SECTION 8 MAINTENANCE AND REPAIR - Manitex

SECTION 8MAINTENANCE AND REPAIR

IMPORTANT This section does not contain maintenanceand repair instructions for the truck. Refer to the truck man-ufacturer’s manual for instructions pertaining to the truck.

SAFETYPrevent injury to personnel ordamage to crane and property.Take following precautions when

making maintenance checks, adjustments, or re-pairs to crane:

–Apply truck parking brakes.

–Lower all loads to ground so wire rope is slack.

–Move all controls to off.

–Disengage power takeoff and turn off engine.

–Attach CAUTION sign to start controls warning per-sonnel that crane is being serviced and must not bestarted.

–Do not stick hands or tools into any hole in boomsections while power is on or boom sections aremoving.

–Do not perform maintenance, adjustment, or repairprocedures unless authorized to do so. Make sureall applicable instructions have been read and arethoroughly understood.

–Do not check for hydraulic leaks with hands. Oil un-der pressure can penatrate human skin causing se-rious injury. Oil under pressure can be nearlyinvisible; therefore, check for hydraulic leaks with apiece of cardboard or wood.

–Hydraulic oil is flammible; do not check inside hy-draulic tank with open flame.

–Do not alter specified flow and pressure settings.Higher than specified flow and pressure can causedamage to crane and hydraulic components. Lowerthan specified flows and pressures can result inloss of control.

–Do not weld or burn close to hydraulic lines andcomponents without first placing a protective coverover them.

–Do not remove cylinders until working parts areresting on ground or are securely blocked frommovement.

–Components are heavy. Do not attempt to lift themby hand; use a chain hoist, jacks, or blocking.

–Do not place crane back into service until all guardsand covers have been securely reinstalled and allservice equipment has been removed.

–This crane has a step and two grab handles forclimbing onto and off pedestal on either side ofcrane. Crane owner/user shall provide sturdy lad-ders for personnel to gain access to componentswhich cannot be reached either from platform orfrom top of flatbed. Do not allow personnel to climb

onto turret, winch, or top of boom; use a sturdy lad-der to gain access to these locations.

STORING COMPONENTS1. Store new components (valves, pumps, motors, cylin-ders, hoses, tubes, fittings) in a clean, dry indoor location.

2. Do not unpack components or remove port plugs untilthe components are needed.

3. Once unpacked, carefully inspect each component fordamage that may have occured during shipping

4. Fittings, hoses, and tubes that are not equipped withshipping caps or plugs must be carefully cleaned beforethey are used. Flush the fittings, hoses, and tubes withclean hydraulic oil. Then seal all openings until use at as-sembly.

IMPORTANT Do not use rags to plug openings. Use cleanplastic shipping plugs and caps.

LABELING COMPONENTS AT DISASSEMBLY1. Before disconnecting wires, hoses, or tubes, tag themfor proper identification at reassembly.

2. Before removing a component (pump, motor, valve,etc.), match mark its mounting position with relation to theadja- cent component.

3. Before disassembling any multiple section component(pump, motor, valve), matchmark the position of each sec-tion with relation to each other. Do not mix parts from onesection with those from another; keep parts segregated.

4. Before removing shims, tie them together and identifytheir location.

CLEANLINESS1. Before removing a component from the crane, thor-oughly clean the area around it to prevent dirt from enter-ing the mating component or the hydraulic system. Coverall openings with plastic to prevent dirt and water from en-tering.

2. Carefully clean the area around fittings before discon-necting hoses and tubes. Install plastic plugs or caps onthe ends of hoses and tubes and the mating ports of allcomponents to prevent dirt and water from entering.

3. Disassemble components on a clean work bench (freefrom dust, dirt, and metal particles).

4. Use tools that are clean and in proper working order.

5. Clean metal parts in nonflammable safety solvent.Clean rubber parts in warm soap and water lubricate allparts with clean oil at assembly.

Manitowoc Boom Trucks, Inc

A Manitowoc Company 8-1

TORQUE VALUESThe torque values for fasteners which must be torqued to aspecific value are identified in Table 8-1 and shown in Fig-ure 8-2.

Loose or improperly torquedsubframe mounting studs andslewing ring mounting bolts will

cause studs or bolts to fail, possibly allowing craneto come off truck.

IMPORTANT Observe following precautions when install-ing fasteners; failing to do so will seriously weaken attach-ment.

– Make sure each fastener is of correct size, length, andgrade; if in doubt, refer to parts pages for specifications.

– Do not interchange grade 5 fasteners with grade 8 fasten-ers and vice versa (see Figure 8-1 for identification).

– Use grade 8 nuts (see Figure 8-1) with grade 8 bolts.

– Use hardened flat washers under head of screws and un-der each nut of bolts and studs.

– Make sure threads are clean and free of burrs.

– Torque fasteners to proper torque values; semiannuallycheck items 1 through 5, Table 8-1.

– Use a torque wrench which is properly calibrated. Checkcalibration of torque wrench on a regular basis.

NOTE Use grade 2 nuts with grade 5 bolts. Grade 2 nutsdo not have any grade marking.

MAINTENANCE CHECKS

GENERAL

Following is a list of preventive maintenance checks whichshould be made to maintain the safety, dependability, andproductivity built into this crane.

INTERVALS

The intervals given are provided as a guide only. Followthese intervals until adequate experience is gained to es-tablish intervals which meet your operating conditions.

Any increase or decrease in the intervals shall be pre-ceded by a complete analysis of how the crane is perform-ing. Carefully study previous maintenance and repairrecords before making any changes in the intervals.

RECORDS

Dated and signed records of all defects and repairs shallbe kept on file so future maintenance needs can be fore-casted.

REPAIRS

Any hazardous or abnormal conditions found while makingthe maintenance checks shall be corrected before thecrane is placed back into service. All adjustments andrepairs shall be made by authorized personnel only.

NOTE Maintenance checks which require the engine tobe running and the power takeoff to be engagedare identified with a bold dot (•). Take every pre-caution to prevent injury from moving partswhen power is on


8-2 A Manitowoc Company

Figure 8-1 Grade Markings

Item Torque

Figure 8-2 Identification Size Grade (ft-lbs)

1 Pedestal Mounting Studs 1 - 8 UNC 5 440

2 Stabilizer Mounting Studs 1 - 8 UNC 5 440

3 Slewing Ring Mounting Bolts ¾ - 10 UNC 5 250

4 Swing Reducer Mounting Bolts ¾ - 10 UNC 5 280

5 Swing Motor Mounting Studs ½ - 13 UNC 5 55

6 Winch Mounting Bolts ¾ - 10 UNC 5 200

7 Telescope Manifold Mounting Bolts ½ - 13 UNC 5 78

8 Winch Motor Mounting Bolts ½ - 13 UNC 5 55

9 Pump Mounting Screws ½ - 13 UNC 5 55

Table 8-1 Torque Values

DAILY CHECKS1. Perform the daily lube services.

2. Clean all debris and dirt from the crane.

3. Check for oil leaks.

4. Check that all guards, covers, stairs, and platforms aresecurely in place.

5. Check the entire crane for obvious signs of damage.

6. Check the wire rope for obvious signs of wear and dam-age.

7. Check the wire rope for proper spooling on the winchdrum and proper reeving through all sheaves. Check thatall sheaves turn freely.

8. Make sure the load line is properly fastened to the loadblock or the overhaul ball.

9. Check that all slings and other loose gear that will beused to make lifts are safe for operation.

10. Check the load block or the overhaul ball (whichever isbeing used) for loose or missing nuts, screws, and cotterpins.

