To avoid personal injury, do not climb, stand,
with the lugs in the main boom and install or walk on the boom. Use a ladder or similar
capscrews, locknuts, and washers. Refer to device to reach necessary areas.
Figure 4-2.
4. Disconnect the plug assembly from the auxiliary
lifting sheave and connect it to the jumper assem­
WARNING bly on the main boom head.
To avoid personal injury, do not climb, stand, 5. Remove and properly store the lockout pin and flag
or walk on the boom. Use a ladder or similar from the main boom head anti‐two block switch.
device as required to reach necessary areas. 6. Remove the anti‐two block weight from the auxilia­
ry lifting sheave and install it on the main boom anti‐
5. Remove the rope guard from the auxiliary lifting two block switch.
sheave. Reeve the winch rope on the center boom 7. Remove the rope guard from the auxiliary lifting
deflector sheave, then over the sheave on the auxil­ sheave. Remove the winch rope and install the
iary lifting sheave. Install the rope guard. rope guard for storage.
8. Adequately support the auxiliary lifting sheave. It
CAUTION weighs approximately 120 lb (54kg). Remove the
capscrews, locknuts, and washers. Remove the
All rope guards must be in proper position auxiliary lifting sheave. Refer to Figure 4-2.
during operation. 9. Properly store the auxiliary lifting sheave, the
capscrews, locknuts, and washers and the winch
6. Disconnect plug assembly from jumper assembly rope which was used on the auxiliary lifting sheave.
on the main boom head and connect it to the auxil­
iary arm connector.
7. Install the anti‐two block weight to the auxiliary lift­
ing sheave anti‐two block switch.
8. Properly install lockout pin and flag in main boom
anti‐two block switch.

Note: When lockout pin and flag is installed, the

anti‐two block switch is inactive. The flag is
there as visual verification of an inactive switch.

When both the main boom and auxiliary sheave

are reeved for operation, the lockout pin and
flag must be removed and properly stored and
an anti‐two block weight must be suspended
from each anti‐two block switch.

9. Check Crane Rating Manual in the operator's cab

for necessary deductions with the auxiliary lifting
sheave installed before continuing operations.
10. Properly set the Rated Capacity Limiter to the cor­
rect crane configuration. Refer to Section 1 of this
Operator's Manual.

Section 4 - Attachments 4-3

Operator's Manual

3
2

Right
Wrong

1. Use The Connecting Lugs And/Or Head Machinery Cross Shafts As 3. Do Not Attach Slings To Lattices, They Will Bend.
Lifting Points.
2. Use The Main Chords As Lifting Points With Nylon Straps Only.

Figure 4-3
Handling The Fly Sections.

4-4 Section 4 - Attachments

 Operator's Manual
Offset Lattice Fly Offset Lattice Fly Sections Installation
1. Park the crane on a firm level surface, position
The crane may be equipped with a two piece offset lat­
transmission shifter to neutral, and engage the park
tice fly. The offset lattice fly sections, as seen in
brake.
Figure 4-5, connect to the main boom head. They can
be mounted in one of three offset positions: 2°, 25°, or
45°. The fly sections extend the boom length for
greater heights. The tip section of the fly extends its
WARNING
overall length from 31ft (9.4m) to 55 ft (16.8m). Once Install the offset fly with the crane level on
fully extended outriggers, all tires clear of the
installed, the offset lattice fly sections can be stored on
ground, the upper directly over the front of the
the right side of the boom base section.
carrier, and the travel swing lock engaged.
The crane may also utilize one or two 15 ft (4.6m) exten­
The fly adaptor lug and offset connecting pins
sions to provide additional fly lengths of 70 ft (21.3m)
must be in the 2° offset position to install,
and 85 ft (25.9m).
remove, erect, or store, the offset fly.
Safety Instructions Refer to the Crane Rating Manual for the
The following points must be observed while maximum boom length the fly can be
performing any fly assembly or disassembly: raised/lowered to/from the ground.
1. Read and understand the instructions outlined in Failure to do the above could result in major
this Operator's Manual before attempting to as­ crane damage, personal injury, and/or the
semble or disassemble the fly. crane tipping.
2. Do not stand inside, on top, or under the fly at any
2. Level the crane on fully extended outriggers with all
time while assembling or disassembling the fly.
tires clear of the ground.
3. To avoid personal injury, do not climb, stand, or
3. Position the upper directly over the front of the car­
walk on the fly. Use a ladder or similar device to
rier and engage the travel swing lock.
reach necessary areas.
4. Check that the fly adaptor lug and offset connect­
4. Use care handling the fly section(s) or extension(s)
ing pins are installed in the 2° offset position. Refer
when loading, transporting, and unloading. Dam­
to Figure 4-8. If necessary change the fly offset to
age that occurs during these operations can go un­
the 2° position. Refer to “Changing The Fly Offset”
detected and could result in failure of the attach­
found later in this Section for detailed instructions.
ment, once subjected to loading. Do not attach
5. Pin the fly base and tip together on secure block­
slings to the lattices, when lifting the fly, as they will
ing. The fly base section weighs 1,790 lb (812kg)
bend. It is recommended that the connecting lugs
and the fly tip section weighs 750 lb (340kg). Refer
and/or head machinery cross shaft be used as the
to Figure 4-4.
lifting points. However, it is permissible to attach
6. Remove the winch rope from the main boom head
nylon straps around all four main chords. Refer to
machinery or the auxiliary lifting sheave, whichever
Figure 4-3.
is to be used on the fly, and lay it aside to prevent
5. Each individual fly section and/or extension must
damage to it during installation of the fly.
be adequately supported before attempting to dis­
assemble the fly. Removing the connecting pins
from the fly before it is supported, may allow the fly
to fall. WARNING
6. Stay clear of pinch points when aligning fly section To avoid personal injury, do not climb, stand,
connecting points. Never place your fingers in or walk on the boom or fly. Use a ladder or
connecting pin holes. similar device to reach necessary areas.
7. Fully assemble the fly before installing it on the
7. Lower the boom and extend it to the fly. Slowly
boom.
raise or lower the boom to engage the fly lugs with
the head machinery cross shafts. Refer to
Figure 4-4.

Section 4 - Attachments 4-5

Operator's Manual

1 1
1. Blocking

Figure 4-4
Installation And Removal Of The Fly
8. Remove the two fly connecting pins from the stor­ 12. Install the anti‐two block weight on the offset lattice
age rings at the rear of the fly base section. Refer to fly anti‐two block switch.
Figure 4-5. Remove the two fly connecting pin 13. Install lockout pin and flag in anti‐two block switch
from the storage holes on the head machinery on the main boom head.
cross shafts. Install all four pins to connect the fly
lugs to the head machinery cross shafts. (Install Note: When lockout pin and flag are installed,
the pins with the head on top and keeper on the the anti‐two block switch is inactive. The flag is
bottom.) Install the pin keepers. there as visual verification of an inactive switch.
When both the main boom and fly are reeved for
operation, the lockout pin and flag must be re­
WARNING moved and properly stored and an anti‐two
All fly tip and base connecting pins must be block weight must be suspended from each
properly installed before operating the crane anti‐two block switch.
with the fly erected. Damage could occur to
14. Properly set the Rated Capacity Limiter to the cor­
the fly if all connecting pins are not properly
rect crane configuration. Refer to Section 1 of this
installed.
Operator's Manual.
9. Remove the rope guards from the fly base and 15. Check the Crane Rating Manual, in the operator's
boom head deflector sheaves. Reeve the winch cab, for deductions to the lifting capacities with the
rope over the boom center deflector sheave, then fly installed before continuing operations.
on the fly base deflector sheave.
WARNING
CAUTION The fly adds weight to the boom which must
All rope guards must be in proper position be considered in lifting capacities when the fly
during operation. is erected. When making lifts from the main
boom or auxiliary lifting sheave with the fly
10. Remove the rope guards from either the fly base or erected, refer to the Crane Rating Manual for
fly tip head sheaves, whichever is to be used. the appropriate deductions from lifting
Reeve the winch rope over the appropriate head capacities. Do not use the offset lattice fly
sheave and install the rope guards. while on tires or fully retracted outriggers,
11. Disconnect plug assembly from jumper assembly level the crane on fully extended outriggers.
on the main boom head and connect it to the offset
lattice fly section connector.

4-6 Section 4 - Attachments

 Operator's Manual
Offset Lattice Fly Sections Removal 7. Install all fly base and tip rope guards at the deflec­
1. Park the crane on a firm level surface, position tor and head sheaves. Install the boom head and
transmission shifter to neutral, and engage the deflector sheave rope guards.
park brake. 8. Extend the boom until the fly tip sheave rests on the
ground.
9. Securely block up the fly sections to support it. Re­
WARNING fer to Figure 4-4. The fly base section weighs
Remove the offset fly with the crane level on 1,790 lb (812kg) and the fly tip section weighs 750
fully extended outriggers, all tires clear of the lb (340kg).
ground, the upper directly over the front of the
carrier, and the travel swing lock engaged.
The fly adaptor lug and offset connecting pins WARNING
must be in the 2° offset position to install,
Use extreme care when removing the tapered
remove, erect, or store, the offset fly. fly connecting pins. They could pop out
Refer to the Crane Rating Manual for the suddenly and cause personal injury.
maximum boom length the fly can be
raised/lowered to/from the ground. 10. Remove the four fly connecting pins and store two
of the pins and keepers in the storage rings at the
Failure to do the above could result in major
rear of the fly. Install the remaining two pins and
crane damage, personal injury, and/or the
keepers in the storage holes on the left side of the
crane tipping.
boom head machinery cross shafts to prevent the
2. Level the crane on fully extended outriggers with all shaft from rotating. Refer to Figure 4-5
tires clear of the ground. Note: If only the fly tip section is to be removed,
3. Position the upper directly over the front of the car­ remove the connecting pins from the fly tip lugs.
rier and engage the travel swing lock. Store the fly tip connecting pins in the holes pro­
4. If the fly is not in the erected position, erect it per vided in the ramp bracket on the side of the
“Erection Of The Fly Base & Tip Sections From The boom base section.
Stored Position” found later in this Section.
5. Check that the fly adaptor lug and offset connect­ 11. Properly reeve or secure the winch rope which was
ing pins are installed in the 2° offset position. Refer used on the fly.
to Figure 4-8. If necessary change the fly offset to 12. Remove and properly store the lockout pin and flag
the 2° position. Refer to “Changing The Fly Offset” on main boom head. Refer to Figure 4-2.
found later in this Section for detailed instructions. 13. Remove the anti‐two block weight from the offset
6. Remove all fly base and tip rope guards. Remove lattice fly and install it on the main boom head anti‐
boom head and deflector sheave rope guards and two block switch.
lay the winch rope aside. 14. Remove the plug assembly from the offset lattice
fly and connect it to the jumper assembly on the
main boom head.
WARNING 15. Retract the boom away from the fly.
To avoid personal injury, do not climb, stand, 16. Properly set the Rated Capacity Limiter to the cor­
or walk on the boom or fly. Use a ladder or rect crane configuration. Refer to Section 1 of this
similar device to reach necessary areas. Operator's Manual.
17. Properly store fly section to prevent damage to it.

Section 4 - Attachments 4-7

Operator's Manual
Storage Of The Fly Base Section 9. Remove rope guards from fly base head sheave,
1. Park crane on a firm level surface, position trans­ fly base deflector sheave, the boom head sheave,
mission shifter to neutral, and engage the park and boom deflector sheave. Refer to Figure 4-5.
brake. Remove the winch rope and lay it aside. Install
2. Level the crane on fully extended outriggers with all rope guards at all sheaves for storage.
tires clear of the ground. 10. Ensure the rear ramp bracket is in the lowered
3. Position the upper directly over the front of the car­ position. If not, plug the hand held remote control
rier and engage the travel swing lock. box into the receptacle on the front fly storage
bracket. Use the remote control box to lower the
rear ramp bracket, then unplug the control box.
WARNING Refer to Figure 4-6 for receptacle location.
11. Turn the t‐handle (8) to back the pad away from the
Store the fly with the crane level on fully
bottom chord of the fly. Refer to Figure 4-6.
extended outriggers with all tires clear of the
12. Rotate the locking plate (10) to unlock the pivot pin
ground, the upper directly over the front of the
release handle (13).
carrier, and the travel swing lock engaged.
13. Properly store winch rope which was used on fly.
The fly adaptor lug and offset connecting pins Attach a hand line to the tip of the fly base section.
must be in the 2° offset position to install, 14. Remove the two fly base connecting pins (7) on the
remove, erect, or store, the offset fly. left side of the fly base section and store them in the
Refer to the Crane Rating Manual for the storage holes (8) on the boom head machinery
maximum boom length the fly can be cross shafts (5) located on the left side of the boom.
raised/lowered to/from the ground. Refer to Figure 4-5.
Failure to do the above could result in major
crane damage, personal injury, and/or the
crane tipping. WARNING
Do not remove fly base connecting pivot pins
4. Check that the offset connecting pins (1) are in­ on the right side of the boom until the fly base
stalled in the 2° offset position. Refer to to boom base pivot pin is fully engaged in the
Figure 4-8. If necessary change the fly offset to pin hole and the locking plate is rotated to the
the 2° position. Refer to “Changing The Fly Offset locked position. Fly could fall causing crane
Angle” found later in this Section for detailed in­ damage and/or personal injury.
structions.
5. Fully retract the boom and position it at a -3° 15. Place the boom at a 2° angle.
angle.
6. Disconnect plug assembly from fly and connect it
to the jumper assembly on the main boom head.
7. Remove lockout pin and flag from main boom head
WARNING
Use a hand line to control fly swing. Fly could
anti‐two block switch. Properly store lockout pin
swing around the boom rapidly. Keep all
and flag.
personnel clear of swing path to avoid injury.
8. Remove the anti‐two block weight from the fly sec­
tion and install it on the main boom anti‐two block
16. Slowly swing the fly base section around to the
switch.
right side of the boom and onto the front bracket
until the fly base to boom base pivot pin (6) is fully
engaged in the pin hole. Refer to Figure 4-6.
WARNING 17. Place the boom at a -3° angle.
To avoid personal injury, do not climb, stand, 18. Rotate the locking plate (10) to lock the pivot pin re­
or walk on the boom or fly. Use a ladder or lease handle (13).
similar device to reach necessary areas.

