Operator's Manual

iSection 1 - Operating Instructions

Table Of Contents

Crane Nomenclature 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Safety 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Boom Safety Instructions 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Dangers 1-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radio Frequency Or Electro Magnetic Interference (RFI Or EMI) 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective Equipment 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signal Persons And Bystanders 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Inspections And Adjustments 1-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Rope 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane And Area Clearance 1-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weights, Lengths, And Radii 1-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling 1-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leaving The Station 1-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personnel Handling Guidelines 1-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 1-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Authorization 1-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment 1-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance, Lubrication, And Adjustments 1-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection And Rigging 1-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Test Procedures 1-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation And Safety 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Requirements For Offshore Cranes 1-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Cab Controls 1-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dash Panel 1-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Engine Idle Shutdown System 1-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Engine Shutdown Override 1-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse Panel 1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Cab Foot Operated Controls 1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Transmission Shift Lever 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Transmission Control 1-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

ii Section 1 - Operating Instructions

Shifting The Main Transmission 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double‐Clutching Procedures 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual Switch Range Selector Style Shifter 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Up Shifting 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Down Shifting 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Skip Shifting 1-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Engine Brake 1-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Engine Brake Controls 1-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Engine Brake Operation 1-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Descending A Grade 1-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slippery Pavement 1-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Column And Wheel 1-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Cab Seat 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Cab Heater Shutoff 1-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Engine Diagnostic Connector 1-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Disconnect, Remote Jumper Terminals, Carrier Engine Fuses, And Circuit Breakers 1-49. . . . .

Ether Start System 1-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing the Ether Fuel Cylinder 1-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Engine Block Preheater 1-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Outrigger Operation 1-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Extend Main Outriggers 1-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Retract Main Outriggers 1-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bumper Outrigger Operation 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bumper Outrigger Control Switch 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bumper Outrigger Overload Warning System 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Extend The Bumper Outrigger 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Retract The Bumper Outrigger 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outrigger Removal System 1-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Outrigger Box Removal 1-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Outrigger Box Installation 1-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Outrigger Box Removal 1-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Outrigger Box Installation 1-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

iiiSection 1 - Operating Instructions

Lift Axle 1-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Raise the Lift Axle 1-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Lower the Lift Axle 1-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Operator's Cab Controls 1-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane System Controls 1-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Engine Throttle Controls 1-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Hoist Operation 1-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Hoist Limit System 1-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Angle Indicator 1-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum Control Lever Locks 1-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front And Rear Drum Operation 1-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating In “AUTO BRAKE MODE” 1-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating In “FREE MODE” 1-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Third Drum Control 1-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum Rotation Indicator 1-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Horn 1-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Operation 1-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing (Park) Brake 1-74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Brake Lock Out 1-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two Position House Lock 1-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Swing The Upper 1-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Monitoring System 1-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Inoperative or Malfunctioning 1-77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti‐Two Block System 1-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Conditioner Controls 1-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Seat 1-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering And Exiting The Upper Operator's Cab 1-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gate Lock Lever 1-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Break‐In Period 1-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Starting Operations 1-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher 1-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

iv Section 1 - Operating Instructions

Engine Starting Procedure 1-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Start The Carrier Engine 1-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Start The Upper Engine 1-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Shutdown 1-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Engine Shutdown Procedure 1-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Engine Shutdown Procedure 1-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Operation 1-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

During Operation 1-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Counterweight Installation And Removal 1-85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Installation 1-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Handling And Assembly 1-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising The Counterweight To Upper 1-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Removal 1-89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering The Counterweight From Upper 1-89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Disassembly And Handling 1-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bumper Counterweight 1-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 1-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal 1-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Signals 1-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling The Crane 1-95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel 1-95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel Without A Load 1-95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel, Boom Only (No Load) 1-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel,Boom With Jib (No Load), Maximum 1 mph (1.6km/h) 1-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel,Boom Only (No Load), Maximum 1 mph (1.6km/h), Boom Horizontal 1-98. . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel,Boom Only (No Load), Maximum 1 mph (1.6 km/h), Boom Horizontal With Assist Crane or Dolly 1-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pick And Carry Operation 1-100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Assembly Link 1-101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 ft (3.05m) Self Assembly Section With Lifting Sheaves 1-102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Highway Travel 1-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing The Crane 1-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

vSection 1 - Operating Instructions

Transporting The Crane 1-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting The Tubular Boom 1-104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Storage 1-106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Short Term Storage 1-106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Long Term Storage 1-106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

vi Section 1 - Operating Instructions

1-112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

1-1Section 1 - Operating Instructions

Figure 1-1Crane Nomenclature

1. Boom Head Machinery2. Basic Pendants3. Live Mast4. Boom Backstops5. Upper Counterweights

6. Carrier Cab7. Bumper Counterweight8. Bumper Outrigger9. Front Outrigger10. Carrier

11. Upper12. Rear Outrigger13. Upper Operator's Cab14. Basic Boom15. Hook Block

11

5

3

9 8

4

6 7

10

14

12

13

2

1

15

Operator's Manual

1-2 Section 1 - Operating Instructions

Figure 1-2Diesel exhaust fumes can be harmful.

Diesel exhaust fumes can beharmful. Start and operateengine in a well ventilated area.If it is necessary to operate in anenclosed area, vent the exhaustto the outside. Properlymaintain the exhaust system toits original design.

Figure 1-3Keep hands and tools clear of moving parts.

Keep clear ofmoving parts toprevent seriousbodily injury.

Operating SafetyRemember SAFETY every day. Someone's LIFE maydepend on it, MAYBE YOUR OWN.

Safe operations of a crane requires a well trained,qualified operator. Crane operation is more involvedthan it may appear, and operation by a careless or un­qualified person can result in a serious accident.

When a crane is maintained and used properly it canbe a safe, highly productive piece of equipment, but ifnot used properly, it can be dangerous.

Think Safety - You, the operator, are in charge of animportant piece of equipment. It is very important thatyou know what it can do. It is also important that youknow what it should not do. No set of instructions cananticipate all of the situations you will encounter. Therules given here cover the general usage and some ofthe more common specific cases. If conditions arisenot covered by these rules, contact your Link‐Belt Dis­tributor. A phone call could save someone's life.

General Safety Rules

The following is a list of safety rules which should be fol­lowed during all crane operations.

Wrong

Figure 1-4Ensure the load will clear any obstruction.

Operator Awareness1. Read this Operator's Manual and heed it. This Op­

erator's Manual contains important information.2. An operator must not eat, read, or otherwise divert

his attention while operating a crane. Remem­ber-operating is a full‐time job.

3. Don't smoke when fueling or fuel up near an openflame. Keep the nozzle in contact with the fillerneck to prevent static electric sparks. Shutdownthe engine(s) when fueling.

4. Start and operate engine(s) in a well ventilatedarea. Diesel exhaust fumes can be harmful. If it isnecessary to operate in an enclosed area, vent theexhaust to the outside. Properly maintain the ex­haust system to its original design.

5. Keep your shoes clean. Before entering the cab(s),clean any mud, snow, ice, gravel, moisture, grease,etc. from your feet. Slippery shoes could cause mo­mentary loss of control of crucial foot operated controls.

6. Keep all walking surfaces (steps, ladders, plat­forms, etc.) and non‐skid materials on the craneclean. Non‐skid materials are placed on the craneto assist operators and service personnel with safeaccess/egress to/from the crane and to/from ad­justment and inspection areas. Do not allow non‐skid materials to become contaminated with mud,snow, ice, oil, paint, wax, etc. Any contaminationcan cause the non‐skid materials to become slick,reducing their effectiveness for safety while walk­ing on the crane. If any non‐skid materials becomeineffective due to wear, age, or destroyed in anyway, they must be replaced.

7. Keep fingers, feet, and clothing away fromsheaves, drums, and wire ropes unless the craneis shutdown and everyone knows what you are do­ing. Do not place a hand on wire ropes whenclimbing on the crane. A sudden movement couldpull them into the drums or sheaves. Never wearloose clothing which may be caught in machinery.

Operator's Manual

1-3Section 1 - Operating Instructions

WrongRight

Figure 1-5Level the crane.

A Small Side Tilt CanReduce Capacities By

Over 50%.

Grade Ground Level Or Block UnderCrane. The Load Line Should Hang

Parallel With The Boom.

8. The operator and person in charge of the loadmust observe the following rules:a. Loads must be well secured before lifting. En­

sure that the rigging cannot slip off or pull awayfrom the load or get out of position on the load.Ensure the load is rigged so it will not turn over.

b. Chains and slings must be of adequate size, ingood condition, and not twisted around eachother.

c. The load must not catch on an obstructionwhen lifting or swinging. Ensure the load, hoistwire ropes, or any other parts of the crane donot snag or strike any obstruction.

d. Do not allow the load to rotate out of control.Personal injury to ground personnel, loaddamage, crane damage, or damage to Anti‐two block system may occur.

e. When hoisting with single part line, especiallyin long falls applications, the design of wirerope and hook ball is crucial to minimize thepotential for uncontrolled wire rope and/orload rotation. Rotation resistant wire rope isrecommended for single part of line applica­tions. See Wire Rope Capacity Chart in theCrane Rating Manual for the specific types ofrotation resistant wire rope recommended foryour crane.

f. Avoid sudden starts and stops. Lift carefully,swing gently, brake smoothly, lower and setloads carefully. Jerking the load, swinging andengaging swing brake roughly, and loweringthe load rapidly and slamming on brakes willput shock loadings and possible side loadingson the boom. Unnecessary abuse labels theoperator as a beginner. Be a professional.

g. Do not wrap the winch wire rope around theload. Do not use discarded, worn, or dam­aged wire ropes for slings. They may breakand drop the load.

h. The crane must be level before making a lift.Use the bubble level to level the crane. Checkits accuracy, frequently, with a carpenter'slevel. Remember, a three degree side tilt canreduce capacities by 50% or more.

The hook block and/or hook ball and hoist wireropes can also be used as a “plumb bob” tolevel a crane. Pick up a compact load2,000-3,000 lb (907-1 360kg) a few inches(centimeters) above the ground. If crane islevel, hoist wire ropes will hang directly be­tween the boom foot. Now swing over the side.The lines should still hang directly between theboom foot. Don't use this method on a windyday.

Operator's Manual

1-4 Section 1 - Operating Instructions

Just A Little BumpLike This ...........

Can Cause This!Wrong

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

Wrong

Figure 1-7Do not use the boom to pull sideways.

9. Don't let the load or bucket hit the boom or jib.Don't let the boom or attachment rest on, or hit, abuilding or any other object. A dent or other dam­age could result, which will weaken the boom or at­tachment. If the damage is major, the attachment

could collapse. If a lattice or diagonal bracingmember on the boom or jib is broken, cracked, orbent, contact your Link‐Belt Distributor for repairprocedures. If the boom or jib is struck or dam­aged by anything, STOP. The loading on a boom orattachments increases as they are lowered, there­fore their suspension systems could collapse dur­ing lowering. Use another crane to lower a dam­aged boom or attachment.

10. Don't pull sideways on the boom or jib, not even alittle. Lift straight up on every load. Moving trucks,rail cars, barges, or anything else pulling sidewayson the winch wire rope could buckle the boom orjib. It could also damage the swing mechanism.Pulling sideways on a boom or jib can overturn thecrane.

11. Do not “two block” (pulling the hook block, hookball, or load into the head machinery) as this cancause winch wire rope breakage, sheave damage,or could pull the boom backwards over the craneresulting in an accident.

12. Ensure the boom hoist drum lock switch is alwaysin the “ON” position (pawl engaged) except whenlowering the boom. Don't rely on the boom hoistbrake alone to hold the boom. Wear, improper ad­justment, water or oil on linings, and many otherfactors may affect the ability of the brake to hold theboom.

13. Watch the load or signal person at all times. A sus­pended load must have your undivided attention.

14. Operate the crane from the operator's seat only.Operating the crane from any other position, such

Operator's Manual

1-5Section 1 - Operating Instructions

as reaching in a window, constitutes a safety haz­ard.

15. After slack winch wire rope operation, ensure thewinch wire rope is properly seated in sheaves andon drums before continuing to operate. Use a stickor mallet to set the winch wire rope, not yourhands.

16. Do not lower the load beyond the point where onlythree full wraps of winch wire rope are left on thedrum. This condition could occur when lowering aload beyond ground level. If all the winch wire roperuns off the drum, the load will jerk which couldbreak the winch wire rope.

17. Ensure that there is a safety latch on the hook andthat it works properly. Without a latch, it is possiblefor slings or chains to come off the hook, allowingthe load to fall.

18. Don't alter any part of the crane. Additions to orchanges in any part of the equipment can createloadings for which the crane was not designed.Such changes may have a major affect on the us­able capacities and make the entire Crane RatingManual invalid. Such changes can dangerouslyoverload or weaken critical parts and may causemajor failures.

19. Do not exceed the rated capacities of the crane un­der any circumstances. While a crane has morestability when lifting over a corner (as compared tostraight over the side) the crane capacity is not in­creased. Anytime the load exceeds the rated ca­pacities listed in the Crane Rating Manual, thecrane is overloaded. Overloads can damage thecrane and such damage could cause failure andaccidents.

20. Lifts where two or more cranes work together canbe hazardous and should be avoided. Such liftsshould be made only under the direction of a quali­fied engineer. If a multiple crane lift is unavoidable,observe the following rules:a. The cranes must be level and positioned on

firm surfaces.b. The cranes should be the same size and ca­

pacity, use the same boom length, and bereeved similarly.

c. Cranes must be positioned so that each boompoint is directly over its load attaching point.The winch lines must be vertical during allphases of the lift.

d. The rigging must be placed so each crane liftsa share of the load well within the crane's ca­pacity.

Right

Figure 1-8Crane level, beams fully extended and

tires clear of the ground.

e. Ensure that during handling more load is nottransferred to any crane than it can handle.

f. Don't attempt to travel when making multiplecrane lifts.

g. Coordinate plans with the other operator be­fore beginning to lift.

h. Use only one signal man.i. Use of an operable load and angle indicating

system is desirable.21. When operating on outriggers, the beams must be

fully extended. Jacks must be extended so all tiresare clear of the ground, and the crane must belevel. Ensure that pontoons are set on a firm sur­face, adequate to support the blocking, pontoon,crane, and load without settling, slipping, or col­lapsing. Blocking or matting under pontoons mustform a smooth level surface under the entire pon­toon. Do not block under outrigger beams insideof pontoons as this reduces stability. Blockingmust be under pontoons only. Remember-thereare tremendous loadings on pontoons and block­ing - the weight of the entire crane plus any load.

When blocking or matting under pontoons, ensurethat each pontoon is supported fully - no unsup­ported pontoon area is permissible. Ensure pon­toons are on a smooth surface. Rough surface,rocks, etc., under pontoons will cause unequalloadings, and can puncture them, causing them tocollapse.

Operator's Manual

1-6 Section 1 - Operating Instructions

Wrong

Figure 1-9Watch that carrier cab.

Capacities are based on outriggers fully extended.Working with outriggers partially retracted will re­duce capacities and crane stability considerablyand could cause an accident. If any outriggerbeam cannot be fully extended, lifts must be madewhile on tires, using only “on tires” capacities, withthe outriggers fully retracted. Do not make any liftswith a outrigger beam partially extended.

22. Before attempting to move the carrier, ensure thereis enough air pressure to operate the brakes. Al­ways check the brake operation before travelingthe crane.

23. Brake firmly in one application. Avoid fanning thebrakes. This could exhaust air pressure so fast thatthe compressor may not supply enough air.

24. Do not coast downhill with the transmission in neu­tral. It makes control of the crane more difficult anddangerous.

25. Shift the carrier transmission to neutral before op­erating the crane. Crane operation can causemovement which can damage the transmission ordrive line. When parking, shift to neutral and en­gage the park brake. Block wheels if on an unlevelsurface.

26. When operating over the front, use care not to hitthe carrier cab or front of the crane with the load orboom.

Wrong

Figure 1-10Submerged Loads

27. When lifting submerged loads, the suction causedby the load resting on the bottom acts to increasethe weight of the load - in some cases the actualload weight. This same effect can occur on land,for example, when a load is embedded in mud. Tobreak a load loose from suction, don't pull side­ways or a boom may collapse. If possible, rig theload so it is lifted from one end. Don't jerk on theload. A steady pull, maintained for several min­utes, will often free the load without over loadingthe equipment.

When a submerged load reaches the surface,don't attempt to lift it out of the water all at once. Itmay be saturated with water and will weigh manytimes what you expect. Allow it to drain as youraise the load slowly. Be patient, as draining maytake a long time. A load when removed from thewater, even when fully drained, will have a greatereffective weight than it will when submerged be­cause of buoyancy.

Operator's Manual

1-7Section 1 - Operating Instructions

Wrong

Figure 1-11Extracting Pilings

28. Don't extract piling, casings, or other such loads byjerking on them. The practice of pulling on the loaduntil the crane has tipped, then releasing the hoistline, allowing the crane to drop back and catchingthe hoist line on a clutch or brake may break theboom. If the piling or casing won't pull out with asmooth, steady pull, use an extractor, pullingframe, or some similar rigging intended for this pur­pose. Pulling on a load that is not free to be liftedcan develop loadings on the crane far in excess ofthe normal weight of the load. Imposing suchloads on a crane can damage the crane and maycause disastrous failure. When using a pile extrac­tor, use a shock or vibration insulator unit.

29. Operating with auxiliary equipment such as piledriver leads, pile hammers, or caisson boring at­tachments imposes additional loading in thecrane. This causes a major reduction in lifting ca­pacities of the crane. Changes in auger and kellybar lengths with drilling attachments and in pilehammer attachments further complicate the man­ner in which lifting capacities are reduced. Theweight of each piece of auxiliary equipment is to beconsidered a part of the live load acting at the ra­dius of the center of gravity of the piece.

30. Demolition work can be particularly hazardous.Shock loadings and side loadings from demolitionball and clamshell bucket work can cause majordamage. The repetitive nature of such work im­poses heavy demands on all parts of the crane.Restrict demolition ball weights to not exceed over50% of crane capacity (on tire capacities for truckcranes) at maximum radius at which you handlethe ball, with the boom length you are using. In nocase however, should the ball weight exceed 50%of the available line pull.

31. When using demolition ball, avoid sudden clutchand brake applications. Work steadily andsmoothly. Don't try to knock the whole structuredown with one blow. Use good aim. If the ballmisses its target, out swing could cause crane tip­ping or overload. When swinging back, ball mayhit the boom and damage it.

32. When using a clamshell bucket on demolition workand taking a bite on a piece of unknown weight, beready to release the closing line as more weight thanyou can handle may break loose. Be prepared todrop the load. Always stay within the boom lengthand load limitations shown in the lifting capacity chartin the Crane Rating Manual. Failure to do so maycreate fatigue which can lead to eventual failure.

Operator's Manual

1-8 Section 1 - Operating Instructions

Wrong

Figure 1-12Demolition Work

33. When dismantling a structure where a portion isbeing cut loose while suspended by a crane, en­sure the weight of the portion being cut loose isknown, and the crane pull on the load is equal tothe weight. The point of attachment must be di­rectly above the center of gravity of the load. Thehoist wire ropes must be vertical. This is an ex­tremely hazardous operation. The services of aprofessional engineer should be used to plan andsupervise such lifts.

34. Cold weather operation requires some special at­tention by the operator to allow for changes in eve­ryday routines:a. Clean the crane, especially the boom, of accu­

mulated amounts of ice or snow. The addedweight of the ice or snow can cause a major re­duction in the capacity of the crane. Operatingthe crane with an ice covered boom is danger­ous, as there is no way to determine how muchto deduct for the added weight.

b. During colder temperatures, any air reservoirson the crane will need more frequent draining.

c. If cold weather starting aids are provided onyour crane, use them. The use of aerosol start­ing sprays can be dangerous if the manufac­turer's directions are not closely followed.

d. Pay close attention to the gauges in the cab(s)when starting the engine(s). Normal “warmup” times will be longer. Confirm that pres­sures and temperatures are within normalranges before beginning operations.

e. Always handle flammable materials accordingto the supplier's instructions. Propane or die­sel or other fuel, for auxiliary heaters, can bedangerous if not properly handled. Do notstore such fuels on the crane.

f. Use caution when lifting any load during freez­ing weather, as it may be frozen to the groundor the supporting surface. The added tension,to break the load free, could cause an unex­pected overload situation. Also, when the loaddoes finally break loose it could create an er­ratic motion causing damage or injury.

Operator's Manual

1-9Section 1 - Operating Instructions

Pendants Incorrectly

Located For Boom Disassembly.

Do Not Stand Inside, On Top Of,

Or Under The Boom.

Wrong

RightPendants Correctly Located At Or Behind

Boom Connection To Be Disassembled.

Stand Outside The Boom.

Drive Connecting Pin To The Inside.

Figure 1-13Boom Safety

Boom Safety Instructions

Disassembly of any pin connected boom can be haz­ardous. Removing the wrong connecting pins or re­moving the connecting pins without first properly re­connecting pendants will cause the boom to fall. If youare under the boom when it falls, you may be killed. Al­ways block securely under both ends of each boomsection before removing any of the connecting pins.

The following points must be observed whileperforming any boom assembly or disassembly:

1. Read and understand the step by step instructionsoutlined in this Operator's Manual beforeattempting to assemble or disassemble the boom.

2. Do not stand inside, on top, or under the boom atanytime while assembling or disassembling theboom. Refer to Figure 1-13.

3. Do not climb, stand, or walk on the boom. Use aladder or similar device to reach necessary areas.

4. When removing or installing the boom sectionconnecting pins, drive the pins from the outside ofthe boom toward the inside.

Operator's Manual

1-10 Section 1 - Operating Instructions

Pendants Tight And

Located Behind Boom

Connection To Be

Disassembled.

Centerline Of

Boom Straight.

Boom Head Machinery

Resting on Secure Blocking.

Lower Pins Only

May Be Removed.

Wrong

Right

Wrong

Pendants Incorrectly

Located In Front Of

Connection To Be

Disassembled.

Lower Pins Removed.

WARNING - BOOM WILL FALL!

WARNING - BOOM WILL FALL!

Pendants Were

Located Behind Boom

Connection To Be

Disassembled.

Boom Head Machinery

Was Not Resting On

Secure Blocking When The

Pins Were Removed.

Upper Pins Removed.

Figure 1-14Pin Connected Boom Disassembly

Operator's Manual

1-11Section 1 - Operating Instructions

Wrong

Figure 1-15Block Under The Boom Top Section

Upper PinsRemoved.

Boom Top SectionNot On Blocking.

5. Always wear proper eye protection when drivingconnecting pins.

6. Block under both ends of the boom top section be­fore unpinning from extensions. Since the boomtop section is tapered, it will fall to the ground whenunpinned. This could result in an accident.

7. Do not remove any connecting pins which are be­hind the pendants which are supporting the boom.Refer to Figure 1-14.

8. Stay clear of pinch points when aligning boomsection connecting lugs. Never place your fingersin connecting pin holes.

9. Know the maximum amount of boom that can becantilevered, (projected beyond point of suspen­sion) during boom assembly and disassembly. Ex­ceeding this amount can cause boom or boomsuspension failure.

10. If the boom length is such that midpoint suspen­sions are required, ensure they are installed andproperly adjusted. Long booms may buckle in themiddle from their own weight without this suspen­sion.

11. Use caution when disconnecting the dead end ofwire ropes. Reeved wire rope can become twistedon the sheaves. When the dead end pin or socketis removed, the wire rope may spin.

Figure 1-16Cantilevering The Boom

Point OfSuspension.

Amount Of BoomBeing Cantilevered.

Figure 1-17Boom Section Nomenclature

1

2

3

54

1. Connecting Lug2. Diagonal3. Picture Frame

4. Lattices5. Main Chord

Operator's Manual

1-12 Section 1 - Operating Instructions

Figure 1-18Handling Boom And Jib Sections

RightWrong

1. Use The Connecting Lugs Or Main Chords As Lifting Points.2. Do Not Attach Slings To Lattices, They Will Bend.

1 2

Right

12. Use care handling the boom and jib sections whenloading, transporting, and unloading. Also payattention to the pendants stored on top of eachboom section. Damage that occurs during theseoperations can go undetected and could result infailure of the attachment. Do not attach slings tothe lattices as they will bend. Use the connectinglugs or main chords as the lifting points. Use onlysoft nylon straps minimum 3 inches (7.62cm) inwidth of sufficient strength to handle sections.

13. Block under and between the boom and jib sec­tions when loading them on a transport vehicle.When securing sections to a transport vehicle, it isbest to use synthetic webs or slings. If using wirerope slings, pad the section to protect it from dam­age. Do not overtighten the tie downs or you maydamage the section. Do not use chain tie downs,as they may dent and damage the section as well.

14. Thoroughly inspect all the elements of each boomor jib section before installing it on the crane.Check each main chord, picture frame, diagonal,lattice, and connecting lug for bends, dents, and

cracked or corroded welds. Picture frames mustbe square. Do not use any boom or jib section thatis even slightly damaged. Contact your Link‐BeltDistributor for the proper repair procedures.