11. Check that the hook has a hook latch and that the hooklatch operates properly.

12. Check that the Capacity Chart is present at the controlstation.

� 13. Test the anti-two block/overload warning horn as fol-lows:

a) Start the truck engine and engage the power takeoff.

b) Lift the anti-two block weight by hand so the chain isslack.

c) The warning horn should sound (beep) and theWINCH UP and TELESCOPE OUT functions shouldbe inoperable.

d) Release the weight so it hangs freely. The warninghorn should go off and the WINCH UP and TELE-SCOPE OUT functions should be operable.

� 14. Test the overload warning horn and, if equipped, theshutdown device, as follows:

a) Slowly raise the boom to its maximum angle (80°).The warning horn should sound.

b) If equipped with overload shutdown, the BOOMDOWN, WINCH UP, and TELESCOPE OUT func-tions should be inoperable.

c) If equipped with overload shutdown, hold in the boomdown bypass button. Try to lower the boom; it shouldlower and the warning horn should shut off. Releasethe button once the boom starts to lower. The boomshould continue to lower.

� 15. Test the Load Moment Indicator.

See Pre-Operation Inspections section in separateOperator’s Manual for daily routine to be performed.

� 16. Check for proper operation of the engine and powertakeoff controls.

� 17. Check for proper operation of all accessory devices(horn, gauges, lighting systems, etc.).



Figure 8-2 Fasteners

3-Outer Ring

3-Inner Ring

5

2

4

6

1

9

7

8

� 18. Check for proper operation of each crane function in re-sponse to control lever movement.

When any control lever is returned to off, the correspond-ing function must come to a complete stop and remain inposition.

� 19. Check that all boom sections extend and retractequally.

20. Check the condition of the truck tires and make surethey are inflated to the proper pressure.

21. Check for proper operation of the truck parking brake.

22. Remove all rust, corrosion and dirt from the oil coolercore (if equipped) to ensure proper heat transfer. If neces-sary, steam clean the core.

NOTE The oil cooler fan comes on only when the temper-ature of the hydraulic oil rises to 160°F.

WEEKLY CHECKS1. Perform the daily and weekly lube services.

2. Perform the daily maintenance checks.

3. Check all mechanical control linkage for excessive wearand binding; oil the linkage as required.

4. Clean the vent plug on the winch.

5. Check for missing bolts, pins, keeper plates, retainingrings, and cotter pins.

6. Check the winch drum and all sheaves for excessivewear, cracks, or other damage.

7. Check the boom angle indicators for accuracy over theirfull range of operation.

8. Check Load Moment Indicator. See separate owner’shandbook under Service and Maintenance for weeklycheck routine to be performed

MONTHLY CHECKS1. Perform the daily, weekly, and monthly lube services.

2. Perform the daily and weekly maintenance checks.

3. Check the boom and all structural components of thecrane for deformed, cracked or corroded members. Payclose attention to all welds.

4. Clean, prime, and paint any rusted surfaces.

5. Thoroughly inspect the wire rope for damage.

6. Check that the hook and hook housing on the load blockand the swivel on the overhaul ball rotate freely without ex-cessive play. Faulty operation indicates faulty bearings orinadequate lubrication.

7. Check the load block or the overhaul ball for signs ofoverloading: spread side plates, elongated holes, bent orelongated tie bolts, and cracks.

8. Check the gap between the shank and the barrel of theswivel on the overhaul ball. The gap must not exceed 1/16inch.

9. Carefully check the hook on the load block or the over-haul ball for signs of distortion or cracks.

IMPORTANT Hooks shall be discarded if cracks exist or ifthroat opening is 15% more than original throat opening.

Hook shall also be discarded if bent or twisted more than10° from plane of normal configuration.

10. Check that the wire rope clip is tight at the dead endwedge socket.

11. Retighten the fasteners for the subframe, the slewingring, the swing reducer, and the winch to the specifiedtorque values.This is an initial service only (see Semian-nual Checks).

12. Inspect all electric wiring and devices for malfunctioning,signs of deterioration, and dirt or moisture accumulation.

13. Inspect all hydraulic hoses and tubes for the following:

– Evidence of excessive scrubbing or abrasion on the outersurface of hoses, tubing, and fittings.

– Dented, kinked or cracked tubing.

– Evidence of leakage at the surface of hoses caused byblistering or abnormal deformation of the outer cover.

– Leakage at threaded, clamped, or welded connections.

14. Check the hydraulic pumps and motors for the following:

– Loose bolts or fasteners.

– Leaks at joints between sections.

– Shaft seal leaks.

– Unusual noise and vibrations.

– Loss of operating speed or pressure.

– Excessive heating of the oil.

15. Check the hydraulic valves for the following:

– Cracks in the valve housings.

– Leaks at the spools or between the sections.

– Sticking spools.

16. Check the hydraulic cylinders for the following:

– Drift caused by internal leakage.

– Rod seal leakage.

– Leaks at welded joints.

– Scored, nicked, or dented cylinder rods.

– Dented case (barrel).

– Loose or deformed rod eyes or connecting joints.

� 17. Check the adjustment of the crowd rope system in theboom. This is an initial service only; see SemiannualChecks.

18. Check that all nameplates and decals are readable andsecurely attached at the proper locations on the crane.

19. Check the levers at each control station for proper ad-justment.

SEMIANNUAL CHECKS1. Perform the daily, weekly, and monthly lube services.

2. Perform the daily, weekly, and monthly maintenancechecks.

3. Tighten all fasteners on the crane. Tighten those fasten-ers which require torquing to the specified value (includingslewing ring bolts).



� 4. Check the adjustment of the crowd rope system in theboom.

5. Check the boom slider pads for wear and proper adjust-ment.

� 6. Check relief valve settings for all crane functions.

ANNUAL CHECKS1. Perform the daily, weekly, monthly, and semiannuallube services.

2. Perform the daily, weekly, monthly, and semiannualmaintenance checks.

3. Check each hook for cracks using a nondestructive test.

WIRE ROPE MAINTENANCE

LUBRICATION

New wire rope is lubricated during manufacturing, but thislubrication is only adequate for initial storage and the earlystages of operation. To prevent the damaging effects ofcorrosion and to reduce wear, the wire rope must be lubri-cated at regular intervals.

The lubrication interval and the type of lubricant to be useddepend on the type of wire rope, the severity of duty, andthe type of corrosive elements the wire rope is subjectedto; therefore, contact the nearest wire rope dealer for lubri-cation recommendations.

The wire rope must be properly protected at all times;therefore, the gaps between the strands and wires must be

filled with lubricant to provide a complete seal. Use one ofthe methods shown in Figure 8-3 to lubricate the wire rope.For maximum penetration, the lubricant should be appliedwhere the wire rope “opens up” as it travels around asheave or winds onto the drum.

The wire rope must be clean and dry before applying the lu-bricant; an air jet, steam, and a wire brush are some clean-ing methods.

INSPECTION

How Often

It is impossible to predict when a wire rope will break; how-ever, regular careful inspection will indicate when the po-tential for breakage exists.

The wire rope shall be visually inspected by a qualified per-son for obvious signs of gross damage once each workshift.

The entire length of wire rope shall be thoroughly and care-fully inspected by a qualified person once each month.This interval also applies to any rope being placed into ser-vice which has been idle for one month or longer.

A dated and signed report of the wire rope’s condition ateach inspection interval shall be kept on file at all times.The data on these reports can then be used to determinewhen the wire rope needs to be replaced.

When inspecting the wire rope, pay particular attention tothe condition of the wire rope in the following areas:

1. PICK-UP POINTS – sections of wire rope that are re-peatedly stressed during each lift, such as those sectionsin contact with sheaves.

2. END ATTACHMENTS – the point where a fitting is at-tached to the wire rope, or the point where the wire rope isattached to the drum.