4-8 Section 4 - Attachments

 Operator's Manual
19. Plug the hand held remote control box into the re­ Storage Of The Fly Base And Tip
ceptacle on the front fly storage bracket. Use the
remote control box to raise the ramp bracket to
Sections
1. Park crane on a firm level surface, position trans­
take the fly load off the right side head shaft con­
mission shifter to neutral, and engage park brake.
necting pins.
2. Level the crane on fully extended outriggers with all
tires clear of the ground.
3. Position the upper directly over the front of the car­
WARNING rier and engage the travel swing lock.
Do not remove the fly base connecting pivot
pins on the right side of the boom until the fly
base to boom base pivot pin is fully engaged WARNING
in the pin hole and the locking plate is rotated Store the fly with the crane level on fully
to the locked position. The fly could fall extended outriggers with all tires clear of the
causing crane damage and/or personal injury. ground, the upper directly over the front of the
carrier, and the travel swing lock engaged.
20. Turn the t‐handle (8) until the head shaft connect­ The fly adaptor lug and offset connecting pins
ing pins are loose. Refer to Figure 4-6. must be in the 2° offset position to install,
21. Remove two fly base connecting pivot pins (10) remove, erect, or store, the offset fly.
from the right side of the boom. Refer to Refer to the Crane Rating Manual for the
Figure 4-5. maximum boom length the fly can be
22. Remove the two fly tip to fly base connecting pins, raised/lowered to/from the ground.
from their storage location, on the ramp bracket.
Refer to Figure 4-6 Failure to do the above could result in major
crane damage, personal injury, and/or the
crane tipping.
CAUTION
4. Check that the offset connecting pins (1) are in­
Before operating or traveling the crane,
stalled in the 2° offset position. Refer to
ensure the right side fly connecting pins are
Figure 4-8. If necessary change the fly offset to
properly stored in the bottom of the front fly
the 2° position. Refer to “Changing The Fly Offset
pivot storage bracket and the left side
Angle” found later in this Section for detailed in­
connecting pins are stored in their storage
structions.
holes in the boom head machinery cross
5. Fully retract the boom and position it at a -3°
shafts. Damage could result to the fly and/or
angle.
boom if fly connecting pins are not properly
6. Disconnect plug assembly from fly and connect it
stored.
to the jumper assembly on the main boom head.
23. Push the fly base in against the stored fly tip section 7. Remove lockout pin and flag from main boom head
until the fly base to fly tip connecting pin (1) fully en­ anti‐two block switch. Properly store lockout pin
gages into the pin hole. Refer to Figure 4-6. and flag.
24. Install the two fly tip to fly base connecting pins, in 8. Remove the anti‐two block weight from the fly sec­
their storage location, on the ramp bracket. Refer tion and install it on the main boom anti‐two block
to Figure 4-7. switch. Disconnect the plug assembly from the fly
25. Install the two right side fly connecting pins in the tip to fly base and store it.
bottom of the front fly pivot storage bracket (9). Re­
fer to Figure 4-6.
26. Properly set the Rated Capacity Limiter to the cor­ WARNING
rect crane configuration. Refer to Section 1 of this To avoid personal injury, do not climb, stand,
Operator's Manual. or walk on the boom or fly. Use a ladder or
27. Check the Crane Rating Manual for lifting capaci­ similar device to reach necessary areas.
ties with the fly in the stored position before con­
tinuing operations.

Section 4 - Attachments 4-9

Operator's Manual
9. Remove rope guards from fly base head sheave,
fly tip head sheave, fly base deflector sheave, the
boom head sheave, and boom deflector sheave.
WARNING
Refer to Figure 4-5. Remove the winch rope and Do not remove fly base connecting pivot pins
lay it aside. Install rope guards at all sheaves for on the right side of the boom until the fly base
storage. to boom base pivot pin is fully engaged in the
10. Ensure the rear ramp bracket is in the lowered pin hole and the locking plate is rotated to the
position. If not, plug the hand held remote control locked position. Fly could fall causing crane
box into the receptacle on the front fly storage damage and/or personal injury.
bracket. Use the remote control box to lower the
rear ramp bracket, then unplug the control box. 18. Using the hand line to restrain movement of the fly
Refer to Figure 4-6 for receptacle location. base section, place the boom at a 2° angle.
11. Turn the t‐handle (8) to back the pad away from the
bottom chord of the fly. Refer to Figure 4-6.
12. Rotate the locking plate (10) to unlock the pivot pin WARNING
release handle (13). Use a hand line to control fly swing. Fly could
13. Properly store winch rope which was used on fly. swing around the boom rapidly. Keep all
Attach a hand line to the outer end of the fly tip sec­ personnel clear of swing path to avoid injury.
tion.
14. Remove the two fly tip connecting pins (15) on the 19. Slowly swing the fly base section around to the
left side of the fly tip section (13). Refer to right side of the boom until the fly base to boom
Figure 4-5. base pivot pin (6) is fully engaged in the pin hole.
Refer to Figure 4-6.

WARNING
Use a hand line to control fly swing. Fly tip WARNING
could swing around fly base rapidly. Keep all
Do not remove the fly base connecting pivot
personnel clear of swing path to avoid injury.
pins on the right side of the boom until the fly
base to boom base pivot pin is fully engaged
15. Using the hand line attached to the fly tip section,
in the pin hole and the locking plate is rotated
slowly swing the fly tip section around to the right
side of the fly base section until the fly base to fly tip to the locked position. The fly could fall
connecting pin (1) fully engages in the pin hole. causing crane damage and/or personal injury.
Refer to Figure 4-6.
20. Place the boom at a -3° angle.
Note: It may be necessary to boom up slightly to 21. Rotate the locking plate (10) to lock the pivot pin re­
initiate movement of the fly tip section toward its lease handle (13).
stored position. Be sure to boom back down to 22. Plug the hand held remote control box into the re­
-3° angle after the fly base to fly tip connecting ceptacle on the front fly storage bracket. Use the
pin (1) fully engages in the pin hole. remote control box to raise the ramp bracket to
take the fly load off the right side head shaft con­
16. Move the hand line to the outer end of the fly base necting pins.
section. 23. Tighten the t‐handle (8) until the right side fly base
17. Remove the two fly base connecting pins (7) on the connecting pivot pins are loose. Remove the pins
left side of the fly base section and store them in the and store the pins and keepers in the bottom of the
storage holes (8) on the boom head machinery front fly pivot storage bracket (9). Refer to
cross shafts (5) located on the left side of the boom. Figure 4-6.
Refer to Figure 4-5.

4-10 Section 4 - Attachments

 Operator's Manual
24. Push the fly assembly in against the boom base
CAUTION until the fly tip to boom base connecting pin (2) en­
Before operating or traveling the crane, gages in the pin hole. Refer to Figure 4-6.
ensure the right side fly connecting pins are 25. Store the pins and keepers, removed from the left
properly stored in the bottom of the front fly side of the fly tip to fly base connection, in the ramp
pivot storage bracket, and the left side bracket. Use the two holes closest to the boom
connecting pins are stored in their storage base section. Refer to Figure 4-7.
holes in the boom head machinery cross 26. Properly set the Rated Capacity Limiter to the cor­
shafts. Damage could result to the fly and/or rect crane configuration. Refer to Section 1 of this
boom if fly connecting pins are not properly Operator's Manual.
stored.

Section 4 - Attachments 4-11

Operator's Manual

12
17
14
18
13

14

15
16

11 18

10
1
9

8
2
7
3
4
5
6

1. Offset Connecting Pins (2° Position Shown) 10. Right Side Fly Base Connecting Pin (Pivot Pin)
2. Offset Connecting Pin Storage Ring 11. Fly Base Section
3. Fly Adaptor Lug 12. Fly Tip Rope Guards
4. Fly Connecting Pin Storage Rings 13. Fly Tip Section
5. Boom Head Machinery Cross Shaft 14. Fly Base Rope Guard
6. T‐Handle 15. Left Side Fly Tip Connecting Pin
7. Left Side Fly Base Connecting Pin (Fly Erected Position) 16. Fly Base Head Sheave
8. Left Side Fly Base Connecting Pin (Fly Stored Position) 17. Right Side Fly Tip Connecting Pin (Pivot Pin)
9. Boom Head 18. Fly Base Deflector Sheave

Figure 4-5
Offset Lattice Fly - Erected Position

4-12 Section 4 - Attachments

 Operator's Manual
Erection Of The Fly Base Section
1. Park crane on a firm level surface, position trans­ DANGER
mission shifter to neutral, and engage the park
To properly store the fly tip section, the fly
brake.
connecting pins must be in the correct
2. Level the crane on fully extended outriggers with all
storage location on the ramp bracket. Failure
tires clear of the ground.
to use the correct storage location could
result in the fly tip section falling off the
storage brackets. Use the storage holes
WARNING which will lock the fly tip section to the ramp
Erect the fly with the crane level on fully bracket to avoid property damage and/or
extended outriggers with all tires clear of the personal injury.
ground, the upper directly over the front of the
carrier, and the travel swing lock engaged. 9. Remove the fly connecting pins, from the ramp
The fly adaptor lug and offset connecting pins bracket, which locks the fly base section to the
must be in the 2° offset position to install, boom base section.
remove, erect, or store, the offset fly. 10. Pull the fly base release handle (3, Figure 4-6) to
disengage the pin and release the fly base from the
Refer to the Crane Rating Manual for the
fly tip section.
maximum boom length the fly can be
11. Roll the fly base on the ramp bracket, out away
raised/lowered to/from the ground.
from the boom, allowing the fly base to pivot on the
Failure to do the above could result in major pivot pin until the fly lugs align with the holes in the
crane damage, personal injury, and/or the boom head machinery cross shafts.
crane tipping. 12. Properly store the the fly base section connecting
pin in the ramp bracket.
3. Position the upper directly over the front of the car­ 13. Remove the two fly connecting pins from the front
rier and engage the travel swing lock. fly pivot storage bracket. Install one of the fly base
4. Fully retract the boom. Lower the boom to -3°. connecting pins through the top fly base pivot lug
5. Remove the winch rope from the head machinery on the right side of the boom. If required, turn the
or the auxiliary lifting sheave whichever is to be t‐handle (8) to line up the bottom lug with the boom
used on the fly and lay it aside to prevent damage head machinery cross shaft hole. Install the other
to it during erection of the fly. fly base connecting pin through the bottom fly
6. Ensure the rear ramp bracket (5) is in the raised base pivot lug. Refer to Figure 4-6. (Install the
position. If not, plug the hand held remote control pins with the head on top and the keeper on the
box into the receptacle (12) on the front fly storage bottom.) Install the pin keepers.
bracket. Use the remote control box to raise the 14. Plug the hand held remote control box into the re­
rear ramp bracket, then unplug the control box. ceptacle on the front fly storage bracket. Use the
Refer to Figure 4-6 for receptacle location. remote control box to lower the ramp bracket. Re­
7. Attach a hand line to the outer end of the fly base fer to Figure 4-6. Unplug the hand held remote
section. control box.
8. Remove the fly tip connecting pins from the top 15. Rotate the locking plate (10) to unlock the pivot pin
and bottom lugs between the fly tip and base sec­ release handle (13).
tions. Store the pins in the ramp bracket. Be sure 16. Place the boom at a 4° angle.
to use the holes which will lock the fly tip to the 17. Turn the t‐handle (8) to back the pad out away from
ramp bracket. Refer to Figure 4-7. the bottom chord of the fly base section.

Section 4 - Attachments 4-13

Operator's Manual
18. Pull the pivot pin release handle and hold it down
while turning the t‐handle (8) to push the fly base CAUTION
away from the fly base to boom base pivot pin. All rope guards must be in proper position
19. Place the boom at a 2° angle and use the hand line during operation.
to swing the fly base around the boom head until
the fly lugs engage with the head machinery cross 23. Disconnect the plug assembly from the jumper as­
shafts on the left side of the boom. sembly on the main boom head and connect it to
the connector assembly on the fly base section.
24. Install the anti‐two block weight on fly. Refer to
WARNING Section 1 of this Operator's Manual.
25. Properly install lockout pin and flag in the anti‐two
Use a hand line to control fly swing. The fly block switch on main boom head.
could swing around the boom rapidly. Keep
all personnel clear of the swing path to avoid Note: When lockout pin and flag is installed, the
injury. anti‐two block switch is inactive. The flag is
there as visual verification of an inactive switch.
20. Place the boom at -3° angle.
21. Remove the two fly connecting pins from the stor­ When both the main boom and fly are reeved for
age location (8) on the boom head machinery operation, the lockout pin and flag must be re­
cross shaft on the left side of the boom. Refer to moved and properly stored and an anti‐two
Figure 4-5. Install one pin through the top fly lug block weight must be suspended from each
on the left side of the boom. Turn the t‐handle (6) to anti‐two block switch.
push and align the bottom left fly lug and the bot­ 26. Properly set the Rated Capacity Limiter to the cor­
tom boom head machinery cross shaft. Install the rect crane configuration. Refer to Section 1 of this
bottom left fly connecting pin. (Install the pins with Operator's Manual.
the head on top and the keeper on the bottom.) In­ 27. Check the Crane Rating Manual for lifting capaci­
stall the pin keepers. Turn the t‐handle (6) to back ties with the fly installed before continuing opera­
the crank away from the bottom left fly lug. tions.

WARNING WARNING
All four fly base connecting pins must be The fly adds weight to the boom which must
properly installed before operating the crane be considered in lifting capacities when the fly
with the fly base erected. Damage to the fly is erected. When making lifts from the main
base may occur if all connecting pins are not boom or auxiliary lifting sheave with the fly
properly installed. erected, refer to the Crane Rating Manual for
the appropriate deductions from lifting
22. Remove the rope guards from the fly base head, capacities. Do not use the fly while on tires,
and deflector sheaves. Refer to Figure 4-5. level the crane on outriggers.
Reeve the winch rope on the boom deflector
sheave then over the fly deflector and head
sheaves. Install all rope guards.

4-14 Section 4 - Attachments

 Operator's Manual

A B

A B
1 2

3 4

9
5
8
1. Fly Base To Fly Tip Connecting Pin
2. Fly Tip To Boom Base Connecting Pin
3. Fly Base Release Handle 10
4. Fly Base And Tip Release Handle
5. Ramp Bracket LOCKING PLATE

11 12 UNLOCK

6. Fly Base to Boom Base Pivot Pin See Operator's

Manual for
operation.
LOCK
13
7. Front Fly Pivot Storage Bracket
8. T‐Handle
9. Right Side Fly Connecting Pin Storage
10. Locking Plate - Lock Position
11. Locking Plate - Unlock Position
12. Hand Held Remote Control Box Receptacle
13. Pivot Pin Release Handle

Figure 4-6
Offset Lattice Fly - Stored Position

Section 4 - Attachments 4-15

Operator's Manual
3. Position the upper directly over the front of the car­
rier and engage the travel swing lock.
4. Fully retract the boom. Lower the boom to -3°.
5. Remove the winch rope from the head machinery
or auxiliary lifting sheave whichever is to be used
and lay it aside to prevent damage to it during erec­
tion of the fly.
6. Ensure the rear ramp bracket (5) is in the raised
position. If not, plug the hand held remote control
box into the receptacle (12) on the front fly storage
bracket. Use the remote control box to raise the
rear ramp bracket, then unplug the control box.
1
Refer to Figure 4-6 for receptacle location.
7. Attach a hand line to the tip of the fly base section.
8. Ensure that the pivot pins between the fly base and
2 the fly tip are properly installed.
3 9. Remove the fly tip connecting pins, from the ramp
bracket, that lock the fly base to the boom base
section. Refer to Figure 4-7.
1. LH Connecting Pins Storage-Locks Fly Tip To Ramp Bracket 10. Pull the fly base and tip release handle (4) to disen­
2. RH Connecting Pins Storage-Locks Fly Base To Ramp Bracket gage the pin and release the fly base and tip from
3. Ramp Bracket the boom base. Refer to Figure 4-6.
Figure 4-7 11. Roll the fly on the ramp bracket out away from the
Fly Tip Connecting Pin Storage boom allowing the fly to pivot on the pivot pin until
the fly lugs align with the holes in the boom head
machinery cross shafts.
Erection Of The Fly Base And Tip 12. Remove the two fly connecting pins from the front
fly pivot storage bracket (9). Install one of the fly
Section base connecting pins through the top fly base pivot
1. Park crane on a firm level surface, position transmis­ lug on the right side of the boom. If required, turn
sion shifter to neutral, and engage the park brake. the t‐handle (8) to line up the bottom lug with the
2. Level the crane on fully extended outriggers with all boom head machinery cross shaft hole. Install the
tires clear of the ground. other fly base connecting pin through the bottom
fly base pivot lug. Refer to Figure 4-6. (Install the
pins with the head on top and the keeper on the
WARNING bottom.) Install the pin keepers.
Erect the fly with the crane level on fully 13. Plug the hand held remote control box into the re­
extended outriggers with all tires clear of the ceptacle on the front fly storage bracket. Use the
ground, the upper directly over the front of the remote control box to lower the ramp bracket. Re­
carrier, and the travel swing lock engaged. fer to Figure 4-6. Unplug the hand held remote
The fly adaptor lug and offset connecting pins control box.
must be in the 2° offset position to install, 14. Rotate the locking plate (10) to unlock the pivot pin
remove, erect, or store, the offset fly. release handle (13).
15. Place the boom at a 4° angle.
Refer to the Crane Rating Manual for the 16. Turn the t‐handle (8) to back the pad out away from
maximum boom length the fly can be the bottom chord of the fly.
raised/lowered to/from the ground. 17. Pull the pivot pin release handle (13) and hold it
Failure to do the above could result in major down while turning the t‐handle (8) to push the fly
crane damage, personal injury, and/or the base away from the fly base to boom base pivot pin.
crane tipping.