Electrical Dangers1. All electrical power lines are dangerous. Contact

with them, whether insulated or not, can causedeath or injury. When operating near power lines,the best rule is to have the power company turn offthe power and ground the lines. However, in somecases, the operator may be unable to have thepower turned off. Follow these rules whether thepower is turned off or not.a. Be alert. You are working around conditions

which can cause death.b. Keep all parts of the crane, hoist wire ropes,

hook block, hook ball and load at least the min­imum distance away from power lines as spe­cified in the “High Voltage Power Line Clear­ance Chart” or other distances specified by ap­plicable codes. Slow down crane operation.

Operator's Manual

1-13Section 1 - Operating Instructions

Figure 1-19Stay away from power lines.

WrongELECTROCUTION HAZARD.Keep all parts of crane awayfrom electrical power lines.Refer to the Operator'sManual for minimumrequired clearances.

Stay away from craneif close to power lines.Crane, load, andground can becomeelectrified and deadly.Refer to the Operator'sManual for minimumrequired clearance.

c. Assume that every line is electrically energized(“Hot” or “Live”).

d. Appoint a reliable person equipped with a loudsignal (whistle or horn) to warn the operatorwhen any part of the crane is working aroundthe power line. This person should have noother duties while the crane is working aroundthe power line.

e. Erect a suitable barricade to physically restrainthe crane and all attachments (including theload) from entering an unsafe distance fromthe power source.

f. Warn all personnel of the potential danger.Don't allow unnecessary persons in the area.Don't allow anyone to lean against or touch thecrane. Don't allow ground workers to holdload lines or rigging gear unless absolutelynecessary. In these cases use dry plasticropes as tether lines. Ensure that everyonestays at least the minimum distance away fromthe load as specified in the “High Voltage Pow­er Line Clearance Chart”, or such distance asrequired by applicable codes.

Minimum Clearance When Operating Near HighVoltage Power Lines Or During Crane

Assembly/Disassembly.

Normal Voltage, kV(Phase to Phase)

Minimum Required Clearance, ft (m)See Note 1

To 200 15 (4.57)

Over 200 To 350 20 (6.10)

Over 350 To 500 25 (7.62)

Over 500 To 750 35 (10.67)

Over 750 To 1000 45 (13.72)

Over 1000

As established by the power lineowner/operator or registered profes­sional engineer who is a qualified per­son with respect to electrical powertransmission and distribution.

Minimum Clearance When Traveling With No Load

To 345 15 (4.57)

Over 345 To 750 16 (4.87)

Over 750 To 1000 20 (6.10)

Over 1000

As established by the power lineowner/operator or registered profes­sional engineer who is a qualified per­son with respect to electrical powertransmission and distribution.

Note 1: Maintain 50 ft (15.2m) minimum clearance from powerlines if voltage is unknown. If unknown but yet known to be lessthan 350 kV, maintain 20 ft (6.1m) minimum clearance.

Note 2: Environmental conditions such as fog, smoke, or precipit­ation may require increased clearances.

High Voltage Power Line Clearance Chart

Operator's Manual

1-14 Section 1 - Operating Instructions

Wrong

Figure 1-20Crane equipped with proximity

warning device on the entire boom.

Shaded area shows “sensitivity zone” with full boom length sen­sor used. Contact can be made outside this zone by the falllines, winch wire rope, cab(s), etc. In such cases, the alarm willnot sound, but the crane will be electrified and deadly.

g. The use of boom point guards, proximity de­vices, insulated hooks, or swing limit stops donot assure safety. Even if codes or regulationsrequire the use of such devices, you must fol­low the rules listed here. If you do not followthem, the result could be serious injury ordeath.

h. Grounding the crane can increase the danger.Poor grounding, such as a pipe driven into theground, will give little or no protection. In addi­tion, a grounded crane may strike an arc soheavy that a live line may be burned down.This could cause the crane and the areaaround it to be electrified.

Wrong

Figure 1-21Crane equipped with proximity

warning device on the boom tip.

Shaded area shows “sensitivity zone” with the probe near theboom peak. Contact can be made outside this zone by the falllines, winch wire rope, cab(s), etc. In such cases, the alarm willnot sound, but the crane will be electrified and deadly.

i. When operating near radio or T.V. transmittingstations, high voltage can be induced in metalparts of the crane or in the load. This can occureven if the crane is some distance from thetransmitter or antenna. Painful, dangerousshocks could occur. Contact trained elec­tronic personnel before operating the crane todetermine how to avoid electrical hazards.

j. Overhead lines can move when the wind blowsagainst them. Allow for this when determiningsafe operating distances.

Operator's Manual

1-15Section 1 - Operating Instructions

This Man Is Not Protected.

Wrong

Figure 1-22Crane equipped with insulated link.

1. Insulated Link

1

2. What do you do if a power line is touched by a

crane or load?

a. Remain calm - think - a mistake can killsomeone.

b. Warn all personnel to keep clear.c. If crane will still operate, try to move it away

from contact. You, the operator are reasonablysafe in the cab(s) unless the crane is on fire oran arc is cutting through the cab(s).

d. Move away from contact in the reverse direc­tion to that which caused the contact. Exam­ple: If you swing left to the wire, swing to theright to break contact. Remember - once anarc has been struck, it will stretch out much far­ther than you think before it breaks. Keep mov­ing until the arc has been broken.

e. When the arc breaks, continue moving awayuntil you are at least the minimum distanceaway as specified in the “High Voltage PowerLine Clearance Chart” or as specified by localcodes). Stop the crane. Make a thorough in­spection for crane damage before further use.

f. If you cannot disengage from the electricalline, and the crane is not on fire or no arc is cut­ting through the cab(s), stay in your seat untilpower line can be turned off.

Wrong

Figure 1-23Crane equipped with insulated link and boom

point guard.

1. Insulated link if wet or contaminated will not provide protec­tion.

1

g. If you must leave the crane, don't step off.Leap from the crane as far as you can, landingwith feet together, then hop away from thecrane with feet together, or shuffle feet to keepthem close together. This could help preventpersonal injury.

3. When using a magnet:a. Lifting magnet generators produce voltage in

excess of 200 volts and present an electricalshock hazard. Only trained personnel shouldwork on the magnet, controller, or wiring.Don't open the controller door with the genera­tor running.

b. Do not let workmen touch magnet or load.c. Do not let workmen get between magnet and a

metal object.d. If necessary, use a dry, wooden stick to posi­

tion the load.e. Open magnet disconnect switch at magnet

control panel before connecting or discon­necting leads.

Operator's Manual

1-16 Section 1 - Operating Instructions

Wrong

Figure 1-24No hook riders.

Radio Frequency Or Electro MagneticInterference (RFI Or EMI)

Certain areas may contain high Radio Frequency OrElectro Magnetic Interference (RFI or EMI). In theseareas the boom can act like an antenna and producean electrical current that may cause electrical shocksand/or the crane to malfunction. If operating in an areawhere these conditions may exist, test the crane orhave the area tested for the magnitude of this interfer­ence before operating the crane. Operation may notbe possible or boom length may be limited. Complywith all local, state, and federal laws when operating inhigh RFI/EMI areas.

Protective Equipment1. Always replace protective guards and panels be­

fore operating the crane.2. Always wear hard hats, safety glasses, steel toe

shoes, hearing protection, and any other safetyequipment required by local job conditions,OSHA, or regulations. Do not wear loose clothingwhich could get caught in moving machinery.

3. Always wear safety glasses when drilling, grinding,or hammering. Flying chips could injure the eyes.

4. Always wear a mask to prevent breathing any dust,smoke, fumes, etc. while cleaning, drilling, weld­ing, grinding, sanding, etc. on any part of thecrane. Breathing dust, smoke, fumes, etc. can bevery hazardous.

5. Keep a dry chemical or carbon dioxide fire extin­guisher of 5BC rating or larger in the cab(s) or inthe immediate area of the crane at all times. In­struct all operating and maintenance personnel inproper use of the extinguisher. Check periodicallyto ensure it is fully charged and in working order.

6. Do not tamper with safety devices. Keep them ingood repair and properly adjusted. They were puton the crane for your protection.

Wrong

Figure 1-25Use a signal person, back safely.

7. When operating a crane equipped with any form ofload indicating mechanism, overload warningsystem, anti‐two block system or any automaticsafety device, remember that such devices cannotreplace the skill and judgment of a good operator.For instance, such devices cannot tell when a craneis positioned on a supporting surface that will giveaway, that too few parts of line are being used to lift aload, cannot correct for the effects of wind, warn thatthe device may be improperly adjusted, correct forside pulls on the boom, or for many conditions whichcould occur and create hazards.

It requires all the skill, experience, judgment, andsafety consciousness that a good operator can de­velop to attain safe operation. Many safety devicescan assist the operator in performing his duties, buthe should not rely on them to keep him out of trouble.

Signal Persons And Bystanders1. Don't allow crane loads to pass over people or en­

danger their safety. Remove all loose objects fromload. All unnecessary personnel should leave theimmediate area when crane is operating.

2. Do not allow anyone to ride on the hook block, hookball or any part of the load or attachment for construc­tion work or recreational activities. (This applies to rec­reational activities such as “bungee jumping” or “bun­gee cord jumping”.) Cranes are intended to lift objects,not people. They are not elevators.

3. Always look before you back up and post a signalperson to guide you. If crane is equipped with aback up alarm, ensure it is working properly. Usethe horn as a signal. Use a code such as one beep- stop, two beeps - forward, and three beeps -backward. Confirm that everyone on the job siteknows the code.

4. Do not make a lift which is not in plain sight. Thiscan lead to an accident or crane damage. Post asignal person, if necessary, to fully observe thesituation and guide the operator.

Operator's Manual

1-17Section 1 - Operating Instructions

Figure 1-26Allow engine(s) to cool before removing the

radiator cap

Crane Inspections And Adjustments1. Inspect crane daily. Do not operate a damaged or

poorly maintained crane. Pay particular attentionto the clutches, brakes, attachments, and wireropes. If a component is worn or damaged, re­place it before operating. Clutch and brake liningsmust be dry and oil free. Oil soaked linings must bereplaced.

2. Labels, plates, decals, etc. should be periodicallyinspected and cleaned as necessary to maintaingood legibility for safe viewing. If any instruction,caution, warning, or danger labels, decals, orplates become lost, damaged, or unreadable, theymust be replaced.

3. Use extreme caution when removing radiatorcaps, hydraulic pressure caps, etc. They can fly offand hit you, or you could be burned by hot oil,water, or steam.

4. When performing repetitive lift applications, espe­cially at or near maximum strength limited capaci­ties, an inspection of the major structural areas ofthe crane, for cracks or other damage, should beconducted on a regular basis. (A non‐destructivetest such as magnetic particle or dye penetrantmay even be considered.) Along with inspectionfor cracks and damage, frequently check the criti­cally loaded fasteners, such as the turntable bear­ing mounting capscrews, to ensure they have notbeen stretched. Not only does frequent inspectionpromote safety, but it is also much easier and lessexpensive to perform a repair when a crack issmall, before it has a chance to traverse through astructural member. Any sign of cracks or damagemust be repaired before continuing operations.Contact your Link‐Belt Distributor for repairs.

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

CRANE OUT OF SERVICE

Signed:

DANGER

Figure 1-27Remove the keys from the ignition and post a

sign to make others aware of repair activity

Do not operate the crane or start theengine without first notifying thismechanic. Personel within the cranecould be hurt or killed. Crane damagemay also result from prematureoperation of systems which are stillunder repair.

5. When performing maintenance on the crane, per­form the following:a. Lower the boom to the ground.b. Shutdown the engine(s) and work all control

levers back and forth to relieve pressure andrelax the attachment.

c. If the above instructions cannot be followed,block securely under the attachment so it can­not move.

d. Bleed any precharge off the hydraulic reservoirbefore disconnecting any line.

e. Hydraulic oil becomes hot during operation. Insome cases it becomes hot enough to causeserious burns. Be careful not to let hydraulic oilcome in contact with skin.

f. Disconnect battery cables and remove ignitionkey so crane can't be started. Post warningsigns in cab(s) so no one will try to start the en­gine(s). Never adjust, maintain, or repair a ma­chine while it is in operation.

6. When making repairs which require welding, useproper welding procedures. Also the followingprecautions must be taken.a. All paint in the area should be removed to pre­

vent burning the paint. The smoke and fumesfrom the burning paint can be very hazardous.

b. Disconnect the carrier and upper batteries.Move the battery disconnect switches on thecarrier to the “OFF” position. Disconnect thebatteries from the upper.

c. The welding ground cable should be attachedto the portion of the crane being welded. Ifwelding on the upper, ground on the upper. Ifwelding on the carrier, ground on the carrier.Failure to take this precaution may result inelectrical arcs in the turntable bearing.

Operator's Manual

1-18 Section 1 - Operating Instructions

Right

Figure 1-28Use a tire cage when inflating tires

d. The welding ground cable should always beconnected, as close as possible, to the areabeing welded. This minimizes the distancethat electricity must travel.

e. Disconnect computers and other electronicequipment (such as Rated Capacity Limitersand engine computers) to prevent damage.Contact the Link‐Belt Distributor for properprocedures.

f. Remove all flammables from the proximity ofthe welding area.

7. Keep the crane clean, in good repair, and in properadjustment. Oil or grease on the decks may causefalls. Improper adjustments can lead to cranedamage, load dropping, or other malfunctions.

8. Check tires daily for correct pressure. Do not standin front of a tire when inflating it. The lock ring canfly off and injure you. Use a clip on inflator, andstand aside. Use a tire cage in front of the tire.

9. Inspect the tires for nicks and cuts, embeddedstones, and abnormal wear. Make certain dualwheels are properly matched for diameter andtread wear. Check for stones and other objectswedged between tires on dual wheels. Ensure alllug nuts are properly torqued.

10. Keep all walking surfaces (steps, ladders, plat­forms, etc.) and non‐skid materials on the craneclean. Non‐skid materials are placed on the craneto assist operators and service personnel with safeaccess/egress to/from the crane and to/from ad­justment and inspection areas. Do not allow non‐skid materials to become contaminated with mud,snow, ice, oil, paint, wax, etc. Any contaminationcan cause the non‐skid materials to become slick,reducing their effectiveness for safety while walk­ing on the crane. If any non‐skid materials becomeineffective due to wear, age, or destroyed in anyway, they must be replaced.

Wrong

Figure 1-29Do not use an open flame near the battery

WARNINGBattery posts, terminals, and relatedaccessories contain lead and lead

compounds. Wash hands after handling.

11. When checking battery fluid level, use a flashlight,not an open flame. If the battery explodes, you canget acid in your eyes, which could cause blind­ness. Don't check battery charge by shortingacross posts. The resulting spark could cause thebattery to explode. Check with a tester or hy­drometer. Don't smoke near batteries.

12. When using jumper cables to start an engine, al­ways connect negative post to negative post andpositive post to positive post. Always connect thetwo positive posts first. Then make one negativepost connection. Make the final negative connec­tion a safe distance from the battery. It can bemade on almost any bare metal spot on the crane.Any spark could cause the battery to explode.

13. Test the winch brake by raising the load a few inches(centimeters) and holding. It should hold withoutslipping. It takes more braking power to hold a loadin the air when the drum is full of wire rope than whenit is a few inches (centimeters) above the ground withonly a few wraps on the drum.

14. Always reduce pressure in hydraulic system tozero before working on any part of the system.

15. Use extreme care when working with circuits withaccumulators. Check that hydraulic pressure is re­lieved before opening the circuit for repairs.

16. When setting pressures, never exceed the manufac­turer's ratings. Always follow instructions exactly.Over pressurization can cause hydraulic componentdamage or failure of mechanical parts on the crane.Either of the above can lead to an accident.

Operator's Manual

1-19Section 1 - Operating Instructions

Wrong

Figure 1-30Do not operate the crane with worn or

damaged wire rope.

“I thought I could savemoney by running thiswire rope until Friday.”

Thursday . . . .

Wire Rope1. Inspect all wire rope thoroughly. OSHA (Occupa­

tional Safety And Health Act) regulations state “athorough inspection of all wire ropes shall be madeonce a month and a full written, dated, and signedreport of the wire rope condition be kept on filewhere readily available.” Replace any worn ordamaged wire rope. Pay particular attention towinch wire ropes. Check end connections (pins,sockets, wedges, etc.) for wear or damage.

2. Use at least the number or parts of winch linespecified on the Wire Rope Capacity Chart to han­dle the load. Local codes may require more partsof line than is shown. Check code requirementsand use them where applicable.

3. Non‐rotating, rotation resistant, or spin resistantwire ropes are recommended for single part of lineapplications. This is of utmost importance for longfall hoist line applications. Only if certain criteria aremet may a swivel hook ball be used with rotationresistant wire rope. Refer to “Single Part Line Hoist­ing” and “Hook Ball Usage With Rotation ResistantWire Rope” in Section 5 of this Operator's Manual.

4. Do not handle wire rope with bare hands. Alwaysuse gloves to prevent possible injury from frayed ordamaged spots in the wire rope.

5. Inspect head machinery and hook block often asdamaged or deteriorating sheaves can cause ma­jor wear of the wire rope.

6. When reeving wire rope on the crane, do not climb,stand, or walk on the boom or jib. Use a ladder orsimilar device to reach necessary areas.

Figure 1-31Pinch Point Label

Crane And Area Clearance1. Know your job site conditions. Familiarize yourself

with work site obstructions and other potential haz­ards in the area which might lead to mishaps.Make any necessary arrangements to eliminateany potential hazards, if possible.

2. Erect barricades around the immediate work areato prevent unauthorized personnel from wander­ing onto the job site.

3. Ensure your work area is clear. Confirm that thereis proper clearance for the crane, boom, and load.Don't swing, travel, lift, or lower loads, raise orlower jacks, without first making sure no one is inthe way. If your vision is obscured, locate a signalperson so you can see him, and he can see all ar­eas you can't. Follow his signals. Confirm that youand the signal person understand each other's sig­nals. See Hand Signal Chart Figure 1-88. Use thehorn to signal or warn. Confirm that everyone onthe job site understands signals before starting op­erations.

4. When working inside a building, check overheadclearance to avoid a collision. Check load limits onfloors or ramps so you won't crash through.

5. Don't operate close to an overhang or deep ditch.Avoid falling rocks, slides, etc. Don't park cranewhere a bank can fall on it, or it can fall in an exca­vation. Don't park where rain can wash out footing.

6. Pinch points, which result from relative motion be­tween mechanical parts, can cause injury. Keepclear of the rotating upper or moving parts.

Operator's Manual

1-20 Section 1 - Operating Instructions

Wrong

Figure 1-32Know your load.

“It looked likeabout 5 tons.

7. Watch the tailswing of the upper revolving frameand counterweight. Even though the original set‐up may have been clear, situations change.

8. Do not store material under or near electricalpower sources. Make material handlers aware ofthe dangers involved with storing material underpower lines or in the vicinity of any other hazards.

Weights, Lengths, And Radii1. Know your load. Don't try to guess or estimate the

load. Use a scale or a load indicating system to de­termine exact weight. Remember the weight youare lifting includes the weight of any lifting slings orgear, the hook block or hook ball, and any otherweight on the hook. If lifting off the boom with thejib installed, the weight of the jib and rigging mustalso be considered as part of the load. The totalload weight must never exceed the rated capacityof the crane, as listed on the capacity charts in theCrane Rating Manual, for the position, boomlength, load radius, and condition of operation be­ing used. Remember - capacity ratings are basedon ideal conditions:

a. Standing on firm, level surfaceb. Calm windc. No side loads or out swing of loadd. Good visibilitye. Crane in top condition and equipped as when

leaving the factory

Wrong

Figure 1-33Do not lift two loads at the same time.

When such conditions cannot be attained, loadsbeing handled must be reduced to compensate.The amount loads are reduced depends upon howgood or how poor, the actual operating conditionsare. It is a matter of judgment and experience.When in doubt, do not take a chance. Reduce rat­ings more than you think you need. Some factorswhich may require reduction of capacities are:

a. Soft or unpredictable supporting surfacesb. Windc. Hazardous surroundingsd. Inexperienced personnele. Poor visibilityf. Fragile loadsg. Crane in poor conditionh. Condition and inflation of tires

2. Avoid working a crane in high winds. If you mustwork in a wind, reduce capacities below thoseshown in the “Wind Restrictions Guide” in theCrane Rating Manual. Wind blowing against theload and the boom produces a side load on theboom and reduces its capacity.

When lifting loads in a wind which have large sur­face areas, such as building panels, movement ofthe load may pose a danger to workmen or build­ing structures. Out swing of a load will increase theload radius, and may overload the crane. Thiscould lead to boom failure or the crane tipping.

3. When operating off the main boom with the jib orother attachment erected, deductions must bemade for its weight. The weight of the added at­tachment, pendants, etc., must be subtracted toobtain a `NET' capacity. Failure to do so could re­sult in an overloading condition and cause boom

Operator's Manual

1-21Section 1 - Operating Instructions

failure. Refer to the Crane Rating Manual foramounts to be deducted.

4. Do not lift loads on the boom and jib at the sametime, even if the total load weight is within crane ca­pacity. Loads on the boom and jib at the same time,stress the boom and drastically reduce its ability tohandle loads. Your full attention cannot be given toboth loads, creating a dangerous situation.

5. Some capacities on cranes are based on strengthof materials. In these cases, overloads will causethe crane to break, before it will tip. Do not usesigns of tipping as a warning of overload.

6. Don't lash a crane down. Lashing a crane downencourages overloading. Crane damage or injurycould result.

7. Do not shock load and/or overload the crane atanytime. Shock loading or overloading the cranewill reduce the fatigue life of crane componentsand could result in component failure.

8. When performing repetitive lift applications, espe­cially at or near maximum strength limited capaci­ties, be aware that these applications may reducecomponent life. These applications include re­peated lifting (or lifting and swinging) of near 100%strength limited capacities and repeated liftingmaximum moment loads. These applications mayfatigue the major structural portions of the crane.Although the crane may not break during these ap­plications, they can reduce the fatigue life andshorten the service life of the crane. To improve theservice life, while performing repetitive lift applica­tions, consider reducing the capacities to 70% ofmaximum strength limited capacities to reduce fa­tigue cracking. Frequently perform a thorough in­spection of all the structural areas of the crane.Any sign of cracks or damage must be repaired be­fore continuing operations. Contact your Link‐BeltDistributor for repairs.

9. Always refer to the capacity charts in the CraneRating Manual after changing the arrangement ofthe attachments for the correct lifting capacities.

10. Tubular booms must be assembled in the correctmanner before making a lift. The capacity chartsfor such booms is based on proper boommake‐up. Correct placement of boom extensions,based on length and chord wall thickness, is cru­cial. On cranes which have multiple chord wallthicknesses, refer to the boom make‐up label forcorrect boom section arrangements.

11. Do not use the boom to push or pull. It is not de­signed for this purpose. Such action can damagethe boom and lead to an accident.

Wrong

Figure 1-34Use caution when booming to minimum radius.

12. Know the load radius. Don't guess at it. Determinethe load radius by using the boom angle indicator,the boom length, and the capacity chart in theCrane Rating Manual, or measure it with a steeltape. Remember - Radius is the horizontal dis­tance from the centerline of rotation of the upper tothe center of gravity of the load, when the load ishanging free.

13. Do not operate the crane at radii or lengths wherecapacity charts in the Crane Rating Manual showno capacity. Don't use a boom or jib not shippedwith or for your crane. Either of the above can tipthe crane over or cause attachment failure. Insome cases, the crane can tip over with no load onthe hook, forward or backward! Also, if the boom islong at a low angle, the crane may tip until theboom touches the ground. In any of these cases,injury or crane damage could result.

14. When you lift a load with any crane, the load mayswing out or sideways. The load radius will in­crease. The increase or out swing of the load canoverload the boom, and lead to boom failure or tip­ping. Also, movement of the load can cause it to hitsomething. Confirm that the load being lifted willremain within capacity as it is lifted and the boomdeflects.

15. When lowering a boom with a load, the load radiusincreases. As the load radius increases, capacitydecreases. If capacity is exceeded, the boom maybend or the crane may tip. Sometimes at low an­gles, the boom can be lowered with a load, butcannot be raised. If an operator lowers the boomunder load, he may not be able to raise the boomand may get into a dangerous situation.

Operator's Manual

1-22 Section 1 - Operating Instructions

Wrong

Figure 1-35Watch that side tilt.

Just a little side tilt whenworking over the end.

SIDE TILT

Look what happensover the side . . . .

LOAD RADIUS INCREASESBY THE AMOUNT OF SIDE TILT!

16. Use caution when booming up to minimum radius.Be prepared to stop boom travel. If the boom limitdevice malfunctions, the boom and backstopsmay be damaged or someone may be hurt. Do notintentionally boom into boom limit device duringnormal operation.

17. When operating near minimum radius, be ready toboom down as you set the load down, to compen­sate for the tendency of the boom to move backagainst the backstops when the load is released.This action occurs because of the elasticity in theboom and boom hoist system. Major bending inthe boom can occur if it is allowed to bear againstthe backstops too heavily.

18. When booming down, the load will move awayfrom the crane and lower as well. To keep the loadfrom lowering as it moves away from the crane, theoperator must hoist up on the winch wire rope si­multaneously. When booming up, the load willmove toward the crane as well as raise. Whenbooming up, the operator must hoist down as wellto keep from raising the load. Booming up withoutwinching down, can lead to “two blocking”. This iswhen the hook block, hook ball, or load contactsthe head machinery. Two blocking can lead tosheave or wire rope damage.