3. ABUSE POINTS – points where the wire rope is sub-jected to abnormal scuffing and scraping.

Replacement

No precise rules can be given for determining when to re-place a wire rope. Wire rope replacement depends uponthe good judgement of the qualified person making the in-spection and upon comparison of the data recorded onprevious inspection reports. Any deterioration resulting inan appreciable loss of wire rope strength, such as listedbelow, shall be sufficient cause for removing the wire ropefrom service:

1. Six randomly distributed broken outer wires in one ropelay length or three broken outside wires in one strand ofone rope lay length (see Figure 8-4).



Figure 8-3 Lubricating Wire rope

Bathing

CasingFilled withSwab andLubricant

HandSwabing

Brushing

Pouringonto Slow

MovingSheave

Take every precaution toprotect hands from injury

Figure 8-4 Rope Lay Length

ONE ROPE LAY is distance measured alonga rope in which one strand makes onecomplete revolution around rope core.

One Wire

Core

One Strand

2. One broken outside wire at the point the wire contactsthe core. The broken wire will have worked its way out ofthe rope structure and either protrude or loop out from therope structure. Additional inspection of this area of the wirerope is required to determine if there is core damage.

3. Wear of one-third the original diameter of outside wires.

4. Kinking, crushing, birdcaging, core protrusion, or anyother damage resulting in distortion of the rope structure.

5. Evidence of heat damage from any cause.

6. Reductions from the nominal diameter of more than:

1/64" for rope diameters through 5/16"1/32" for rope diameters 3/8" through 1/2"3/64" for rope diameters 9/16" through 3/4"1/16" for rope diameters 7/8" through 1-1/8"3/32" for rope diameters 1-1/4" through 1-1/2"

Measure the wire rope diameter across the crowns of thestrands only so the true diameter is measured as shown inFigure 8-5.

7. Core failure. This type of damage is usually indicated bya reduction in the nominal diameter or by an increase inrope lay length. When a reduction in diameter or an in-crease in rope lay length is noted, “open up” the wire ropeas shown in Figure 8-6 and carefully inspect the core. Thewire rope should be replaced if any wires in the core arebroken.

8. Severe corrosion

SHEAVE AND DRUM INSPECTION

Proper operation of the sheaves and the winch drum has adirect affect on wire rope wear; therefore, the sheaves andwinch drum must be inspected monthly for the followingdefects:

1. Check the depth, width, and contour of each sheave us-ing a groove gauge as shown in Figure 8-7. Replacesheaves that have over or under-size grooves.

2. Replace the winch drum or any sheave that has brokenor cracked flanges.

3. Check that the winch drum and all sheaves turn true onthe shafts. If the drum or any sheave has a wobble to it, re-place the bearings.

DISTRIBUTING WIRE ROPE WEAR

Wire rope wear at the “critical wear points” can be reducedand the life of the wire rope extended by moving the rope atregular intervals so different sections of the rope are sub-jected to the wear points. This practice can also help cor-rect spooling problems and rope vibration.

To move the wire rope, cut off a piece of wire rope at thedrum and refasten it. The piece cut off should be longenough to move the wire rope at least one full drum wrap.

If the wire rope is too short to allow cutting off a piece, re-verse the wire rope end for end and refasten it.

HYDRAULIC SYSTEM MAINTENANCE

INSPECTING SYSTEM

The damaging effects of dirt, heat, air, and water in the hy-draulic system can only be prevented by regular, thoroughinspection of the system. The frequency of inspection de-pends on operating conditions and experience with thesystem; however, the more often the system is inspectedand deficiencies corrected, the less likely the system willmalfunction.

A good inspection program will include the followingchecks:

1. Keep accurate records so future maintenance needscan be projected.

2. Only use approved hydraulic oil in the system (see Lubri-cation Section).



Figure 8-5 Measuring Wire Rope diameter

Figure 8-6

Figure 8-7 Measuring Sheave Groove

3. Check the level of the oil in the tank daily. Carefullyclean the area around the fill cap before removing it to addoil to the tank.

IMPORTANT When adding oil to tank, filter oil through a10-micron filter.

4. Clean the exterior of the system often; do not let dirt ac-cumulate on or around any part of the system.

5. Check for external leaks. Leaks are not only unsafe,they also attract dirt and in some cases allow air and waterto enter the system.

Remember! Do not to use your hands to check forleaks.

– Look for oil leaking from fittings and from between partsthat are bolted together. Tighten loose fittings and attach-ing bolts to the proper torque; do not overtighten.

If leakage persists at these points, replace the seals orgaskets.

– Look for oil leaking from pump and motor shaft ends, fromvalve spool ends, and from cylinder shaft ends. Replacethe seal(s) if leakage is found at any of these points.

– Replace tubes that are cracked, kinked, or bent.

– Replace hoses that are cracked, split, or abraded.

– Listen to pumps and motors for unusual noises; a highpitched whine or scream can indicate that air is beingdrawn in.

An air leak can be pinpointed by flooding the inlet fitting,hose, or tube with oil. If there is an air leak, the oil willcause a noticeable reduction in the noise. Correct thecause for any air leak, or the pump or motor will be ruined.

IMPORTANT Do not return leakage oil back to hydraulictank.

NOTE A high pitched whine or scream from the pump canalso indicate cavitation (pump being starved of oil).This condition is caused by the following problems:

–Collapsed or plugged suction line.

–Plugged/Clogged Suction Screen

–Wrong oil (viscosity too high).

6. Look for signs of overheating: heat peeled parts, burnedand scorched oil odor, and darkening or thickening of theoil. The maximum temperature of the oil in the tank mustnot exceed 200° F.

7. Have the hydraulic oil analyzed at regular intervals todetermine the condition of the oil and the extent of systemcontamination.

By having the oil analyzed on a regular basis, an oil changeinterval that meets your operating conditions can be estab-lished.

NOTE Contact your oil supplier for the availability of oilanalysis services and the steps that should betaken to obtain these services.

REPLACING HYDRAULIC FILTER ELEMENT (Figure 8-8)

Replace the filter element when the pressure gauge on thehead reads 25 psi with the engine at high idle and the oilwarm from operation.

NOTE The filter has a 25 psi bypass which opens whenthe element is plugged with dirt.

IMPORTANT Do not operate crane when filter is bypass-ing oil (gauge reads 25 psi); otherwise, unfiltered oil will bedrawn into system and faulty operation or damage to partswill result.

1. Stop engine.

2. Remove and discard the old element.

3. Wipe clean the base of the filter head.

4. Apply clean oil to the gasket on the new element.

5. Thread the new element onto the head until the gasketcontacts the head. Then hand tighten the element an addi-tional 3/8 to 1/2 turn. Do not use a wrench to tighten ele-ment.

6. Check the element for leaks during operation. If neces-sary, tighten the element until the leak stops.

REPLACING HYDRAULIC TANK BREATHER(Figure 8-8)

If equipped with a spin-on breather, replace it every 3months. Do not attempt to clean and reuse the breather.

1. Remove and discard the old breather.

2. It is not necessary to apply thread sealant to the threadsof the breather. Install the new breather hand tight; do nottighten with a wrench.

CHANGING OIL

Drain and refill the hydraulic system every 6 months unlessan alternate interval has been established by an oil analy-sis program.

1. Operate the crane until the oil is at its normal operatingtemperature. This step will help prevent impurities fromsettling in the system.

2. Move all controls to off and stop engine.

3. Remove the drain plug from the bottom of the tank todrain the oil (see Figure 8-8).

NOTE Crack open one of the hydraulic fittings in a line atthe high point of the system. This step will vent thesystem so that all of the oil drains out. Tightlyclose fitting once oil has drained.



Figure 8-8 Hydraulic Tank & Level Gauge

Gauge

Level Gauge

Breather Fill Cap

Drain Plug (at bottom)Filter Element

4. Thoroughly clean all dirt from the access cover on thetank and remove the access cover.

5. Clean out any sediment from inside the tank.

6. If equipped, remove and clean the suction strainer. Soakin solvent and blow out with compressed air. Then securelyreinstall the strainer.