4-16 Section 4 - Attachments

 Operator's Manual
18. Place the boom at a 2° angle and use the hand line
to swing the fly base and tip around the boom head
until the fly lugs engage with the head machinery
WARNING
cross shafts on the left side of the boom. All four fly tip connecting pins must be
properly installed before operating the crane
with the fly tip erected. Damage could occur
to the fly tip if all connecting pins are not
WARNING properly installed.
Use a hand line to control fly swing. The fly
could swing around the boom rapidly. Keep 24. Remove the rope guards from the fly base head,
all personnel clear of the swing path to avoid deflector, and fly tip head sheaves. Refer to
injury. Figure 4-5. Reeve the winch rope on the boom
deflector sheave then over the fly deflector, head
19. Place the boom at a -3° angle. and fly tip head sheaves. Install all rope guards.
20. Remove the two fly connecting pins from the stor­
age location (8) on the boom head machinery
cross shaft on the left side of the boom. Refer to
CAUTION
Figure 4-5. Install one pin through the top fly lug All rope guards must be in proper position
on the left side of the boom. Turn the t‐handle (6) to during operation.
push and align the bottom left fly lug and the bot­
25. Disconnect the plug assembly from the jumper as­
tom boom head cross shaft. Install the bottom left
sembly on the main boom head and connect it to
fly connecting pin. (Install the pins with the head
the connector assembly on the fly.
on top and the keeper on the bottom.) Install the
26. Install the anti‐two block weight on fly. Refer to
pin keepers. Turn the t‐handle (6, Figure 4-5) to Section 1 of this Operator's Manual.
back the crank away from the bottom left fly lug. 27. Properly install lockout pin and flag in the anti‐two
block switch on main boom head.

WARNING Note: When lockout pin and flag is installed, the

anti‐two block switch is inactive. The flag is
All four fly base connecting pins must be there as visual verification of an inactive switch.
properly installed before operating the crane
with the fly base erected. Damage to the fly When both the main boom and fly are reeved for
base may occur if all connecting pins are not operation, the lockout pin and flag must be re­
properly installed. moved and properly stored and an anti‐two
block weight must be suspended from each
21. Attach a hand line to the tip of the fly tip section. anti‐two block switch.
Pull the fly base to fly tip release handle (3) to disen­
gage the pin and release the fly tip from the fly base 28. Properly set the Rated Capacity Limiter to the cor­
section. Refer to Figure 4-6. rect crane configuration. Refer to Section 1 of this
Operator's Manual.
29. Check the Crane Rating Manual for lifting capaci­
ties with the fly installed before continuing opera­
WARNING tions.
Use a hand line to control fly swing. The fly
could swing around the boom rapidly. Keep
all personnel clear of the swing path to avoid
injury.
WARNING
The fly adds weight to the boom which must
be considered in lifting capacities when the fly
22. Use the hand line to swing the fly tip section around
is erected. When making lifts from the main
the fly base section until the fly tip lugs engage with
boom or auxiliary lifting sheave with the fly
the fly base lugs on the left side of the fly. erected, refer to the Crane Rating Manual for
23. Install the fly tip connecting pins through the fly tip the appropriate deductions from lifting
connecting lugs on both the top and bottom. (In­ capacities. Do not use the fly while on tires,
stall the pins with the head on top and the keeper level the crane on outriggers.
on the bottom.) Install the pin keepers.

Section 4 - Attachments 4-17

Operator's Manual
1 2 1
WARNING
COMPLY WITH THE FOLLOWING TO PREVENT PERSONAL INJURY OR
MACHINE DAMAGE.
PINS MUST BE PROPERLY INSTALLED ON BOTH SIDES OF FLY.
REST FLY SHEAVE ON GROUND BEFORE CHANGING OFFSETS.
INSTALL PINS PER 2 OFFSET TO STORE OR ERECT FLY

OFFSET FLY PIN PLACEMENT

2° OFFSET

PIN LOCATION

25° OFFSET

PIN LOCATION

45° OFFSET
PIN LOCATION 7 5

4
3
6

1. Offset Connecting Pin (2° Position Shown) 5. Fly Connecting Pin Storage Ring
2. Fly Adaptor Lug 6. Fly Tip Head Sheave
3. Offset Lattice Fly Tip Section 7. Offset Connecting Pin Storage Location
4. Offset Lattice Fly Base Section

Figure 4-8
Changing The Fly Offset Angle

Changing The Fly Offset Angle

1. Park the crane on a firm level surface, position
transmission shifter to neutral, and engage the
park brake.
2. Level the crane on fully extended outriggers with all
tires clear of the ground.
3. Position the upper directly over the front of the car­
rier and engage the travel swing lock.

4-18 Section 4 - Attachments

 Operator's Manual
d. Slowly boom up to allow the fly section to ad­
WARNING just itself to the desired offset angle.
Change the fly offset angle with the crane If the existing offset angle is 25° and a 2°
level on fully extended outriggers with all tires offset is desired:
clear of the ground, the upper directly over the a. Carefully extend and/or lower the boom until
front of the carrier, and the travel swing lock the 2° angle is reached.
engaged. b. Remove the offset connecting pin from the
The fly adaptor lug and offset connecting pins storage ring on the fly and install it through the
must be in the 2° offset position to install, fly adaptor lug, in one of the 2° offset holes.
remove, erect, or store, the offset fly. c. Relocate the other offset connecting pin from
the 25° offset position to the 2° offset position.
Refer to the Crane Rating Manual for the
d. Make sure to properly locate the offset con­
maximum boom length the fly can be
necting pins on both sides of the fly and ensure
raised/lowered to/from the ground.
that the keeper pins are securely installed.
Failure to do the above could result in major e. Slowly boom up to allow the fly section to ad­
crane damage, personal injury, and/or the just itself to the desired offset angle.
crane tipping.
If the existing offset angle is 25° and a 45°
4. If the offset lattice fly section is not in the erected offset is desired:
position, erect it per “Erection Of The Fly From The a. Relocate the offset connecting pin from the
Stored Position” found earlier in this Section. 25° offset position to the 45° offset position.
b. Make sure to properly locate the offset con­
CAUTION necting pins on both sides of the fly and ensure
that the keeper pins are securely installed.
Do not extend the boom or boom down to the c. Slowly boom up to allow the fly section to ad­
point of over stressing the offset lattice fly just itself to the desired offset angle.
section. Structural damage to the fly could
occur if care is not taken. Use a signalman to If the existing offset angle is 45° and a 2°
aid the operator in lowering the fly head offset is desired:
sheave to the ground. a. Carefully extend and/or lower the boom until
the 2° angle is reached.
5. Carefully extend and/or lower the boom until the fly b. Remove the offset connecting pin from the
tip head sheave is resting on the ground. Use a storage ring on the fly and install it through the
signalman to alert the operator when the sheave is fly adaptor lug, in the rear 2° offset hole.
resting on the ground. c. Make sure to properly locate the offset con­
necting pins on both sides of the fly and ensure
Note: If the fly tip section is not erected, lower that the keeper pins are securely installed.
the fly base section until the fly base head d. Slowly boom up to allow the fly section to ad­
sheave is resting on the ground. just itself to the desired offset angle.
6. Use one of the following procedures and the infor­ If the existing offset angle is 45° and a 25°
mation label, located on the offset lattice fly sec­ offset is desired:
tion, to determine the correct offset connecting pin a. Carefully extend and/or lower the boom until
locations for the desired offset angle of the fly. Re­ the 25° angle is reached.
fer to Figure 4-8. b. Relocate the offset connecting pin from the
If the existing offset angle is 2°: 45° offset position to the 25° offset position.
a. Locate one offset connecting pin in the correct c. Make sure to properly locate the offset con­
location for the desired offset angle. necting pins on both sides of the fly and ensure
b. Remove the other offset connecting pins from that the keeper pins are securely installed.
d. Slowly boom up to allow the fly section to ad­
each side of the fly and place it in the storage
just itself to the desired offset angle.
ring provided.
c. Make sure to properly locate the offset con­ 7. Properly set the Rated Capacity Limiter to the cor­
necting pins on both sides of the fly and ensure rect crane configuration before continuing opera­
that the keeper pins are securely installed. tions. Refer to Section 1 of this Operator's Manual.

Section 4 - Attachments 4-19

Operator's Manual
8. Check the Crane Rating Manual, in the operator's
cab, for deductions from the lifting capacities with
the fly installed before continuing operations.

WARNING
The fly adds weight to the boom which must
be considered in lifting capacities when the fly
is erected. When making lifts from the main
boom or auxiliary lifting sheave with the fly
erected, refer to the Crane Rating Manual for
the appropriate deductions from lifting
capacities. Do not use the offset lattice fly
while on tires or fully retracted outriggers,
level the crane on fully extended extended
outriggers.

4-20 Section 4 - Attachments

 Operator's Manual

3 2 1

4 4 4 4

1. Fly Base Section 3. Fly Tip Section

2. Fly Extension 4. Blocking

Figure 4-9
Fly Assembly On Blocking

Fly Extensions
If the crane is equipped with a two piece offset lattice DANGER
fly, one or two extensions are available to extend the To avoid serious injury, carefully read and
overall fly length to 70 ft (21.3m) or 85 ft (25.9m). These understand all safety instructions outlined in
extensions pin between the fly base and tip sections. this manual. Failure to follow these
The fly tip must be removed from the crane before add­ instructions could result in severe personal
ing or removing the fly extensions. Also the fly base injury or death.
and tip sections can not be stored on the side of the
boom with the extensions installed.

Section 4 - Attachments 4-21

Operator's Manual
Adding Fly Extensions Removing Fly Extensions
The fly tip section must be removed from the crane be­
fore adding or removing fly extensions. Remove the fly
tip section and place adequate blocking under each WARNING
end of the section before removing any connecting pin. Properly remove the fly tip and extensions
Add or remove fly sections as required to achieve the from the crane before attempting to modify
desired fly length. Refer to the instructions in this Sec­ the length. Do not place any part of your body
tion for proper removal and installation procedures. under the fly when it is being assembled or
disassembled. Removing any connecting
pins from the fly before it is properly
WARNING supported may allow the fly to jackknife and
Properly remove the fly tip section from the injure someone. Adequately support each
crane before attempting to modify the length. end of each section before attempting to
Do not place any part of your body under the lengthen or shorten the fly.
fly when it is being assembled or
disassembled. Removing any connecting 1. Extend the boom and lower the fly tip and exten­
pins from the fly before it is properly sions onto secure blocking. Remove the extension
supported may allow the fly to jackknife and connecting pins and disassemble the fly sections.
injure someone. Adequately support each 2. Re‐pin the desired fly sections. Install the pins with
end of each section before attempting to the head on top and the keeper on the bottom. In­
lengthen or shorten the fly. stall the pin keepers.
3. Lower the boom and fly base section, extend it to
1. Extend the boom to a length that is greater than the the fly. Slowly raise or lower the boom to engage
length of extension to be added. the fly lugs.
2. Set the tip section on secure blocking. Remove the 4. Install all four connecting pins through the front fly
fly tip to fly base connecting pins. base lugs. Install the pins with the head on top and
3. Retract the boom and the fly base away from fly tip the keeper on the bottom. Install the pin keepers.
section.
4. Position blocking and assemble the fly extensions
to the fly tip section. Install all the connecting pins.
Install the pins with the head on top and the keeper
on the bottom. Install the pin keepers.
5. Extend the boom and fly base section into the ex­
tension lugs. Install all four connecting pins
through the front fly base lugs. Install the pins with
the head on top and the keeper on the bottom.
Install the pin keepers.