19. Know the boom length. Don't guess. Use of an in­correct boom length can cause an accident.

20. The winch wire rope and boom must be verticalwhen starting to lift. If not, the load will swing in,out, or sideways when lifted from the ground. Thecrane will lean toward the load when lifting heavyloads. This is caused by elasticity of the crane andthe boom. This lean will increase operating radiusso the load will swing outward when it clears theground. This out swing is dangerous to anything inthe path of the load, and because of the increase inload radius may overload the crane. To overcomethis out swing, boom up as the load is lifted sowinch wire ropes remain vertical. When setting theload on the ground, lower boom after the loadtouches down to avoid hook block or hook ballspinning when it is unhooked from load or theboom contacting the backstops.

Operator's Manual

1-23Section 1 - Operating Instructions

Right

Figure 1-36Boom angle and single part line operation.

A

B

21. Use special care when handling loads on singlepart line with boom at or near minimum radius. Insingle line operation, ensure angle “A” is alwaysgreater than angle “B”, or the boom could fall back­wards uncontrollably. Refer to Figure 1-36. Thissituation is more likely when the winch line is off therear drum. Four (4) parts of hoist line and a 3,500 lb(1 589kg) hook block must be used at or near mini­mum radius on all booms 100 ft (30.5m) or less.

22. Lifting heavy loads can cause the crane to tilt orlean toward the load. When swinging a load fromover the end to over the side, the tilt of the crane willincrease. Since tilt acts to increase load radius, itmust be compensated for when swinging the load.Swing slowly. Change boom angle (raise theboom) while swinging, to maintain a constant ra­dius, and prevent in swing or out swing of load. Ifnot, a dangerous condition could result.

23. Watch out for centrifugal force when swinging aload. Swing gently. Centrifugal force tends to in­crease load radius. This increase in radius couldoverload the crane and cause crane damage or tip­ping. When stopping the swing, over swing of theload can side load the boom.

24. Keep the winch wire ropes as short as possible toprevent excessive swinging. Always use the short­est boom length which will do the job. Remember- the shorter the boom, the better the capacity.

25. Do not move a crane away from the load while han­dling near capacity loads. Due to load inertia(weight) the load will tend to stay in position whenthe crane starts to move and then will swing in to­wards the crane. The inertia effect will tend to in­crease load radius and decrease stability. Thiscould lead to boom failure or crane tipping.

1. Load Radius At Rest2. Load Radius Increases Due To Centrifugal Force

Wrong

Figure 1-37Watch that centrifugal force.

12

26. Know how much counterweight is on the crane.The Crane Rating Manual may list different capaci­ties for differing amounts of counterweight. Ensureyou know how your crane is equipped and use thecorrect column on the chart to ensure proper loadlimitations.

Don't modify the counterweight(s). Don't storeanything on the crane that will act as additionalcounterweight. Remember that anything whichhas weight, if carried behind the crane's center ofgravity, acts as counterweight. Adding counter­weight affects backward stability of the crane, par­ticularly when working over the side. It also en­courages overloading of the crane.

27. Working areas for cranes are defined per the Work­ing Areas Diagram in the Crane Rating Manual.Permissible loads per the Crane Rating Manual,will vary from lifting quadrant to lifting quadrant.The operator must ensure capacity ratings are notexceeded regardless of which quadrant he is oper­ating in or when swinging from one quadrant to an­other.

28. When working on tires, the tires must be inflated topressures shown in the Crane Rating Manual.

Operator's Manual

1-24 Section 1 - Operating Instructions

Wrong

Figure 1-38Watch for narrow or low clearances.

Traveling1. Traveling with a suspended load should be

avoided if possible. It is especially hazardouswhen terrain is rough or irregular, on a side slope,or in a hilly area. When traveling with a load, ob­serve the following rules:

a. Use a hand line to control the load and reduceload swing.

b. Travel by the smoothest, most level route. If asmooth, level route is not available, don't travelwith a suspended load. Grade the route to pro­vide a smooth, level path. If it is not possible tograde the route, move the load by stepping.Level the crane on outriggers, lift the load andset it down ahead of the crane. Travel the un­loaded crane beyond the load, level the craneon outriggers, lift the load, swing, and set itdown farther along the route. Continue thisprocedure 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 thecrane sinks into ground, stability can be af­fected to the point of tipping the crane.

g. Keep all personnel clear of crane and load. Beprepared to set load down quickly at anytime.

h. Fully extend outrigger beams. Extend thejacks until pontoons just clear the ground.

i. Check clearance for the extra width of thecrane with the outriggers extended. Outriggerbeams or pontoons must not catch on any ob­struction.

j. Inflate tires to the values shown on the TireInflation Chart in the Crane Rating Manual orthe Tire Inflation Label on the carrier.

k. Refer to “Pick And Carry Operation” in this Sec­tion of this Operator's Manual for more details.

2. Do not exceed the maximum axle load ratings aslisted on the gross weight rating plate.

3. Road the crane safely. Watch for narrow bridgesand low clearances. Check load limit, height,width, and length restrictions in the area you aretraveling. Confirm that the crane complies with allregulations.

4. When roading the crane, note the following:a. Operate with lights on. Use proper warning

signs, flags, and other devices. Use an escortservice if required.

b. Engage two position house lock.c. Remove or restrain the hook block and/or

hook ball.d. Check for maximum allowable travel speed,

maximum amount of boom that can be trans­ported and any other travel limitations. Don'texceed these maximums. Crane damage oran accident could result.

e. When traveling, outriggers must be fully re­tracted.

f. Remove all pontoons from the outrigger jacksand store them properly.

5. See “Traveling The Crane” in this Section of thisOperator's Manual for more detailed travelinginstructions.

6. If the crane must be towed, shift the transmissionto neutral and move slowly. Slowly take up slack inthe wire rope or chain. Don't jerk, the chain or wirerope may break. Keep the chain or wire rope tightwhile towing.

Operator's Manual

1-25Section 1 - Operating Instructions

Leaving The Station1. Do not get on or off a crane in motion. Use both

hands when climbing on or off of the crane. If a lad­der is provided, use it. Remain in three point con­tact with the crane at all times (two hands and onefoot or two feet and one hand).

2. Whenever an operator leaves the control station forany reason, the following must be done:a. Lower the load to the ground.b. Engage the swing brake, move the drum con­

trol switch to the “ON” position, and move thecontrol lockout switch to the “OFF” position.Shutdown the engine(s) and remove the keys.

c. Do not depend on a brake to suspend a loadunless the operator is at the controls, alert, andready to handle the load. Brake pedal locksare intended to allow the operator to rest hislegs when suspending a load, but the operatormust remain in his seat with his feet on the ped­als. Brake slippage, vandalism, or mechanicalmalfunctions could cause the load to drop.

3. Do not leave crane unattended with engine(s) run­ning.

4. When changing work shifts always notify the nextoperator of any changes or problems with thecrane.

Personnel Handling Guidelines

Introduction

The following information is intended to provide Link‐Belt's recommended minimum requirements that mustbe followed when handling personnel with a personnelbasket or work platform (hereafter referred to as a workplatform) suspended by wire rope from the boom of Link‐Belt cranes. These requirements are based upon severalsources and are put forth in recognition of current in­dustry practices. However, safety, when handling per­sonnel, remains the full responsibility of job site manage­ment and is dependent upon the responsible action ofevery person on the job involved in the related work.

This information is intended to supplement and not to su­persede or replace any more restrictive federal, state, orlocal regulations, safety codes, or insurance require­ments. It is intended to serve users of personnel workplatforms in achieving the following objectives.1. Reduce risk of personal injuries to users and the

public.2. Inform users of their respective responsibilities.3. Provide standards of equipment requirements.4. Provide standards for tests and inspections.5. Provide standards of operation to promote safety.

Link‐Belt cranes are designed and intended for handlingmaterial. They are not normally equipped with secondarysystems or other devices required by personnel lift or el­

evator standards and are not intended for handling per­sonnel for construction or amusement purposes. Use ofcranes for these purposes is hazardous and is not re­commended by Link‐Belt. However, Link‐Belt under­stands that circumstances may occur (in constructionwork) when lifting or lowering personnel on a materialshandling crane load line is the only or the least hazardousmethod available to position personnel. In fact, Occupa­tional Safety and Health Administration (OSHA) Part 29,CFR 1926.1431 states “The use of equipment to hoistemployees is prohibited except where the employerdemonstrates that the erection, use, and dismantling ofconventional means of reaching the work area, such aspersonnel hoist, ladder, stairway, aerial lift, elevating workplatform, or scaffold, would be more hazardous, or is notpossible because of the project's structural design orworksite conditions.”

Much corollary and supplementary information is con­tained within the following resource documents per­taining to both cranes and personnel work platforms.Job site management must ensure all requirements lis­ted in these resource documents are followed for allpersonnel handling operations.� American National Standards Institute Reference -

ANSI Standards A10.28, A92.2, A92.3, B30.5, andB30.23.

� Power Crane and Shovel Association (PCSA) Bureauof the Association of Equipment Manufacturers(AEM) Reference - PCSA Standard No. 4.

� American Petroleum Institute (A.P.I.) Specification 2C.� OSHA Part 29, CFR 1926.1431 Cranes and Derricks.

Authorization

Authorized use of a work platform may be permittedonly after the following on‐site procedures have beenperformed:1. A competent person on the job site (job site man­

ager) specifically responsible for the overall workfunction to be performed has determined thatthere is no practical alternative means to performthe needed work and has authorized a personnellifting operation.

2. For each instance of such lifting, a competent per­son responsible for the task has attested to theneed for the operation by issuing a written state­ment describing the operation and its time frameand itemizing that each of the on-site authoriza­tion requirements has been met. The written state­ment, after being approved by a qualified person,shall be retained at the job site. (Refer to Personnel

Handling Pre‐Lift Check List For Link‐Belt Cranes inthis Section for a sample check list.)

3. Review of crane inspection records has been con­ducted to ensure the crane being used meets ap­plicable provisions in ANSI B30.5 and B30.23.

Operator's Manual

1-26 Section 1 - Operating Instructions

4. Review of the work platform inspection recordsand specifications has been conducted to ensure itmeets applicable design standards (refer to ANSIA10-28).

5. Review of the personnel lifting operation practicesspecified in these instructions have been conduc­ted with job site managers and crane operator(s),foreman, designated signal person, personnel tobe lifted, safety supervisor, and any other per­son(s) who has jurisdiction over the operation toensure that they are aware of the hazards of the op­eration and they are aware of provisions of theseinstructions that must be adhered to before andduring the personnel lifting operation.

Equipment1. The crane system shall be equipped with the fol­

lowing:a. A fully functional working operational aid such

as a Rated Capacity Limiter (RCL) system - Asystem consisting of devices that sense craneloading, boom length (extendable boomsonly), boom angle, and also automaticallyprovide an audible/visual signal when theloading conditions approach, reach, and/orexceed the rated capacity values. When theActual Load exceeds the Rated Capacity, thesystem supplies a signal to a function cutoutsystem. The operational aid shall be equippedwith these additional devices:1. Anti‐two block device to prevent damage

to the hoist wire rope, other crane com­ponents, or attachments, and subsequentendangerment of personnel.

� It is required that the anti‐two blockdevice warn both audibly and visually aswell as have the capability to cutout thecontrols/functions that may cause a twoblock condition.

2. Boom angle indicator.

� Cranes with extendable booms mustutilize a boom angle indicator having“high and low” set points and audible/visual alarm(s) capable of activatingfunction cutouts.

b. Boom hoist and load line shall have powerlowering and raising and shall have an auto­matic brake which is applied when the applic­able control is in neutral, or when the anti‐twoblock device is actuated.

c. If the crane is equipped with a “free‐fall” hoist,steps shall be taken to ensure its use is notpossible during the use of the work platform.(Note: A.P.I. applications do not permit thecrane to be equipped with free‐fall.)

d. Each crane shall have a mechanical swingpark brake or swing lock capable of being setat any swing position, and shall have a variableswing brake or swing controls capable of stop­ping the upper swing motion smoothly. Theswing brake must be properly maintained at alltimes to ensure its holding capability.

Note: All operational aids and equipmentmust be maintained in operable condition.Alternative measures are not permitted.

2. The work platform shall be designed by a qualifiedengineer competent in structural design. Its main­tenance, and its attachment to the crane load line,is the responsibility of the job site management.Their arrangement shall comply with the followingas a minimum:a. The work platform harness must be of suffi­

cient length to prevent any portion of the workplatform or the harness from coming in contactwith the boom at any working boom angle.

b. Audible and visual alert systems shall beprovided to the personnel in the work platformto signal for assistance in the event of an emer­gency.

c. Hooks on hook block assemblies, hook ballassemblies, or other assemblies, shall be of atype that can be closed and locked, (with aworking safety latch) eliminating the hookthroat opening, and shall be full load‐bearing,and contain a manual trigger release.

3. No unauthorized alterations or modifications areallowed to be made to the basic crane.

Maintenance, Lubrication, And Adjustments1. The crane operator must have a complete under­

standing of the crane's maintenance, lubrication,and adjustment instructions as outlined in theOperator's Manual.

2. The crane shall be maintained, lubricated, and ad­justed, by a designated person, as specified in theOperator's Manual.

3. The crane and work platform decals must be un­derstood and maintained.

4. All decal precautions and instructions shall bestrictly observed.

Inspection And Rigging1. The lift crane and work platform shall be inspected

immediately prior to commencement of operation.(Refer to the Crane Operator's Manual and ANSIB30.5, Section 5, Section 5-2.1.2 and 5.2.4, andANSI B30.23 for the required inspection proceduresfor the crane. Refer to ANSI A10-28 for inspectionprocedures required for the work platform.)

Operator's Manual

1-27Section 1 - Operating Instructions

Telescopic Booms

Main Boom HeadSheaves

Auxiliary Head Sheaves Fixed Fly Sheave

Allowed Allowed Allowed

Offset Fly SheaveOffset Fly With

Extension(s) SheaveA-Frame Jib Sheave

Allowed Allowed Not Recommended

Conventional LatticeTubular or Angle Booms

Main Boom HeadSheaves

Tip Extension Sheaves Jib Head Sheave

Allowed Allowed Allowed

LuffingAttachments

Luffing BoomAuxiliary Head

SheavesMidfall Sheaves

Luffing Jib HeadSheaves

Fixed Jib HeadSheave

Not Recommended Allowed Allowed Not Recommended

Lifting Sheaves For Personnel Handling With Suspended Work Platforms

2. The inspection shall be performed once daily whenthe crane is being used in work platform service oreach time the crane is converted from material lift­ing to personnel handling operation. In the eventthe operator is replaced, a new inspection is re­quired. Written documentation of all inspectionsmust be kept on the job site during personnelhandling operations.

3. Inspect the crane and work platform for any loose,damaged, or missing components.

4. Any structural or functional defect which adverselyaffects the safe operation of the lift crane shall becorrected before any operation utilizing a workplatform begins or continues.

5. The hoist drum shall have at least three full wraps ofwire rope remaining on the drum at all times whenusing a work platform.

6. Minimum load hoist and boom hoist wire ropedesign factors for the combined weight of the lift at­tachments, work platform personnel, and tools shallbe 10:1 for “Non‐Rotating” and “Rotation Resistant”wire ropes. All other wire rope types require a 7:1design factor. (Note: A.P.I. applications require 10:1design factor for all wire rope construction.)

7. The work platform shall be suspended from a wirerope that is reeved from an allowed lifting sheave.Refer to “Lifting Sheaves For Personnel HandlingWith Suspended Work Platforms” chart to determ­ine the allowed sheave(s).

8. Inspect the wire ropes, sheaves, hoist drumbrakes, and other mechanical and rigging equip­ment vital to the safe operation of the crane.

9. Ensure that all wire rope sockets and dead endlugs are properly installed and are in good workingcondition.

10. Ensure that all wire rope guards are in good workingorder and that they are properly installed and adjus­ted to prevent wire rope from jumping off sheaves.

11. Inspect all structural members of all boom sec­tions, fly sections, luffing jib sections, and livemast, as equipped.

12. In addition to other regular inspections, visual inspec­tion of the crane and work platform shall be conductedimmediately after testing and prior to lifting personnel.The following inspections shall be conducted on ex­tendable booms prior to lifting personnel:a. Full power style booms:

1. Inspection of all extension wire ropes atthe access points in the boom where theend connections are visible - Refer to theOperator's Manual for inspection and ad­justment procedures.

b. Pinning and latching style booms:1. Inspection of the latching mechanism,

sensors, and hydraulic/electrical circuit atthe access points.

2. Inspection of all pins and pinning locationsin the individual boom sections and at thefully retracted position.

3. Verification of the accuracy of the boomlength indicator. Refer to the Operator'sManual for the procedures.

13. The following inspections shall be conducted onfixed length style booms prior to lifting personnel:a. Inspection of all pendants, pendant links,

pendant spreader bars, links, etc.b. Inspection of all mechanical linkages, shafts,

drums, etc.14. A written record of all the above inspections must

be maintained on the job site.

Crane Test ProceduresThe test procedures listed below shall be conducted atthe following intervals:� Daily,� At each job site before hoisting employees,

Operator's Manual

1-28 Section 1 - Operating Instructions

� After any repairs or modifications to the equipment,� When an operator is replaced, and� When, in the judgement of responsible job site man­

agement, or controlling entity, there has been a signi­ficant change in the conditions of the personnel liftingoperation.

Note: No personnel are allowed to ride the work

platform during any of the tests recommended inthis Section.

1. The work platform and rigging shall be proof testedto 125 percent of the work platform's rated capa­city. (The proof test may be done concurrently withthe trial lift by completing the following test proced­ures.) Do not exceed the rated lifting capacity ofthe applicable lift crane as listed on the crane capa­city charts. (Refer to ANSI A10.28 for suspendedwork platform testing and inspection.)a. This test load shall be tested for stability.

� The operator and signal person shall con­duct this test.

� This test shall include movement of the workplatform through its entire intended range ofmotion, simulating the specific operation tobe undertaken.

� A successful stability test must not produceinstability of the crane or cause permanentdeformation of any component.

b. This test load shall be raised and lowered atmaximum power controlled line speed (NOTFREE‐FALL). The acceleration must besmooth and the deceleration capability of thecontrol/braking system shall be confirmed bybringing the work platform to a smooth stop.The work platform shall be held in a suspen­ded position for a minimum of five minutes withthe test load evenly distributed on the workplatform. (This experience is intended tosharpen the skill of the operator in handling thework platform and to give the operator an op­portunity to evaluate the crane's perform­ance.) The work platform shall then be inspec­ted for any evident sign of damage or defect.

2. All limiting and warning devices shall be tested byactivation of each appropriate control function.

3. With pinning and latching style extendable booms,a visual inspection shall be conducted to verify thatthe boom extend pins are properly set in the exten­ded boom sections.

4. At the beginning of each lift, the work platform mustbe hoisted a few inches (mm) with the personneland materials/tools on board and inspected by acompetent person to ensure;� The work platform is secure and properly bal­

anced,

� All wire ropes are free of deficiencies such askinking, crushing, corrosion, etc.,

� Any multiple part lines are not twisted,� The primary attachment is centered over the

work platform, and� If any load rope is slack, it must be inspected to

ensure that all ropes are properly seated on thedrum and in the sheaves.

5. Any condition found during any of these tests/in­spections that fails to meet requirements or maycreate a safety hazard, must be corrected beforehoisting personnel.

Operation And Safety1. The Operator's Manual for the crane shall be read

and fully understood by operating personnel. TheCrane Operator's Manual shall be available tothem at all times.

2. Safety when handling personnel remains the fullresponsibility of job site management and is de­pendent upon the responsible action of every per­son on the job involved in the related work.

3. Mobile lift cranes shall be erected to obtain maxim­um crane stability. The crane must be level and onfirm ground. It is recommended that the outriggersbe fully extended and the tires must be clear of theground before beginning any operation.

4. The operator shall not leave the operator's stationwhen the work platform is occupied. The operatorshall remain alert in a position of readiness at thework station with the engine running and the mas­ter clutch engaged, if crane is so equipped.

5. Unauthorized personnel shall not be in the operat­or's cab on the lift crane, or near the lift crane whilea work platform is suspended from the load line.

6. Any operation in which a work platform is to be sus­pended from the load line shall be carefullyplanned by the operator, supervisory personnel,designated signal person, and personnel to be lif­ted prior to commencement of such operation.They are to be advised:a. That the crane does not have safety devices nor­

mally used on personnel handling equipment.b. That the safety of the operation depends on

the skill and judgment of the crane operatorand others present.

c. Of procedures to enter and leave the work plat­form and other safety procedures.

7. After positioning of the work platform:a. All brakes and locks on the lift crane shall be

set before personnel perform any work.b. With pinning and latching style extendable

booms, a visual inspection shall be conductedto verify that the boom extend pins are properlyset in the extended boom sections.

Operator's Manual

1-29Section 1 - Operating Instructions

8. Telescope operation is not recommended with anyextendable boom with personnel in a suspendedwork platform.

9. A work platform attached to load line of lift cranesshall not be used for working on any energized elec­tric power line, or any energized device or facilityused for electric power generation or transmission.Minimum working clearance shall be at least twicethat recommended for material handling operationsin ANSI B30.5b section 503.4.5 and ANSI B30.23.

10. The combined weight of the work platform, any at­tachment device, personnel, tools, and otherequipment shall not exceed 50% of the lifting capa­city of the applicable lift crane as listed on the cranecapacity chart. (Note: A.P.I. applications require25% of lifting capacity as the limit.)

11. Use caution when utilizing pendant supported lat­tice jibs on tubular or angle booms as the jib candrift backwards into the jib backstops under cer­tain conditions. This is most likely with short jiblengths with minimum jib offset and maximumboom angle. Pay special attention to detect thepossibility of jib drift during the work platform testlift. An additional test lift is recommended with anempty work platform when operation at or nearthese conditions.

12. The following actions and operations are strictlyprohibited when working with personnel suspen­ded in a work platform:a. Cranes shall not travel while personnel are in

the work platform.b. No lifts shall be made on another of the crane's

load lines with personnel suspended in a workplatform.

c. No external load is allowed to be lifted by at­taching it to the work platform.

d. Work platform lifts shall be a single crane oper­ation. A work platform shall not be lifted usingtwo cranes.

e. Hoisting of personnel shall be discontinuedupon indication of any dangerous weatherconditions, wind, or other impending danger.

f. The emergency manual mode operation ofpinning and latching style extendable boomsshall not be utilized.

g. Free‐fall (if equipped) shall not be used.13. Movement of the work platform with personnel shall

be done in a slow, controlled, cautious manner withno sudden movements of the crane or work platform.Do not use high speed functions, if equipped.

14. Do not use multi‐function crane operation. If loadhoist, boom hoist, and swing functions must beused to position the work platform, perform eachfunction individually.

15. Clear, unobstructed visibility between personnelon the work platform and the crane operator shallbe maintained at all times except where a desig­nated signal person has been assigned and posi­tioned such that he is visible to both. Such desig­nated signal person shall have no other duties toperform when personnel are in the work platform.

16. Voice communication between work platform per­sonnel, the crane operator, and designated signalperson, if assigned, shall be maintained.

17. If other cranes or equipment may interfere with thelifting of personnel, signals or other means of com­munication between all crane or equipment oper­ators shall be maintained to avoid interference withindividual operations.

18. If the work platform is not landed, it shall be tied to astructure before personnel mount or dismount thework platform.

19. Personnel in the work platform shall wear personalfall arrest systems. Anchors used for attachment ofpersonal fall arrest equipment shall be independ­ent of any anchors being used to support or sus­pend work platforms. Personnel shall keep allparts of body, tools, and equipment inside workplatform during raising, lowering, and positioning.

20. Personnel shall always stand firmly on the floor ofthe work platform and shall not sit or climb on theedge of the work platform or use planks, ladders,or other devices for attaining a work position. (Thisdoes not apply to offshore personnel transfer bas­kets. Personnel must ride on the exterior of thistype of personnel handling device to assure great­er safety of the operation.)

21. When welding is done by personnel in the workplatform, the electrode holders shall be protectedfrom contact with metal components of the workplatform. If electrically connected electrode hold­ers contact work platform, work platform could bedropped due to burning/melting of wire ropes sus­pending the work platform.

22. A pre‐lift meeting must be conducted with thecrane operator, signal person, employee(s) to behoisted, person responsible for the task to be per­formed, and anyone else that is directly involvedwith the lift (as applicable) to review all the require­ments and procedures that must be followed tocomplete the lift.

23. Follow all procedures for determining the rated ca­pacity and perform all testing as outlined in theCrane Operator's Manual, the Crane Rating Manu­al, and this Safety Manual.

Operator's Manual

1-30 Section 1 - Operating Instructions

Additional Requirements For Offshore Cranes1. Link‐Belt offshore cranes are designed to handle

materials. However, due to the special conditionscommonly existing offshore, the use of cranes totransfer personnel between vessels or from a ves­sel to a work platform is an established practice.The safety of the personnel, if a materials handlingcrane is used in transferring personnel, dependsupon the skill and judgment of the crane operatorand alertness of the personnel being transferred.Sea and weather conditions may create additionalhazards beyond the skill of persons involved.