7. Reinstall the cover on the hydraulic tank. Install a newgasket if necessary.

8. Replace the filter element

9. Replace the spin-on breather, if equipped; otherwise,soak the fill cap breather in solvent and blow it clean withcompressed air.

10. Clean any metal particles from the drain plug. Installand securely tighten the drain plug.

NOTE If a new pump or motor has been installed, fill allports with clean oil before connecting any lines.This step will provide initial lubrication of the unit.

11. Fill the hydraulic tank to the proper level with approvedhydraulic oil (see Lubrication Section).

IMPORTANT Filter new oil through a 10-micron elementwhen filling tank.

12. Connect and securely tighten any hydraulic lines thatare disconnected.

IMPORTANT If equipped with optional suction line shut-offvalve, open valve before starting engine or engagingP.T.O.; otherwise, the pump will cavitate and be ruined.

13. Start the engine, engage the power takeoff, and oper-ate the pump for at least two minutes with no load at low-est possible rpm. During this priming period, the pumpshould run smoothly and not develop excessive heat.

14. Gradually increase speed and operate all functions(cylinders and motors) to purge all air from the system. Op-eration will be sluggish or erratic until all air is purged.

15. Once the functions are operating smoothly, speed andloading can be increased to normal.

16. Stop the engine. Fill the hydraulic tank to the properlevel.

IMPORTANT If hydraulic system is extremely dirty (gum orlacquer formation on parts indicated by jerky, sluggish, orerratic operation) repeat Changing Oil procedure afternext 48 hours of operation.

BLEEDING OVERLOAD PILOT LINE

Before operating the crane after the pilot lines between theboom hoist cylinder and the transducers for the load mo-ment indicator have been disconnected, all air must bebled from the pilot line on the extend side of the hoist cylin-der, as follows:

Load moment indicator may notoperate properly if air is not bledfrom the overload pilot line.

1. Securely connect all of the pilot lines between the boomhoist cylinder and the transducers inside the pedestal ofthe crane.

2. Start and run the engine at low idle.

3. Locate hose attached to port labeled “TE” on the baseend of the boom hoist cylinder. Identify transducer insidecrane pedestal to which pilot hose is attached (Figure 8-9).

4. Crack open the pilot line fitting at the transducer.

5. Raise the boom as slow as possible.

NOTE If the boom is raised too fast, the flow meter in thepilot line to the transducer will close, and no oil willflow to the transducer.

6. Securely tighten the pilot line fitting when a steadystream of oil appears.

7. Wipe up any spilled oil and inspect for leaks.

TIGHTENING HYDRAULIC CONNECTIONS

General

1. Make sure the fittings and O-rings being used are theproper size and style.

2. Flush sealing surfaces with clean hydraulic oil to removeany dirt.

3. Carefully inspect threads and sealing surfaces for nicks,gouges, and other damage. Do not use damaged parts,because they will leak.

4. Carefully inspect O-rings for cuts and other damage. Donot use damaged O-rings, because they will leak.

5. Always lubricate O-rings with clean hydraulic oil at as-sembly.

6. Be careful not to cut O-rings when assembling them tofittings. Use a thimble as shown in Figure 8-10 when as-sembling an O-ring over threads.



Figure 8-9 Transducers

Hoses

Transducers

View insidePedestals

Figure 8-10 O-Ring Installation

O-Ring

Plastic or Metal ThimbleCovering Threads

Pipe Thread Connection

1. Apply sealant (Loctite 92 or equivalent) to the malethreads, never to the female threads. Do not apply seal-ant to the first two male threads.

IMPORTANT Do not use TFE-flourocarbon tape to sealthreads; pices of tape will enter hydraulic system andcause damage.

2. Tighten the fittings about 4-1/2 turns by hand and then 3additional turns with a wrench.

SAE Straight Thread Connection

This type connection leaks most often because the jam nutand washer are not backed up before assembly

When the jam nut and washer are not backed up, there isnot enough room for the O-ring when the squeeze takesplace and the washer will not seat properly as shown inView A, Figure 8-11. The compressed rubber between thewasher and the spot face will cold flow out of compression,causing the fitting to loosen and leak shown in View B, Fig-ure 8-11.

Tighten the SAE straight thread connection, as follows:

1. Back up the jam nut and washer to the end of the smoothportion on the fitting as shown in View A, Figure 8-12.

2. Lubricate the O-ring with clean oil; this is very impor-tant.

3. Thread the fitting into the port until the washer bottomsagainst the spot face as shown in View B, Figure 8-12.

NOTE If an elbow is being used, back it out as necessaryto align it with the hose.

4. Tighten the jam nut. When the fitting is properly in-stalled, the O-ring will completely fill the seal cavity and the

washer will be tight against the spot face as shown in ViewB, Figure 8-12.

Split Flange Connection

1. Lubricate and install the O-ring in the groove of theshoulder (see Figure 8-13).

2. Align the shoulder with the port and assemble theflanges over the shoulder.

IMPORTANT Bolts used must be grade-5 or better.Grade-5 bolt has three dashes in head.

3. Snug the bolts in a diagonal manner (see Figure 8-13) to1/3 of the torque given in Table 8-4.

4. Repeat step 3 to 2/3 of the final torque. Repeat step 3 tothe final torque.



Causes Cures

1. Fitting loose. Tighten

2. Fitting too tight causing threaddistortion.

Replace damaged parts.

3. Thread on fitting or in portwrong size.

Use proper size threads.

4. Thread dirty, galled or nicked. Clean or replace parts.

5. Straight thread used instead oftapered thread.

Use proper type and sizethread.

6. Female threads expanded fromheat.

Tighten when hot.

7. Fitting loosened by vibration. Retighten.

Table 8-2 Pipe Thread Leakage

Causes Cures

1. Jam nut and washer not backedup at assembly, causing O-ringto be pinched.

Replace O-ring and tighten fit-ting properly.

2. O-ring cut. Replace.

3. O-ring wrong size. Replace with proper size.

4. Sealing surfaces gouged orscratched.

Repair if possible or replacedamaged parts.

5. Sealing surfaces dirty Clean and lubricate.

Table 8-3 Straight Thread Leakage

Figure 8-11 Improper Assembly ofSAE Straight Thread Fitting

Washer will not seat properly on spot face. Compressedrubber between washer and spot face will cold flow out of

compression. Causing fitting to loosen and leak.

Jam Nut

Washer O-ring

View A View B

When jam nut and washer are not backed up, there is notenough room for O-ring when squeeze takes place

Figure 8-12 Proper Assembly ofSAE Straight Thread Fitting

Jam Nut

Washer O-ring

Spot Face

View BView A

Nut and washer backed up toend of smooth portion on fitting

Figure 8-13 Split Flange Connection

TubeFlange

Shoulder

PortO-ring

SAE 37° Flare Connection

1. Tighten the nut finger tight until the sealing surfacestouch.

2. Mark a line (use a felt pen or marker) on the adapter andextend in onto the connector nut (see View A, Figure 8-14).

3. Using wrenches, tighten the connector nut the numberof flats shown in Table 8-7 (see View B, Figure 8-14).

4. The misalignment of the marks will show how much thenut has been tightened, and best of all that it has beentightened.

SAE Face Seal Connection

1. Lubricate and install the O-ring in the groove in theadapter (see Figure 8-15).

2. Lubricate the threads.

3. Tighten the nut to the torque value given in Table 8-8.



“A” Dimensioninch

FlangeSize

Torquein-lbs. N-m

Standard Pressure Series

1-1/21-7/82-1/162-5/162-3/43-1/16

-08-12-16-20-24-32

175-225225-350325-425425-550550-700650-800

20-2525-4037-4848-6262-7973-90

High Pressure Series

1-9/1622-1/42-5/83-1/83-13/16

-08-12-16-20-24-32

175-225300-400500-600750-900

1400-16002400-2600

20-2534-4557-6885-102158-181271-294

Table 8-4 Split Flange Assembly Torque

A

Causes Cures

1. Flanges not tight. Tighten bolts evenly to propertorque.

2. Flanges tightened unevenlycausing extrusion of O-ring.

Replace O-rings. Tighten boltsevenly to proper torque.