4-22 Section 4 - Attachments

 Operator's Manual
Table Of Contents
Crane Rating Manual And Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Wire Rope Capacity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Wire Rope Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Wire Rope Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Wire Rope Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Wire Rope Inspection And Replacement Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Wire Rope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Wire Rope Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Wire Rope Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Winch Roller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Uncoiling Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Anchoring Wire Rope To Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Winding Rope On Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Wire Rope Reeving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Socket And Wedge Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Rope Break‐In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Single Part Line Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Rotation Resistant Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Rope Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Hook Ball Usage With Rotation Resistant Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Non‐Swivel Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Swivel Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Wire Rope Sockets With Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Wire Rope Clip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Cutting Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Wire Rope Reeving Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Crane Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Upper Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Fly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Cab and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Rated Capacity Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Section 5 - General Information i

Operator's Manual
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Load Hoist System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Travel Speeds and Gradability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Travel Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Transport Configuration And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Axle Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

ii Section 5 - General Information

 Operator's Manual
quired to make the lift. Use at least that number of parts
Crane Rating Manual And of line to make the lift. When making a lift with more
Serial Number parts of line than is needed to make the lift, remember
to add one and one half (1.5) pound (0.68kg) for each
The Crane Rating Manual is located in the lower right one (1) foot (0.3m) of extra rope required to reeve the
interior of the operator's cab. This manual has the extra parts of line, to the actual load weight. The extra
crane serial number on it. The serial number is also parts of line act as additional load weight.
stamped on the top of the bumper on the right side of
the carrier and on the right side of the upper frame just
below the boom hoist cylinder mounting lug. The serial
number must be used with any correspondence with
WARNING
Do not exceed the capacities listed for wire
the factory concerning parts or warranty. This manual
rope strength or crane capacity, whichever is
also lists the maximum allowable lifting capacities for
less, when making a lift. Serious personal in­
the crane. The manual should be checked for the
jury or crane damage may result.
proper lifting capacities before making any lifts.
If the Crane Rating Manual becomes lost, dam­
aged, or unreadable, it must be replaced before op­
erating the crane. Information contained in the Crane
Wire Rope Specifications
Rating Manual is important and failure to follow the in­ The specifications for the wire rope used on this crane
formation it contains could result in an accident. A re­ are on the Wire Rope Capacity chart located in the
placement manual can be ordered through your dis­ Crane Rating Manual. Refer to Figure 5-1 for a typical
tributor. example. Always refer to the Wire Rope Capacity chart
in the Crane Rating Manual when ordering replace­
ment wire rope.
WARNING
The Crane Rating Manual in the crane is the
Wire Rope Diameter
only authorized listing of lifting capacities for In standard practice, the nominal diameter of wire rope
the crane. It supercedes any other printed lit­ is the minimum acceptable diameter. It is always made
erature which lists lifting capacities. It alone is larger, not smaller, than the nominal diameter accord­
to be used for determining crane capacities. ing to the allowable tolerances shown in the following
chart:

Wire Rope Capacity Chart Nominal Rope Diameter

Allowable
Limits
The Wire Rope Capacity chart gives the maximum lift­
ing capacities based on wire rope strength. A typical Thru 1/8” (3.2mm) -0 +8%
example is shown Figure 5-1. The actual chart is lo­ Over 1/8” (3.2mm) thru 3/16” (4.8mm) -0 +7%
cated in the Crane Rating Manual. It lists the maximum
Over 3/16” (4.8mm) thru 5/16” (8.0mm) -0 +6%
load that should be lifted with different sizes and types
of wire rope. The weights shown are based on wire Over 5/16” (8.0mm) and larger -0 +5%
rope strength alone. Exceeding these load weights
may result in rope damage or failure. Wear and stress tend to reduce the diameter. It should
be measured periodically and replaced if the size is be­
Before making a lift, compare the weight being lifted low the nominal size of the wire rope being used as
(remember to add the weight of the hook block, slings, shown in the chart on page 5-4. It should always be
and riggings to the actual load weight) with the Wire measured across the largest diameter that will fit inside
Rope Capacity chart located in the Crane Rating Manu­ a true circle. Refer to Figure 5-2.
al. Check the chart for the number of parts of line re­

Section 5 - General Information 5-1

Operator's Manual

Wire Rope Capacity

Maximum Lifting Capacities Based On Wire Rope Strength
Parts 7/8” 7/8”
of Notes
Line Type RB Type ZB
1 17,520 20,920 Capacities shown are in pounds and working loads must
2 35,040 41,840 not exceed the ratings on the capacity charts in the
Crane Rating Manual.
3 52,560 67,760 Capacity deducts for auxiliary lifting devices do not apply
4 70,080 83,680 for wire rope strength capacities.
5 87,600 104,600 Study Operator’s Manual for wire rope inspection proce-
dures and single part of line applications.
6 105,120 125,520
7 122,640 146,440
8 140,160 167,360
9 157,680 188,280
10 175,200 209,200
11 192,720 230,120
12 210,240 251,040
LBCE TYPE DESCRIPTION
19 Strand, Compacted Strand, Rotation Resistant -High Strength - Preformed Right Regu­
RB lar Lay
ZB 34 X 7 Non‐Rotating - Extra Improved Plow Steel - Right Regular or Right Lang Lay

Note: The Wire Rope Capacity chart depicted above is shown as an example only. Use the official Wire
Rope Capacity chart located in the Crane Rating Manual. Use it to determine the correct parts of line
required for the given wire rope type and diameter.

Figure 5-1
Typical Wire Rope Capacity Chart (Example Only)

Right
Wrong

Figure 5-2 CD00325

Measuring Wire Rope Diameter

5-2 Section 5 - General Information

 Operator's Manual

WIRE ROPE INSPECTION REPORT

Crane S/N Owned By Crane Location

Date of Inspection Rope Application Rope Description

Manufacturer's Ident. No. Applicable Standards
1/3 of
Criteria for Removal Outside 1
Wire Dia.
Broken Wires End Attachments
Location Rope Lay
on Rope In 1 In 1 Strand Broken Corrosion Fitting Measurement
Rope Lay of 1 Lay Wires of Rope Condition

Signature:

Figure 5-3
Typical Wire Rope Inspection Report

According to ASME standards, all wire ropes in active

Wire Rope Inspection And service MUST BE visually inspected daily. A qualified,
Replacement trained person should be appointed to conduct the in­
spection. Also on a monthly basis, that person is re­
Recommendations quired to inspect all wire ropes and keep a dated, written
record noting any damage and recording when ropes
The three basic reasons for deterioration of wire rope are replaced.
are abrasion, corrosion, and damage, caused by fa­
tigue bending, crushing, kinking, and forces or abuse These inspections should be done to determine the de­
acting against the rope during normal usage. gree of deterioration of the rope at any given section
(refer to the following on rope replacement). This will
When wire rope is replaced, use the type specified on determine the suitability of the rope for continued serv­
the Wire Rope Capacity chart located in the Crane Rat­ ice. A sample inspection report is shown in
ing Manual. Cranes are designed to use a specific type Figure 5-3. (It can be reproduced and used if de­
and size of rope. Using ropes other than those recom­ sired).
mended, may result in short life or even failure of the
rope.

Section 5 - General Information 5-3

Operator's Manual
Wire Rope Inspection Wire Rope Replacement
Any of the following are reasons to question rope Any of the following are reasons for rope replacement:
safety: 1. In running ropes, six randomly distributed broken
1. More than one broken wire in any one strand wires in one rope lay, or three broken wires in one
should be cause for caution. Breaks that occur on strand in one rope lay.
the worn crowns of the outside wires usually indi­ For rotation resistant ropes, two randomly distrib­
cate normal deterioration. Breaks that occur in the uted broken wires in six rope diameters, or four
valleys between strands can indicate an abnormal randomly distributed broken wires in thirty rope di­
condition, possibly fatigue and breakage of other ameters.
wires that are not readily visible. One or more val­ 2. In pendants or standing ropes, evidence of more
ley breaks should be cause for replacement. than two broken wires in one lay in sections be­
2. Wire breaks generally occur in those portions of yond end connections or more than one broken
wire rope which pass over sheaves, wind onto wire in one rope lay at end connection.
drums, or receive mechanical abuse. Breaks that 3. One outer wire broken at the contact point with the
occur near attached fittings are apt to result from core of the rope which has worked its way out of
fatiguing stresses concentrated in these localized the rope structure and protrudes or loops out from
sections. Breaks of the latter type should be cause the rope structure.
for replacement of the rope or renewal of the at­ 4. Abrasion, scrubbing, or peening causing loss of
tachment to eliminate the locally fatigued area. more than 1/3 the original diameter of individual
When running ropes over nylon sheaves, inspect wires.
the wire rope where it travels over the sheaves. In­ 5. Evidence of rope deterioration from corrosion.
spect for a loss of diameter and then bend the rope 6. Kinking, crushing, “bird caging”, or other damage
to inspect the internal wires for breaks and wear. resulting in distortion of the rope structure.
3. Heavy wear, or broken wires, may occur in sections 7. Evidence of any heat damage.
under equalizer sheaves or other sheaves where 8. Marked reduction in diameter indicates deteriora­
rope travel is limited, or in contact with saddles. tion of the core resulting in lack of proper support
Particular care should be taken to inspect rope at for the load carrying strands. Excessive rope
these points. If wire rope wear is detected at these stretch or elongation may also be an indication of
locations, these wear points can be shifted by re­ internal deterioration. Reduction from nominal di­
moving the rope from the drum and cutting a 20 ft ameter or more than:
(6.1m) section off at the drum end. This may assist
in extending the wire rope life. Reduction of Nominal Rope Diameters
4. Rope stretch is generally greatest during initial 1/64” (0.4mm) up to and including 5/16” (8mm)
stages of operation when the strands are becom­
1/32” (0.79mm) over 5/16” (8mm) to 1/2” (13mm)
ing adjusted and seated. This is accompanied by
3/64” (1.2mm) over 1/2” (13 mm) to 3/4” (19mm)
some reduction in rope diameter.
5. Time for rope replacement is indicated by the ex­ 1/16” (1.6mm) over 3/4” (19mm) to 1‐1/8” (29mm)
tent of abrasion, scrubbing, and peening on the 3/32” (2.4mm) over 1‐1/8” (29mm)
outside wires, broken wires, evidence of pitting or 9. Noticeable rusting or development of broken wires
severe corrosion, kink damage, or other mechani­ in the area of connections.
cal abuse resulting in distortion of the rope struc­
ture.
6. Sheaves, guards, guides, drums, flanges, and
Wire Rope Installation
other surfaces contacted by wire rope during op­ When installing wire rope, the primary concern is get­
eration should be examined at the time of inspec­ ting the rope onto the drum without trapping any twist
tions. Any condition harmful to the rope in use at that may have been induced during handling. Use the
the time should be corrected. The same equip­ following procedures to install the rope on the crane.
ment and particularly sheave and drum grooves
should be inspected and placed in proper condi­
tion before a new rope is installed.

5-4 Section 5 - General Information

 Operator's Manual
5 8 7

6 3 2 1 4 6
1. Torsion Spring 4. Setscrew 7. Roller Arm
2. Bolt 5. Capscrew 8. Roller
3. Torque Shaft 6. Setscrew

Figure 5-4
Winch Roller Adjustment

Winch Roller Adjustment the torque shaft, then securely tighten set­
screws.
Before installing wire rope on the drum, adjust the d. Reposition breaker bar or wrench on
drum roller. Refer to Figure 5-4. capscrew.
1. Check that the roller is centered between the drum e. Repeat Steps b thru d until tension is fully
flanges. If not, loosen setscrews, center roller, and relieved from torsion spring.
tighten setscrews. 3. Turn the capscrew, which will rotate the torque
shaft, until the bolt through the torque shaft con­
tacts the torsion spring.
WARNING
Do not attempt to service winch roller before CAUTION
properly relieving torsion spring tension. If
proper directions are not followed, the torsion Do not overtighten the spring. Damage to the
spring could rapidly and forcefully uncoil. wire rope may occur.
This may result in serious personal injury and
component damage. Always release tension 4. With the roller arms resting against the stops and
on torsion spring before attempting any winch the bolt through the torque shaft just contacting the
roller repair. torsion spring, rotate the torque shaft one com­
plete turn (360_) to preload the torsion spring. The
2. Properly release torsion spring tension as follows. torque required to turn the shaft 360_ is approxi­
This procedure is greatly simplified by using two mately 105 ft lb (142Nm).
service technicians. (One to hold the breaker 5. Tighten setscrews. The roller should roll freely
bar/wrench, the other to loosen and tighten when the drum rotates.
setscrews.)
a. Ensure capscrew is tightened securely in
torque shaft.
b. Using a breaker bar or long handle wrench,
hold tension on torsion spring while loosening
the setscrews on both ends of torque shaft.
c. Allow torque shaft to rotate counterclockwise,
as far as possible while maintaining control of

Section 5 - General Information 5-5

Operator's Manual
3
Right
2

4
1. Winch Drum
2. Wire Rope
3. Wedge
Figure 5-5 4. Seizings For Type ZB Rope Only (Remove After Installation)
Uncoiling Wire Rope
Figure 5-6
Anchoring Wire Rope to Drum
Uncoiling Wire Rope
1. To avoid twists, unreel the entire rope on the
ground in line with the boom deflector sheave and Anchoring Wire Rope To Drum
drum. Set the reel up horizontally so it can rotate as
the rope is reeled off. Refer to Figure 5-5. Reel the
rope off slowly, so the reel won't tend to “throw” the CAUTION
rope off. If the new rope cannot be laid out on the The ends of type ZB rope must be fuse
ground, further steps are necessary: welded. Failure to do so may cause the core
a. Mount the reel on a shaft through flange holes to slip and/or the strands to loosen causing
and on jack stands, making sure the reel is set serious rope damage.
to be unreeled over the top. Do not allow the
reel to “free‐wheel”. Brake the reel by applying
If crane is equipped with type ZB wire rope, attach
pressure to a flange. Do not apply braking
two seizings (hose clamps are an effective and effi­
pressure to the rope on the reel or pass rope
cient alternative if traditional seizings are not avail­
between blocks of wood or other material.
2. Reeve the rope over the boom deflector sheave able) about 24 inches (609.6mm) from the end with
a 3 inch (76.2mm) space between them. Refer to
and anchor it to the drum.
Figure 5-6. The seizings will prevent any looseness
Note: When replacing wire rope, the sheaves of the outer strands from traveling up the rope dur­
and grooves in drums should be checked for ing installation. Insert the free end of the rope into
wear or damage and replaced if necessary. the small opening of the anchor pocket. Loop the
Damaged, worn, or undersized sheaves will rope and push the free end about ¾ of the way back
damage the rope. On older equipment, remem­ through the pocket. Install the wedge, then pull the
ber that new rope is usually larger in diameter slack out of the rope. If using type ZB rope, remove
than the worn rope it replaces. The sheave the seizings after the rope is secured in the drum.
grooves may be worn to the smaller diameter of Keep tension on the rope to prevent the rope from
the old rope. becoming slack and forming loops or kinks and also
to allow uniform winding on the drum. It is important
A new rope should be broken in by running it
that original rope lay is maintained at all times.
slowly through its working cycle for a short pe­
riod under a light load. Refer to “Rope Break‐In”
found later in this Section of the Operator's
Winding Rope On Drum
Manual. Proper winding of the first layer of rope on a multiple
wrap drum is important. If the first layer is properly
wound, succeeding layers will be easier to control.
This is especially important on ungrooved drums.
When starting new wire rope on such drums, drive
each wrap of the first layer lightly with a wooden mallet
so each wrap barely contacts the preceding one. Keep
tension on the rope to prevent the rope from becoming

5-6 Section 5 - General Information

 Operator's Manual
slack and forming loops or kinks and also to allow uni­
form winding on the drum. It is important that original Right
Wrong
rope lay is maintained at all times.
It's important to apply a tensioning load while spooling
the rope on the drum. (If not, the lower layers may be
loose enough that the upper layers become wedged
into the lower layers under load, which can seriously
damage the rope.) The tensioning load should range
from 1 to 2% of the rope's nominal strength.

Wire Rope Reeving

Hook blocks should be reeved correctly so they hang
straight and do not cause excessive wear on the rope
and sheaves. Refer to Figure 5-7.

WARNING
To avoid personal injury, do not climb, stand,
or walk on the boom or fly. Use a ladder or
similar device to reach necessary areas when Figure 5-7
Hook Block Reeving
reeving the crane.
Only if certain criteria are met may a swivel
hook ball be used with rotation resistant rope. Socket And Wedge Connections
Refer to “Hook Ball Usage With Rotation Re­
sistant Rope” found in this Operator's Manual.

The crane can use multiple parts of line when reeving

WARNING
the main winch, depending on the lift being made and Use the proper size wedge with a wire rope
the number of sheaves available. When reeving the socket or lagging. The use of an off‐size
main winch, odd parts of line dead end at the hook wedge in a socket or lagging is dangerous as
block and even parts dead end at the boom head. The it may not hold. Wedges and sockets shipped
auxiliary lifting sheave may be reeved with either one or from the factory are stamped with size and
two parts of line. The fly section may be reeved with type identification. A lagging or socket may
two parts of line for better line control. Figure 5-14 be stamped for two or more sizes of rope and
and Figure 5-15 gives the proper reeving for various a wedge for one or two. The size on the lag­
parts of line. The reeving patterns illustrated must be ging, socket, and wedge must correspond
used at all times. To determine how many parts of line with the size of rope being used.
to use for a particular lift, check the Wire Rope Capacity
chart and the Winch Performance chart located in the The correct and incorrect methods of attaching a sock­
Crane Rating Manual. et and wedge to wire rope are shown in Figure 5-8.
Note: Do not use a swivel at the dead end of a The dead end of the wire rope must always be on the
multi‐part reeving sloped portion of the socket. The load line must be in a
straight line pull with the eye of the socket. If the rope is
installed wrong as shown in Figure 5-8, a permanent
Note: Rope guards must always be used during op­ set will develop at the point where the rope enters the
erations. They must be pinned in place to prevent socket.
wire rope from jumping off the sheaves.
Before installing type ZB wire rope into a socket or
wedge attach two seizings (hose clamps are an effec­
tive and efficient alternative if traditional seizings are
not available) approximately 3-4 feet (.9-1.2 m) from
the end with a 3 inch (76.2 mm) space between them.
Refer to Figure 5-8.