This operation is approved by the American Petro­leum Institute (A.P.I.). By adopting procedures forthis operation, the institute has determined that the

transfer of personnel may be performed safely un­der certain offshore conditions. Therefore,whenever an offshore crane is used to transfer per­sonnel, all persons involved in the operation mustknow and implement the A.P.I. procedures andverify that sea and weather conditions are withinsafe limits for the transfer.

In addition to all previous requirements in these In­structions, A.P.I. 2C requires the following:

� Boom and load hoists used shall be approved bythe hoist manufacturer for personnel handlingand shall be so indicated on their name plate.

� Refer to A.P.I. 2C Section 6 for further details andprocedures.

Operator's Manual

1-31Section 1 - Operating Instructions

Personnel HandlingPre‐Lift Check List for Link‐Belt Cranes

1

I am the designated person responsible for verifying that all safety requirements are met for thispersonnel handling operation;

Name: Title:

Signature: Date: / / Initials

2 I have verified that there are no conventional means to handle personnel for this operation.

3I have a written statement authorizing personnel handling from a competent person on the jobwho accepts full responsibility, or I accept full responsibility for the operation.

4The Crane Operator acknowledges that he has read and fully understands the CraneOperator's Manual and Crane Rating Manual. All personnel involved have been informed andunderstand the tasks required to complete the personnel lifting operation.

5The crane has been maintained, lubricated, and adjusted by a designated person, asspecified in the Crane Operator's Manual.

6 The lift crane is equipped, and all devices operate properly as follows:

� Anti-two block device with hydraulic cutouts� Power load raising and lowering with automatic brakes and function cutouts - Free-Fall (if

equipped) shall not be used� Boom angle indicator with high and low set points and function cutouts� Boom length indicator (telescopic booms only) and function cutouts� Load Indicating System or Rated Capacity Limiter System� A variable swing brake or swing controls capable of stopping upper swing motion smoothly� A mechanical swing park brake or swing lock to hold the upper in position while personnel

are working from the work platform� 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.

9 The wire rope used to lift the work platform is reeved from an allowed lifting sheave

10 Crane travel is not allowed with personnel in the work platform.

11 Telescoping the boom is not recommended with personnel in the work platform.

12When handling personnel with pinning and latching style booms, it is recommended boom bekept in a pinned position. Inspections must be made to ensure boom extend pins are set.

13 All wire rope sockets and dead end lugs are properly installed and are in good working condi­tion. All Wire rope guards are properly installed and adjusted to hold all ropes on the appropri­ate sheaves.

14Voice communications between the Crane Operator and the personnel in the work platformare 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.

17 A Proof‐Test/Trial Lift was completed with 125% of the work platform's rated capacity.

18 The total load being lifted will not exceed 50% of the standard lift crane capacity charts.

19 Cranes with outriggers have them equally extended with tires clear of the ground.

20 A Pre‐Lift meeting was held with all appropriate personnel to review all aspects of the lift.

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

Operator's Manual

1-32 Section 1 - Operating Instructions

Figure 1-39Carrier Cab Dash Panel

1. Battery Gauge2. Carrier Engine Oil Pressure Gauge3. Coolant Temperature Gauge4. Mirror Adjustment Control5. Tachometer6. Turn Signal Indicator Light7. High Beam Indicator Light8. Speedometer/Odometer Message Center9. Cigarette Lighter10. Air System Pressure Gauges11. Fuel Gauge

12. Air Suspension Control13. Lift Axle Control Switch (If Equipped)14. Park Brake Control Knob15. Diesel Particulate Filter Regeneration

Switch16. Cruise Set/Resume Switch17. Cruise Enable Switch18. Carrier Engine Fan Override Switch19. Carrier Engine Emission Malfunction

Indicator Light20. High Exhaust Temperature Indicator Light

21. Diesel Particulate Filter Regeneration In­dicator Light

22. Park Brake Indicator Light23. Carrier Engine Torque Limit Indicator

Light24. Stop Engine Indicator Light25. Check Engine Indicator Light26. Rotating Beacon Switch27. Heater/Defroster Fan Switch28. Dash Lights Dimmer Switch29. Headlight Switch30. Carrier Engine Brake Switches31. Carrier Engine Diagnostic Request Switch

1131 2 5 76 8 10

142224

9

29

6

28 2531 18 16172330 2627

4 4

192021 15 1213

Carrier Cab ControlsThe following is a description of the gauges, switches,and controls in the carrier cab, along with an explana­tion of their function and/or operation.

Dash PanelThe dash panel is directly in front of the operator. It con­tains the following controls and is shown inFigure 1-39.

Note: When the key is turned on, the gauges will gothrough an initialization sequence to allow the oper­

ator to verify correct operation of the gauges and in­

dicator lights. The gauge needle will move counter‐

clockwise to just below minimum scale for a 1/2

second, then clockwise to minimum scale and the

indicator light within each gauge will flash. When

initialization sequence is complete, all indicatorlights will distinguish, gauge needles will indicate

actual readings, and the odometer will display in

the speedometer gauge.

Operator's Manual

1-33Section 1 - Operating Instructions

If a gauge is not monitoring its respective function:(1) the indicator light will flash slowly and the gauge

needle will stay at minimum scale. This indicates

the gauge is not receiving data from the data bus.

(2) the indicator light will flash rapidly and the gauge

needle will go to full or minimum scale. This indi­

cates the gauge has received invalid or out‐of‐

range data. (3) the indicator light will flash slowly

(about once per second) and the gauge needle will

go to full or minimum scale. This indicates the

gauge is not receiving any data from the system

control unit (SCU). Repair the problem before driv­ing crane.

1. Battery Gauge

This gauge registers the charge in the battery andthe output of the alternator through the regulator. Itshould read 12 volts with the key on, and 12.5 to 14volts with the carrier engine running. When thecharge or the voltage in the battery is not withinnormal operating range an indicator light within thegauge will illuminate and the message “VOLTS”will appear in the LCD area of the speedometer/odometer message center.

2. Carrier Engine Oil Pressure Gauge

This gauge registers the carrier engine oil pres­sure. For proper oil pressure operating range, re­fer to the carrier engine manufacturer's manual. Ifthere is no carrier engine oil pressure after 10-15seconds of running time, shutdown the carrier en­gine immediately and repair the problem to avoidcarrier engine damage. When the oil pressure isnot within normal operating range an indicator lightwithin the gauge will illuminate, an alarm buzzerwill sound, the stop engine light will illuminate, and

the message “OILPSI” will appear in the LCD areaof the speedometer/odometer message center.

3. Coolant Temperature Gauge

This gauge registers the carrier enginecooling system temperature. For propercooling system operating temperature

range, refer to the carrier engine manufacturer'smanual. If the cooling system overheats, reducecarrier engine speed or shift to a lower gear, orboth, until the temperature returns to normal oper­ating range. If carrier engine temperature does notreturn to normal temperature, refer to carrier en­gine manufacturer's manual. When the coolanttemperature exceeds normal operating range anindicator light within the gauge will illuminate, analarm buzzer will sound, the stop engine light willilluminate, and the message “H20TEMP” will ap­pear in the LCD area of the speedometer/odometermessage center.

4. Mirror Adjustment Control

Use these controls to adjust the carrier cab mirrors.

5. Tachometer

The Tachometer registers carrier enginespeed in revolutions per minute (rpm). Re­fer to the carrier engine manufacturer's

manual for suggested operating speeds.

6. Turn Signal Indicator Light

This light will blink to indicate that a turn sig­nal is on or the hazard lights are flashing.

7. High Beam Indicator Light

This light will illuminate to indicate when theheadlights are on high beam.

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1-34 Section 1 - Operating Instructions

8. Speedometer/Odometer Message Center

The speedometer registers crane travelspeed in miles per hour (mph) or kilometersper hour (km/h) The Message Center por­

tion of the gauge is used most often to display theodometer. The Message Center display disap­pears when the ignition is turned off. To view thedisplay when the ignition is off, press the Mode but­ton in the bottom portion of the gauge. It remainsactivated until ten seconds after the button is lastpushed.

To view a different function, press and release theMode button until one of the following functions ap­pears:

� Odometer - reads in miles and tenths (for ex­

ample, 123456.7). The odometer is not reset­table.

� Trip 1 Odometer - reads in miles and tenths,

preceded by a 1 (for example, ).

� Trip 2 Odometer - reads in miles and tenths,

followed by a 2 (for example, ).

� Hour meter - reads in hours, followed by the

letters HR (for example, 123456HR).

If a warning alarm is triggered, a warning messagewill override all other Message Center displays untilthe alarm condition is corrected. The warningmessage may be temporarily overridden for twentyseconds as described in “Warning Alarms” in thisSection of this Operator's Manual.

Setting and Resetting Functions in the Message

Center

Trip Odometers

To Display The Trip 1 Or 2 Odometer

Press and release the Mode button until the de­sired trip odometer is displayed.

To Reset A Trip Odometer To Zero1. Display odometer to be reset (Trip 1 or Trip 2).2. Press and hold the Set button until the mileage

is reset to zero (about three seconds).

Warning Alarms

If a condition that requires attention develops dur­ing operation, a warning will be displayed in one ofthree ways:

� A warning message can appear in the

Speedometer Message Center display.

� The red warning light in the associated gauge

will illuminate.

� An audible warning tone will sound (for select

functions only).

Once a warning alarm is triggered, it will continueuntil the condition that caused it is corrected. Atthat time, the visual and audible alarms will stopand the Speedometer Message Center will displaya Reset message for twenty seconds. Pressing theSet button clears the Reset message sooner.

Temporarily Overriding a Warning Message1. Press the Set button.2. Press the Mode button to display another func­

tion. After twenty seconds, the warning mes­sage will reappear.

The red warning light in the gauge and the warningtone cannot be overridden and will continue untilthe condition is corrected.

The following identifies the possible warning mes­sages and the conditions that cause them.

Function Message AlarmLow Fuel Warning LOFUEL NoEngine Oil Press Warning OILPSI YesCoolant Temp Alarm H2OTEMP YesHydraulic Oil Temp Alarm HYDTEMP YesFront Air Pressure Alarm LOAIR1 YesRear Air Pressure Alarm LOAIR2 YesBattery Voltage Warning VOLTS No

System Diagnostic Test Mode

To access the System Diagnostic Test mode, turnthe ignition on and press the Mode button until“DIAGTST” appears in the display. Then press theSet button to enter the System Diagnostics Testmode. “AUTO” will be displayed.

Note: The System Diagnostics Test mode is

only enabled when the ignition is on.

The System Diagnostic Test has three functionsavailable:

� Auto - A fully automatic test of all modules,displays, and indicators.

� Manual - Manual selection of individual mod­

ules and telltales to test.

� Fault Display - Recalls up to 128 device fault.

Auto Test SequencePressing the Set button while “AUTO” is displayedstarts the Auto Test sequence. During the AutoTest, the system control unit (SCU) generates itsown gauge needle positioning data and warningLED data. The sequence begins with all gaugeneedles at zero scale and a blank Message CenterDisplay. The SCU moves the gauge needle in uni­son to mid‐scale, full scale, back to mid‐scale,

1 123456.7TRIP MI

2 123456.7TRIP MI

Operator's Manual

1-35Section 1 - Operating Instructions

back to zero, and then exits to the Normal Opera­tion mode.

Pressing the Mode or Set button during the se­quence halts the sequence and returns the displayto “AUTO”.

If the instrumentation passes the Auto Test, it is agood indication that the entire instrumentation sys­tem is functioning properly.

Manual Test FunctionPressing the Mode button while “AUTO” is dis­played activates the Manual Test function andcauses “MANUAL” to be displayed. The ManualTest is the same as the Auto Test except that theuser can select which modules to test.a. Use the Set button while MANUAL is displayed

to select the module to be tested. The mod­ule's name will appear in the display, startingwith SCU.

b. Press the Set button to start the test, or pressthe Mode button to select a different module.

c. To end the test and display the module name,press the Mode button at any time during thesequence. The Manual Test sequence is iden­tical to the Auto Test sequence except that theuser must press the Set button to move fromone phase to the next.

Fault Codes

When a device (or ECU) attached to the crane databus detects a fault, it can place an active fault codeon the data bus. The active fault code describes aspecific type of failure (for example, low oil pres­sure). Each fault code includes a device fault codethat identifies the device which detected the fault.Pressing the Set button when “FAULTS” is dis­played tells the SCU to send a request over thecrane data bus for all devices to send their activefault codes. During this time the SCU displays“POLLING”. After all the active fault codes havebeen received, the SCU displays the device faultcodes one‐at‐a‐time in 3-second intervals. Up to128 device fault codes can be displayed. Pressingthe Mode or Set button during this time exits theFault mode.

Note: A device fault code does not contain actu­

al failure data, only the identification of the de­

vice that detected the fault.

9. Cigarette Lighter

Push knob in to heat element. The knob willeject when the element is hot. The ciga­rette lighter can also be used as a power

point for connecting electrical accessories.

CAUTIONDo not connect an accessory to any part of thecrane other than the cigarette lighter. Damage

to the crane's electrical system may result. If

it is necessary to do so, contact your Link‐Belt

Distributor.

10. Air System Pressure Gauges

These gauges register the air pressure inthe front and rear systems. The front gaugeregisters the pressure of the front brake

system. The rear gauge registers the pressure ofthe rear brake system. Normal operating range onboth systems is 100-120 psi (690-827kPa). Ifthey do not register within this range, correct theproblem before operating. When the air pressureis not within the normal operating range an indica­tor light within the gauge will illuminate, an alarmbuzzer will sound, and the message “LOAIR1” or“LOAIR2”will appear in the LCD area of thespeedometer/odometer message center.

11. Fuel Gauge

This gauge registers the level of fuel in thefuel tank. The fuel tank capacity is 95 gal(359.6L). Refer to the carrier engine manu­

facturer's manual for the correct grade of dieselfuel. When the fuel level reaches an eighth of atank, an indicator light within the gauge will illumi­nate and the message “LOFUEL” will appear in theLCD area of the speedometer/odometer messagecenter.

12. Air Suspension Control

This control is used to select the crane's airspring suspension depending on the applica­tion. When traveling on the job site, move the

control to the down position. When traveling on thehighway, move the control to the up position.

13. Lift Axle Control Switch (If Equipped)

This switch may be used to operate the liftaxle but only if the ground control switch is inthe “DOWN” position and it is assured that

the air pressure is properly adjusted by the pressureadjustment knob in the ground control box. Refer to“Lift Axle” in this Section of this Operator's Manual.

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1-36 Section 1 - Operating Instructions

14. Park Brake Control Knob

This knob controls engaging and releasingthe park brake.

WARNINGAvoid using the park brake to stop the crane inmotion (as a service brake) except in cases of

extreme emergency. Brake wear will not be

distributed evenly and application cannot be

controlled.

To Engage Park Brake

a. Bring the crane to a full stop.b. Shift the transmission to neutral.c. Pull the knob out.

To Release Park Brake

a. Fully depress service brake.b. Push the knob in.

Note: If the park brake knob will not stay in the

released position, check the air system pressure.

It must be at least 60 psi (414kPa) before the

brake will release. The emergency park brake willalso begin to apply, and will fully engage if pres­

sure decreases below 40 psi (276kPa).

15. Diesel Particulate Filter Regeneration Switch

This switch is used to initiate a “Parked Re­generation” of the Diesel Particulate Filter.This switch is disabled until the Diesel Par­

ticulate Filter Regeneration Indicator light is illumin­ated. Refer to the carrier engine manufacturer'smanual for the proper filter regeneration proce­dures.

DANGERThe temperature of the exhaust gas and theexhaust system components can reach up to

1,200°F (650°C) during regeneration. An

unexpected failure of the carrier engine or

regeneration system may increase exhaust

gas temperature at the particulate exhaust

filter to as high as 1,650°F (900°C). This may

result in fire, burn, or explosion hazards,which may result in personal injury or death.

The crane must be outside and exhaust gas or

exhaust system components must not be

exposed to flammable material or explosive

atmospheres during regeneration.

16. Cruise Set/Resume Switch

Press the top part of the switch (set) mo­mentarily to set cruise speed to the speedcurrently being traveled. Holding the top

part of the switch down while in cruise allows thecrane speed to decrease (coast). Release of theswitch sets cruise to the lower crane speed.

WARNINGDo not use the cruise control in heavy traffic oron roads that are winding, slippery, or un­

paved.

Press the bottom part of the switch (resume) mo­mentarily to restore the previously set cruisespeed, if cruise control has been disabled with thebrake or clutch. Holding the bottom part of theswitch down while in cruise control causes thecrane speed to increase. Release of the switchsets cruise to the higher speed. Momentary press­ing the bottom part of the switch at initiation ofcruise operation will also set the cruise speed.

17. Cruise Enable Switch

Press the bottom part of the switch to en­able the cruise control. Press the top part ofthe switch to disable the cruise control.

18. Carrier Engine Fan Override Switch

The carrier engine fan override switch isused to help control carrier engine temper­ature. With the switch in the off position

(top part of switch) the fan will automatically comeon when the temperature reaches 195°F (90°C)and will shut off at 175°F (80°C). With the switch inthe on position (bottom part of switch) the fan willrun continuously. Normally the switch should re­main in the off position except for example whenclimbing a grade. Before climbing the grade turnthe switch on to prevent an unexpected power re­duction of the carrier engine.

19. Carrier Engine Emission MalfunctionIndicator Light

This indicator light will illuminate to alert theoperator that there is a malfunction in the car­rier engine emission system. When this light

illuminates carrier engine operation may continue.However, refer to the carrier engine manufacturer'smanual and determine the problem as soon aspossible to avoid prolonged operation of the mal­functioning emission system.

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1-37Section 1 - Operating Instructions

20. High Exhaust Temperature Indicator Light

This indicator light will illuminate to alert theoperator that the outlet temperature in thediesel particulate filter is above 977�F

(525�C) and the crane is traveling less than 5mph(8km/h). Refer to the carrier engine manufacturer'smanual for the proper procedures.

DANGERThe temperature of the exhaust gas and theexhaust system components can reach up to

1,200°F (650°C) during regeneration. An

unexpected failure of the carrier engine or

regeneration system may increase exhaust

gas temperature at the particulate exhaust

filter to as high as 1,650°F (900°C). This may

result in fire, burn, or explosion hazards,which may result in personal injury or death.

The crane must be outside and exhaust gas or

exhaust system components must not be

exposed to flammable material or explosive

atmospheres during regeneration.

21. Diesel Particulate Filter RegenerationIndicator Light

This indicator light will illuminate to alert theoperator that a “Parked Regeneration” of theDiesel Particulate Filter is required. If the re­

generation is not performed when the indicator lightis illuminated, the soot load in the filter may continueto increase, leading to a blinking indicator light, and acarrier engine derate and/or carrier engine shut­down. Refer to the carrier engine manufacturer'smanual for the proper filter regeneration proce­dures.

22. Park Brake Indicator Light

This light will come on anytime the parkbrake is engaged and the ignition is on.

Note: When the park brake control knob ispushed in (released), the park brake remains

engaged until the indicator light goes off.

23. Carrier Engine Torque Limit IndicatorLight

When the transmission is shifted into anyreverse gear or into “LO-LO”, this light willilluminate to alert the operator the carrier

engine torque limit system has been activated toprotect power train components.

24. Stop Engine Indicator Light

This red indicator light will illuminate alongwith an alarm buzzer to make the operatoraware of critical carrier engine problems.

When this light illuminates stop operations imme­diately and shutdown the carrier engine. Refer tothe carrier engine manufacturer's manual and de­termine the problem before any further operationof the carrier engine. This light will also flash whenusing the carrier engine diagnostic request switchto retrieve active carrier engine fault codes storedin the electronic control module (ECM).

Note: The stop engine light will illuminate mo­

mentarily when the ignition switch is turned onas a means of testing the indicator light. The

light should go out after a short period of time.

25. Check Engine Indicator Light

This amber indicator light will illuminatealong with an alarm buzzer to make the op­erator aware of minor carrier engine prob­

lems. When this light illuminates carrier engine op­eration may continue. However, refer to the carrierengine manufacturer's manual and determine theproblem as soon as possible to avoid prolongedoperation of the malfunctioning carrier enginewhich could develop into a major problem. Thislight will also flash when using the carrier enginediagnostic request switch to retrieve inactive carri­er engine fault codes stored in the electronic con­trol module (ECM).

Note: The check engine light will illuminate mo­

mentarily when the ignition switch is turned on

as a means of testing the indicator light. Thelight should go out after a short period of time.

26. Rotating Beacon Switch

This switch operates the optional rotatingbeacon on the carrier cab. Press the bot­tom part of the switch to operate the rotat­

ing beacon, press the top part of the switch to turnthe rotating beacon off.

27. Heater/Defroster Fan Switch

This switch operates the heater/defrosterfan. Press the bottom part of the switch tothe first detent position to operate the de­

froster fan in low speed. Push this switch to thesecond position to operate the fan in high speed,press the top part of the switch to turn the defrosterfan off.

Operator's Manual

1-38 Section 1 - Operating Instructions

28. Dash Lights Dimmer Switch

This switch is used to dim the dash lights. Rotatethe switch down to dim the lights and rotate backup to illuminate dash lights.

29. Headlight Switch

Press the top half of this switch to turnheadlights, park lights, and instrumentpanel lights on. Press the bottom half to

turn them off.

30. Carrier Engine Brake Switches

These switches operate the carrier enginebrake. One switch activates the carrier en­gine brake and the other switch controlsthe retarding levels. Refer to “Carrier En­gine Brake” in this Section of this Opera­tor's Manual for additional details and oper­

ating instructions.

31. Carrier Engine Diagnostic Request Switch

This switch is used to activate the checkand stop engine indicator lights to flash ac­tive and inactive carrier engine fault codes.

The stop engine light will flash active codes and thecheck will flash inactive codes. The switch is usedto flash codes in the following circumstances:A. When the carrier engine is not running and

with the ignition on, pressing and holding thebottom part of the switch will flash out carrierengine fault codes.

B. When the carrier engine is idling and not in aprotected condition, pressing and holding thebottom part of the switch will flash out carrierengine fault codes.

Refer to carrier engine manufacturer's manual forthe carrier engine fault code descriptions.

Operator's Manual

1-39Section 1 - Operating Instructions

Carrier Engine Idle Shutdown SystemTo reduce emissions and conserve fuel, the carrier en­gine control system is programmed to automaticallyshutdown the carrier engine when idling and certainconditions are met.

Five Minute Carrier Engine Idle Shutdown

When the transmission is in neutral and the park brakeis applied, the carrier engine will automatically shut­down in approximately five minutes. The CheckEngine Light will flash to alert the operator that the carri­er engine will shutdown in approximately 30 seconds.In the final 15 seconds before a carrier engine idle shut­down, the Stop Engine Light will flash and the CheckEngine Light will continue to flash. Pressing the brakeor throttle pedal or changing the park brake status dur­ing the final 30 seconds before a shutdown would oth­erwise occur will prevent the carrier engine from shut­ting down and will reset the shutdown timer.

Fifteen Minute Carrier Engine Idle Shutdown

When the transmission is in neutral and the park brake isnot applied, carrier engine will automatically shutdown inapproximately fifteen minutes. The Check Engine Lightwill flash and the Stop Engine Light will illuminate to alertthe operator that the carrier engine will shutdown in ap­proximately 20 seconds. In the final 10 seconds before acarrier engine idle shutdown, the Stop Engine Light willflash and the Check Engine Light will continue to flash.Pressing the brake or throttle pedal or changing the parkbrake status during the final 20 seconds before a shut­down would otherwise occur will prevent the carrier en­gine from shutting down and will reset the shutdowntimer.

After an automatic shutdown, the carrier engine may berestarted and operated normally. An automatic carrierengine shutdown does not shut off electrical power andthe Check Engine and Stop Engine Lights will continue toflash.

The carrier engine idle shutdown can also be moment­arily overridden using the Carrier Engine DiagnosticRequest Switch. Refer to “Carrier Engine ShutdownOverride” in this Section of this Operator's Manual andthe carrier engine manufacturer's manual for the prop­er carrier engine shutdown override procedures.

Carrier Engine Shutdown Override

The carrier engine shutdown override allows the operatorto momentarily override the automatic carrier engineshutdown sequence when the Stop Engine Light illumin­ates or the Check Engine Light and Stop Engine Lightflashes simultaneously. The Carrier Engine DiagnosticRequest Switch is used to override the automatic carrierengine shutdown sequence. The carrier engine shut­down override resets the shutdown timer, restoringpower to the level when the Stop Engine Light was illu­minated. Use the carrier engine shutdown override untilthe crane can be brought to a stop in a safe location.Refer to the carrier engine manufacturer's manual for theproper carrier engine shutdown override procedures.