3. O-ring cut. Replace.


5. Sealing surfaces not smooth;scratched or gouged.

Repair if possible or replaceparts.

6. Sealing surfaces dirty. Clean.

7. Flanges keep getting loose inservice.

Use SAE grade 5 bolts orbetter. Retighten bolts after sys-tem is hot.

Table 8-5 Split Flange Leakage

Causes Cures

1. Joint loose. Tighten properly.

2. Sealing surfaces dirty. Clean.

3. Sealing surfaces not smooth;scratched or gouged.

Replace faulty parts.

4. Sealing surfaces cracked. Replace faulty parts.

5. SAE 45° parts used with SAE37° parts.

Only use SAE 37° parts.

Table 8-6 SAE 37� Flare Leakage

Connector Nut Sizeinch across flats

FittingSize

Adapter Flats toRotate

9/165/8

11/167/81

1-1/41-1/2

22-1/4

-04-05-06-08-10-12-16-20-24

2-1/22-1/2

22

1-1/2 to 21

3/4 to 13/4 to 1

1/2 to 3/4

Table 8-7 SAE 37� Flare Tightening

Figure 8-14 SAE 37� Flare Connection

View A

View B

Connector Nut Adapter

Turn connector nutrequired number of

flats (Table 8-7)

Nut Sizeinch across flats

FittingSize

Torquein-lbs. N.m

5/813/1615/161-1/81-3/81-5/81-7/8

-04-06-08-10-12-16-20

120-145203-245380-470550-680763-945

1110-12601500-1680

14-1623-2843-5362-7786-107125-142170-190

Table 8-8 SAE Face Seal Assembly Torque

Causes Cures

1. Nut Loose Tighten to proper torque.

2 O-ring Cut Replace.


4. Sealing surfaces gouged orscratched.

Repair if possible or replacedamaged parts.

5. Sealing surfaces dirty. Clean and lubricate.

Table 8-9 SAE Face Seal Leakage

Figure 8-15 SAE Face Seal

Adapter

O-ring

Nut

ADJUSTING RELIEF VALVES

General

The relief valves are factory set and should not be tam-pered with unless poor performance is experienced.

Any relief valve which has been removed for inspection,cleaning, or replacement must be adjusted after installa-tion.

NOTE Refer to Figure 8-16 for identification of the reliefvalves. The cover on the control console must beremoved to gain access to the relief valves.

Main Relief Valve for 7-Section Valve

1. Operate the hydraulic system until the oil is warm fromoperation.

2. Move all of the control levers to off.

3. Increase engine speed to full throttle.

4. Fully retract the boom to stall the hydraulic system byslowly moving the telescope control lever in the INdirecation. Leave all other control levers in off.

5. Observe the system pressure gauge on the right sideconsole (see Figure 8-17); the gauge should read 2,500psi.

IMPORTANT Move telescope control lever to off as soonas pressure reading is obtained; otherwise, hydrauliccompoanents may be damaged from overheating.

6. If the proper pressure is not obtained, proceed as fol-lows:

a) Remove the acorn nut from the adjusting screw(seeFigure 8-16).

b) Hold the adjusting screw with a screwdriver andloosen the locknut.

c) Turn the adjusting screw IN to INCREASE pressureor OUT to DECREASE pressure.

d) Repeat “Main Relief Valve” steps 3 through 5 and 6cuntil the specified pressure is obtained.



7-SectionControl Valve

MainRelief Valve

SwingRelief Valve

WinchRelief Valve

WinchControl Valve

Mid-InletSection

Valve Arrangementfor Triple Pump

Valve Arrangementfor Tandem Pump

WinchControl Valve

WinchRelief Valve

Swing RightRelief Valve

MainRelief Valve

Swing LeftRelief Valve

7-SectionControl Valve

AcornNut

AdjustingScrew

Locknut

Relief Valve

Figure 8-16 Relief Valve Identification

Figure 8-17 System Pressure Gauge

Pressure Gauge onDriver Side ControlConsole

e) Hold the adjusting screw with a screwdriver andtighten the locknut. Reinstall the acorn nut on the ad-justing screw. Torque both nuts to 10 ft-lbs.

Swing Relief Valves (with Tandem Pump)

1. Check that the main relief valve is set for the specifiedpressure.

2. Operate the hydraulic system until the oil is warm fromnormal operation.

3. STOP ENGINE. Do not perform step 4 until the engine isoff.

4. Disconnect the brake release hose from the elbow onthe swing brake (see Figure 8-18).

5. Connect an accurate 0-3,000 psi hydraulic pressuregauge to the end of the brake release hose. The hose has a1/4 inch SAE face seal fitting.

6. Start and run the engine at full throttle.

7. Slowly move the swing control lever in the SWING LEFTdirection. The applied swing brake will stall the hydraulicsystem.

8. Observe the pressure gauge; the gauge should read1,500 psi.

IMPORTANT Move swing control lever to off as soon aspressure reading is obtained; otherwise, hydrauliccompoanents may be damaged from overheating.

9. If the specified pressure is not obtained, proceed as fol-lows:

a) Remove the acorn nut from the adjusting screw onthe SWING LEFT relief valve (see Figure 8-16).



d) Repeat “Swing Relief Valves” steps 6 through 8 and9c until the specified presure is obtained.


10. Repeat “Swing Relief Valves” steps 6 through 9e forthe SWING RIGHT relief valve. Operate the swing controllever in the SWING RIGHT direction.

11. STOP ENGINE. Disconnect the hydraulic gauge fromthe brake release hose and reconnect the hose to the fit-ting at the swing break.

Swing Relief Valve (with Triple Pump)


2. STOP ENGINE. Do not perform step 3 until the engine isoff.

3. Disconnect the brake release hose from the elbow onthe swing brake (see Figure 8-18).

4. Connect an accurate 0-3,000 psi hydraulic pressuregauge to the end of the brake release hose. The hose has a1/4 inch SAE face seal fitting.

5. Start and run the engine at full throttle.

6. Slowly move the swing control lever in either direction.The applied swing brake will stall the hydraulic system.

7. Observe the pressure gauge; the gauge should read1,500 psi.

IMPORTANT Move swing control lever to off as soon aspressure reading is obtained; otherwise, hydraulic compo-nents may be damaged from overheating.

8. If the specified pressure is not obtained, proceed as fol-lows:

a) Remove the acorn nut from the adjusting screw onthe SWING relief valve (see Figure 8-16).



d) Repeat Swing Relief Valve steps 5 through 7 and 8cuntil the specified presure is obtained.


9. STOP ENGINE. Disconnect the hydraulic gauge fromthe brake release hose and reconnect the hose to the fit-ting at the swing brake.

Winch Relief Valve

1. Operate the hydraulic system until the oil is warm fromoperation.

2. Reeve the boom point for one part of hoist line.

3. Retract the boom to its shortest length.


5. To stall the hydraulic system, slowly lift against a10,000 pounds at a 20 foot radius or less.

Do not exceed load or radius instep 5; structural damage or tip-ping will occur.

6. Observe the system pressure gauge on the right sideconsole (see Figure 8-17); the gauge should read 2,800psi.



Figure 8-18 Swing Drive

Elbow

Disconnect hose here

Brake Release Hose

Swing Brake

IMPORTANT Move winch control lever to off as soon aspressure reading is obtained; otherwise, hydraulic compo-nents may be damaged from overheating.