Section 5 - General Information 5-7

Operator's Manual

Right
Wrong
Right
Wrong

4
2
5

6
3

Figure 5-9
1. Seizings (Type ZB Only) (Remove After Installation) Socket & Wedge Installation
2. Wire Rope Live End
3. Socket
4. Dead End Seizing
5. 20 Rope Diameters Minimum Tail Length
6. Wedge

Figure 5-8
Socket & Wedge Connections

The dead end must also be seized and a minimum tail

length of 20 rope diameters (15 inches for 3/4 inch
rope) is required. The seizings will help prevent core
slippage and any looseness of the outer strands from
traveling up the rope during installation while still allow­
Type RB Type ZB
ing the rope strands to be free to adjust. If using type
ZB rope, remove seizings from the live end after rope is Figure 5-10
securely installed into the socket. Wire Rope Identification
Note: Refer to Figure 5-10 to identify which type of
rope is installed on the crane. Rope Break‐In
After the rope has been installed and the ends secured
CAUTION in the correct manner, the new rope must be run
through a break‐in period. This allows the component
The ends of type ZB rope must be fuse welded parts of the new rope to gradually adjust itself to actual
and the tail length of the dead end must be a operating conditions.
minimum of 20 rope diameters (15 inches for 1. Level the crane on fully extended outriggers with all
3/4 inch rope). Failure to do the above may tires clear of the ground. Swing the upper over the
cause the core to slip and/or the strands to front of the carrier and engage the travel swing
loosen causing serious rope damage. lock.
2. Fully raise and fully extend the boom. Attach a light
When anchoring the socket to the boom head, make load at the hook and raise it a few inches off the
sure the flat face is facing out as shown in Figure 5-9. ground. Allow to stand for several minutes.
If socket is not installed correctly structural damage to 3. Run the rope through a cycle of operation at very
the boom head may occur. slow speeds. During this trial operation, a very
It is recommended that the wire rope socket and close watch should be kept on all working parts-
wedge connection be reestablished on an annual ba­ sheaves, drums, roller, etc. to make certain that the
sis. This can be accomplished by cutting the rope 6” rope runs freely, and without any possible obstruc­
(.15m) above the socket and wedge connection. (See tions as it makes its way through the system.
“Cutting Wire Rope” found in this section of this Opera­
tor's Manual). Install the socket and wedge connection
as shown in Figure 5-8.

5-8 Section 5 - General Information

 Operator's Manual

The Double‐Saddle‐Clip Method The Loop Back Method

Figure 5-11
Wire Rope Socket With Clip

Note: Run these loads with reeving that places has tension on it, opposing rotational forces are
the loads on the block with all rope off the drum created between the core and outer strands. If a swivel
except the last three wraps. If this is not pos­ hook ball is utilized with rotation resistant rope, the
sible, alternate methods must be used to assure rope is allowed to twist. The outer strands unwind and
proper tensioning of the rope on the drum. get longer while the inner core is forced to rotate in the
same direction and shortens in length. As a result of
4. If no problems appear in running the rope, repeat this treatment, the inner core sees a disproportionately
procedure with an increased load. greater load, and core damage may occur due to
shock loading or overloading. A rotating load on an un­
Single Part Line Hoisting restrained, non‐swivel hook ball without a tagline, af­
fects the internal loading of the rope in this manner.
Non‐rotating, rotation‐resistant, or spin‐resistant wire This practice, or any other which allows the rope to ro­
ropes are recommended for single part of line applica­ tate while in service, leads to unbalanced loading be­
tions. This is of utmost importance for long fall hoist line tween the inner and outer layer of strands, which may
applications. Link‐Belt type “RB”, “ZB”, and “GC” are result in core failure. Wire rope manufacturer's testing
examples of ropes recommended for single part hoist­ has shown that rotation resistant rope utilized with a
ing. See the Wire Rope Capacity Chart in the Crane swivel hook ball has reduced the breaking strength by
Rating Manual for the specific types of rotation resist­ as much as 50% if excessive rotation occurs.
ant wire rope recommended for your crane.
The use of non‐rotation resistant rope is not recom­ Rope Inspection
mended for long falls of single part of line hoisting since
Marked reduction in diameter indicates deterioration of
the rope and load may spin. If the crane operator al­
the core resulting in lack of proper support for the load
lows either the load or the rope to rotate, the crane or
carrying strands. Excessive rope stretch or elongation
rope can be damaged. The anti‐two block weight may
may also be an indication of internal deterioration. Ma­
also become entangled with the wire rope and could
jor concerns and replacement recommendations in­
damage the anti‐two block system, wire rope, and/or
clude:
head machinery.
1. Loss of rope diameter (in excess of those listed in
the table in the “Wire Rope Replacement” section
Rotation Resistant Wire found earlier in this Operator's Manual), abnormal
lengthening of rope lay, or protrusion of wires be­
Rope tween the outer strands.
The rotation resistant characteristic is achieved by lay­ 2. 2 randomly distributed broken wires in 6 rope di­
ing the outer strands around an independent wire rope ameters, or 4 randomly distributed broken wires in
that is wound in the opposite direction. When the rope 30 rope diameters.

Section 5 - General Information 5-9

Operator's Manual
Minimum No. Amount OF Rope
Clip Size Torque
of Clips To Turn Back*
Inches mm Quantity Inches mm ft lb Nm
1/4 3.2 2 3‐1/4 82.5 --- ---
3/16 4.7 2 3‐3/4 95.2 --- ---
1/4 6.3 2 4‐3/4 120.6 15 20.0
5/16 7.9 2 5‐1/4 133.3 30 40.7
3/8 9.5 2 6‐1/2 165.1 45 60.1
7/16 11.1 2 7 177.8 65 86.8
1/2 12.7 3 11‐1/2 292.1 65 86.8
9/16 14.3 3 12 304.8 95 126.9
5/8 15.9 3 12 304.8 95 126.9
3/4 19.0 4 18 457.2 130 173.6
* If a greater number of clips are used than shown in this table, the amount of rope turnback should be increased proportionally.

Figure 5-12
Wire Rope Clip Application Recommendation

Hook Ball Usage With Rotation

Resistant Rope WARNING
Regularly inspect the integrity of the wire rope
Non‐Swivel Usage at the point of exit at the dead end side. High
A non‐swivel hook ball in conjunction with a tagline or velocity spin of wire rope when loading and
other device to control load spin should be used when unloading can cause the rope to flip‐flop, fa­
the crane is equipped with rotation resistant wire rope. tigue, and finally break off.
This is to avoid unrestrained rotation of the wire rope.
The use of wire rope clips with a socket and wedge
Swivel Usage connection can weaken the connection if done improp­
A swivel hook ball can be used with rotation resistant erly. Do not attach the dead end of the rope to the live
rope if: side with the clip as this will seriously weaken the con­
1. The wire rope is not shock loaded or overloaded. nection. The clip may ultimately take the load and may
2. Wire rope working strength is reduced to maintain deform or break the rope.
original design factors. If using the loop back method, the loop formed must
3. The wire rope is inspected frequently as outlined not be allowed to enter the wedge, or the connection
below. will be weakened. The tail length of the dead end must
be a minimum of 20 rope diameters (15 inches for 3/4
Wire Rope Sockets With Clips inch rope).

Some codes require the use of a wire rope clip in con­

junction with a socket and wedge connection. CAUTION
Figure 5-11 illustrates some typical methods of clip The ends of type ZB rope must be fuse welded
installation with sockets. In some cases, particularly in and the tail length of the dead end must be a
wrecking ball work, there is a chance that the wedge minimum of 20 rope diameters (15 inches for
can loosen, releasing the socket from the rope. This 3/4 inch rope). Failure to do the above may
could be caused by the banging action and alternate cause the core to slip and/or the strands to
loading and unloading of the rope that occurs during loosen causing serious rope damage.
this type work.

5-10 Section 5 - General Information

 Operator's Manual
Wire Rope Clip Installation Right
The correct method of installing wire rope clips is
shown in Figure 5-13. The u‐bolt must always be over
the short end of the wire rope and the base must al­
ways contact the long end.
Clips should NOT be staggered, that is u‐bolt of one
clip over short end and u‐bolt of next clip over long end.
This practice will not only distort the wire rope exces­
sively, but will prevent maximum strength of this type
fastening. Placing all clips with the u‐bolt over the long
end of the wire rope will damage strands and result in
an unsafe condition.
The distance between clips should be not less than six
times the wire rope diameter. In relation to size of wire
rope, the minimum number of clips recommended for
safe connections is given in Figure 5-12.
Wrong

CAUTION
Apply the initial load and retighten nuts to the Figure 5-13
recommended torque. Rope can stretch and Wire Rope Clip Installation
reduce in diameter when loads are applied.
Inspect periodically and retighten as re­
quired.

Cutting Wire Rope

CAUTION
The ends of type ZB rope must be fuse
welded. Failure to do so may cause the core
to slip and/or the strands to loosen causing
serious rope damage.

When wire rope is to be cut, seizings should be placed

on each side of the point where the rope is to be cut, to
keep the strands in place. On preformed rope such as
type RB, one seizing on each side of the cut is enough.
On non‐preformed rope less than 7/8 inch (23mm) di­
ameter such as type ZB, two seizings are recom­
mended. On non‐preformed rope over 7/8 inch
(23mm) diameter, three seizings are recommended.
Original rope lay must be maintained at all times.
Three Basic methods of cutting wire rope are recom­
mended:
1. Abrasive cutting tools.
2. Shearing tools. (Wire cutters on small rope, a wire
rope cutter and hammer for larger ropes.)
3. Oxy/acetylene fuel torch. This is the only sug­
gested method for cutting type ZB rope.

Section 5 - General Information 5-11

Operator's Manual

3 Parts
1 Part 2 Parts 4 Parts

5 Parts 6 Parts 7 Parts 8 Parts

10 Parts 11 Parts
9 Parts

Auxiliary Sheave
2 Parts
12 Parts
Note: Some of the diagrams shown may not apply to this particular crane.
Note: Do not use a swivel at the dead end of a multi‐part reeving

Figure 5-14
Wire Rope Reeving Diagrams

5-12 Section 5 - General Information

 Operator's Manual

Auxiliary
Deflector Sheave
Sheaves

Head Sheaves

Rear Drum

Front Drum

Hook Block

Note: Reeving shown is typical. Either drum may be reeved over head sheaves or auxiliary sheave.

Figure 5-15
Wire Rope Reeving Diagrams

Section 5 - General Information 5-13

Operator's Manual
Crane Specifications
The following information is general in nature and is used for reference purposes only. Depending upon the vintage
of the crane, some features may no longer be available. Standard and optional features may vary from crane to
crane. Consult the factory to verify the specific information if required.

47’ 10”
(14.58m)
40’ 1.63”
(12.23m)
CL Rotation
8’ 6.56”
(2.61m)
12’ 10”
(3.90m)

12’ 2”
(3.71m)

12’ 11.63” 13.75”

(3.95m) (0.35m)

7’ 1.88”
(2.18m)
5’ 10.5”
(1.79m) 27_
27_

15_

15_ 8’ 0.5” 2’ 0” (0.61m)

2’ 5” (2.45m)
(0.73m) 8’ 0.5”
(2.45m) 13’ 0”
13’ 0”
(3.96m) (3.96m)

15’ 4.88” 15’ 4.88”

(4.70m) (4.70m)
w/o outrigger box − 12’ 4.88” (3.68m) w/o outrigger box − 12’ 4.88” (3.68m)
12’ 0”
(3.65m)
9’ 11”
(3.02m) General Dimensions feet metric
Turning Radius (4−wheel steer −centerline
of tires 21’ 6.4
Turning Radius (2−wheel steer −centerline
of tires 35’ 10.67
Turning Radius (4−wheel steer − outside
front outrigger box 25’ 6” 7.77
Turning Radius (2−wheel steer − outside
17.75” front outrigger box 37’ 0” 11.28
(0.45m)
Tailswing of counterweight 12’ 10” 3.90

7’ 7.38” (2.32m)
Centerline of tires
10.29”
(0.26m)
11’ 2” (3.40m)
Full Retraction 28”
(0.71m)

18’ 7” (5.66m)
Intermediate Extension

26’ 0” (7.93m)
Full Extension

Upper Structure
Boom
Formed Construction Design
S U−shaped boom utilizes formed plates to resist buck- Standard Boom
ling using high strength 130,000 psi (896mPa) steel. S 40’ − 150’ (12.19 − 45.72m) five−section full power
Increased wear pad area for improved load distribu- boom.
tion and longer life.

5-14 Section 5 - General Information

 Operator's Manual
S Standard mode is the full power, synchronized S Audible swing alarm S Mirrors
mode of telescoping all sections proportionally. S Warning horn S Top hatch window wiper
S A−max 1 mode (or mode ‘A1’) extends only the in- S Backup alarm S Cup holder
ner and center sections to 95’ (29m) offering in- S Travel lights S Fire extinguisher
creased capacities for in−close, maximum capacity S 12−volt accessory outlet SCirculating fan
picks. S Sun screen S Windshield washer
S A−max 2 mode (or mode ‘A2’) tip, outer, and center S Electric windshield wiper
sections extend to 122.5’ (37.34m) offering maxi- Optional
mum stability. S Amber strobe light
S Mechanical Boom Angle Indicator S Hot water cab heater
Boom Head S Amber rotating beacon
S Six, 16.38” (0.42m) root diameter nylon sheaves han- S Air conditioning
dle up to twelve parts of wire rope. Controls
S Quick−reeve design Hydraulic controls (joystick type) for:
S Rope dead end lugs provided on each side of boom S Front winch
head S Boom hoist
S Easily removable wire rope guards S Optional rear winch
S Fly pinning alignment tool S Swing
Boom Elevation S Drum rotation indicators
S One Link−Belt designed hydraulic cylinder with holding S Single−axis controls − optional
valve and bushings in each end. S Hand−held outrigger controls and sight level bubble
S Hand control for controlling boom elevation from −3_ also provided in upper cab.
to 80_. Foot controls for:
Optional Auxiliary Lifting Sheave S Boom telescope
S Single 16.38” (0.42m) root diameter nylon sheave S Swing brake
with removable wire rope guard. S Engine throttle with throttle lock
S Use with one or two parts of line. S Service brake
S Does not affect erection of fly or use of main head Cab Instrumentation
sheaves for multiple reeving. Corner−post mounted gauges with integral
Optional audio/visual warning system for:
S 100−ton (90.72mt) 6−sheave, quick reeve hook block, S Tachometer
with safety latch S Voltmeter
S 80−ton (72.57mt) 5−sheave, quick reeve hook block S Oil pressure
with safety latch S Fuel
S 12−ton (10.89mt) hook ball (swivel) with safety latch S Hydraulic oil temperature
S Boom floodlight S Water temperature

Fly Rated Capacity Limiter

Optional S MicroGuard Graphic audio−visual warning system
S 31’ − 55’ (9.45 − 16.76m) two−piece (bi-fold) stow- built into the corner post with anti−two block and func-
able, offsettable to 2_, 25_ or 45_. tion limiters.
S Two, 15’ (4.57m) fly extensions provide a total fly S Anti−two block weight designed for quick reeve of
length of 85’ (25.9m). hookblock.
Operating data available includes:
Cab and Controls S Machine configuration S Head height
Environmental ULTRA CABt S Actual load S Radius of load
S LCF−2000 construction process featuring laminated S Boom length S % of allowed load
fibrous composite material. S Boom angle S Allowed load
S Isolated from sound with acoustical vinyl insulation. Presettable alarms include:
S Six−way adjustable operator’s seat with retractable S Maximum and minimum boom angles.
seat belt. S Maximum tip height.
S Four−way adjustable tilting−telescoping and locking S Maximum boom length.
steering wheel. S Swing left/right positions.
S All windows are tinted and tempered safety glass. S Operator defined area alarm is standard.
S Slide-by door opens to 3’ (0.91m) width.
S Sliding rear and right side windows and swing up roof
window for maximum visibility and ventilation.