Operator's Manual

1-40 Section 1 - Operating Instructions

Figure 1-40Carrier Fuse Panel

1. Fuse Panel2. Fuses3. Fuse Designation Label

1

2

3

GOOD BURNT

ABCD H

GFE J

KLM

N TUP

RS W

V

FUSEINDENTIFICATION

A 30 AMP-HAZARD LIGHTSB 15 AMP-ETHER INJECTOR, DAYTIME RUNNING LIGHTS

D SPAREE 15 AMP-HORN, DOME LIGHTF 10 AMP-ROTATING BEACON (OPT.)G 15 AMP-TURN SIGNAL, BRAKE LIGHTSH 15 AMP-START & RUN RELAY, CLOCKJ 15 AMP-WIPER, WASHERK 10 AMP-LIGHTER, SUSP HEIGHT IND

L 25 AMP-OIL COOLER FANM 10 AMP-HEATER FANN 5 AMP-GAUGES, PARK BRAKE IND LIGHT

C 10 AMP-REMOTE MIRRORS P 10 AMP-AIR DRYERR 10 AMP-PUSHER AXLE, FUEL COOLERS 5 AMP-HIGH IDLE, TORQUE LIMIT & CLUTCH RELAYT 10 AMP-BACK-UP LIGHTS & ALARMU 10 AMP-DASH LIGHTS & CAB MARKER LIGHTSV 10 AMP-RHT SIDE & TAIL LIGHTS

W 10 AMP-LFT SIDE & TAIL LIGHTS REAR ID LIGHT

LICENSE PLATE LIGHTLIGHTS

Fuse Panel

The carrier fuse panel is mounted under the carrier cabdash. A label which designates the electrical circuitprotected by each fuse is near the fuse panel. Whenhaving electrical problems, check these fuses to en­sure they are not burnt. Refer to Figure 1-40. CircuitBreakers and individual carrier engine fuses are alsomounted under the carrier engine hood, behind thebattery disconnect switches. Refer to Figure 1-49.

Carrier Cab Foot Operated Controls

The following is a description of the foot controls in thecarrier cab, along with an explanation of their functionand/or operation. Refer to Figure 1-41.

1. Clutch PedalThe clutch pedal controls engaging/disengagingthe clutch. Release clutch pedal to engage theclutch. Depress clutch pedal to disengage clutch.The clutch is equipped with a brake to stop thetransmission gears from rotating. This aids in shift­ing smoothly from neutral to first or neutral to re­verse. To apply the clutch brake, shift the transmis­sion to neutral and push the clutch pedal down tothe limit of its travel.

Note: The clutch pedal must be fully depressed

to start the carrier engine.

CAUTIONDo not apply the clutch brake whendownshifting. Do not apply the clutch brake

before the transmission is in neutral. either of

these applications will cause rapid wear of the

clutch brake.

2. Service Brake Pedal

The air brakes are controlled by the brake pedal.Press the pedal down to apply the brakes. Releasethe pedal to release the brakes.

Air Brake Operation

The distance the service brake pedal is movedregulates the amount of air delivered to the brakechamber, which determines the braking force.

The smoothest stop results when the brake appli­cation is as hard at first as crane speed and roadconditions will permit. Then gradually release thepedal as crane speed decreases. As the cranestop is completed, the brake application shouldonly be enough to hold the crane stationary. Arough stop will occur if the application is light at firstand increased as crane speed decreases.

Do not fan the service brake pedal. This wastescompressed air and increases stopping distance.Depress the pedal fully only in cases of emergencyas this makes control of the crane difficult.

If the air system pressure drops far below the normaloperating range of 100-120 psi (690-827kPa), stopthe crane and repair the problem. As the air systempressure falls below 60 psi (414kPa), the park brakewill automatically begin to apply.

3. Throttle Pedal

Carrier engine speed is controlled by the throttlepedal. Press down on the throttle pedal to increasecarrier engine speed. Release the throttle pedal todecrease carrier engine speed.

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1-41Section 1 - Operating Instructions

Figure 1-41Main & Auxiliary Transmission Controls

1. Clutch Pedal2. Service Brake Pedal3. Throttle Pedal4. Main Transmission Shift Lever5. Auxiliary Transmission Shift Lever

54

21 3

A

A

Auxiliary Transmission Shift LeverA four speed auxiliary transmission is used in the car­rier to provide a low gear ratio for slow, careful move­ment around the job site, and higher ratios for highwayuse. The low ratio is not for extra tractive effort or forheavy pulls. For highway use, the lever should be in the“3” or “4” position. For job site use, the lever should bein the “1” or “2” position. Refer to Figure 1-41.

Note: Upshifts of the auxiliary transmission to posi­tions “1”, “2”, or “3” and all downshifts must be done

with the crane at a complete stop. Upshifting of the

auxiliary transmission from position “3” to position

“4” may be done with the crane at a complete stop or

with the crane in motion. To shift from position “3” to

position “4” with the crane in motion, allow the main

transmission to shift through all gears, move the aux­iliary transmission from position “3” to position “4”,

and let off the throttle pedal momentarily. The auxili­

ary transmission will shift to the fourth speed.

Operator's Manual

1-42 Section 1 - Operating Instructions

Dual SwitchRange Selector

Figure 1-42Manual Transmission Shift Control

1. Range Preselection LeverDown Position - LO RangeUp Position - Hi Range

2. Deep Reduction Button“In”/Forward Position - Deep Reduction“Out”/ Rearward Position - Deep Reduction

1

2

Main Transmission ControlThe main transmission has a 5 speed front section anda high‐low range section which allows the operator toselect 8 evenly spaced forward speeds and one “LO”speed using a single control lever and a two positionrange control switch. Refer to Figure 1-43. An addi­tional “LO-LO” deep reduction speed may be selectedby using a deep reduction button. The “LO” and “LO-LO” speeds are for off highway use. The transmissionalso has 3 reverse speeds.

CAUTIONDo not preselect. When making the shift froma deep reduction ratio to low range, move the

deep reduction valve from “IN” to “OUT”

immediately before making the shift. This is

not a preselect valve and only torque will hold

the deep reduction gear after the button is

moved to the “OUT” position. The shift

cylinder will make the shift by air as soon astorque is released.

Figure 1-43Transmission High & Low Range Shift Pattern

With Deep ReductionLever/Button in the“OUT”/REARWARDposition . . .

Shift LO-1-2-3-4 inLOW RANGE.

Range Shift . .

Shift 5-6-7-8 in HIGHRANGE.

Figure 1-44Transmission Deep Reduction Shift Pattern

WHILE IN LOW RANGEONLY and shift lever inLO . . .

LO-LO can be obtainedby moving Deep Reduc­tion Lever/Button to the“IN”/FORWARD position.

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1-43Section 1 - Operating Instructions

Shifting The Main Transmission

The following instructions cover the actual shifting ofthe transmission. It is assumed that the operator is fa­miliar with and can successfully coordinate the neces­sary movements of the shift lever and clutch pedal, tomake progressive and selective gear engagements ineither up shifting or down shifting the transmission.

Double‐Clutching Procedures

Smooth upshifting and downshifting of the main trans­mission requires double‐clutching. When the operatoris ready to make a shift:1. Depress the clutch pedal, to disengage the clutch.2. Move the gear shift lever to neutral.3. Release the clutch pedal to engage the clutch.

a. Upshifts: Decelerate the carrier engine untilthe carrier engine rpm and road speed match.

b. Downshifts: Accelerate the carrier engine untilthe carrier engine rpm and road speed match.

Note: By engaging the clutch with the gear

shift lever in the neutral position, the opera­tor is able to control the rpm of the transmis­

sion since it is regulated by the carrier en­

gine rpm. This procedure enables the op­

erator to match the speed of the transmis­

sion with the road speed.

4. Quickly depress the clutch pedal to disengage theclutch and move the gear shift lever to the next gearspeed position.

5. Release the clutch pedal, to engage the clutch.

Dual Switch Range Selector Style Shifter

This style shifter uses two dual position switches to se­lect the shift range of the transmission. Three rangesare available: Deep Reduction (Lo-Lo), Low Range,and High Range. Refer to Figure 1-43 andFigure 1-44 for the associated shift pattern for eachrange.

Up Shifting

There are several patterns of upshifting dependingupon conditions of road and load. Check gear ratios todetermine the best ratio progression for your particularcondition. The following instructions are recom­mended for normal conditions:1. Move the deep reduction valve to the “OUT” posi­

tion to disengage the deep reduction gears.2. With the gear shift lever in neutral, the carrier en­

gine started and the air system pressure normal,push the range control lever down to the “LOW”range position.

3. Put the auxiliary transmission in 3rd.

4. Start the vehicle in 1st gear of the low range shiftpattern. Once the carrier is moving and adequatemomentum has been obtained, the transmissioncan be shifted from 1st through 2nd, 3rd and 4thwhile in low range.

5. When ready to upshift from 4th in low range , movethe range control lever up to the “HIGH” positionand move the gear shift lever to 5th gear. As theshift lever passes through neutral, the transmis­sion will automatically shift from low to high range.

6. As the vehicle speed increases, continue shiftingthrough 6th and 7th to the 8th gear position.

7. Shift the auxiliary transmission from 3rd to 4th.

Note: A road speed limiter is incorporated in the

carrier engine governor to keep road speed be­

low 50 mph (80 km/h) when the crane is factory

equipped with restricted speed tires.

Down Shifting1. Shift the auxiliary transmission from 4th to 3rd.2. Shift from 8th through 7th, 6th and to the 5th gear

position.3. When ready for the next down shift, push the range

control lever down to the “LOW” position and shiftthe transmission control lever to the 4th gear posi­tion. As the shift lever passes through neutral, thetransmission will automatically shift from high tolow range.

4. Shift down from 4th through 3rd, 2nd and to the 1stgear position.

Note: When down shifting, it should not be nec­

essary to shift into deep reduction ratios. The

low range gear ratios should be sufficient in

most operating conditions.

Skip Shifting

After becoming proficient in shifting the transmission,the operator may want to skip some shifts. Skip shift­ing may be done while up shifting providing the rangelever is pulled up before the shift which passes 4thgear. Skip shifting is possible while down shifting, pro­vided the range lever is pushed down to the low rangeposition before the shift which passes 5th gear.

Note: The auxiliary transmission can be left in 3rd

or 4th position and all shifting done in the main

transmission if desired.

When shifting the auxiliary transmission, move the

shift control valve before disengaging the clutch to

make the shift. This allows time for air pressure to

build in the shift cylinders to make the shift.

Operator's Manual

1-44 Section 1 - Operating Instructions

Figure 1-45Carrier Engine Brake Switches

1. Carrier Engine Brake Master Switch2. Carrier Engine Brake Retarding Level Switch

1 2

Carrier Engine Brake

The carrier engine brake is a device which uses the car­rier engine itself to aid in slowing and controlling thecarrier. When activated, the carrier engine brake altersthe operation of the carrier engine's exhaust valves sothe carrier engine works as a power‐absorbing air com­pressor. This provides a retarding action to the wheels.

WARNINGThe carrier engine brake is a vehicle slowingdevice. It is not a substitute for the service

braking system. The carrier's service brakes

must be used to bring the crane to a complete

stop.

Carrier Engine Brake Controls

Two switches are used to control the carrier enginebrake system. The master switch turns the system onand off and the retarding level switch is used to regu­late the amount of braking force made available: 0(Low), 1 (Med), and 2 (High). Refer to Figure 1-45.Another switch used to give the carrier engine brake itsfully automatic feature is the clutch pedal, activated byits position.

Carrier Engine Brake Operation

Once the carrier engine brake master switch is pressedto activate the system, operation of the carrier enginebrake is fully automatic. Since the carrier engine brakedepends on the free flow of carrier engine oil for opera­tion, always let the carrier engine warm up beforeswitching it on. The carrier engine brake can be left onwhenever driving, providing the weather and road con­ditions are favorable.

To activate the carrier engine brake, simply removeyour foot from the throttle pedal. Note that the carrierengine brake remains activated even after the brakepedal has been depressed, giving the combinedpower of both the carrier engine and service brakes.The carrier engine brake alone will slow the carrier.However, it is essential that the service brakes be usedto bring the carrier to a complete stop.

To deactivate the carrier engine brake, reapply thethrottle pedal, depress the clutch pedal, or press themaster switch to deactivate the system. Always deac­tivate the carrier engine brake master switch when youshutdown the carrier engine.

Descending A Grade

An explanation of “control speed” is helpful in under­standing how to use the carrier engine brake while de­scending a grade. Control speed is the constantspeed at which the forces pushing the carrier forwardon a grade are equal to the forces holding it back, with­out using the service brakes. For example, you may beable to descend a grade safely at 10 mph, without acarrier engine brake. With the carrier engine brake,you might be able to descend that same grade at 25mph, and still remain under control.

Under some circumstances, you may want to comedown a grade at a faster rate than the control speed.This can be done by selecting a higher gear, or a lowerposition on the retarding level switch. However, youmay have to apply your service brakes intermittently toprevent over speeding the carrier engine and to keepthe vehicle at a safe speed.

WARNINGFrequent use of the service brakes, while de­scending a grade, will cause them to heat up

and reduce their stopping ability. The result

can be dangerous “brake fade”.

Operator's Manual

1-45Section 1 - Operating Instructions

Since the carrier engine brake is most effective at ratedcarrier engine speeds, gear selection is very important.You obtain maximum retarding power when you usethe lowest possible gear without exceeding the recom­mended carrier engine speed. Refer to the carrier en­gine manufacturer's manual for rated carrier enginespeeds.

There are other circumstances in which you might wantto descend a grade at a rate slower than the controlspeed. This is done by selecting a lower gear, one thatwill not over speed the carrier engine. You may have toapply the service brake to obtain the desired lowerspeed.

As a general rule for maintaining control speed, esti­mate the gear that you would use to climb the grade.Usually this is the same gear that can be used for a con­trolled descent with a carrier engine brake.

It's always a good idea to determine if the carrier enginebrake is operational before beginning a long steep de­scent. This can be done by briefly lifting your foot off thethrottle. You will feel the carrier engine brake going intoaction.

Slippery Pavement

If the carrier engine brake is new to you, it is recom­mended that it not be use on slick roads until you havesome experience with it on dry pavement.

Since the operation of any vehicle under slippery con­ditions is unpredictable, always have plenty of distancewhen testing service brakes or the carrier enginebrake.

When driving on wet or icy pavement, start with the car­rier engine brake master switch in the “OFF” positionand use the same gear you would normally use underthese conditions. Put the retarding level switch in the“0” position.

Before activating the carrier engine brake ensure thatthe vehicle is maintaining traction and stability usingthe natural retarding of the carrier engine alone.

If the vehicle is maintaining traction, you may then acti­vate the carrier engine brake by turning on the masterswitch. If the drive wheels begin to lock or there is a“fishtail” motion, immediately turn off the carrier enginebrake master switch. Don't turn the carrier enginebrake on until road conditions improve.

If there was no tendency for the drive wheels to losetraction and you desire greater slowing power, movethe control switch to the “1” position. If the drive wheelstend to lock, immediately switch the carrier enginebrake switch into the “0” position. Do not attempt touse the “1” or “2” position until road conditions im­prove.

In changing weather conditions, check the proper po­sitioning of the control switch often. Remember: donot skip a step when operating the retarding levelswitch switch. Always go from the “0” position, then tothe “1” position, and then to the “2” position.

Operator's Manual

1-46 Section 1 - Operating Instructions

Figure 1-46Steering Column And Wheel

1. Horn2. Ignition Switch3. Tilt/Telescope Lever

4. Hazard Flasher Switch5. Turn Signal Lever6. Steering Wheel

3

5

6 1

2

4

Steering Column And WheelThe steering column and wheel are the conventionalautomotive type equipped with a tilt function. The fol­lowing is a description of the switches and controls onthe steering column, along with an explanation of theirfunction and/or operation. Refer to Figure 1-46.

1. Horn

The button in the center of the steering wheel acti­vates the horn. Press the button to sound the horn.

2. Ignition Switch

The ignition switch is the key operated, conven­tional, automotive type. It controls carrier engineoff/run/start and energizes the instrument panelgauges in the carrier cab.

3. Tilt/Telescope Lever

This lever controls the tilt (angle) and telescopefunction of the steering wheel. To change steeringwheel tilt and/or telescope:

A. Bring the crane to a complete stop.B. Engage the park brake and shift the transmis­

sion to neutral.C. To change the steering wheel angle, pull the

tilt/telescope control lever toward the steeringwheel and hold. Position the steering wheel atthe desired angle and release the lever.

D. To change the steering column length, pushthe tilt/telescope control lever away from thesteering wheel and hold. Position the steeringcolumn at the desired length and release thelever.

E. Check all steering wheel functions before con­tinuing operation.

4. Hazard Flasher Switch

This switch controls the hazard warning flashers.Press the switch to turn the flashers on. Push theswitch again to turn the flashers off.

5. Turn Signal Lever

The turn signal lever controls the following func­tions:

A. Turn Signals: Push the lever down for left turnsignal, pull the lever up for right turn signal.

B. Headlight Beam Control: Pull the lever towardthe steering wheel to change to high beamheadlights. Pull the lever toward the steeringwheel again to return to low beam headlights.

C. Windshield Wiper: Rotate the turn signal levercounterclockwise to activate the windshieldwiper. Rotate the lever counterclockwise to thefirst through fifth detent for intermittent wipersand to the sixth detent for low speed wiper, tothe seventh detent for high speed wiper. Ro­tate fully clockwise to turn wiper off.

D. Windshield Washer: Push in on the end of thelever to spray washer fluid onto the windshield.

6. Steering Wheel

Turn the steering wheel clockwise for right turnsand counterclockwise for left turns.

Operator's Manual

1-47Section 1 - Operating Instructions

Carrier Cab SeatThe operator's seat in the carrier cab is fully adjustable.For average conditions, the seat cushion surfaceshould be level while the operator is seated. The seatshould ride freely up and down, without bottoming out,during normal crane movement. Refer to Figure 1-47.

Seat back angle and the forward and backward posi­tion of the seat should be adjusted to provide operatorcomfort. The seat is adjusted by manual controls.

Note: For optimum comfort and proper seat adjust­

ment, the operator should “sit back in the seat” and

sit erect while making any adjustment.

WARNINGDo not make seat adjustments while crane isin motion. Properly park crane before making

seat adjustments.

1. Air Control Valve

The air control valve is used to adjust the cushionangle and weight resistance for maximum drivercomfort. Increase the cushion angle and weightresistance for a heavier operator or bumpy roadconditions; decrease for light, smooth road condi­tions by using the air control valve. Push valve in toincrease the resistance; pull it out to decrease it.

2. Height Adjustment Latch

To Raise The Seat:

1. Pull out on the air control valve to exhaust allthe air.

2. While holding the height adjustment latch inthe released position, push the air controlvalve in to raise the seat to the desired height.

3. Once the desired height is reached, releasethe air control valve and the height adjustmentlatch.

4. Adjust the air pressure as needed to obtain thedesired ride.

To Lower The Seat:

1. Firmly pull up on the height adjustment latchwhile pulling out on the air control valve, ex­hausting air until the latch releases.

2. Once the desired height is reached, releasethe air control valve and the height adjustmentlatch.

3. Adjust the air pressure as needed to obtain thedesired ride.

Figure 1-47Carrier Cab Seat

1

2

3

4

1. Air Control Valve2. Height Adjustment Latch3. Seat Release Lever

4. Seat Back Adjustment Knob5. Seat Belt6. Fire Extinguisher

5

6

3. Seat Release LeverTo move the seat forward or backward, pull theseat release lever outward and hold. Position theseat as desired and release the lever to lock theseat in place.

4. Seat Back Adjustment Knob

To recline the seat back, turn the seat back adjust­ment knob clockwise. To bring the seat back for­ward, turn the knob counterclockwise.

5. Seat Belt

A seat belt is provided for operator safety whiledriving the crane. The seat belt must be used at alltimes while driving the crane.

Fire ExtinguisherA fire extinguisher is mounted directly behind the driv­er's seat in the carrier cab. Refer to Figure 1-47. It isan A B C type fire extinguisher, meaning it is capable ofextinguishing most types of fires. The operator shouldbe familiar with its location, the clamp mechanism usedto secure it in place, and foremost the operation of thedevice. Specific instructions, regarding operation, aregiven on the label attached to the fire extinguisher. Acharge indicator on the fire extinguisher monitors thepressure within the tank. Check the indicator daily toensure the fire extinguisher is adequately charged andready for use.

Operator's Manual

1-48 Section 1 - Operating Instructions

Figure 1-48Carrier Cab Heater Shutoff Valve

1. Shutoff Valves

1

1

Carrier Cab Heater ShutoffNormally the carrier engine coolant circulates throughthe heater core in the carrier cab regardless of whetherthe heater switch on the carrier dash is turned on ornot. During warm weather conditions, the operatormay wish to shutoff the flow of hot carrier engine cool­ant to the heater core to reduce the temperature in thecarrier cab. A shutoff valve is mounted on the carrierengine block which performs this function. Shutdownthe carrier engine and rotate the handle on the shutoff

valve clockwise to stop the flow of carrier engine cool­ant to the heater core; counterclockwise to restore it.Refer to Figure 1-48.

WARNINGShutdown the carrier engine and allow the it tocool before operating the heater shutoff

valve. The valve may be hot and could cause

serious burns.

Operator's Manual

1-49Section 1 - Operating Instructions

Figure 1-49Battery Disconnect, Carrier Engine Fuses, And Remote Jumper Terminals

1. Battery Disconnect Switches2. Torque Limiter Box3. Circuit Breakers - Thermal Reset

4. Carrier Engine Fuse -15 Amp5. Carrier Engine Fuse - 10 Amp

6. Carrier Engine Fuses - 5 & 7.5 Amp7. Remote Jumper Terminals

2

1

5

OFF ON

OFF ON

BATTERY DISCONNECTSWITCHES

JUMPER POSTS

12 VOLTS

7

3

4

6

Figure 1-50Carrier Engine Diagnostic Connector

1. Engine Diagnostic Connector

1

Carrier Engine DiagnosticConnectorThe carrier engine diagnostic connector is mounted un­der the carrier cab dash to the left of the steering col­umn. Refer to Figure 1-50. The connector allows thecarrier engine service technician to attach the carrierengine diagnostic data reader (DDR) for diagnosingcarrier engine problems. When the check or stop en­gine light illuminates, contact the carrier engine servicetechnician to retrieve the fault codes and repair the car­rier engine.

Battery Disconnect, Remote

Jumper Terminals, CarrierEngine Fuses, And Circuit

BreakersThe battery disconnect switches and remote jumperterminals are mounted at the left rear corner of the carri­er engine hood. Refer to Figure 1-49. Move all dis­connect switches to the “OFF” position anytime weld­ing is being done on the crane, to protect the craneselectronic components from damage due to an electricarc type welder.

The remote jumper terminals are provided to ease ac­cess to the battery terminal connections. The terminalsare clearly marked to show positive (+) and negative(-) connections.

Three fuses and four, 40 amp, thermal reset type circuitbreakers are used to protect the carrier wiring circuits.The three fuses are specifically used for the carrier en­gine wiring. Refer to Figure 1-49 for position and sizeof fuses. A fuse panel is also mounted in the carrier cabdash to protect individual electrical functions. Refer toFigure 1-40.

Operator's Manual

1-50 Section 1 - Operating Instructions

1. Ether Injector Relay (EIR)2. Cylinder Clamp3. Ether Fuel Cylinder

4. Valve5. Metering Orifice6. Carrier Engine Control Module (ECM)

Figure 1-51Ether Start System

1

A

A

2

3

5

4

6

Ether Start SystemThe ether start system is a fully‐automatic carrier en­gine starting fluid system designed to spray a con­trolled amount of ether into the air intake system duringand immediately after cranking. The carrier enginecontrol module (ECM) determines when the systemshould function. The ECM sends a signal to the etherinjection relay (EIR) which activates the valve assemblyto inject ether. Whenever the carrier engine does notstart within a normal period of cranking the ether fuelcylinder may be empty. Check the low cylinder indica­tor on the EIR and replace the cylinder as required. Theether fuel canister is on the right side of the carrier en­gine compartment. Refer to Figure 1-51.

Note: The EIR requires a constant power supply inorder to preserve the memory of the amount of

ether used. There is an internal backup circuit that

allows the EIR to retain its memory for 72 hours

without a battery connection. If the battery is dis­

connected for longer than 72 hours, the EIR will re­

set. The ether fuel cylinder should be replaced tosynchronize the counter with the amount of ether

left in the cylinder.

WARNINGWhen maintaining or troubleshooting etherstart system, always ensure 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, ensure it is pointed away from you.

The ethyl ether fuel used in this system is

extremely flammable, toxic, harmful, and canbe fatal.

Changing the Ether Fuel Cylinder1. Park crane on a firm level surface, engage the park

brake, shift the transmission to neutral and shut­down the carrier engine.

2. Clean all dirt from the neck of the fuel cylinder andtop of the valve. Refer to Figure 1-51.

3. Loosen the cylinder clamp.4. Turn the fuel cylinder counterclockwise to remove

the cylinder from the valve. Remove the old gasketfrom the valve and properly discard.

Operator's Manual

1-51Section 1 - Operating Instructions

5. Install the protective cap to protect the top of thevalve from dirt after removal.

6. Find the new gasket from the inside of the threadprotective white cap on the new fuel cylinder.

7. Install the new gasket into the valve.

Note: Replace gasket inside of valve each time

a cylinder is replaced. Read the entire cylinderlabel for additional information on cylinder and

valve gasket installation.

8. Coat the new cylinder's threads with clean engineoil.

9. Install the cylinder by turning the cylinder clock­wise until the cylinder dirt and moisture seal o‐ringcontacts the valve.

10. Tighten an additional 1½ turns. Do notovertighten.

CAUTIONDo not overtighten the cylinder.Over‐tightening may damage the valve or the

cylinder.