7. If the proper pressure is not obtained, proceed as fol-lows to adjust the winch relief valve:

a) Remove the acorn nut from the adjusting screw (seeFigure 8-16).



d) Repeat Winch Relief Valve steps 4 through 6 and 7cuntil the specified presure is obtained.


Stabilizer Out Relief Valve

NOTE The stabilizer OUT relief valve is mounted insidethe rear of the subframe.

Because it is dificult to gain acces to the reliefvalve, it is recommended that the hydraulic lines beconnected to the relief valve and the relief valve beadjusted before it is fastened to the subframe.


2. Move all control levers to off.


4. Move the stabilizer IN/OUT control lever to the OUT po-sition and hold. Leave all other control levers in off.

5. Once the stabilizer boxes are fully extended and stalled,observe the sytem pressure gauge at the right side controlstation (see Figure 8-17); the gauge should read 1000 psi.

IMPORTANT Return stabilizer IN/OUT control lever to offas soon as pressure reading is obtained; otherwise, hy-draulic components may be damaged from overheating.

6. If the proper pressure is not obtained, proceed as fol-lows to adjust the relief valve (see Figure 8-19):

a) Hold the adjusting screw with a wrench and loosenthe locknut.

b) Turn the adjusting screw IN to INCREASE pressureor OUT to DECREASE pressure.

c) Repeat “Stabilizer OUT Relief Valve” steps 3 through6b until the specified presure is obtained.

d) Hold the adjusting screw with a wrench and tightenthe locknut.

PUMP INSTALLATIONIMPORTANT Rotation of pumps must match rotation ofpower takeoff (P.T.O.). If pumps are rotated in wrong di-rection, they will be damaged.

Perform the following steps before installing a new or re-paired pump on the P.T.O.:

1. Start and run the engine at low idle.

2. Observe the P.T.O.’s output shaft.

3. If the P.T.O.’s output shaft turns CLOCKWISE (viewedfrom shaft end), the pump must be assembled for COUN-TERCLOCKWISE rotation.

If the P.T.O.’s output shaft turns COUNTERCLOCKWISE(viewed from shaft end), the pump must be assembled forCLOCKWISE rotation.

NOTE If it is necessary to change the rotation of thepumps, refer to the pump manufacturer’s overhaulmanual for instructions.

Be sure to change rotation of cartridge in eachpump section.

ADJUSTING LEVELSCheck the adjustment of the levels on the control consolesevery month using the following procedure:

1. Extend the outriggers and the stabilizers so the crane islevel according to the level on either control console.

2. Raise the boom to the maximum angle (80) and fully re-tract the boom.

Do not swing boom over eitherside of truck until AdjustingLevels step 2 has been per-

formed; otherwise, crane may tip over.



Figure 8-19 Stabilizer OUT Relief Valve

Access Hole inBottom of Subframe

Viewinside

Rear ofSubframe

Relief ValveCartridge

Locknut

AdjustingScrew

Figure 8-20 Positioning the carpenter’s Level

Turret

Carpenter’sLevel

3. Place an accurate carpenters level on either side of theturret (Figure 8-20). Do not lay the level across the top ofthe bolts.

4. Adjust the outriggers and stabilizers so the crane is levelfrom front to rear according to the carpenter’s level.

5. Swing the boom 90° over either side of the truck and ad-just the outriggers and stabilizers so the crane is level fromside to side according to the carpenters level.

6. Repeat “Adjusting Levels” steps 4 and 5 until the craneis level with all tires off the ground.

7. Check the bubble in the level on each control console. Ifnecessary, adjust the levels as follows:

a) Loosen adjusting screws (Figure 8-21) until springunder level is no longer compressed.

b) Preload spring by tightening adjusting screws evenly.Do not overtighten as this will cause loss of adjust-ment range.

c) Turn adjusting screws until the bubble is centered inthe glass.

INSTALLING SLEWING RING/ADJUSTING GEARBACKLASH

NOTE The following instructions assume that the boomhas been removed from the turret.

1. Thoroughly clean any dirt, grease, or oil from all mount-ing surfaces and remove any burrs.

2. Remove the swing reducer from its mounting positionand lay it on the control console. It is not necessary to dis-connect the hydraulic lines when performing this step.

3. Lift the turret onto the slewing ring so the high spot of thegear (marked with paint or punch marked) is centered asclose as possible between the boom hoist cylinder mount-ing lugs on the turret (see Figure 8-22).

NOTE The high spot of the ring gear teeth should be ei-ther painted or punch marked for identification. Ifthe teeth are not painted or punch marked, locatethe high spot with a dial indicator.

Install the bolts, hardened flat washers, and nuts to fastenthe slewing ring to the turret as shown in Figure 8-23.Tighten the nuts to 100 ft-lbs. Then retighten the nuts to250 ft-lbs.

4. If it was removed, install the swing limiting device at thistime.

5. Lift the turret and slewing ring into position over the ped-estal.

6. Rotate the inner ring so the loading plug (Figure 8-22) ispositioned approximately 90° to the left of the swing pinioncenterline (viewed from top).

7. Install the bolts, hardened flat washers and nuts to fas-ten the inner ring to the pedestal (see Figure 8-23). Do nottighten the nuts.

NOTE Access holes are provided in the turret for installingthe bolts in the inner ring.

Install three 4 inch long bolts in the tapped holesnearest the front of the pedestal.

8. Temporarily assemble the swing reducer with the ec-centric plate to the pedestal.

NOTE When performing step 8, position the eccentricplate so it is in the middle of its adjustment asshown in Figure 8-24.



Figure 8-21 Level on Control Console

Level

Adjusting Scew(3 each)

Figure 8-22 Slewing Ring Orientation

Loading Plug(approximately 90� to left of swing pinion position) Pedestal

SwingPinion

Turret

SwingLimitingDevice

Figure 8-23 Slewing Ring Installation

¾-10 UNCGrade 8 Nut

Acces Hole

Pedestal

¾-10 UNC SocketHead Bolt

¾-10 UNC SocketHead Bolt

OuterRing

HardenedFlat Washer

Turret

Outer Ring

Guard

Acces Hole HardenedFlat Washer

¾-10 UNCGrade 8 Nut

9. Push the turret and slewing ring toward the swing re-ducer so there is no backlash between the ring gear andthe swing pinion.

10. Remove the swing reducer from its mounting position.

11. Tighten the nuts for the inner ring to 100 ft-lbs. Thentighten the nuts to 250 ft-lbs.

NOTE It will be necessary to rotate the turret to gain ac-cess to all of the bolts through the access holes.

One person must hold the heads of the bolts with ahex socket wrench while another person tightensthe nuts from inside the turret.

12. Reinstall the swing reducer so the mounting screws areloose

13. Rotate the outer ring so the high spot of the ring gearteeth is in mesh with the swing pinion.

14. Rotate the eccentric plate (see Figure 8-25) with ahammer and punch until there is no backlash between theswing gear and the swing pinion.

IMPORTANT Backlash must be adjusted any time slewingring or swing reducer is removed; otherwise, gears maybind when swinging.

15. Tighten the swing reducer mounting screws to 280ft-lbs.

16. Reconnect any hydraulic lines that may have been dis-connected from the swing reducer or the swing motor.

BOOM SERVICE

NOTE The item numbers used for the “Boom Service” in-structions correspond to the item numbers on the“Boom Assembly” drawing in the parts section ofthis manual.

SLIDER PAD REPLACEMENT AND ADJUSTMENT

Rear Top Slider Pads (see Figure 8-28)

1. Remove the access cover from the rear of the boombase.

2. Fully retract the boom so rear top slider pads (57) on the3rd section line up with the access holes in the rear of theboom as shown in Figure 8-26.