Section 5 - General Information 5-15

Operator's Manual
Optional S O−Ring Face Seal (ORFS) technology throughout
S Internal RCL light bar: Visually informs operator with hydraulic oil cooler.
when crane is approaching maximum load capacity Reservoir
(kickouts and presettable alarms) with a series of S 255 gal. (965 L) capacity. Diffuser for deaeration.
green, yellow, and red lights.
Filtration:
S External RCL light bar: Visually informs ground
S One 7−micron filter located inside hydraulic reser-
crew when crane is approaching maximum load ca-
voir.
pacity (kickouts and presettable alarms) with a series
S Accessible for easy replacement.
of three lights; green, yellow, and red.
S One 7−micron charge filter located next to the reser-
Swing voir with an in−cab indicator light
S Bi−directional hydraulic swing motor mounted to a Control Valves:
planetary reducer for 360_ continuous smooth swing at S Five separate, pilot operated control valves allow si-
1.5 rpm. multaneous operation of all crane functions.
S Swing park brake − 360_ electric over hydraulic S All control valves are pressure compensated for im-
(spring applied, hydraulic released) multi−disc brake proved metering.
mounted on the speed reducer. Operated by switch S Adjustable fine metering control on winch, boom
in left hand controller. hoist, and swing functions.
S Swing brake − 360_, foot operated, hydraulic ap-
plied disc brake mounted on the speed reducer. Load Hoist System
S Swing lock − Standard; two position travel lock op- Standard
erated from the operator’s cab. S 2M front winch with grooved lagging.
S Counterweight − 24,000 lbs. (10 886kg) hydrauli- S Two−speed motor and automatic brake.
cally removable modular components. Capacities for S Power up/down mode of operation.
0 (0kg) and 12,000 lbs (5 443kg) also available. S Controls for future addition of rear winch.
Optional S Bi−directional, piston−type hydraulic motor, driven
S 360_ pawl−in−gear swing lock (meets New York City through a planetary reduction unit for positive opera-
requirements). tor control under all load conditions.
S Asynchronous parallel double crossover grooved
Hydraulic System drums minimize rope harmonic motion.
S Rotation resistant wire rope.
Main Pumps
S A Two−section gear pump, mounted to a mechanical Line Pulls and Speeds
pump drive, driven by the diesel engine supplies hy- S Maximum line pull 21,000 lbs. (9 525kg) and maxi-
draulic power for the boom hoist, telescope, and mum line speed of 430 f.p.m. (131m/min) on stan-
charge circuits. Section one can deliver 47 gpm at dard 15” (0.38m) root diameter grooved drum.
4,400 psi and section two can deliver 38 gpm at 4,400
psi. Optional
S Two, closed−loop piston pumps are mounted to a S 2M rear winch with two−speed motor, automatic
mechanical pump drive, driven by the diesel engine brake, grooved lagging, and power up/down mode of
and serve as travel pumps. These two pumps supply operation.
hydraulic power to the wheel motors and are capable S Hoist drum cable followers.
of delivering 88 gpm at 6,090 psi each. S Third wrap indicators.
S Two closed loop piston pumps are mounted to the
rear of the two travel pumps. The left pump drives the Carrier
front winch and the right pump drives the optional
rear winch. Each pump is capable of delivering 49 Type
gpm at 4,150 psi. S 9’ 11” (3.02m) wide, 156.75” (4.19m) wheelbase.
S A pressure compensated piston pump mounted to S 6 x 6 x 6 − (6−wheel steer, 6−wheel drive) for rough
the rear of the left winch pump supplies hydraulic terrain with limited turning area.
power to the outrigger, counterweight removal (op- Frame
tional), oscillation, and travel brake circuits. This S 100,000 psi (689.5mPa) steel, torsion resistant,
pump can deliver 21 gpm at 3,000 psi. single−box construction.
S A single section gear pump mounted to the rear of the S Integral 100,000 psi (689.5mPa) steel outrigger
right side winch pump supplies hydraulic power to the boxes.
swing and steering circuits. This pump can deliver 27
gpm at 3,000 psi.

5-16 Section 5 - General Information

 Operator's Manual
Standard Carrier Equipment Steering
S One front, one rear, and two mid−point carrier ladders S Hydraulic front−wheel, rear−wheel, coordinated six−
S Non−slip safety strips on carrier deck wheel, and six−wheel “crab” steering
S Full deck fenders S Modes selected by rotary switch on overhead con-
S Pontoon storage sole.
S Full lighting package S All modes are fully coordinated and controlled by
S Front towing shackles steering wheel.
S Hook block tie back
Optional
S Carrier mounted mirrors
S Rear steer indicator
Optional
S Front and rear mounted pintle hook Tires
S Hydraulic power pinning outrigger boxes
Front and Rear
Engine S Standard 23.5R25 2−Star radials.
Optional
Engine Detroit Diesel S Spare tires and rims
Series 40

Cylinders − cycle 6−4

Brakes
Bore 4.59 in. (116.59mm) Service
Stroke 5.35 in. (135.89mm)
S Two fully hydraulic caliper disc−type brakes at each
Displacement 530 cu. in. (8.69 L)
Maximum brake hp 300 @ 2,000 rpm wheel end with independent front and rear system.
Peak torque (ft. lb.) 1,050 @ 1,300 rpm Controlled by foot pedal in cab.
Electric system 12 volt Parking/Emergency
Starting system 12 volt
Fuel capacity 95 gallons (360 L)
S Spring applied, hydraulic released, cab controlled,
Alternator 130 amps wet, multiple disc−type integral to the front wheel
Crankcase capacity 28 qts. (26.5 L) drive motors.
(total system)
Outriggers
S Water/fuel separator on engine
S 110−volt block heater S Three position operation capability.
S Optional − Ether injection package S Four hydraulic, telescoping beam and jack outrig-
gers.
S Vertical jack cylinders equipped with integral holding
Transmission valve.
S Hydrostatic type consisting of two variable speed S Beams extend to 26’ (7.93m) centerline−to−center-
piston pumps supplying hydraulic power to six hy­ line and retract to a 12’ (3.6m) width.
draulic cam lobe wheel drive motors computer con­ S Equipped with stowable, lightweight 26” (0.66m)
trolled for smooth and reliable operation. round steel pontoons.
S Hand−held controls and sight level bubble located in
Axles upper structure cab.
S Six heavy−duty Link−Belt fabricated axle housings Confined Area Lifting Capacities (CALCt) System
that support the wheel drive motors and connect to S Three operational outrigger configurations are avail-
the steering and suspension system. able:
S Full extension − 26’ (7.93m)
Suspension S Intermediate position − 18’ 7” (5.66m)
S Fully independent double “A” Arm construction with S Full retraction − 11’ 2” (3.22m)
automatic axle oscillation S For confined area operation, rated lifting capacities
are provided for the intermediate and fully retracted
outrigger positions.
S When the outrigger position levers (located on the
outrigger beams) are engaged, the operator can set
the crane in the intermediate or full retraction outrig-
ger position without leaving the cab.

Section 5 - General Information 5-17

Operator's Manual
Travel Speeds and Gradability
With outrigger boxes and counterweight Without outrigger boxes and counterweight

Tires 23.5R25 2−Star radials Tires 23.5R25 2−Star radials

Maximum Speed 18.5 (29.77km/h) Maximum Speed 18.5 (29.77km/h)

Gradability at 1.0 mph 50% Gradability at 1.0 mph 88%

(1.6km/h) (1.6km/h)

Maximum Tractive Effort at 1.0 61,180 lbs. (27 751kg) Maximum Tractive Effort at 1.0 61,180 lbs. (27 751kg)
mph. (1.6km/h) mph. (1.6km/h)

Travel Load
Max. Axle Load @ 20 mph
Tire
(32.20 km/hr)

23.5R25 2−Star 57,300 lbs. (25 991kg)

Transport Configuration And Weights

A

Total Weight: 89,365 lbs. (40 536kg), equipped with: Axle Group Weights B
S 40’ − 150’, Five−Section Boom
S 80−ton Hookblock Truck Wt. Bed Length Steer Drivers Trailer A
S One winch with 850’ of 7/8” rope 45,200 lbs. 24’ 10,068 lbs. 58,030 lbs. 66,400 lbs. 10.5”
S 31’ − 55’ Bi−fold fly (20 502kg) (7.32m) (4 561kg) (26 129kg) (29 816kg) (0.27m)
S Ether injection system
S Hot water cab heater
S Air Conditioning 54,200 lbs. 34’ 10,101 lbs. 59,280 lbs. 74,185 lbs. 50.5”
S Tow Shackles (24 585kg) (10.36m) (4 577kg) (26 700kg) (33 340kg) (1.28m)
S Pintle Hooks
B − 18” (0.46m) or 24” (0.61m)
Drop Off Load Weight: 41,642 lbs. (18 889 kg)
S Two outrigger boxes Normal Suspension Collapsed Suspension
S 24,000 lbs (10 886kg) Counterweight C (with 18” Trailer Height) 13’ 8” (4.17m) 13’ 5” (4.09m)
S Two, 15’ (4.57m) Fly Sections C (with 24” Trailer Height) 14’ 2” (4.32m) 13’ 11” (4.24m)

5-18 Section 5 - General Information

 Operator's Manual
Axle Loads
Base crane with standard 40’ − Upper facing front Upper facing rear
150’ (12.19 − 45.72m) five−sec-
tion boom, 2M main winch with G.V.W.

2−speed hoisting and power up/ Front axle Rear axle group Front axle Rear axle group
down, 850’ (259m) of 7/8”
(22mm) wire rope. 6x6x6 carrier
with Detroit Diesel Series 40 en- lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg.
gine, 23.5R25 tires, 95 gals. (360
L) of fuel, tow shackles, hook
block tieback, and 24,000 lbs. 125,000 56 700 39,430 17 885 85,570 38 814 56,870 25 796 68,130 30 903
(10 886kg) of counterweight.
Remove outrigger boxes and
beams −15,960 −7 239 −6,035 −2 737 −9,925 −4 502 −6,035 −2 737 −9,925 −4 502

Remove main counterweight −24,182 −10 969 12,928 5 864 −37,110 −16 833 −31,518 −14,296 7,336 3 328
Cold weather start aid − ether in-
jector 19 9.5 −2 −0.9 21 10 −2 −0.9 8 4

Pintle hook, front 20 9 29 13 −9 −4 29 13 −9 −4

Pintle hook, rear 20 9 −9 −4 29 13 −9 −4 29 13
Rear steer indicator 10 4.5 −2 −1 12 5 −2 −1 12 5
Winch roller − rear winch 110 50 −82 −37 192 87 166 75 −56 −25
Winch roller − front winch 94 42 −42 −4 141 64 119 54 −25 −11
2M Auxiliary Winch 1,700 771 −1,143 −518 284 1,289 2,449 1 110 −749 −348
500’ (152m) of 7/8” (22mm) wire
rope on auxiliary winch 862 391 −579 −263 1,441 518 1,242 563 −380 −172

Cab heater 10 4.5 8 3.6 2 1 0 0 10 4.5

Air conditioning in operator’s cab 120 54 48 22 72 33 44 20 76 34
360 degree swing lock 139 63 35 16 104 47 71 32 68 31
Fly brackets to boom base sec-
tions for fly options 277 126 372 169 −95 −43 −159 −72 436 198

31’ − 55’ (9.45 − 16.76m) offset

fly (stowed) 2,632 1 194 4,223 1 916 −1,591 −722 −2,200 −998 4,832 2 192

Floodlight to boom base section 10 5 26 12 −16 −7 −18 −8 28 13

100−ton (90.72mt) capacity hook
block to front/rear bumper 1,750 794 2,537 1 151 −787 −357 −1,192 −541 2,942 1 334

80−ton (72.57mt) capacity hook

block to front/rear bumper 1,411 640 2,046 928 −635 −288 −961 −436 2,372 1 076

12−ton (10.9mt) capacity hook

ball to front/rear bumper 722 327 1,047 475 −325 −147 −492 −223 1,214 551

Auxiliary lifting sheave 120 54 347 157 −227 −103 −254 −115 374 170

− Adjust gross weight and axle loading according to component weight. Note: All weights are  3%.