11. Tighten the cylinder clamp.12. Reset the low cylinder indicator by passing a mag­

net over the reset area 3 or 4 times. The lampshould flash indicating a reset. Refer toFigure 1-52.

Note: The magnet must be capable of lifting a

minimum of two pounds.

Figure 1-52Ether Injector Relay

Operator's Manual

1-52 Section 1 - Operating Instructions

Figure 1-53Electric Carrier Engine Block Preheater

1. Preheater Receptacle

1

Carrier Engine BlockPreheaterThe electric carrier engine block preheater uses electri­cal power to heat the coolant and circulate it throughthe carrier engine. The electric carrier engine blockpreheater receptacle is mounted on the left side of thecarrier. Refer to Figure 1-53.

To Start The Electric Carrier Engine BlockPreheater1. Park crane in suitable area for storage, engage the

park brake, position the transmission shifter toneutral, and shutdown the carrier engine.

WARNINGAreas adjacent to the preheater must be cleanand free of oil and debris to avoid possible fire

hazard.

2. Plug an approved extension chord into the recep­tacle on the left side of the carrier. Plug the otherend into a 110V to 120V electrical source.

Note: Unplug the carrier engine block preheater be­

fore starting the carrier engine.

To Stop Electric Carrier Engine Block Heater1. Unplug preheater cord from electrical source.2. Store the cord

Operator's Manual

1-53Section 1 - Operating Instructions

Right FrontRight Rear

Left FrontLeft Rear

Figure 1-54Outrigger Controls

Main Outrigger OperationThe outriggers are controlled with the levers at one offour ground control stations mounted at each end ofthe outrigger boxes. Each station has levers which in­dividually control the outrigger jacks and outriggerbeams of the crane. Refer to Figure 1-54. Five throttleswitches are also provided to regulate the carrier en­gine speed. These throttle switches are mountedalong the fender and positioned near each outriggerstation.

A bubble level is provided, at each station except theright rear, to assist the operator in determining whenthe crane is level. The bubble levels are mounted onthe top of the outrigger boxes.

Properly install the outrigger pontoons before extend­ing the jack cylinders. The pontoon must set on asmooth, solid surface flush with the ground with no hillsor valleys under them or they may be damaged or de­stroyed. If there is any doubt as to the ground condi­tions, use mats under the pontoons. Check pontoonsbefore and during operations. If they are allowed to

settle, they may lose their effectiveness and make con­tinued operations unsafe.

To Extend Main Outriggers1. Park the crane in the desired location. Engage

park brake and shift the transmission to neutral.

WARNINGPontoons must be attached to outrigger jacksbefore crane is set on outriggers. If thepontoons should settle, the jacks coulddisengage from the pontoons, causing a lossof stability.

2. Remove the pontoons from storage, and attachone to each outrigger jack.

Operator's Manual

1-54 Section 1 - Operating Instructions

Figure 1-55Outrigger Bypass Control Switch

1. Outrigger Bypass Switch2. Oil Cooler

1

2OUTRIGGERSSWITCH MUST BE IN THE BYPASSPOSITION WHEN THE OUTRIGGER IS REMOVED FROM THE CRANE

AND TO DISCONNECTOR CONNECT THE OUTRIGGER

HOSES.

ENGAGED BYPASS

3. Move the outrigger bypass switch, mounted on theright side of the crane below the oil cooler, to the“ENGAGED” position. Refer to Figure 1-55.

WARNINGDo not extend or retract an outrigger beam orjack unless it is in full view of the operator or asignal person. Confirm that all personnel andobstructions are clear from path of machinery.

4. At the right front outrigger box, pull the individualbeam lever to extend the beam. Hold the lever untilbeam is fully extended; release lever.

Note: If faster operation is desired, move the

throttle switch to increase carrier engine speed.

5. Repeat step 4 for the other outrigger beams of thecrane until all four beams are fully extended.

WARNINGOutrigger beams must be fully extendedanytime “On Outrigger” capacities are used.Do not attempt to make any lifts with anoutrigger beam only partially extended. If anoutrigger cannot be fully extended, “On Tire”capacities must be used with outriggers fullyretracted.

6. At the left front outrigger box, pull the right and leftoutrigger jack levers alternately until the pontoonscontact the ground; release the lever. Do not ex­tend jacks on opposite side of crane unless a sig­nal person is used.

7. Repeat Step 6 for rear outrigger jacks of crane.

8. Using the jack levers on the left side of the front andrear outrigger boxes, fully extend the jack cylin­ders. Raise or lower the jacks as required to levelthe crane.

9. Check that all tires are clear of the ground and pon­toons are not settling.

WARNINGAll capacities listed in the Crane RatingManual, when on outriggers, are based on alltires clear of the ground, all outrigger beamsfully extended, and the crane setting level on afirm, solid surface. Serious reductions in thecrane lifting capacity and unsafe operatingconditions can result if these conditions arenot met.

10. Properly set the front bumper outrigger. Refer tothe appropriate instructions in this Section of thisOperator's Manual.

To Retract Main Outriggers1. Disassemble or position the boom so that it is

within an acceptable “ON TIRES” working area asspecified in the Crane Rating Manual.

2. If any of the cranes counterweights are to be re­moved, do so before retracting the outriggers. Re­fer to the appropriate procedures in this Section ofthis Operator's Manual.

3. Check that the carrier park brake is applied and theoutrigger bypass switch, mounted on the right sideof the crane below the oil cooler, is in the “EN­GAGED” position. Refer to Figure 1-55.

4. Retract the front bumper outrigger. Refer to the ap­propriate instructions in this Section of this Opera­tor's Manual.

5. At the left front outrigger box, push the left and rightoutrigger jack levers alternately and carefully lowerthe jacks until the carrier is sitting on tires and thejack are fully retracted. Do not retract the jacks onthe opposite side of the crane unless a signal per­son is used.

WARNINGDo not extend or retract an outrigger beam orjack unless it is in full view of the operator orsignal person. Confirm that all personnel andobstructions are clear from the path of themachinery.

Note: If faster operation is desired, move the

throttle switch to increase carrier engine speed.

Operator's Manual

1-55Section 1 - Operating Instructions

6. Repeat step 5 for the rear outrigger jacks. Thejacks must be in full view of the operator unless asignal person is used.

7. Push an individual beam lever to retract the beam.Hold the lever until the beam is fully retracted; re­lease lever.

8. Repeat step 7 for retracting all outrigger beams onthe crane.

9. Remove and store all pontoons in the brackets pro­vided.

Bumper Outrigger OperationThe front bumper outrigger is required, along with thefour main outriggers, for all “On Outrigger” capacities.All outriggers must also be properly set before swing­ing the upper equipped with the “A”, “AB” or “ABC”counterweight. Always set the four main outriggers be­fore attempting to use the front bumper outrigger.

Bumper Outrigger Control Switch

The control switch for the bumper outrigger is mountedon the left side of the carrier adjacent to the front bump­er. Push the switch down to extend the outrigger orpush it up to retract it. Refer to Figure 1-56.

Bumper Outrigger Overload

Warning System

The bumper outrigger has a warning system built in toprevent excessive stress on the carrier frame. If thebumper outrigger is overloaded for any reason, a pres­sure sensitive switch in the hydraulic circuit will soundthe carrier horn. Under normal circumstances, the car­rier horn will not sound during operation within the ca­pacities in the Crane Rating Manual. If the hornsounds, lower the load to the ground immediately, andreset all the outriggers before continuing operation.

To Extend The Bumper Outrigger

CAUTIONAlways level the crane on the main outriggersbefore extending the bumper outrigger.

Failure to do so could result in structural

damage to the crane as the bumper outrigger

alone will not properly support the weight of

the crane.

1. Level the crane on the four main outriggers.2. Pin the pontoon to the bumper outrigger jack.

Figure 1-56Bumper Outrigger Control Switch

1. Throttle Switch2. Bumper Outrigger Control Switch

1 2

ENGINETHROTTLE

JACKSWITCH TO

INCREASE ORDECREASE

ENGINE SPEEDSWITCH DOWN

TO EXTEND

SWITCH UPTO RETRACT

WARNINGAlways stand in clear view of the outriggerjack when operating it. Confirm that nothing isin the path of it to avoid personal injury ordamage to the crane.

3. Push the bumper outrigger control switch down toextend the cylinder. Hold the switch until the pon­toon rests firmly on a solid surface and the hydrau­lic system goes over relief. Release the lever.

To Retract The Bumper Outrigger

CAUTIONThe bumper outrigger must be retractedbefore the main outriggers. It alone will notproperly support the weight of the crane.

The bumper outrigger pontoon must beremoved from the outrigger jack and storedbefore any travel.

1. Push the bumper outrigger control switch up andhold until cylinder is fully retracted.

2. Remove and properly store the pontoon.

Operator's Manual

1-56 Section 1 - Operating Instructions

1. Outrigger Beam2. Cotter Pin & Lock Pin3. Jack Cylinder4. Lock Valve5. Shackle

Figure 1-57Tilting Left Front Jack Cylinder

1

2

3

4

5

Outrigger Removal SystemThe front and rear outrigger boxes can be removedfrom the carrier to reduce the overall weight of thecrane. A double rod hydraulic pin cylinder system isstandard equipment on rear of the crane and optionalequipment on the front. It eases removal of theoutrigger boxes from the carrier frame. Quick discon­nect type hydraulic fittings are also utilized to reducethe effort of removing the outrigger boxes. The frontoutrigger box assembly weighs approximately 9,000 lb(4 082kg) and the rear outrigger box assembly weighsapproximately 10,000 lb (4 536kg).

The left outrigger jack, on the front outrigger box, is de­signed to pivot out away from the carrier to allow clear­ance of the carrier frame as it is being removed from thecarrier. The carrier frame is equipped with tracks andthe front outrigger box with rollers. These rollers movealong the tracks to ease removal of the front outriggerbox out from under the right side of the carrier once thejack is pivoted. Sturdy skids are required to set the boxon after it has been removed.

The live mast can be rigged as a boom or the 10 ft(3.05m) self assembly section with lifting sheaves canbe used to perform all the lifting procedures required toremove and install the outrigger boxes. Refer to the livemast capacity chart or the 10 ft (3.05m) self assemblysection with lifting sheaves capacities in the Crane Rat­ing Manual for allowable lifting capacities. If the livemast or the 10 ft (3.05m) self assembly section with lift­ing sheaves is not utilized for lifting, an auxiliary liftingdevice will be required to remove and install the outrig­ger boxes. The auxiliary lifting device, skids and anyrigging used must be capable of handling the entireweight of an outrigger box assembly.

Figure 1-58Front Outrigger Box Pin Lock

1. Pin Lock2. Capscrew & Washer

1 2

Front Outrigger Box Removal1. With crane parked on a firm, level surface, shift

transmission to neutral and apply park brake.2. Fully retract all outrigger jacks and beams.3. Remove the pontoon on the left outrigger jack and

properly store it on the carrier.4. Move the outrigger bypass switch, mounted on the

right side of the crane below the oil cooler, to the“ENGAGED” position. Refer to Figure 1-55.

5. Partially extend both front outrigger beams. Leftoutrigger beam must be extended enough to gainaccess to the lock pin. Refer to Figure 1-57.

WARNINGOutrigger jack cylinders must be supportingthe weight of the outrigger box only. Failure toproperly support outrigger box beforeretracting hydraulic pin cylinder can result inpersonal injury and/or crane damage.

6. Extend both jack cylinders until they just contactthe ground and are supporting the weight of theoutrigger box only. If ground is soft use mats underoutrigger jacks.

7. Remove the pin locks from both the front hydraulicpin cylinders. Refer to Figure 1-58. Store thelocks on the tapped blocks on the outrigger box.

8. At both the front outrigger stations, lift the hydraulicpin cylinder locking lever to unlock the pin cylinder.Refer to Figure 1-54. Retract both hydraulic pincylinders. At this point the entire weight of the out­rigger box is on the jacks.

Operator's Manual

1-57Section 1 - Operating Instructions

Note: It may be necessary to raise and/or lowerthe jack cylinder slightly to relieve the pressure

on hydraulic pin cylinder.

9. Slowly and carefully retract both outrigger jacksuntil both pairs of rollers on the outrigger boxmoves down into the tracks under the carrier. Donot fully retract jack cylinders at this time. Leavethem just contacting the ground.

10. Remove cotter pin and lock pin from beam andjack cylinder. Refer to Figure 1-57.

WARNINGStand clear of jack cylinder during thisprocedure. Cylinder may tilt out rapidlycausing an injury.

11. Slowly and carefully extend left outrigger beam un­til jack cylinder tilts out away from the carrier.

12. Install lock pin and cotter pin into beam.13. Fully retract both jacks. Remove pontoon on right

outrigger jack and properly store it on the carrier.14. Shutdown the carrier engine or move the outrigger

bypass switch, mounted on the right side of thecrane below the oil cooler, to the “BYPASS” posi­tion. Refer to Figure 1-55.

WARNINGRelieve hydraulic pressure before removing orinstalling any outrigger circuit hydraulic hose.Move the outrigger bypass switch to the“BYPASS” position or shutdown carrier engine.Failure to do so could result in serious injury.

15. Remove the power beyond hose from the powerbeyond port and connect it to the pressure port onthe outrigger coupler. Remove tank hose from tankcoupler. Install pressure hose to the power beyondport on the carrier coupler. Install dust plugs andcaps to the open ports and lines to prevent con­tamination of the system. Refer to Figure 1-59.

16. Attach a sling to the shackle on the right jack cylin­der. Connect the sling to the live mast, the 10 ft(3.05m) self assembly section with lifting sheaves,or an appropriate lifting device.

WARNINGWhen using the live mast as a boom or the 10 ft(3.05m) self assembly section with liftingsheaves to handle the outrigger boxes,always refer to the Crane Rating Manual toensure lifting capacities are not exceeded.

17. Lift the outrigger box until the right pair of rollersclear the stops at the end of the tracks.

18. Slowly slide the outrigger box along the tracks untilthe left front roller contacts the stop at the end ofthe track on the right side of the carrier.

19. Lower box to ground or skid and remove sling fromshackle on jack cylinder and reattach it to bothslots on the top of the outrigger box. Refer toFigure 1-59.

20. Lift the outrigger box until the left pair of rollers clearthe stop at the end of the tracks. Place and secureoutrigger box on a sturdy skid.

21. Lift outrigger box away from crane and onto atransport crane.

22. Before transporting the crane ensure all hydraulichoses and mounting pins are secure.

Front Outrigger Box Installation1. With crane parked on a firm level surface, shift the

transmission to neutral and apply the park brake.2. Rig a sling to the slots in the top of the outrigger

box. Connect sling to the live mast or an appropri­ate lifting device.

WARNINGWhen using the live mast as a boom or the 10 ft(3.05m) self assembly section with liftingsheaves to handle the outrigger boxes,always refer to the Crane Rating Manual toensure lifting capacities are not exceeded.

3. Lift the outrigger box off the transport crane andset it down on the right side of the carrier, position­ing it for installation. Lift the box enough to align theleft pair of rollers of the box with the tracks underthe right side of the carrier.

4. Taking care not to damage the tilted left jack cylin­der, position left pair of rollers in the tracks, and setright end of outrigger box on the ground or skids.

5. Remove the slings from the outrigger box and rigthe sling to the shackle on the right outrigger jack.

6. Carefully lift right end of the outrigger box, off theground enough to allow the tilted left jack cylinderto clear the bottom of the carrier frame.

7. Slowly and carefully slide the outrigger box alongthe tracks until the left rear roller just contacts thestop on the left side of the track.

8. Slowly lower the right end of the outrigger box,making sure the right pair of rollers are inside thestops at the right end of the tracks. Remove thesling from the right jack cylinder.

Operator's Manual

1-58 Section 1 - Operating Instructions

157

1114

1413

15

12117

7

8

10

9

8

7

6

5

4

321

Figure 1-59Front Outrigger Box Assembly

16 16

Right Side

Front of Machine

1. Carrier Engine Speed Switch2. Power Beyond3. Tank Port4. Pressure Hose

5. Tank Hose6. Power Beyond Hose7. Right Rollers8. Removal Tracks

9. Pressure Port10. Right Front Outrigger Jack11. Slots (For Lifting Slings)12. Right Hydraulic Pin Cylinder

13. Left Hydraulic Pin Cylinder14. Left Rollers15. Bubble Level16. Pin Cylinder Alignment Cam

Operator's Manual

1-59Section 1 - Operating Instructions

9. Shutdown the carrier engine or move the outriggerbypass switch, mounted on the right side of thecrane below the oil cooler, to the “BYPASS” posi­tion. Refer to Figure 1-55.

WARNINGRelieve hydraulic system pressure beforeremoving or installing any outrigger circuithydraulic hose. Move the outrigger bypassswitch to the “BYPASS” position or shutdowncarrier engine. Failure to do so could result inserious injury.

10. Remove power beyond hose from the pressureport and remove pressure hose from power be­yond port. Connect the power beyond hose to thepower beyond port. Connect the pressure hose tothe pressure port and tank hose to the tank port.Refer to Figure 1-59.

11. If carrier engine was shutdown, properly start carri­er engine and allow the system pressure to reachnormal operating range.

12. Move the outrigger bypass switch, mounted on theright side of the crane below the oil cooler, to the“ENGAGED” position. Refer to Figure 1-55.

13. At the left control station, extend the left outriggerbeam enough to gain access to the lock pin. Referto Figure 1-57.

14. Remove the lock pin from the outrigger beam.15. Slowly extend the left jack cylinder until it just con­

tacts the ground. If the soil is soft, use mats underthe the jack cylinder.

WARNINGStand clear of jack cylinder during thisprocedure. Cylinder may tilt up rapidlycausing an injury.

16. Slowly retract the left outrigger beam until tilted cyl­inder pivots up into the vertical position. Install lockpin and cotter pin.

17. Fully retract left outrigger jack and install pontoonsto both outrigger jacks.

18. Extend both jack cylinders to raise the box up offthe tracks until the pin alignment wedges on theoutrigger box contact the carrier frame. Refer toFigure 1-59. If the soil is soft, use mats under thejack cylinder.

19. Pull the hydraulic pin control lever to extend the cyl­inder pin through the carrier mounting lug eyes.Do this on both sides of carrier. Stand in clear viewof cylinder pin while extending.

20. Install the pin locks to both the hydraulic pin cylin­ders. Refer to Figure 1-58.

WARNINGOutrigger pin locks must be installed to thehydraulic pin cylinders to prevent accidentalpin removal.

Rear Outrigger Box Removal1. With crane parked on a firm, level surface, shift

transmission to neutral and apply park brake.2. Fully retract all outrigger jacks and beams.3. Remove the pontoons from each outrigger jack

and properly store them on the carrier.4. Remove the pin locks from the hydraulic pin cylin­

der. Refer to Figure 1-61. Store the locks on thetapped blocks on the outrigger box.

WARNINGAll outrigger jacks and beams must be fullyretracted before hydraulic pin cylinder isretracted. Failure to do so can result inpersonal injury and/or crane injury.

5. Lift the cylinder lock lever to unlock the hydraulicpin cylinder. Refer to Figure 1-54. Retract hy­draulic pin cylinder.

6. Shutdown the carrier engine or move the outriggerbypass switch, mounted on the right side of thecrane below the oil cooler, to the “BYPASS” posi­tion. Refer to Figure 1-55.

WARNINGRelieve hydraulic system pressure beforeremoving or installing any outrigger circuithydraulic hose. Move the outrigger bypassswitch to the “BYPASS” position or shutdowncarrier engine. Failure to do so could result inserious injury.

7. Remove power beyond and tank hose from theirports on the carrier. Remove pressure hose fromoutrigger box port and connect it to the power be­yond port on the carrier. Install power beyond hoseto the pressure port on the outrigger box. Alwaysmatch up and mate the dust caps and plugs fromall the quick disconnect fittings to keep them cleanfor future use. Refer to Figure 1-60.

Operator's Manual

1-60 Section 1 - Operating Instructions

Figure 1-60Rear Outrigger Box Assembly

12

3

4

5

6

9 887

6

5

Right Side

Front of Machine

1. Tank Port2. Power Beyond Port3. Pressure Hose

4. Pressure Port5. Power Beyond Hose6. Tank Hose

7. Lifting Shackles8. Mounting Pins9. Hydraulic Pin Cylinder

7

Operator's Manual

1-61Section 1 - Operating Instructions

Figure 1-61Rear Outrigger Box Pin Lock

1. Pin Lock2. Capscrew & Washer

1

2

OUTRIGGER PIN PULLERDO NOT PUSH PIN PULLER LEVERWHEN CRANE IS ON OUTRIGGERS

WARNINGWhen using the live mast as a boom or the 10 ft(3.05m) self assembly section with liftingsheaves to handle the outrigger boxes,always refer to the Crane Rating Manual toensure lifting capacities are not exceeded.

8. Using the live mast, 10 ft (3.05m) self assemblysection with lifting sheaves, or an appropriate lift­ing device, rig a sling to lifting shackles on top ofoutrigger box.

9. Lift the outrigger box up and away from the crane.Place and secure outrigger box on a sturdy skid.

10. Place and secure outrigger box onto a transportcrane.

11. Before transporting the crane confirm that all hy­draulic hoses and mounting pins are secure.

Rear Outrigger Box Installation1. With crane parked on a firm, level surface, shift

transmission to neutral and apply park brake.2. Rig a sling to the lifting shackles on the top of the

outrigger box. Refer to Figure 1-60.

WARNINGWhen using the live mast as a boom or the 10 ft(3.05m) self assembly section with liftingsheaves to handle the outrigger boxes,always refer to the Crane Rating Manual toensure lifting capacities are not exceeded.

3. Using the live mast, 10 ft (3.05m) self assemblysection with lifting sheaves, or an appropriate lift­ing device, lift the outrigger box off the transportcrane and set it down to the rear of the carrier, posi­tioning it for installation.

4. Carefully lift the outrigger box enough to align themounting pins of the box with the mounting lugs ofthe carrier. Lower the box onto lugs.

5. Shutdown the carrier engine or move the outriggerbypass switch, mounted on the right side of thecrane below the oil cooler, to the “BYPASS” posi­tion. Refer to Figure 1-55.

WARNINGRelieve hydraulic system pressure beforeremoving or installing any outrigger circuithydraulic hose. Move the outrigger bypassswitch to the “BYPASS” position or shutdowncarrier engine. Failure to do so could result inserious injury.

6. Connect power beyond and tank hoses to powerbeyond and tank ports on the carrier. Connect thepressure hose to the pressure port on the outriggerbox. Install all dust plugs to any open port.

7. Properly start carrier engine and allow the systempressure to reach normal operating range.

8. Move the outrigger bypass switch, mounted on theright side of the crane below the oil cooler, to the“ENGAGED” position. Refer to Figure 1-55.

9. Pull the hydraulic pin cylinder control lever to ex­tend the cylinder pin through the carrier mountinglug eyes.

WARNINGOutrigger pin locks must be installed to thehydraulic pin cylinders to prevent accidentalpin removal.

10. Install the pin locks on each end of the hydraulicpin cylinder. Refer to Figure 1-61.

Operator's Manual

1-62 Section 1 - Operating Instructions

1. Air Pressure Adjustment Knob2. Lift Axle Control Switch (In Control Box)3. Pressure Gauge4. Lift Axle Control Switch (In Carrier Cab)

5. Lift Axle Control Box6. Lift Axle7. Standard Tandem Rear Axle

Figure 1-62Lift Axle Controls

Carrier Cab Dash1 2 3

4

5 6 7

Right Side of

Lift AxleThe crane can be equipped with a lift axle. The lift axleis a third rear axle, mounted in front of the standard tan­dem rear axles. The lift axle is used to help distributeweight in order to meet road weight limitation laws.

Note: When using the lift axle, observe all local

road weight laws.

The lift axle can be raised off the road and carried with­out any load on it, or it can be properly lowered and setto carry a specific amount of load. When the lift axle isnot required to distribute weight, lift the axle. When thelift axle is needed for weight distribution, properly lower

it and adjust the air pressure so the lift axle will carry theproper amount of the load.

WARNINGThe lift axle must be in the raised positionwhen making lifts on tires or during offhighway travel. Traveling the crane offhighway with the lift axle in the loweredposition may damage the lift axle. Making liftson tires with the lift axle in the loweredposition will affect the crane stability whichmay cause the crane to tip.

Operator's Manual

1-63Section 1 - Operating Instructions

To Raise the Lift Axle1. Properly park the crane, shift the transmission to

neutral, and engage the park brake. Keep the car­rier engine running for air supply.

2. Locate the lift axle control switch in the lift axle con­trol box on the left side of the carrier. Refer toFigure 1-62.

Note: The crane may be equipped with a control

switch on the carrier cab dash. This switch may

also be used to operate the lift axle but only if

the ground control switch is in the “DOWN”

position.

3. Move the control switch to the “UP” (raise) positionand allow the lift axle to fully raise.

To Lower the Lift Axle1. Properly park the crane on a firm, level surface,

shift the transmission to neutral, and engage thepark brake. Keep the carrier engine running for airsupply.

CAUTIONDo not use the lift axle for off highway travel.The lift axle must be used for on highway

travel only. Damage to the lift axle may occur

when using the lift axle during off highway

travel.

2. Locate the lift axle control switch in the lift axle con­trol box on the left side of the carrier. Refer toFigure 1-62.