3. Stop engine.

NEVER reach into any boom sec-tion unless all sections are an-chored together, the PTO is

disengaged and engine is OFF. Serious injury willoccur if boom is telescoped.

4. Measure the thickness of slider pads (57). Replace bothslider pads if either has worn to the dimension given in Ta-ble 8-10.



Figure 8-24 Eccentric Plate Orientation

Drivers Sideof Truck

High Side ofEccentric Plate

Console Side of Pedestal

Low Side ofEccentric Plate

Figure 8-25 Eccentric Plate Installation

Turret

Outer Ring

EccentricPlate

Pedestal

SwingPinion

Figure 8-26 Rear Top Slider Pads

Rear TopSlider Pads

(57)

Shims(58,59,60)

AccessHoles

Item(Figure 8-27)

Location(Section)

NewThickness

ReplaceThickness

51 Rear Side (1st, 2nd, 3rd)*and Extend Sheave Bracket*

1/2" 3/8"

55 Front Bottom (Crowd)* 3/8" 1/4"

56 Front Side (Crowd)* 3/8" 1/4"

57 Rear Top (2nd, 3rd)and Front Bottom (Base, 1st)

1/2" 3/8"

61 Front Bottom (2nd Section) 1/2" 3/8"

62 Front Side (Base, 1st, 2nd)and Rear Side (Inside 3rd)*

3/8" 1/4"

* Can only be checked or replaced when boom is disassembled. All otherslider pads can be checked or replaced when boom is assembled.

Table 8-10 Slider Pad Replacement

5. Measure the clearance between rear top slider pads(57) and the adjacent section.

6. If necessary, loosen the mounting screws and addshims (58, 59, or 60) under the slider pads to provide theclearance given in Figure 8-28.

NOTE The shims come in three thicknesses: 3/64 inch,5/64 inch, and 9/64 inch.

7. Securely tighten the mounting screws after the shimsare installed.

8. Extend the boom so rear top slider pads (57) on the 2ndsection line up with the access holes in the boom as shownin Figure 8-28.

9. Repeat “Rear Top Slider Pads” steps 3 through 7 for the2nd section.

10. Extend the boom so rear top slider pads (57) on the 1stsection line up with the access holes in the boom as shownin Figure 8-26.

11. Repeat “Rear Top Slider Pads” steps 3 through 7 forthe 1st section.

Front Side Slider Pads (see Figure 8-28)

NOTE Rear side slider pads (51 & 62) can only be re-placed and adjusted when the boom is disassem-bled.



1. Extend the boom approximately 6 inches.

2. Stop engine.

3. Measure the thickness of front side slider pads (62)shown in Figure 8-27. Replace all of the front side sliderpads for the respective section if any front side slider padhas worn down to the thickness given in Table 8-10.

4. Fully extend the boom and stop engine.

5. Adjust the sections from side to side so the boom is asstraight as possible.

6. If necessary, add shims (63, 64, or 65) behind the frontside slider pads to keep the boom straight (see Figure 8-28for clearance specifications).


It is possible to have more shims on one side of theboom than on the other side, as long as the boom isstraight.


IMPORTANT End of mounting screws for front side sliderpads must not rub against adjacent section. If necessary,install washers under head of mounting screws so screwsfully engage nuts in slider pads, but do not rub against sec-tion.

Front Bottom Slider Pads (see Figure 8-28)

1. Extend the boom approximately 8 inches.

2. Stop engine.



3. Measure the thickness of front bottom slider pads (57 or61) shown in Figure 8-27. Replace both front slider padsfor the respective section if either slider pad has worndown to the dimension given in Table 8-10.

NOTE It will be necessary to lift the ends of the sectionswith a hoist to remove and adjust the front bottomslider pads.

Front bottom slider pads (57) are fastened tomounting pads; therefore, the mounting pads mustbe removed to gain access to the slider pads.

Be sure to readjust retract ropes after reinstallingthe mounting pads between the 1st and 2nd sec-tions.

4. Measure the clearance between the sections.

5. If necessary, add shims (58, 59 & 60) under the front bot-tom slider pads to provide the clearance given in Figure8-28.





Figure 8-27 Front Side & Bottom Pads

Front SideSlider Pad

(62)

Front BottomSlider Pad(57 or 61)



Figure 8-28 Slider Pad and Shim Identification

BOOM REMOVAL1. If equipped, remove the jib.

2. Fully retract and lower the boom onto the boom rest.

3. Remove the load block or the overhaul ball and spool theload line onto the winch.

4. Disengage the PTO and stop engine.

5. Tag and disconnect the telescope hydraulic lines fromthe valve manifold on the end of the telescope cylinder.

6. Lift against the rod end of the boom hoist cylinder and re-move the rod end pin (at boom).

7. Lower the boom hoist cylinder onto blocking on the flat-bed.

8. Lift against the boom at the center of gravity with anothercrane. The center of gravity is approximately 14 feet 10inches forward of the boom hinge pin.

9. Remove the boom hinge pin.

10. Lift the boom onto stands or blocking. Stands orblocking must be installed close to both ends of boombase to provide a sturdy support.

BOOM DISASSEMBLY AND ASSEMBLY

NOTE Refer to “Boom Assembly Drawing” found in theparts section of this manual for assembly and dis-assembly procedure.

NOTE Some of the adjustment procedures wil require ahydraulic power source to be available. The sourceshall be capable of providing 2500 psi of hydraulicpressure.

The rear end of the boom basemust be chained andcounterweighted when boom

service is performed on stands or blocking. Theboom will tip off stands or blocking when extendedif it is not properly secured.

IMPORTANT To avoid confusion when reassemblingboom, keep slider pads and shims in matched sets as theyare removed. Also, keep bolts, capscrews, lockwashers,and nuts with parts they retain.

BOOM INSPECTION1. Inspect all slider pads for wear or damage. Replace theslider pads if they have worn down to the “Replace Thick-ness” given in Table 8-10.

2. Inspect all bearings for wear. The sheaves must turntrue on the shafts without any wobble.

3. Inspect the extend and retract ropes for wear anddamaage; see “Wire Rope Maintenance” for wire rope re-placement criteria.

4. Inspect the sheaves for wear and damage; see “Sheaveand Drum Inspection.”

BOOM INSTALLATION1. Lift the boom into position at the turret and install theboom hinge pins.

2. Lower the boom onto the boom rest.

3. Lift the rod end of the boom hoist cylinder into position atthe lugs on the boom and install the rod-end pin.

4. Connect the hydraulic lines to the proper ports at themanifold on the telescope cylinder.

5. Adjust the crowd rope system.

6. Assemble cover (71) to the top of the base section.

7. Install the load line over the sheaves on the boom point.

8. If equipped, assemble the jib to the side of the boom.

9. Check anti-two block system for proper operation.

IMPORTANT If ATB/LMI cable from cable reel to the limitswitch on the boom point has been disconnected, then thepotentiometer in the length transducer must be reset. Oth-erwise, boom length sensor may malfunction, and causepossible damage to crane and property due to an overload.

10. Check length display in the load moment system’s cen-tral microprocessor unit. Refer to the PAT troubleshootingmanual under “3 Broken Length Cable”, for instructionswhen replacing cable and checking or resetting potentiom-eter in length transducer.

11. Operate the telescope cylinder in both directions untilall air is bled from the system. Fill the hydraualic tank to theproper level.

CROWD ROPE ADJUSTMENT

THREE-SECTION BOOM

(Refer To Figure 8-29)

1. Check that the jam nuts and the locking nuts are looseon the extend (28 and 29) and retract ropes (32).

2. Fully retract the boom. Ensure the second section hasstopped against the first. If necessary, push againstthe end of the second section to further ensure theboom is fully retracted.

3. Put match-marks (A and B) on the side of the first andsecond sections, the mark should be flush with the endof the adjacent section, refer to Figure 8-29.