Section 5 - General Information 5-19

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5-20 Section 5 - General Information

 Operator's Manual
Table Of Contents
Fundamental Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Section 6 - Fundamental Terms i

Operator's Manual

ii Section 6 - Fundamental Terms

 Operator's Manual
Auger: A boom attachment used to drill holes into the
Fundamental Terms ground.
Many terms are used which refer to crane function, as­ Automatic Brake: Drum brake system that is applied
sembly, operation, and maintenance. The following list automatically any time the drum control lever is in neu­
gives a brief definition as to how the terms are used in tral.
Link‐Belt technical literature.
Auxiliary Lifting Sheave: A unit which connects to the
A‐frame Jib: The outer most attachment on a hydraul­ boom head machinery cross shafts and is used for reev­
ic boom, made of structural channel steel, which is ing winch wire rope for a second (auxiliary) winch drum.
connected to the fly section and is supported by pen­
dants. Auxiliary Transmission (Creeper Transmission): An
additional transmission used in the carrier to provide a
ABS: Anti-Lock Braking System or American Bureau low gear ratio for slow, careful movement around the
of Shipping job site and higher ratios for normal use.
Accumulator: A container in which fluid is stored un­ Backstop: A device used to limit the angle of the
der pressure as a source of hydraulic energy. boom, jib, or mast at the highest recommended angle.
Aeration: The condition when air is present in the hy­ Backward Stability: Resistance to overturning of the
draulic fluid. This causes the fluid to appear milky and crane in a rearward direction.
components to operate erratically because of the com­
pressibility of air trapped in the fluid. Bail (Hanger): A frame equipped with sheaves. The
bail is used in conjunction with the hoist drum(s) and
Aerial Platform: A work platform attached to the main bridle(s) to alter the crane's main boom, luffing boom,
boom head shaft, approved for personnel handling. and/or luffing jib angle.
Anemometer: An instrument for measuring the direc­ Balance Arm: An assembly that attaches to the top of
tion and force, or velocity, of the wind; a wind gauge. the luffing boom and is connected to the live mast with
pendants. It provides a point to attach the luffing jib
Angle Jib: A multiple section steel angle iron boom tip
and luffing jib strut. It also contains a bail assembly for
extension supported by pendants.
luffing jib hoist reeving.
Annually: Once a year
Band Brake: Circular external contracting type brake
Anti‐Lock Braking System (ABS): A system that al­ having a strap lined with heat and wear resistant friction
lows the wheels on the crane to maintain tractive con­ material.
tact with the road surface, preventing the wheels from
Bar Pendants: Pendants fabricated from high
locking up (ceasing rotation) and avoiding uncon­
strength steel plate vs. the normal multi‐wired wire rope
trolled skidding.
pendants.
Anti‐Two Block System (ATB): A system of electro­
Base Section: 1. The segment of a telescoping boom
mechanical devices used to prevent the crane operator
that attaches to the upper frame by the boom foot pin.
from two blocking the crane. Also see “Two Block”.
2. The lower most section of a lattice boom, tower
API: American Petroleum Institute boom, or luffing boom. 3. The lower most section of
any fly or jib.
ATB: Anti‐Two Block
Basic Boom: Lattice boom attachment made up of
ATC: Hydraulic All Terrain Crane only the base and top sections of the boom.
Attachment: 1. The boom assembly, fly section, offset Basic Jib: Jib attachment made up of only the base
fly section, telescoping fly section, tubular jib, A‐frame and top sections of the jib.
jib, or the combination of them. 2. The lattice boom as­
sembly and either an angle jib or tubular jib or the com­ Boom: 1. The assembly of the base and one or more
bination of both. sections (inner power, inner mid, middle, center, outer
power, outer mid, T1 through T7, manual, tip, etc.)
Audio/Visual Warning System: 1. Alarm device that used as the telescoping extension for a two, three, four,
signals the operator of low engine oil pressure, high en­ five, six, or seven section hydraulic attachment. 2. Lat­
gine coolant temperature, and high hydraulic oil and tice structure consisting of multiple sections, pinned or
transmission oil temperature. 2. Device utilizing buzz­ bolted together to a specific length, and their support
er and/or lights as a signal of approaching two block system.
and/or overload condition. See “Rated Capacity Indic­
ator”.

Section 6 - Fundamental Terms 6-1

Operator's Manual
Boom Angle: The angle above or below horizontal of Carrier: The portion of the crane below the turntable
the longitudinal axis of the boom. bearing.
Boom Angle Indicator: An accessory which meas­ Carrier Cab: A housing which covers the driver's sta­
ures the angle of the boom relative to horizontal. tion on the carrier of a truck crane.
Boom Chord: A main corner structural member of a Carrier Frame: The main structure of the carrier sec­
boom. tion of the crane.
Boom Foot: Base of boom where it attaches to the up­ Carrier Roller: Rollers of track mechanism which are
per revolving frame. not power driven but are used to guide the track along
the top of the side frame.
Boom Hoist: 1. The hydraulic method of raising and
lowering the boom to different boom angles. 2. Wire Catwalk: Platforms attached to the crane that provide
rope drum and its drive, or other mechanism, for con­ a walkway along the side of the upper.
trolling the angle of the boom.
Cavitation: A condition where air is introduced into a
Boom Lattice: Structural truss members at angles to, cavity, line, or chamber normally filled with oil. This
and supporting, the boom chords of a boom. condition can cause damage to pumps, cylinders,
valves, etc.
Boom Length: The distance from a straight line
through the centerline of the boom foot pin to the cen­ Center Section: See “Middle Section”.
terline of the boom head sheave shaft, measured along
the longitudinal axis of the boom. Check Valve: A valve which permits flow in one direc­
tion only.
Boom Section: 1. The base, inner power, inner mid,
middle, center, outer power, outer mid, T1 through T6, Chord: A main corner structural member of a lattice
manual, tip, etc. segments which are used as part of a boom, fly, or jib section.
telescoping attachment. 2. Individual lattice structures Circuit: A complete or partial path over which electrical
which are pinned together to form the boom attach­ current, air, or hydraulic fluid may flow.
ment. Lattice booms are usually in two basic sections,
top and base. Such booms may be lengthened by in­ Clamshell Bucket: A device consisting of two or more
sertion of one or more additional extension sections. similar scoops hinged together and used for digging
and moving material.
Bridle: A frame equipped with sheaves. The bridle is
used in conjunction with the hoist drum(s) and bail(s) Closed Center Circuit: A circuit where the fluid only
to alter the crane's main boom, luffing boom, and/or flows through the main control valves when a control
luffing jib angle. valve spool is actuated. This can be done two different
ways: (1) using a pressure compensated pump or (2)
Bumper (5th) Outrigger: An outrigger mounted on using a fixed displacement pump, unloading valve,
the front of the carrier that provides additional stability and an accumulator.
for “On Outrigger” capacities when deployed.
Closing Line: The wire rope reeved from the hoist
Bypass: A secondary passage of fluid, air, or electrical drum to control closing of the clamshell bucket.
flow, in addition to the main flow path.
Clutch: A friction, electromagnetic, hydraulic, or pneu­
Cab Walk: Platform attached to the operator's cab that matic device for engagement or disengagement of
provides a walkway along the side of the cab. power.
CALC: Confined Area Lifting Capacities Collector Ring (Slip Ring): A device used to transmit
Cantilever: Any unsupported boom or jib section that the electrical power from the carrier to the upper utiliz­
projects beyond the supporting point. ing a rotating disk to allow rotation of the upper and
maintain connectivity.
Capacity Chart: The plate or plates on the crane or
charts in the Crane Rating Manual which gives rated Compressibility: The change in volume of air, fluid, or
lifting capacities for the crane under different load gas when it is subjected to a unit change in pressure.
conditions, crane configurations, and setups. Concrete Bucket: Bucket for handling wet concrete,
Carbody: The crawler lower upon which the upper re­ fitted with bail or bridle, usually handled on lifting crane
volving frame is mounted. for hoisting to dumping location.

6-2 Section 6 - Fundamental Terms

 Operator's Manual
Conical Roller: A device which attaches the upper to Drag Rope (Inhaul Rope): Wire rope for pulling in
the carrier and allows the upper to rotate on the carrier. bucket during dragline operations.
Counterbalance Valve (Holding Valve): A valve Dragline: Cranes with dragline attachments are gen­
which regulates fluid flow by maintaining resistance in erally used to excavate material from below the grade
one direction, but allows free flow in the other direction. on which the crane is placed. A dragline bucket is
loaded by the drag rope pulling it toward the crane, is
Counterweight: Weight used to supplement the lifted and carried by the hoist wire rope reeved over the
weight of the crane in providing stability for lifting loads. boom point sheave, and is balanced by the dump wire
Cracking Pressure: The pressure at which a pressure rope interconnecting the drag and hoist wire ropes.
actuated valve begins to open to allow flow. Drive Chain: Chain used to transfer power from the
Crane Configuration: The relative position and ar­ horizontal traction shaft to the track drive sprocket.
rangement of the parts or elements of the crane e.g. Driver Controlled Differential Lock: A driver oper­
amount of counterweight, attachment position, outrig­ ated device which locks the differential gears to pre­
ger position, side frame position, etc. vent wheel spin and provide better traction on slick sur­
Crane Rated Capacity: The maximum weight allowed faces.
to be lifted with the crane setup in a particular crane Drum Lagging: See “Winch Drum”.
configuration.
Drum Rotation Indicator: A device that is used to indi­
Crane Rating Manual: A compilation of the necessary cate winch drum motion and can also be used to moni­
information needed to plan lifts with the crane. It in­ tor speed.
cludes instructions such as the allowable Lifting Capa­
city charts, Working Range diagrams, Working Area Engine Cooling Package: Typically consists of the ra­
diagram, etc. diator, surge tank, and engine fans. Can also include
such components as the hydraulic oil cooler, transmis­
Crane Set Up: The act or instance of preparing the sion oil cooler, and charged air cooler.
crane for operation which entails the positioning of the
crane and its elements. It concerns such details or Event Data Recording (EDR): May be one or more
items such as finding a suitable location to perform the devices that monitor and/or control the crane's per­
lift, setting the outrigger position, leveling, cribbing or formance. These devices can record crane operation,
blocking of the crane, etc. configuration, and function.
Crawler Lower: The portion of a crawler crane below Extension (Boom Or Jib): Sections of the boom or jib
the turntable bearing. which come in various lengths and are used to in­
crease the overall length of the boom or jib.
Creep: Crane movement limited to 200 ft (60.96m) in a
30 minute period, and not to exceed 1 mph (1.6km/h) Fairleader: A combination of sheaves and or rollers
maximum speed. mounted at the front of the crane to guide the drag wire
rope.
Creeper Transmission: See “Auxiliary Transmission”.
Fan Post: An assembly that attaches to the luffing
Cylinder: A device which converts fluid power into me­ boom cap and controls the movement of the luffing jib.
chanical force and motion. It usually consists of a The front fan post provides a connection for the luffing
moveable element such as a piston and piston rod, jib pendants. The rear fan post is connected to the luf­
which operates within a cylindrical bore. fing jib's floating bridle with pendants. Center links are
Data Logging: See “Event Data Recording”. used to connect the front and rear fan posts.

Delivery: The volume of fluid discharge by a pump in a Filter: A device which functions to remove insoluble
given time, usually expressed in gallons per minute contaminants from a fluid by a porous media.
(gpm) or liters per minute (L/min). Fixed Jib: A jib that is attached to the end of the luffing
Derricking: Operation of changing boom angle in a jib.
vertical plane. See “Boom Hoist”. Float: See “Pontoon”.
Displacement: The quantity of fluid which can pass Flow Divider: A valve which divides a flow of oil into
through a pump, motor, or cylinder in a single revolu­ two circuits.
tion or stroke.
Fly Base (Fly Base Section): The lower most section
Double Acting Cylinder: A cylinder in which fluid of the fly.
force can be applied in either direction.

Section 6 - Fundamental Terms 6-3

Operator's Manual
Fly Extension: A fly section, other than the base or tip Grouser: Projecting lugs attached to, or integral with,
section, used to increase the overall length of the fly. track shoes to provide additional traction.
Fly Section: Boom tip extension, pin supported at its Guard Rails: Rails used to help provide safety (pre­
base. vent falls) for personnel when required to be on the up­
per platforms of the crane during maintenance and/or
Force: Any cause which tends to produce or modify adjustment procedures.
motion. In hydraulics, total force is expressed by the
product of pressure (P) and the area of the surface (A) Hanger: See “Bail”.
on which the pressure acts. (Force = P X A)
HC: Highway Crane
Fourth Drum: A fourth hoist drum, in addition to two
main hoist drums and a third hoist drum. HCD: Hydraulic Cab Down

Frame: Structure on which either upper or carrier ma­ Head Machinery: An arrangement of sheaves on the
chinery is attached. end of an attachment used to reeve wire rope.

Free‐Fall: Lowering of the hook and/or load without High Idle: Governed engine speed at full throttle and
using power. The motion is caused by gravity and must no load.
be controlled by a brake. HLA: Heavy Lift Attachment
Freely Suspended Load: Load hanging free with no Hoist: Function of lifting and lowering loads.
direct external force applied except by the hoist line.
Hoist Drum: A rotating cylindrical spool with side
Friction: The property which tends to resist the relative flanges used to wrap the winch wire rope during the
motion of one surface in contact with another surface. raising and lowering of the load with the winch.
It always exerts a “Drag” in the direction opposite of the
motion, thus consumes power. Hoist Wire Rope: The wire rope used to reeve the
winch and the attachments for lifting loads.
Friction Clutch (PTO): Device (which uses friction
discs) used for the transfer or transmission of engine Holding Valve: See “Counterbalance Valve”.
power to the operating functions of the crane.
Hook Ball: Ball with hook attached and used for lifting
Full Flow: In a filter, the condition where all the fluid service. It is used with one part of line only.
must pass through the filter element.
Hook Block: Block with hook attached used in lifting
Full Load Speed: The speed at which an engine runs service. It may have a single sheave for two or three part
when it is delivering its full rated horsepower. line, or multiple sheaves for four or more parts of line.
Full Power Boom: Hydraulic telescopic boom with House Assembly: The housing which covers the ma­
cylinders, or cylinders and cables, to extend/retract chinery mounted on the upper revolving frame.
each extendable section of the boom.
HSC: Hitachi Sumitomo Heavy Industries Construc­
Function Limiter (Function Lockout, Hydraulic Cut­ tion Crane Co., Ltd.
outs, Hydraulic Kickouts): Devices incorporated into
HSL: Hitachi/Sumitomo/Link‐Belt
the anti‐two block system or Rated Capacity Indicator
system which will disable the crane function of winch HSP: Hydraulic Self‐Propelled, Rough Terrain Crane.
up, telescope out, and/or boom down (as applicable)
as two block or overload situations approach. HT: Hydraulic Truck

Function Lockout: See “Function Limiter”. HTC: Hydraulic Highway Truck Crane

Gantry: A structural frame, mounted to the rear of the HTT: Hydraulic Truck Terrain Crane
upper revolving frame and usually extending above the Hydraulic Cutout: See “Function Limiter”.
cab. Retractable means are usually available to lower
to cab height for transportation convenience. Its pur­ Hydraulic Kickout: See “Function Limiter”.
pose is to support the boom hoist system.
Hydraulic Reservoir (Sump Tank): The storage tank
Gradability: The slope which a crane can climb ex­ for hydraulic fluid.
pressed as a percentage. (45° equals 100% slope.)
Idler Roller: Rollers of track mechanism which are not
Ground Pressure: Weight of crane divided by the area power driven but are used to maintain proper tension
of the surface directly supporting the crane. on the track.