Note: The crane may be equipped with a control

switch on the carrier cab dash. This switch may

also be used to operate the lift axle but only ifthe ground control switch is in the “DOWN”

position and one is assured that the air pressure

is properly adjusted by the pressure adjustment

knob in the control box.

3. Move the control switch to the “DOWN” (lower)position.

4. Observe the pressure gauge in the lift axle controlbox to the right of the control valve.

5. Rotate the air pressure adjustment knob to in­crease or decrease air pressure until the requiredaxle load is reached. Approximately 80 psi(552kPa) pressure will give the maximum allowedaxle load of 22,000 lb (9 979kg) .

Note: The amount of air pressure will determine

the amount of load that will be distributed to the

lift axle. Precise axle load determinations must

be made by weighing the crane axle by axle.

Once the air pressure control is adjusted for therequired axle load it does not need to be

changed unless a different axle load is re­

quired.

CAUTIONProperly adjust the amount of air pressure inthe lift axle system as indicated on the air

pressure gauge. Too low of a pressure allows

the lift axle to carry too small of an amount of

the load. Too high of a pressure allows the lift

axle to carry too much of the load. Either case

will cause the lift axle to be ineffective and

could cause major crane damage.

Operator's Manual

1-64 Section 1 - Operating Instructions

Figure 1-63Upper Operator's Cab Controls

1. Winch Drum Control Levers2. Swing Control Lever3. Fire Extinguisher4. Dome Light5. Control Console 26. Hand Throttle

7. Sun Visor8. Control Console 19. Bubble Level10. Control Panel 111. Boom Hoist Control Lever12. Control Panel 2

13. Cab Fan14. Winch Drum Brake Pedals15. Gate Lock Lever16. Swing Lock Control Lever17. Throttle Pedal18. Backstop Cylinders Control Lever

13

6

2

10

7

1

11

14

17

16

9

15

112

4

5 8

18

3

Upper Operator's Cab

Controls

WARNINGRead and understand all “Operating Safety”instructions in this Operator's Manual beforeattempting to operate the crane. This craneshould only be operated by a qualifiedoperator who has read and understood thisentire Operator's Manual.

Upper Operator's Cab ControlConsole 1Refer to Figure 1-64.

1. Live Mast Indicator Light

This light must be off for normal crane operation.Light must be on while using the live mast as aboom. Shutdown the crane and correct the prob­lem if light indicates other than above.

2. Front Drum Free Mode Indicator LightThis light will illuminate to alert the operator whenthe toggle switch on the right lever panel is in the“FREE MODE” position. The automatic brake forthe front drum is inactive and the front drum brakepedal must be used to control the load.

Operator's Manual

1-65Section 1 - Operating Instructions

3. Rear Drum Free Mode Indicator LightThis light will illuminate to alert the operator whenthe toggle switch on the right lever panel is in the“FREE MODE” position. The automatic brake forthe rear drum is inactive and the rear drum brakepedal must be used to control the load.

4. Crane Monitoring System DisplayThis system has function limiter (cutout) ability in­tended to aid the operator in the efficient operationof the crane by continually monitoring the load andwarns of an approach to an overload condition.See “Crane Monitoring System”, in this Section ofthis Operator's Manual.

Note: The Display is only one part of the Crane

Monitoring System. The Display shows what

functions are being monitored.

5. Backstop Cylinder Pressure GaugeThis gauge registers the hydraulic oil pressure inthe boom backstop control system.

6. Systems Override SwitchThis switch is used to override any or all of the func­tion limiters which have been activated on thecrane. This switch is generally used when riggingthe crane, to restore the crane functions whichhave been disabled due to tripped or missing limitswitches on the attachment. When the systemoverride switch is activated, an indicator light adja­cent to the switch will illuminate and all crane func­tions are restored.

7. Systems Override Indicator LightThis light will illuminate to alert the operator that thesystems override switch is activated. For further in­formation, also see “Systems Override Switch”.

8. Boom Hoist Drum Lock SwitchThis switch controls the pawl on the boom hoistdrum. When engaged, the pawl will not allow thedrum to rotate in a lowering direction. However, thedrum pawl will ratchet, allowing the drum to rotatewhen raising the boom. Move the switch forwardto engage the pawl or back to release it. The boomhoist pawl should only be released when loweringthe boom and remain engaged at all other times.

Note: It may be necessary to raise the boomslightly in order to release the drum pawl.

DRUM LOCK CONTROLS

Figure 1-64Upper Operator's Cab Control Console 1

1. Live Mast Indicator Light2. Front Drum Free Mode In­

dicator Light3. Rear Drum Free Mode In­

dicator Light4. Crane Monitoring System

Display5. Backstop Cylinder Pres­

sure Gauge6. Systems Override Switch

7. Systems Override Indica­tor Light

8. Boom Hoist Drum LockSwitch

9. Drum Lock Switches10. Two Block Switch11. Boom Hoist Limit Over­

ride Switch12. Boom Hoist Limit Alarm

Indicator Light

3

4

2

10

116

9

12

7

RELEASE

TWO BLOCK

RELEASE

BOOM RAISING OVER RIDE

OFF

ON

3RD

OFF OFF

ON

BOOM HOISTFRONT REAR

ON

REARFRONT3RD

8

FREE MODE

1

ON

5

9. Drum Lock SwitchesThese switches control the pawls on the front, rear,and third drums. When engaged, the pawls will notallow the winch drum to rotate in a lowering direc­tion, however, the drum pawls will ratchet, allowingthe drums to rotate when raising a load. Move theswitch forward to engage the pawl or back to re­lease it. The drum pawl should only be releasedwhen lowering a load and remain engaged at allother times.

Operator's Manual

1-66 Section 1 - Operating Instructions

Figure 1-65Upper Operator's Cab Control Console 2

1. Pre‐Heater Indicator2. Luffer/Crane Mode Key

Switch

3. Luffer Mode Indicator Light4. Engine Starter Key Switch5. Cigarette Lighters

5

1

4

3

2LOW

HIGH

LUFFER

LUFFER

CRANE

THROTTLE

LIGHTER

STARTER

LIGHTER

HEATER INDICATOR

CER3056

STA

RTE

R

10. Two Block SwitchThis switch is generally used to override a twoblock condition and release a pawl that may bestuck or to slightly hoist a small distance more orboom down slightly. Extreme caution should beexercised when using this switch.

11. Boom Hoist Limit Override SwitchThis switch is used to restore boom hoist functionafter the boom hoist limit switch on the attachmenthas been tripped and the control becomes dis­abled. An audible alarm and indicator light will acti­vate simultaneously signaling the operator whenthe maximum boom angle has been reached. Thealarms will continue to flash and sound even afterthis switch is pushed. For further information, referto “Boom Hoist Limit System” in this Section of thisOperator's Manual.

12. Boom Hoist Limit Alarm Indicator LightThis light will illuminate to alert the operator that theboom is contacting the backstops and the boomhoist limit switch on the attachment has beentripped. An audible alarm will activate simulta­neously and the boom hoist function will becomedisabled. The boom hoist drum control lever willnow operate only in the “LOWERING” position un­less the boom hoist limit override switch or systemsoverride switch is employed. Lower the boom, asrequired, to turn the light off and silence the audiblealarm. For further information, also see “SystemsOverride Switch” and “Boom Hoist Limit OverrideSwitch”.

Upper Operator's Cab ControlConsole 2Refer to Figure 1-65.

1. Pre‐Heater IndicatorThe heater indicator contains a coil wire which canbe viewed through a hole in the top at the indicator.When the upper engine starter key switch is held inthe counterclockwise direction for 20 to 30 sec­onds, this coil will begin to glow red, signaling theoperator that the upper engine heater (glow plug)is hot and the upper engine may be started. At thispoint the key can be rotated clockwise to the startposition. Release the key once the upper enginestarts. Refer to “Upper Engine Starting Procedure”in this Section of this Operator's Manual for com­plete upper engine starting instructions.

2. Luffer/Crane Mode Key SwitchThis key switch is used to switch between the stan­dard conventional boom and the luffing boom at­tachment. Move the key to the “CRANE” modewhen operating with the standard conventionalboom. Move the key to the “LUFFER” mode whenoperating with the luffing boom attachment. Re­move the key after making the selection.

3. Luffer/Crane Mode Indicator LightThis light will illuminate when the Luffer/Cranemode key switch is in the “LUFFER” position.

4. Engine Starter Key SwitchThe starter switch is the conventional, key oper­ated, automotive type. It controls upper engine off/on/start functions and energizes the instrumentpanel in the upper operator's cab. When held inthe counterclockwise direction it energizes the up­per engine heater element (glow plug) for cold up­per engine starts. For further information also see“Pre‐Heater Indicator”.

5. Cigarette LightersPush knob in to heat element. The knob will pop upwhen the element is hot.

Operator's Manual

1-67Section 1 - Operating Instructions

Upper Operator's Cab ControlPanel 1Refer to Figure 1-66.

1. Working Light SwitchThis switch controls the working lights on the up­per. Pull this switch to turn the lights on; push it in toturn the lights off.

2. Front Wiper SwitchThis switch controls the front windshield wiper. Pullthis switch to operate the windshield wiper; push itin to turn it off.

3. Roof Wiper SwitchThis switch controls the roof wiper. Pull this switchto operate the roof wiper; push it in to turn it off.

4. Heater Fan SwitchThe fan speed can be adjusted with the turning ofthis rotary switch. Turn the switch one stage to op­erate the fan at low speed. Turn the switch twostages to operate the fan at high speed.

5. Cab Fan SwitchThis switch controls the upper operator's cab fan.Pull this switch to operate the fan; push it in to turnthe fan off.

6. Lower Jack Cylinder SwitchMove this switch to the “LOWER” position to pro­vide power to the lower jack cylinders.

7. Lower Jack Cylinder Indicator LightThis light will illuminate when the lower jack cylin­der switch is moved to the “LOWER” position andwill go out when the switch is moved to the otherposition.

8. Pump Control System Switch

CAUTIONDo not operate pump control system on the fly.Move all control levers to idle before operating

pump control system. Failure to do so could

cause serious loss of control of the load.

The hydraulic control system employs a two speedpump which can be utilized to provide the operatorwith two speeds of crane operation. The low speedoffers the operator more precise movement of theload, while the high speed gives optimum produc­tivity. This toggle switch is used to activate the sys­tem. An indicator light adjacent to the switch illumi­nates when the system is in the low speed mode.The crane will operate in the high speed mode at alltimes when this switch is in the down position.

Figure 1-66Upper Operator's Cab Control Panel 1

1. Working Light Switch2. Front Wiper Switch3. Roof Wiper Switch4. Heater Fan Switch5. Cab Fan Switch6. Lower Jack Cylinder Switch

7. Lower Jack Cylinder IndicatorLight

8. Pump Control SystemSwitch

9. Pump Control Indicator Light10.Boom Foot Pin Control

Switches

LOWER JACK CYLINDER

FAN

WORKING LIGHT

ROOF WIPER

FRONT WIPER

PUMP CONTROL

SWING HIGH SPEED

TRAVEL HIGH SPEED

LEFT RIGHT

BOOM FOOT PIN

IN

OUT

HEATER

HILO

OFF

1 2

3

4

5

6

7

8

9

10

9. Pump Control Indicator LightThis light will illuminate to alert the operator whenthe pump control system is activated. For furtherinformation on the pump control system, see“Pump Control System Switch”.

10. Boom Foot Pin Control SwitchesThese switches control the hydraulic cylindersused to install and remove the boom foot pins.Move switch to the “IN” position to extend the cylin­der and install a boom foot pin. Move switch to the“OUT” position to retract the cylinder and remove aboom foot pin. Refer to “Boom Base Section In­stallation” in Section 4 of this Operator's Manual forcomplete operating instructions.

Operator's Manual

1-68 Section 1 - Operating Instructions

Figure 1-67Upper Operator's Cab Control Panel 2

1. Service Monitor2. Engine Warning Light3. Drum Rotation Indicator

Switch4. Drum Rotation Indicator Light5. Engine Fuel Level Gauge6. Tachometer

7. Hydraulic Oil PressureGauge

8. Hydraulic Oil TemperatureGauge

9. Engine Water TemperatureGauge

10.Hour Meter

1

3

4

6

7

5

89

1000 0 0 P0

TEMP OIL TEMP FUEL

WARNINGENGINE DRUM

INDICATOR

2

Upper Operator's Cab ControlPanel 2Refer to Figure 1-67.

1. Service MonitorEight individual indicator lights are contained inthis one gauge. Refer to Figure 1-68. The ap­propriate indicator light will illuminate for any of thefollowing conditions:a. Upper engine oil filter is being bypassedb. Low battery charging voltagec. Upper engine air cleaner cloggedd. Swing (Park) brake appliede. Low upper engine oil pressuref. Low battery electrolyte levelg. Low control pressure - Not Usedh. Low upper engine coolant level

Note: All of the indicator lights are tested whenthe starter key switch is moved from the “OFF”position clockwise to the first position. If theselights do not illuminate when tested, locate andrepair the problem before continuing operations.

2. Engine Warning LightThis light will illuminate to alert the operator of up­per engine problems. If this light illuminates, con­tact the upper engine manufacturer for assistance.

3. Drum Rotation Indicator SwitchThis switch controls the drum rotation indicator.When activated, the drum rotation indicator on thewinch control lever will function. For additional in­formation, see “Drum Rotation Indicator” in thisSection of this Operator's Manual.

4. Drum Rotation Indicator LightThis light will illuminate to alert the operator that thedrum rotation indicator switch is activated. For fur­ther information also see “Drum Rotation Indica­tor” in this Section of this Operator's Manual.

5. Engine Fuel Level GaugeThis gauge registers the upper fuel tank fluid level.A sight gauge is also mounted directly on the sideof the fuel tank. The fuel tank capacity is 77 gal(291L). Refer to the upper engine manufacturer'smanual for correct grade of diesel fuel.

6. TachometerThe tachometer registers upper engine speed inrevolutions per minute (rpm). Refer to the upperengine manufacturer's manual for suggested op­erating speeds.

7. Hydraulic Oil Pressure GaugeThis gauge registers the hydraulic oil pressure ofthe crane control system. Normal operating pres­sure is 1,137 psi (80kg/cm2). If the hydraulic oilpressure varies more than ±50 psi (±3.5kg/cm2)shutdown the crane immediately and correct theproblem. The indicator will gradually return to zerowhen the upper engine is shutdown.

8. Hydraulic Oil Temperature GaugeThis gauge registers the hydraulic oil temperaturein the reservoir. Normal operating range will regis­ter in the green area of the gauge, provided theproper viscosity of oil is used. (Operating rangesvary with the oils used in different climates. Refer toSection 2 of this Operator's Manual for proper oilviscosities for operating in different temperatureranges.) If the hydraulic oil exceeds the maximumoperating temperature and the indicator moves tothe red area of the gauge, shutdown the crane im­mediately and correct the problem.

Operator's Manual

1-69Section 1 - Operating Instructions

Figure 1-68Service Monitor

1. Engine Oil Filter Is Being By­passed

2. Low Battery Charging Volt­age

3. Engine Air Cleaner Clogged4. Swing (Park) Brake Applied

5. Low Engine Oil Pressure6. Low Battery Electrolyte Level7. Low Control Pressure - Not

Used8. Low Engine Coolant Level

0 0 0 0 P0

TEMP OIL TEMP FUEL

1 2 3 4 5 6 7 8

9. Engine Water Temperature GaugeThis gauge registers the upper engine cooling sys­tem temperature. For proper cooling system oper­ating temperature range, refer to the upper enginemanufacturer's manual. If the cooling systemoverheats, shutdown the upper engine immedi­ately and repair the problem to avoid upper enginedamage.

10. Hour MeterThe hour meter registers upper engine operatingtime in hours, up to five digits. The smallest digitrepresenting 1/10 of an hour. The hour meter isuseful in determining lubrication and maintenanceschedules. This meter will register only when theupper engine is running.

Crane System ControlsThe following pages give detailed instructions of indi­vidual controls related to crane operation. It is essentialthat the operator knows the function of each controland its duty in the overall operation of the crane.

WARNINGRead and understand all “Operating Safety”instructions in this Operator's Manual beforeattempting to operate the crane. This craneshould only be operated by a qualifiedoperator who has read and understood thisentire Operator's Manual.

Figure 1-69Upper Engine Throttle Controls

1. Hand Throttle2. Throttle Pedal

1

2

Upper Engine Throttle ControlsA throttle pedal is mounted on the upper operator's cabfloor to provide the operator with flexibility of pedal op­eration. Press down to increase upper engine speed;release to decrease upper engine speed. Refer toFigure 1-69. Upper engine speed is registered on atachometer on the control panel. Refer toFigure 1-67.

A hand throttle is mounted to the left of the operator onthe control console. Using the hand throttle gives theoperator the ability to set and hold a specific upper en­gine speed. Sliding the hand throttle lever back in­creases upper engine speed; moving it forward re­duces upper engine speed. Refer to Figure 1-69.

Once the hand throttle is set to a desired upper enginespeed, it will remain in that position until manuallymoved to a new setting. However, upper engine speedmay be increased using the foot pedal without disturb­ing the hand throttle setting.

Operator's Manual

1-70 Section 1 - Operating Instructions

Figure 1-70Boom Hoist Limit Switch

1. Limit Switch2. Boom Foot Pin

82°BoomAngle

1

2

Boom Hoist Operation

Raising and lowering the boom is controlled by theboom hoist control lever, upper engine throttle, andpump control switches. An automatic brake is also in­corporated into the system which remains applied any­time the boom hoist control lever is in the neutral posi­tion. Refer to Figure 1-71.

WARNINGUse a minimum of 4 parts of hoist line and a3,500 lb (1 589kg) hook block on all booms50-100 ft (15.25-30.5m). Live mast canoverhaul boom at short radii. Seriouspersonal injury and/or crane damage couldoccur.

To Raise The Boom

1. Refer to the Crane Rating Manual for proper craneset up based on load radius, working area, etc.

2. Check that the drum lock switch is in the “ON” posi­tion. (The boom hoist pawl will ratchet allowing theboom to raise.)

3. With the upper engine at idle, move the pump con­trol system switch on the control panel to the de­sired position (high or low speed).

4. Pull the boom hoist control lever toward the opera­tor to raise the boom. If desired, increase the up­per engine throttle to speed up the boom.

5. After reaching the desired boom angle, throttledown and slowly move the boom hoist control leverto the neutral position to stop the boom.

To Lower The Boom1. Refer to the Crane Rating Manual for proper crane

set up based on load radius, working area, etc.

CAUTIONWire rope may need to be spooled off the frontand rear winch drums as the boom is lowered.

Failure to do so may cause two blocking.

2. With the upper engine at idle, move the pump con­trol system switch on the control panel to the de­sired position (high or low speed).

3. Move drum lock switch to the “OFF” position.

Note: It may be necessary to raise the boom

slightly in order to release the drum pawl.

CAUTIONDo not lower the boom when boom hoist pawlin engaged as damage to the boom hoist drum

may result.

4. Push the boom hoist control lever forward to lowerthe boom. If desired, increase the upper enginethrottle to speed up the boom.

5. After reaching the desired boom angle, throttledown and slowly move the boom hoist control leverto the neutral position to stop the boom.

Boom Hoist Limit System

The crane is equipped with a boom hoist limit systemthat is used to prevent over hoisting the boom. As theboom is raised to maximum angle, a limit switch at thebase end of the boom is tripped which disables theboom hoist function and prevents the boom from beingraised any further. An audible alarm and indicator lightwill activate simultaneously signaling the operator thatmaximum boom angle has been reached, approxi­mately 82�. Refer to Figure 1-70.

The boom must be lowered in order to silence thealarm. However, to release the boom hoist drum lockand lower the boom, it may be necessary to raise theboom slightly to disengage the boom hoist drum pawl.The boom hoist override switch is then used to reacti­vate the boom hoist function to raise the boom enoughto release the drum lock and lower the boom. The indi­cator light will continue to flash and the audible alarm tosound even after this switch is pushed. To reset theboom hoist limit system, lower the boom until the boomhoist limit indicator light goes off and the audible alarmis silenced. Refer to Figure 1-71.

Operator's Manual

1-71Section 1 - Operating Instructions

Figure 1-71Crane System Controls

1. Swing Control Lever2. Third Drum Control3. Hand Throttle4. Free Mode Indicator Lights5. Front Drum Control Lever (Main)6. Rear Drum Control Lever (Auxiliary)7. Boom Hoist Control Lever

8. Rear Drum Brake Pedal9. Auto Brake/Free Fall Selector Switches10. Throttle Pedal11. Front Drum Brake Pedal12. Third Drum Speed Switch13. Pump Control System Switch14. Pump Control Indicator Light

15. Boom Hoist Override Switch16. Boom Hoist Limit Indicator Light17. Systems Override Switch (For Rigging)18. Systems Override Indicator Light19. Drum Lock Switches20. Drum Control Lever Locks (If Equipped)

19

13

14

15

16

17

4

18

2

SAFETY INSTRUCTIONS

AUTO BRAKE/FREE FALL SELECTOR SWITCH.Fully depress and latch the drum brake pedals inthe fully applied position before operating theselector switch.

RELEASE

TWO BLOCK

RELEASE

BOOM RAISING OVER RIDE

OFF

ON

3RD

OFF OFF

ON

BOOM HOISTFRONT REAR

OFF

ONDRUM LOCK CONTROLS

REARFRONT3RD

LOWER JACK CYLINDER

FAN

WORKING LIGHT

ROOF WIPER

FRONT WIPER

PUMP CONTROL

SWING HIGH SPEED

TRAVEL HIGH SPEED

LEFT RIGHT

BOOM FOOT PIN

IN

OUT

HEATER

HILO

OFF

3

5

6

7

8

10

11

9

12

ON

FREE MODE

ON

1

20

Operator's Manual

1-72 Section 1 - Operating Instructions

Figure 1-72Boom Angle Indicator - Mechanical Type

0

0

Boom Angle IndicatorA bubble type boom angle indicator is mounted to the leftof the upper operator's cab on the base section of theboom. Refer to Figure 1-72. It must be adjusted prop­erly, free from binding and the crane must be level for theunit to accurately indicate boom angles. Even underthese conditions its readings are only approximate.When making near capacity lifts, measure the load radiusto determine crane capacity. Check the adjustment ofthe boom angle indicator daily to ensure its accuracy.

Drum Control Lever Locks(If Equipped)The front and rear winch, boom hoist, and 3rd drumcontrol levers can be locked to prevent inadvertent op­eration of these controls. Position the locks in thelocked position while exiting or entering the upper op­erator's cab, or when movement of the lever(s) is notdesired, to prevent accidental movement of the levers.

Front And Rear Drum OperationRaising and lowering a load is controlled by the frontand rear drum control levers, drum lock switches,pump control switch, and auto brake/free fall selectorswitches. Front and rear drum brake pedals are alsoused to control the load and operate either manually orautomatically. Refer to Figure 1-73.

The front and rear drum control levers have two speedsof operation in both the raising and lowering mode.Moving the control lever forward or backward engagesthe 1st speed of operation. As the control lever ismoved further, a 2nd and faster speed is obtained. Thisdesign, when combined with the pump control feature,provides the operator with four speeds of operation inboth the raising and lowering mode. The upper enginethrottle setting will also effect the speed of operation.Refer to Figure 1-71.

2nd Speed1st Speed

1st Speed

2nd Speed

Lowering

RaisingNeutral

Figure 1-73Two Speed Drum Control Levers

The brake system for the front and rear drums has twomodes of operation. Drum brakes can be selected tooperate in an automatic or manual mode. When thetoggle switch on the drum control lever panel is in the

“AUTO BRAKE MODE” position, the drum brake ap­plies automatically anytime the control lever is in theneutral position. When it is in the “FREE MODE” posi­tion, the drum brake must be manually applied usingthe brake pedal(s) on the upper operator's cab floor.

The following procedures give instructions for raisingand lowering the load based on the the type of brakesystem used. However, variations in load and job siteconditions may require adaptations to these generalprocedures. Crane operations are to be performedonly by a qualified operator who has read and fully un­derstands the entire content of this Operator's Manual.

WARNINGThe weight of the load must be known beforemaking a lift. Compare the load weight to theappropriate capacity chart in the Crane RatingManual to ensure compliance with capacityratings. Compare the load weight to the WireRope Capacity Chart in the Crane RatingManual to determine the number of parts ofline required to lift the load. Rig and set up thecrane to ensure compliance with both thecrane and Wire Rope Capacity Charts.

Operating In “AUTO BRAKE MODE”

1. Refer to the Crane Rating Manual for proper craneset up based on load radius, working area, etc.

2. Position the head machinery directly above the load.Connect the hook block or hook ball to the load.

3. With the upper engine at idle, move the pump con­trol system switch on the console to the desired po­sition (high or low speed).

Operator's Manual

1-73Section 1 - Operating Instructions

4. Check that the drum lock switch is in the “AUTOBRAKE MODE” position. (The drum pawl willratchet allowing the load to be lifted.)

5. Fully apply and latch the drum brake foot pedal onthe upper operator's cab floor.

6. Move the drum brake mode toggle switch on thedrum control lever panel to the “AUTO BRAKEMODE” position. Check to see that the free modeindicator light on the control console is off.