5. Tighten the adjusting nut on each extend rope (28 and29) until the distance from the end of each extend ropeto the edge of each nut is 3/4-inch.

Do not place hands or tools intoany opening in boom sectionswhile power is on or boom sec-

tions are moving.

6. Visually inspect the extend rope tension through thesight hole in the side of the first section. Tighten the ad-justing nut on the loosest rope until all extend ropesare tensioned equally.

NOTE All extend ropes have wrench flats to hold theropes stationary while tightening the nuts.

7. Torque the adjusting nut on both retract ropes (32) to30-35 ft-lb.

NOTE All retract ropes have wrench flats to hold the ropesstationary while tightening the nuts.

8. Fully retract the boom while watching the end of thesections; note which section stops first.



9. Extend the boom approximately six inches and repeatprevious step as slowly as possible. Release thetelescope control lever to off as soon as the corre-sponding sections stops.

10. Determine the remaining stroke to fully retract theboom as follows.

A. If the second section stopped first, measure theremaining stroke between mark A on the first sec-tion and the end of the base section.

B. If the first section stopped first, measure the re-maining stroke between mark B on the second sec-tion and the end of the first section.

11. If the remaining stroke is greater than 1/8-inch, pro-ceed as follows.

A. If the second section stopped first:

Loosen the adjusting nut on the retract ropes (32)three turns for each 1/8-inch of remaining stroke.

Tighten the adjusting nut on the extend ropes (28and 29) four turns for each 1/8-inch of remainingstroke.

B. If the first section stopped first:

Loosen the adjusting nut on the extend ropes (28and 29) four turns for each 1/8-inch of remainingstroke.

Tighten the adjusting nut on the retract ropes (32)three turns for each 1/8-inch of remaining stroke.

12. Repeat previous steps until the remaining stroke is1/8-inch or less.

13. Re-check the torque of retract ropes (32).

14. Install and tighten locking nuts (90 and 91).

FOUR-SECTION BOOM

(Refer to Figure 8-30)

1. Remove the access cover from the top of the basesection at rear.

Do not place hands or tools intoany opening in boom sectionswhile power is on or boom sec-

tions are moving.

2. Loosen the adjusting nut and the lock nut on each ex-tend rope (28 and 29) and on retract ropes (33) so theropes are slack.

3. Visually inspect the extend rope tension (30 and 31)through the sight hole in the side of the first section.Tighten the adjusting nut on the loosest rope until bothropes are tensioned equally.

IMPORTANT If lock nuts are not removed in this step,damage to nuts or base section will result when boom is re-tracted later.

4. Tighten the adjusting nut on each retract rope (32) untilthe distance from the end of each rope to the outsideedge of the adjusting nut is one inch.

5. Fully retract the boom.

6. Put a match-mark on the side of the first section flushwith the end of the base section A, refer to Figure 8-30.Put a match-mark on the side of the second sectionflush with the end of the first section B.

7. Extend the boom approximately eight feet and stopengine. Tighten the adjusting nut on each extend rope(28 through 31) until the distance from the end of eachrope to the outside edge of the adjusting nut is3/4-inch.


9. Visually inspect the extend rope tension (30 and 31)through the sight hole in the side of the first section.Tighten the adjusting nut on the loosest rope until bothropes are tensioned equally.

NOTE Both extend ropes have wrench flats to hold theropes stationary while tightening the nuts.

10. Torque the adjusting nut on both retract ropes (33) to30-35 ft-lb.



Figure 8-29 Three Section Boom Crowd Ropes

3/4-inch Starting Point forExtend Ropes

Stop forSecondSection

BaseSectionLocking

Nut

FirstSection

SecondSection

Adjusting Nut RetractRope (32)

1-inch Starting Pointfor Retract Ropes

Locking NutBA

AdjustingNut

Extend Ropes(28 and 29)

NOTE Both retract ropes have wrench flats to hold theropes stationary while tightening the nuts.

11. Fully retract the boom while watching the third andsecond sections, note whether the third section stopsbefore match-mark B aligns itself with the end of thefirst section.

12. Extend the boom approximately six inches and repeatprevious step as slowly as possible. Release thetelescope lever to OFF as soon as the third sectionstops or as soon as match-mark B is aligned, which-ever occurs first.

13. Determine the remaining stroke to fully retract theboom, as follows.

A. If the third section stopped first, measure the re-maining stroke between match mark B on the sec-ond section and the end of the first section.

B. If match-mark B aligned itself first, measure theremaining stroke between the third and secondsections at location C.

14. If the remaining stroke is greater than 1/8-inch, pro-ceed as follows.

A. Extend the boom approximately eight feet and stopengine.

B. If the third section stopped first:

Loosen the adjusting nut on each retract rope (33)three turns for each 1/8-inch of remaining stroke.

Tighten the adjusting nut on each extend rope (30and 31) four turns for each 1/8-inch of remainingstroke.

C. If match-mark B aligned first:

Loosen the adjusting nut on each extend rope (30and 31) four turns for each 1/8-inch of remainingstroke.

Tighten the adjusting nut on each retract rope (33)three turns for each 1/8-inch of remaining stroke.


16. Recheck the torque of the adjusting nut for retractropes (33).

17. Extend the boom approximately eight-and-one-halffeet and stop engine. Looking through the accessholes in the base section, visually check the tension ofextend ropes (28 and 29). Tighten the adjusting nut onthe loosest ropes until all four ropes are tensionedequally.

NOTE All four extend ropes have wrench flats to hold theropes stationary while tightening the nuts.

18. Torque the adjusting nut on each retract rope (32) to30-35 ft-lb.

NOTE All four retract ropes have wrench flats to hold theropes stationary while tightening the nuts.

19. Fully retract the boom while watching the second andfirst sections, note which section stops first.

20. Extend the boom approximately six inches and repeatprevious step as slowly as possible. Release the

telescope control lever to OFF as soon as the corre-sponding section stops.



Figure 8-30 Four Section Boom Crowd Ropes

View at Top of Boom Base - Cover Removed


First Section

View at Top Rear of Base

Adjusting NutLocking Nut


3/4”Starting Point forall Extend Ropes

View at Front of Boom(shows locknuts removed)

Starting Point forAll Retract Ropes

1”

C

RetractRopes (33)

AdjustingNut

3rdSection

RetractRopes (32)

AdjustingNut

BaseSection

1stSection

2ndSection

BA

21. Determine the remaining stroke to fully retract theboom as follows:

A. If the second section stopped first, measure theremaining stroke between match-mark A on thefirst section and the end of the base section.

B. If the first section stopped first, measure the re-maining stroke between match-mark B on the sec-ond section and the end of the first section.

22. If the remaining stroke is greater than l/8-inch, proceedas follows:

A. Extend the boom approximately eight feet and stopengine.

B. If the second section stopped first:

Loosen the adjusting nut on each retract rope (32)three turns for each 1/8-inch of remaining stroke.

Tighten the adjusting nut on each extend rope (28and 29) four turns for each 1/8-inch of remainingstroke.

C. If the first section stopped first:

Loosen the adjusting nut on each extend rope (28and 29) four turns for each 1/8-inch of remainingstroke.

Tighten The adjusting nut on each retract rope (32)three turns for each 1/8-inch of remaining stroke.


24. Recheck the torque of the adjusting nut for retractropes (32).

25. Install all of the lock nuts and securely tighten them.

26. Cycle the boom two or three more times and checkthat all boom sections are properly synchronized perthe above instructions. If not, check which sections re-quire readjustment and perform the proper adjustmentprocedure for those sections.

27. Repeat until the boom is properly synchronized.

28. Recheck the torque of the adjusting nut for each re-tract rope (32 and 33).

29. Install the access cover on the base section.





Documents

SECTION 8 MAINTENANCE AND REPAIR - Manitex