6-4 Section 6 - Fundamental Terms

 Operator's Manual
Inhaul Rope: See “Drag Rope”. Load Line: Another term for “Hoist Rope”. In lifting
crane service it refers to the main hoist. The secondary
Inner Mid Section: The segment of a four section tele­ hoist is referred to as a “Whip Line”.
scoping boom which is attached to the base and outer
mid sections. Load Moment Indicator (LMI): See “Rated Capacity
Indicator”.
Instability: A “tipping condition” in which the mo­
ments acting to overturn a crane exceed the moments Load Moment Limiter (LML): A device which aids the
acting to resist overturning. operator by automatically sensing the overturning mo­
ment of the crane, i.e. load X radius. It compares this
Jack Shaft: Term applied to an intermediate shaft lifting condition to the crane's rated capacity, provides
used to transfer power. an audible/visual signal when the loading conditions
Jib: A pendant supported extension attached to the approach the rated capacity, and when the rated capa­
boom or fly head to provide added boom length for city is reached and/or exceeded, it limits crane func­
handling specified loads. The jib may be in line, or off­ tions that would result in an overload condition.
set, with the boom. Load Radius: Horizontal distance from a projection of
Jib Base (Jib Base Section): The lower most seg­ the axis of rotation to the supporting surface, before
ment of the jib. loading, to the center of the vertical hoist line or tackle
with load applied. See “Radius”.
Jib Extension: A jib section, other than the base or tip
section, installed to increase the overall length of the Load Stepping: The procedure of moving a load
jib. without traveling the crane when conditions do not al­
low traveling with a load (pick and carry). Park the
Latching Boom: Hydraulic telescopic boom that uses crane on a level area, lift the load, swing around, and
one telescope cylinder to extend/retract all sections of set it down ahead of the crane. Travel the unloaded
the boom. The cylinder extends/retracts one section at crane beyond the load, level the crane, lift the load,
a time and pins them in place until desired length is swing, and set it down farther along the route. Contin­
reached based on the boom extend mode selected. ue this procedure until the load is at its destination.
Lattice Boom: Boom of open construction with angle, Loaded Boom Angle: The angle between the boom
or tubular, lacing between main corner members base section and horizontal with a freely suspended
(chords) in the form of a truss. load at the rated radius.
LBCE: Link‐Belt Construction Equipment Lower Roller: See “Track Roller”.
Lifting Capacity: The rated load for any given load ra­ LS: A track driven crawler crane.
dius and boom angle under specified operating condi­
tions and crane configurations. Luffing Attachment: A crane attachment adaptable to
a basic cable crane. The attachment consists of a verti­
Line Pull: The wire rope pull generated off a wire rope cal luffing boom which is capable of being offset, with a
drum or lagging at a specified pitch diameter. luffing jib (usually the basic crane boom) affixed to the
upper part of the luffing boom.
Line Speed: The wire rope velocity at a wire rope drum
or lagging at a specified pitch diameter. Luffing Boom: The main boom of the luffing attach­
ment. It is connected to the upper frame of the crane
Live Mast: Frame hinged at or near the boom foot and
and can be set at certain angles to provide different
extending above the cab for use in connection with
working ranges for the luffing attachment.
supporting a boom. Head of mast is usually supported
and raised or lowered by the boom hoist wire ropes. Luffing Boom Cap: A structure mounted to the top of
the luffing boom where the luffing jib and fan post are
LMI: Load Moment Indicator.
mounted.
LML: Load Moment Limiter.
Luffing Jib: The working boom of the luffing attach­
Load Factor: Load applied at the boom tip which gives ment. It is connected to the luffing boom cap.
the same moment effect as the boom mass.
Manual Section: The outer most segment (tip) of a
Load Indicator: A device for measuring and display­ four or five section telescoping boom attached to the
ing the net load being lifted. outer mid section. This boom section shares the tele­

Section 6 - Fundamental Terms 6-5

Operator's Manual
scope cylinder used to operate the outer mid boom Outrigger Removal System: A system for removing
section. This section also contains the head machinery front and rear outrigger boxes in order to reduce overall
of the attachment. weight.
Mat: Material, usually of timber or wire construction, Pawl: A pivoting locking lever which will permit move­
for supporting pontoons or tracks on soft surfaces to ment in only one direction. Movement in the opposite
add stability. direction can be achieved only by manually releasing
the mechanism.
Middle Section (Mid Section): The segment of a tele­
scoping boom which is midway between the base and Peak Section: See “Top Section”.
tip sections.
Pendant: A supporting wire rope or bar, which under
Midpoint Pendants: Wire rope pendants used to sup­ tension, maintains a constant distance between its
port the center portion of a long lattice boom at lift off. points of attachment.
Motor (Hydraulic): 1. A rotary motion device which Pick And Carry: The crane operation of lifting a load
changes hydraulic energy into mechanical energy. and traveling with it suspended.
2. A rotary actuator.
Pilot Pressure: Hydraulic pressure used to actuate or
No Load Stability Limit: The radius or boom angle be­ control hydraulic components.
yond which it is not permitted to position the boom be­
cause the crane can overturn without any load on the Pinion: The small gear in a gear train which drives the
hook. other gears.

Offset Fly: A fly section that is capable of being pinned Pitch Diameter: Root diameter of drum, lagging, or
at different working angles for greater reach or height. sheave, plus the diameter of the wire rope.
The working angle can also be changed with hydraulic Planetary: A set of gears used to either speed up or
cylinders. slow down the input vs. the output to gain speed or
Oil Cooler: A heat exchanger used to remove heat power, whichever is applicable.
from the hydraulic or transmission fluid. Platform: A device (basket, work platform, bucket,
Open Center Circuit: A circuit where the pump con­ cage, etc.) designed and fabricated with its intended
tinuously circulates fluid through the control valves use being to position personnel.
when they are in a neutral position. Pontoon (Float): The support which attaches to the
Operational Aid: An accessory that provides informa­ outrigger jack to increase the supporting area.
tion to facilitate operation of a crane or that takes con­ Poppet: A disc, ball, or cone shaped part of certain
trol of particular crane functions without action of the valves, which when closed against a seat, prevents
operator when a limiting condition is sensed. flow.
Operator's Cab (Upper Cab): A housing which cov­ Port: The open end of a passage. May be within or at
ers the operator's station. the surface of a hydraulic component housing or body.
Outer Mid Section: The segment of a four section hy­ Power Take‐Off (PTO): Device used for the transfer or
draulic boom which is attached to the inner mid and transmission of engine power to the operating func­
manual or tip sections. tions of the crane.
Outrigger: An extendable supporting device used to Pressure: Force per unit of area usually expressed in
level the crane and increase stability. pounds per square inch (psi) or Kilopascals (kPa).
Outrigger Beam: The part of the outrigger which ex­ Pressure Drop: The reduction in pressure between
tends horizontally and acts as the support for the out­ two points in a line or passage due to the energy lost in
rigger jack. maintaining flow.
Outrigger Jack: The hydraulic cylinder on the outrig­ Pressure Reducing Valve: A valve which limits the
ger beam which extends vertically to raise and lower maximum pressure at its outlet regardless of the inlet
and support the crane during on outrigger operations. pressure.
Outrigger Pin System: A hydraulic system available PTO: See “Power Take‐Off”.
to facilitate outrigger box removal by means of hydrau­
lic cylinders used in place of the standard outrigger box Pulse: A Link-Belt designed, total crane operating
mounting pins. system that utilizes an in-cab display as a readout and

6-6 Section 6 - Fundamental Terms

 Operator's Manual
operator interface with on-board diagnostics includ­ RTC: Hydraulic Rough Terrain Crane.
ing the rated capacity limiter, wind speed, boom length
and angle, radius of load, and crane configuration. Schematic: A diagram or representation of a system
showing everything in a simple way. No attempt is
Pump (Hydraulic): A device which converts mechani­ made to show the various devices in their actual rela­
cal force and motion into hydraulic fluid flow. tive positions. A schematic points out the operation of
a circuit for troubleshooting purposes.
Pump Disconnect: Device which engages and dIsen­
gages the main hydraulic pump. Disengaging the SCM: Sumitomo Construction Machinery
pump aids in engine start up by reducing cranking re­
sistance. Seasonally: Four times per year

Radius: The horizontal distance from the centerline of Semiannually: Twice per year
rotation of the crane, with no load, to the center of grav­ Service Brake: A foot operated brake which regulates
ity of the hook or suspended load. the amount of air or fluid delivered to the brake cham­
Radius Of Load: The horizontal distance from the ber, which determines the braking force.
centerline of rotation of the crane to the center of gravity Shall: The work shall is to be understood as mandat­
of the suspended load. ory.
Rated Capacity Indicator (RCI): A device that auto­ Shim Pack (Wedge Pack): Wedging mechanism
matically monitors radius, load weight, and load rating used to secure crawler crane side frames to the lower
and warns the crane operator of an overload condition. frame.
Rated Capacity (Load) Limiter (RCL): A device that Should: The word should is to be understood as advis­
automatically monitors radius, load weight, and load ory.
rating and prevents movements of the crane that would
result in an overload condition. Side Frame: Supporting structure of the track mecha­
nism. Side frames are attached to the crawler crane
Rated Load Indicator (RCI): See “Rated Capacity In­ lower frame and may be extendable and/or removable.
dicator”.
Side Load: 1. Load applied at an angle to the vertical
RCI: Rated Capacity Indicator plane of the boom. 2. Horizontal side force applied to
RCL: Rated Capacity Limiter the lifted load either on the ground or in the air.

Reeving: Passing of ropes over pulleys and/or Single Acting Cylinder: A cylinder in which fluid
sheaves. power can only be used in one direction. Another force
must be used to return the cylinder.
Relief Valve: A pressure operated valve which by­
passes pump delivery to the reservoir, limiting system Slew: See “Swing”.
pressure to a predetermined maximum value. Slip Ring: See “Collector Ring”.
Reservoir: A container for storage of fluid. SmartFly: Simple one-person fly erection and stor­
Restriction: A reduced cross‐sectional area in a line age technology that minimizes work at height.
which produces a pressure drop. Speed‐O‐Matic (S‐O‐M): A term which applies to the
Rigging Switch (System Override Switch): A switch hydraulic control system originally developed to apply
which can be used to override any or all of the function two shoe clutches for transmission of power on Link‐
limiters (cutouts) which have been activated on the Belt products.
crane during crane rigging/set up. Spool: Term applied to almost any moving cylindrically
Rope: Refers to wire rope unless otherwise specified. shaped part of a hydraulic component which moves to
See “Wire Rope”. direct flow through the component.

Rotating Joint: Component which transfers fluid, air, Sprocket: The driving element of the track mecha­
and/or electricity between a stationary and a rotating nism. Receiving power through the drive chain, the
member. sprocket meshes with the track to travel the crawler.

Rotating Joint And Center Section: The assembly of Strainer: A filtering device for the removal of coarse
the rotating joint and all its pneumatic, hydraulic, and solids from a fluid.
electrical components.

Section 6 - Fundamental Terms 6-7

Operator's Manual
Stroke: The length of travel of a piston, spool, lever, tension is easily erected by telescoping (pulling) it out
etc. of the center of the fly and then pinning it into position.
Structural Member: Lattice booms, telescopic Third Drum: A third hoist drum, in addition to two main
booms, jibs, gantries, masts, outriggers, carrier hoist drums, often used in piledriving.
frames, and upper frames are considered structural
members per ASME B30.5 Tip Section: The outer most live segment of a tele­
scopic boom. It is attached to a middle, or outer mid,
Suction Line: The hydraulic line connecting the pump section and contains the head machinery of the attach­
inlet port to the hydraulic reservoir. ment.
Sump Tank: See “Hydraulic Reservoir”. Top Section (Peak Section): The upper most section
of a lattice boom or jib which also contains the head
Support Line: The cable reeved from the second hoist machinery of the attachment.
drum for holding the clamshell bucket suspended dur­
ing dumping and lowering operations. Torque: Turning or twisting force usually measured in
foot‐pounds (ft lb) or Newton meters (Nm).
Surge: A very sudden rise in the hydraulic or air pres­
sure or electrical potential in a circuit. Torque Convertor (PTO): Device (which uses hydrau­
lic fluid) used for the transfer or transmission of engine
Swing (Slew): The rotation of the upper with the car­ power to the operating functions of the crane.
rier remaining stationary.
Tower Attachment: A crane attachment usually
Swing Brake: A brake which is used to stop the rota­ adaptable to a basic crane. The attachment consists of
tion of the upper. a vertical tower with a working boom and/or jib at­
Swing Lock: A mechanical lock that engages with the tached to the upper part of the tower.
upper frame in any position over the lower frame. Track: 1. Assembled crawler track shoes and con­
Swing Motor: Hydraulic device which uses a plane­ necting pins around idler rollers and drive sprockets.
tary to rotate the upper on the carrier. 2. That part of the crawler which contacts the ground.

Swing Park Brake: A self contained brake used for Track Roller: Rollers of track mechanism which are
holding the upper, in any position, during normal, sta­ not power driven but are used to guide the track along
tionary crane operations. the ground.

System Override Switch: See “Rigging Switch”. Traction Shaft: The horizontal shaft in the crawler low­
er which transfers power from the gear train in the up­
T1 Section Through T7 Section: Segments of a hy­ per to the track mechanism of the carrier.
draulic boom. Some are numbered starting with the
base section while others are numbered starting with Travel Swing Lock (2 Position Swing Lock): A me­
the section next to the base section. chanical lock that engages with the upper directly over
either the front or the rear of the carrier only. Use of the
Tagline: A wire rope or cable attached to the bucket travel swing lock is mandatory when traveling or trans­
and a spring loaded, counterweighted, or powered porting the crane and during pick and carry operations.
unit keeping it under tension to retard rotation and pen­
dulum swaying of the otherwise freely suspended Tubular Jib: Multiple section lattice extensions sup­
bucket. ported by pendants and attached to the main boom
head.
Tailswing: The distance from the centerline of rotation
of the upper frame to the extreme rear swing arc of the Turntable Bearing: A large bearing which attaches
counterweight. the upper to the carrier allowing the upper to rotate on
the carrier.
TC: 1. Tower crane 2. An upper mounted on any sup­
porting pedestal other than the usual crane lower. Two Block: The situation when the crane's hook
block, hook ball, or load contacts the attachment's
TCC: Telescopic Crawler Crane. head machinery.
Telematics: The use of wireless devices and computer Two Block Warning System: A system of electrome­
module technology to transmit data in real time back to chanical devices used to warn the crane operator of an
an organization. impending two block condition.
Telescoping Fly: An extension to the fly section which UC: Utility Crane
is stored through its center. Mounted on rollers, this ex­

6-8 Section 6 - Fundamental Terms

 Operator's Manual
Unloading Valve: A valve which bypasses flow to tank Winch Drum: A rotating cylindrical spool with side
when a set pressure is maintained on its pilot port. flanges used to wrap the winch wire rope during the
raising and lowering of the load with the winch.
Upper: The portion of the crane above the turntable
bearing. Winch Rope: The wire rope used to reeve the winch
and the attachments for lifting loads.
Upper Cab: See “Operator's Cab”.
Wire Rope (Rope): A flexible, multiwired member usu­
Upper Revolving Frame: The main structure of the ally consisting of a core member around which a num­
upper section of the crane which serves as mounts for ber of multiwired strands are helically wrapped.
other components of the upper.
Wiring Diagram: A diagram which includes all the de­
Upper Roller: See “Carrier Roller”. vices in an electrical system and shows their functional
V-CALC (Variable Confined Area Lifting Capaci­ relationships to each other. Such a diagram gives the
ties): Lift system that features infinite outrigger/crawler necessary information for physically tracing circuits
configurations with real time 360° charts. when troubleshooting is necessary.

Valve: A device for controlling flow rate, flow direction, Work Platform: See “Platform”.
or pressure of a fluid. Working Area: Area measured in a circular arc about
Viscosity: The resistance to flow. High viscosity indi­ the centerline of rotation as shown on the Working
cates a high resistance; low viscosity, a low resistance. Areas diagram.

Wedge Pack: See “Shim Pack”. Working Weight: Weight of crane with full radiator, half
full fuel tank, and attachments installed.
Whip Line: Secondary hoist line. Also see “Load
Line”. YC: Yard Crane

Winch: Function of lifting and lowering loads. 360° Swing Lock: A positive mechanical lock against
rotation of the upper over the carrier during normal, sta­
tionary crane operations.

Section 6 - Fundamental Terms 6-9

Operator's Manual

Notes:

6-10 Section 6 - Fundamental Terms