7. Unlatch and release the drum brake pedal.

WARNINGDo not lift a load to the point where the hookblock, hook ball, or load contacts the headmachinery. “Two blocking” could damage thehook block, hook ball, and/or the headmachinery, allowing the load to fall. Alwayskeep the hook block, hook ball, and load asafe distance from the boom.

8. To Raise The Load: Slowly pull back on the con­trol lever. If desired, increase the upper enginethrottle to speed up the winch once the load beginsto move. After the load reaches the desired height,throttle down and slowly move the control lever tothe neutral position to stop the load.

To Hold The Load: With the control lever in the neu­tral position, fully apply and latch the drum brake footpedal. Check to see that the drum lock switch on thecontrol console is in the “ON” position.

CAUTIONDo not lower the load when the drum pawl isapplied as damage to the drum may result.

To Lower The Load: Unlatch and fully release thedrum brake foot pedal. Move the drum lock switchon the control console to the “OFF” position.

Note: It may be necessary to raise the load

slightly to allow the drum pawl to release whenlowering the load.

Slowly move the control lever forward. If desired,increase the upper engine throttle to speed up thewinch once the load begins to move. After the loadreaches the desired height, throttle down andslowly move the control lever to the neutral positionto stop the load.

Operating In “FREE MODE”

1. Refer to the Crane Rating Manual for proper craneset up based on load radius, working area, etc.

2. Position the head machinery directly above the load.Connect the hook block or hook ball to the load.

3. With the upper engine at idle, move the pump con­trol system switch on the control panel to the de­sired position (high or low speed).

4. Check that the drum lock switch is in the “AUTOBRAKE MODE” position. (The drum pawl willratchet allowing the load to be lifted).

5. Fully apply and latch the drum brake foot pedal onthe upper operator's cab floor.

6. Move the drum brake mode toggle switch on thedrum control lever to the “FREE MODE” position.Check to see that the free mode indicator light onthe control console is illuminated.

WARNINGDo not lift a load to the point where the hookblock, hook ball, or load contacts the headmachinery. “Two blocking” could damage thehook block, hook ball, and/or the headmachinery, allowing the load to fall. Alwayskeep the hook block, hook ball, and load asafe distance from the boom.

7. To Raise The Load: Pull back on the control leverwhile slowly releasing the drum brake foot pedal. Ifdesired, increase the upper engine throttle tospeed up the winch once the load begins to move.After the load reaches the desired height, throttledown and slowly apply the drum brake pedal whilemoving the control lever to the neutral position.

To Hold The Load: With the control lever in theneutral position, fully apply and latch the drumbrake foot pedal. Check to see that the drum lockswitch on the control console is in the “AUTOBRAKE MODE” position.

CAUTIONDo not lower the load when the drum pawl isapplied as damage to the drum may result.

To Lower The Load: Move the drum lock switchon the control console to the “OFF” position.

Note: It may be necessary to raise the load

slightly to allow the drum pawl to release when

lowering the load.

With the control lever in neutral, slowly release thedrum brake foot pedal and allow the load to lowerslowly. The speed at which the load falls is regu­lated by the pressure applied to the drum brakepedal. After the load reaches the desired height,slowly apply the drum brake pedal and bring theload to a complete stop. Engage the drum pawl bymoving the drum lock switch to the “ON” position.

Operator's Manual

1-74 Section 1 - Operating Instructions

Figure 1-74Drum Rotation Indicator

1. Drum Indicators2. Drum Indicator Light3. Drum Indicator Switch

1 23

000 0 P0

TEMP OIL TEMP FUEL

WARNINGENGINE DRUM

INDICATOR

Third Drum ControlThe crane may be equipped with a third drum controllever. The lever is used to control the third drummounted in the boom base section. Refer toFigure 1-71. Refer to “Third Drum Winch” in this Sec­tion of this Operator's Manual for more information.

Drum Rotation IndicatorThis system is used to monitor winch drum speedsthrough the use of a vibration signaling devicemounted on the winch control lever. Refer toFigure 1-74. As the winch drum rotates, a vibrationsignal relative to the speed of the winch drum is felt inthe drum control lever. The faster the rotation of thewinch drum the faster the vibration signal.

Upper HornThe upper horn button is on the swing control lever.Refer to Figure 1-75. To sound the horn, press thebutton.

Swing Operation

Rotation of the upper over the carrier is controlled bythe swing control lever, swing (park) brake switch, andswing control lever. The system also incorporates aswing alarm which sounds anytime the swing controllever is moved out of the neutral position. Refer toFigure 1-75.

The swing control lever, to the left of the operator on thecontrol console, operates the swing function. Move thecontrol lever forward to swing left; move it back to swingright. The swing (park) brake switch is also on the samecontrol lever along with the upper horn button.

Figure 1-75Swing Controls

LIGHT ON (Brake Applied)LIGHT OFF (Brake Released)

When the mark is pressed,

the brake is released.

“Brake”

“Released”

1. Swing Lever2. Swing Brake Release Switch3. Horn Switch

1 2

3

Swing Right

Swing Left

0 0 0 0 P0

TEMP OIL TEMP FUEL

DANGERKeep clear of swingingupper to prevent seriousbodily injury.

Swing (Park) Brake

CAUTIONDo not apply swing (park) brake with theupper in motion. This practice will result in

damage to the swing mechanism. Stop the

swinging upper by slowly engaging the swing

control lever in the opposite direction to that

which started the swing. Apply the swing

(park) brake only after the upper comes to a

complete stop.

Use the swing (park) brake for holding the upper, in anyposition, over the carrier during normal, stationarycrane operations and anytime the upper operator'scab is left unattended. The electrically activated swing(park) brake is applied using the rocker switch on thetop of the swing control lever. Refer to Figure 1-75.

Operator's Manual

1-75Section 1 - Operating Instructions

Figure 1-76Swing Brake Lock Out

1. Needle Valve

1

Swing Brake Lock Out

The swing brake lock out, if equipped, is to be usedonly when traveling the crane on the job site with theboom in a boom dolly. When traveling the crane in thisconfiguration, the upper must be allowed to swingwhile turning. The swing brake automatically applieswhen the upper engine is not running, therefore theswing brake must be held in the released position to al­low the upper to swing. Use the needle valve on theright swing unit to lock out the swing brake. Refer toFigure 1-76.

WARNINGDo not operate the crane with the swing brakelocked out. Always unlock the swing brake

before operating the crane. Swing brake will

not function when the swing brake is locked

out.

Do not allow the upper to swing with the upper

counterweights installed when the crane is on

tires. Lower the upper counterweights to thecarrier deck and secure them to prevent

tipping or remove them from the crane. Crane

will tip causing serious personal injury and/or

major equipment damage.

Figure 1-77Two Position House Lock Control Lever

Disengaged

Engaged

Two Position House Lock

CAUTIONDo not engage the two position house lockwith the upper in motion. This practice will

result in damage to the swing mechanism or

other crane components. Stop the swinging

upper by slowly engaging the swing control

lever in the opposite direction to that which

started the swing. Engage the two position

house lock only after the upper comes to acomplete stop.

The two position house lock control lever is below theoperator's seat. This two position house lock is used tolock the upper directly over the front or rear of the carri­er. The two position house lock will engage in thesetwo positions only. Use of the two position house lockis mandatory when traveling or transporting the craneand during pick and carry operations. Refer toFigure 1-75.

Note: In order to engage the two position house

lock, it may be necessary to swing the upper slightly

in one direction or the other to align the house lockpin and the retaining ring on the carrier.

Operator's Manual

1-76 Section 1 - Operating Instructions

To Swing The Upper1. Compare the boom configuration and length to the

appropriate capacity chart in the Crane RatingManual. Position the boom safely within the limitsspecified on the capacity chart in the Crane RatingManual.

DANGERAll personnel and equipment must be out ofthe path of the rotating upper. Failure to do sowill result in serious personal injury or majorequipment damage.

Swing slowly and cautiously. Watch forcentrifugal force. Out swing of a loadincreases the load radius and thus decreasescapacity. Load out swing may result in tippingor damaging the crane.

2. Check that the two position house lock controllever is in the “ENGAGED” position.

3. Move swing (park) brake rocker switch, on theswing control lever, to the “OFF” position. Check tosee that the swing (park) brake indicator light onthe service monitor is off.

4. Disengage the two position house lock using thecontrol lever below the operator's seat.

Note: In order to disengage the two position

house lock, it may be necessary to swing theupper slightly in one direction or the other to

ease the pressure on the two position house

lock pin, allowing it to release.

5. Move the swing control lever forward or backwardto begin swinging in the desired direction. Releasethe control lever to neutral and allow the upper tocoast as the crane approaches the desired posi­tion. Slowly engage the swing control lever in theopposite direction to that which started the swingin order to slow and then stop the upper.

CAUTIONDo not engage the two position house lock orbrake with the upper in motion. This practice

will result in damage to the swing mechanism.

Stop the swinging upper by easing the swing

control lever in the opposite direction to that

which started the swing. Engage the two

position house lock only after the upper

comes to a complete stop.

6. After coming to a complete stop, apply the swing(park) brake and two position house lock as desired.

Crane Monitoring SystemThe Rated Capacity Limiter is intended to aid the op­erator in the efficient operation of the crane by continu­ously monitoring the load and warning of an ap­proaching overload or unsafe condition. The systemmonitors crane functions by means of high accuracysensors. It continuously compares the load with thecrane capacity charts which are stored in the computermemory. If an overload or unsafe condition is ap­proached, the system warns by means of audible andvisual alarms. Function limiters will also activate undercertain conditions to limit crane movement.

Digital Display Unit

The system also provides the operator with a digitaldisplay of the working radius, the main boom workingangle, the weight of the total load (including hook blockand/or hook ball and attachments) being lifted, and themaximum permitted load for the actual crane condi­tion. See manufacturer's manual for complete operat­ing and maintenance instructions. Refer toFigure 1-78.

The display is secured to the console with a mountingarm that adjusts for optimum viewing. Loosen the ad­juster on the mounting arm and adjust the display tothe desired viewing position. Tighten the adjuster.

Internal Light Bar

The internal light bar is an analog bar‐graph whichgives a visual indication of how much of the crane's ca­pacity is being used and the rate at which an overloadis being approached. Refer to Figure 1-79.

Operator's Manual

1-77Section 1 - Operating Instructions

Figure 1-78Digital Display Unit

System Inoperative or Malfunctioning

When operational aids are inoperative or malfunction­ing, the following recommendations for continued useof the crane should be followed or the crane should beshutdown.1. Steps shall be taken to schedule repairs and recal­

ibration immediately. The operational aids shall beput back into service as soon as replacementparts, if required, are available and the repairs andrecalibration can be carried out. Every reasonableeffort must be made to expedite the repairs and re­calibration.

2. When the Rated Capacity Limiter is inoperative ormalfunctioning, the designated person responsi­ble for supervising the lifting operations shall es­tablish procedures for determining load weightsand shall ascertain that the weight of the load doesnot exceed the crane ratings at the radius wherethe load is to be handled.

3. When a boom angle or radius indicator is inopera­tive or malfunctioning, the radius or boom angleshall be determined by measurement.

Figure 1-79Internal Light Bar

1. Internal Light Bar

1

4. When the anti‐two block warning device is inopera­tive or malfunctioning, the designated person re­sponsible for supervising the lifting operationsshall establish procedures, such as assigning anadditional signal person, to furnish equivalentprotection. This does not apply when lifting per­sonnel in load line supported baskets. Personnelshall not be lifted in load line supported basketswhen the anti‐two block devices are not function­ing properly.

5. When a boom length indicator is inoperative ormalfunctioning, the designated person responsi­ble for supervising the lifting operations shall es­tablish the boom length at which the lift will bemade by actual measurement or markings on theboom.

6. When a level indicator is inoperative or malfunc­tioning, other means shall be used to level thecrane.

7. In situations where inconsistency exists, verifiedweights, measured radii, boom lengths, and au­thorized crane capacities must always take prece­dence over indicator readings.

Operator's Manual

1-78 Section 1 - Operating Instructions

Figure 1-80Anti‐Two Block System

1. Head Machinery Switch2. Winch Wire Rope3. Anti‐Two Block Weight

3

1

2

Jib Head

Boom Head

3

1

2

Anti‐Two Block System

The anti‐two block system is an electromechanicalsystem designed to alert the operator before thehook block, hook ball, or load contacts the headmachinery of the main boom or jib. When a twoblock situation is imminent, an audio/visual alarm isactivated to alert the operator of the pending danger.When the alarm activates it is essential that theoperator discontinue operations immediately andcorrect the two block situation.

Three basic components are used to make up theanti‐two block system. The anti‐two block weight andhead machinery switch, at the head machinery, andthe audio/visual alarm in the upper operator's cab. Re­fer to Figure 1-78 and Figure 1-80.

An anti‐two block weight is suspended from each of thehead machinery switches and is used to hold theswitch in the “OFF” position. When the anti‐two blockweight is lifted by the hook block, hook ball, or load, itallows the switch to activate the audio/visual alarm inthe upper operator's cab. In addition to the audio/vis­ual alarm, function limiters are activated.

CAUTIONDo not allow the load to spin out of controlwhen hoisting. The anti‐two block weight may

become entangled with the wire rope and

could damage the anti‐two block system, wire

rope, or boom. Use rotation resistant wire

rope during single part line hoisting

applications, especially when long fall lifts

are involved.

The added feature of hydraulic function limiters preventthe operator from continuing crane functions which willcause a two block situation to occur. The crane func­tions of winch up and boom down are disabled whenthe anti‐two block weight is lifted. These functions willremain disabled until the two block situation is cor­rected or the override switch on the computer is util­ized.

The main boom head will always have a head machin­ery switch and weight if the crane is equipped with ananti‐two block system. Each of the added attachmentsused on the crane must employ a head machineryswitch, proper cable connections, and weight in orderfor that particular attachment to be monitored by thesystem.

Operator's Manual

1-79Section 1 - Operating Instructions

1. “Off” Switch2. “A/C On” Switch3. Vent Selection Switches

4. Fan Speed Switches5. Temperature Control Switches

Figure 1-81Air Conditioner Controls

1 2 3

4 5

OFF

COOL WARM

A/C

LO HI

Air Conditioner ControlsThe air conditioner controls the temperature in the up­per operator's cab. Use the following control descrip­tions to adjust the temperature inside the upper operat­or's cab.

1. “Off” Switch

Pushing this switch will stop the air flow from thevents.

2. “A/C On” Switch

Push this switch to turn the air conditioner “ON” or“OFF”. The indicator light above the switch will illu­minate to indicate that the air conditioner is “ON”.

Note: If the outside temperature reaches zero,the compressor cannot be started even if the

“A/C ON” switch is pressed.

3. Vent Selection Switches

Use these switches to select the required upperoperator's cab ventilation. Select one switch to al­low air flow from the upper vent and one for the low­er vent. Press both switches to provide air flowfrom both vents for maximum ventilation. The indi­cator light above the switch will illuminate to indi­cate which vent(s) is selected.

4. Fan Speed Switches

Use these switches to control the amount of airflowing from the vents: Low, Medium, or High.

5. Temperature Control Switches

Use these switches to adjust the temperature in theupper operator's cab. Press the Cool switch tolower air temperature and Warm to raise.

Operator's Manual

1-80 Section 1 - Operating Instructions

Figure 1-82Operator's Seat

1. Height Adjustment Lever2. Seat Release Lever3. Seat Back Release Lever

23

1

Operator's SeatThis 6-way adjustable seat is controlled by manualcontrols. Refer to Figure 1-82.

Height Adjustment

To adjust the seat height, rotate the knob on the seatbracket.

Forward/Backward Adjustment

To move the seat forward or backward, move the seatrelease lever to the left and hold. Position the seat asdesired and release the lever to lock the seat in place.

Seat Back Adjustment

To recline the seat back or bring the seat back forward,lift the seat back release lever and hold. Position theseat back as desired and move the lever down to lockthe seat back in place.

Entering And Exiting TheUpper Operator's CabEntering or exiting the upper operator's cab could behazardous if certain aspects are not taken into consid­eration. Numerous hand grips are attached to the up­per operator's cab to provide safe entry to the upperoperator's cab. Remain in three point contact with thecrane at all times (two hands and one foot or two feetand one hand). Use these features to make climbingon the crane as safe as possible.

Figure 1-83Gate Lock Lever

1. Operation Position2. Stop Position

2

1

Gate Lock Lever

When operating, place the lever forward to the “OP­ERATION” position and pull the lever to the “STOP”position when waiting in the upper operator's cab orentering or exiting the upper operator's cab When thelever is pulled to the “STOP” position, the pilot oil pres­sure alarm lamp comes on and all functions arestopped. Even if a control lever is activated, the cranewill not function with the gate lock lever in the “STOP”position. To start operations, after making sure all con­trol levers are in the “NEUTRAL” or “LOCK” position,push the gate lock lever forward to the “OPERATION”position. Refer to Figure 1-83.

WARNINGThe gate lock lever should not be placed in the“STOP” position when operating the crane.This could cause the automatic drum brakesto not adjust correctly, causing the load to fall.

Operator's Manual

1-81Section 1 - Operating Instructions

Break‐In PeriodOperate a new crane at half throttle for the first twenty(20) hours of operation. A break‐in period under mod­erate loads will assist in providing long, troublefree per­formance.

Before Starting OperationsBefore starting daily operations, make the followingchecks and inspections:

Engine

Check fuel, oil, and cooling systems for proper fluidlevels in the upper and carrier engines. Check forleaks. Repair or fill as required. Refer to engine manu­facturer's manual(s) for additional details.

Gear Cases

Visually inspect all gear cases for leaks or damage. Ifleaks or damage exist, repair and fill case to proper lu­brication level.

Hydraulic System

Check all hoses for chafing, bulging, or other damage.Replace as necessary. Inspect hydraulic system for ex­ternal leaks. Repair as needed. Check hydraulic reser­voir oil level. Add oil if necessary.

Fuel System

Drain any accumulated water from the fuel system byopening the petcock on the bottom of the fuel tank. Al­low all the water to drain from the tank into an appropri­ate container until clean diesel fuel begins to flow fromthe drain. Close the petcock and properly dispose ofthe contaminated water.

Lubrication

Lubricate the crane as outlined in Section 2 of this Op­erator's Manual.

Note: Operators may have nothing to do with lubri­

cation or maintenance of the crane, but it could be

advantageous for them to be familiar with it. Knowl­

edge of preventive maintenance makes the opera­

tor more aware of malfunctions in the crane so re­pairs can be made with a minimum of downtime.

Tires And Wheels

Check tire inflation. Inflate to pressures per the Tire In­flation Label, on the carrier. Check wheel lug nut

torque, each day, for the first fifty hours of operationand periodically thereafter. Refer to Section 3 of thisOperator's Manual for additional information.

Wire Rope And Sheaves

Inspect all wire rope and sheaves for damage or dete­rioration. Replace as necessary.

General Inspection

Visually inspect the entire crane for loose or missingcotter pins or bolts, or damaged chords or lattices.Check for oil or fluid leaks. Make repairs as needed.

Electrical System

Check the operation of all lights, windshield wipers,horns, turn signals, etc. Repair as needed.

Carrier Brakes

Start the carrier engine and allow the air system pres­sure to reach its normal operating range, 100-120 psi(690-827kPa). Check park brake and service brakeoperations. Adjust or repair as needed.

Controls

Check all controls for proper operation and adjust­ment. Repair as needed.

DANGERThis Operator's Manual and the enginemanufacturer's manual(s) must be

thoroughly read and understood by the

operator before starting the engine(s).

Personal injury or crane damage could result

from improper operating procedures.

Fire ExtinguisherA fire extinguisher is mounted in the upper rear of theupper operator's cab. Refer to Figure 1-63. It is anABC type fire extinguisher, meaning it is capable of ex­tinguishing most types of fires. The operator should befamiliar with it's location, the clamp mechanism used tosecure it in place, and the operation of the device. Spe­cific instructions, regarding operation, are given on thelabel attached on the fire extinguisher. A charge indica­tor on the fire extinguisher monitors the pressure withinthe tank. Check the indicator daily to ensure the fire ex­tinguisher is adequately charged and ready for use.

Operator's Manual

1-82 Section 1 - Operating Instructions

Engine Starting ProcedureBefore attempting to start the engine(s), the operatorshould carefully read and understand the engine start­ing instructions in the engine manufacturer's man­ual(s) and this Operator's Manual. Attempting to startor run the engine(s) before studying these instructionsmay result in engine(s) damage. The operator shouldlearn and obey all applicable “Rules of the Road” and ifnot already a competent driver, obtain instructions toattain these necessary skills. With crane fully servicedand the operator familiar with all gauges, switches, andcontrols, and having read and fully understood this en­tire Operator's Manual and the engine manufacturer'smanual(s), start the desired engine using one of the fol­lowing procedures:

WARNINGDiesel exhaust fumes can beharmful. Start and operate

engine(s) in a well ventilated

area. If it is necessary to

operate in an enclosed area,

vent the exhaust to the

outside. Properly maintain

the exhaust system to itsoriginal design.

To Start The Carrier Engine1. Walk around the crane to verify that there are no

persons under or in close proximity to the crane.2. Engage the park brake.3. Fully depress the clutch pedal (The carrier engine

will not start unless the clutch pedal is fully de­pressed).

4. Sound the horn twice in succession, wait 10-15seconds while making a visual check to verify thatthere are no persons under or in close proximity tothe crane.

5. Turn the ignition switch to the “ON” position to en­ergize the carrier engine electrical system. Wait forthe Check/Stop Engine Light to go off before start­ing the crane. This will allow the carrier engine tosense ambient conditions for optimal starting.

6. Turn the ignition switch to the “START” position.Release the ignition switch immediately after thecarrier engine starts. If the carrier engine fails tostart in 30 seconds, release the ignition switch andallow the starter motor to cool a few minutes beforetrying to start again. If the carrier engine fails tostart after four attempts, refer to the carrier enginemanufacturer's manual for instructions.

7. Warm Up - Run the carrier engine at low throttlewith no load while the carrier engine is warming up.Observe the following instruments for proper indi­cations.a. Engine Oil Pressure - If there is no carrier en­

gine oil pressure after 10-15 seconds of run­ning time, shutdown the carrier engine imme­diately and repair the problem to avoid majorcarrier engine damage. Refer to the carrier en­gine manufacturer's manual for proper oilpressure operating range.

b. Battery Gauge - Observe indicator to insurebattery and electrical system is working prop­erly. The gauge should indicate 12.5 to 14.0volts while the carrier engine is running. (Itshould read 12.0 volts when the ignition switchis on, without the carrier engine running.)

c. Air Pressure - Normal operating range is100-120 psi (690-827kPa). Do not attemptto operate crane until air pressure reaches itsnormal operating range.

8. When the carrier engine has thoroughly warmedup, after all pressures and temperatures are withinoperating ranges, and all daily checks have beenmade, the crane is ready for operation.

To Start The Upper Engine1. Walk around the crane to verify that there are no

persons under or in close proximity to the crane.2. Check that the gate lock lever is in the “OFF” posi­

tion and all control levers are in the neutral positionto prevent inadvertent operation of the crane.

3. Check that the two position house lock is engagedand the swing park brake switch, on the top of theswing control lever, is in the “ON” position.

4. Ensure both drum brake pedals are latched in thefully applied position and all drum lock switchesare in the “ON” position.

5. Pull back on the hand throttle slightly and move thestarter switch clockwise to first position.

Note: All of the indicator lights of the servicemonitor are tested when the starter key switch is

moved from the “OFF” to the “ACC” position. If

these lights do not illuminate when tested, lo­

cate and repair the problem before continuing

operations.

6. Sound the horn twice in succession, wait 10-15seconds while making a visual check to verify thatthere are no persons under or in close proximity tothe crane.

7. Turn the ignition switch to the “START” position.Release the ignition switch immediately after theupper engine starts. If the upper engine fails to

Operator's Manual

1-83Section 1 - Operating Instructions

start in 30 seconds, release the ignition switch andallow the starter motor to cool a few minutes beforetrying to start the upper engine again. If the upperengine fails to start after four attempts, refer to theupper engine manufacturer's manual for instruc­tions.

8. Warm Up - Run the upper engine at low throttlewith no load while upper engine is warming up.Observe the following instruments for proper indi­cations:a. Service Monitor - Eight individual indicator

lights are contained in this one gauge. The ap­propriate indicator will illuminate for any one ofthe following conditions:- Engine oil filter is being bypassed- Low engine oil pressure- High engine coolant temperature- Low engine coolant level- Swing brake applied- Low battery electrolyte level- Low charging voltage at battery- Restricted air flow at engine air cleaner

b. Hydraulic Oil Temperature Gauge - In coldweather, do not operate the crane until the hy­draulic oil temperature registers in the greenarea of the gauge. If the crane is equipped witha manually operated oil cooler bypass valveinstead of an automatic one, it may be neces­sary to bypass the oil cooler then warm the oilby operating the crane with no load for a shortperiod of time. Once the oil reaches operatingtemperature, bypass the oil cooler, as re­quired, in order to maintain the operating tem­perature.

9. When the upper engine has thoroughly warmedup, after all pressures and temperatures are withinoperating ranges, and all daily checks have beenmade, the crane is ready for operation.

Engine Shutdown

Carrier Engine Shutdown Procedure1. Throttle the carrier engine back to idle. Engage the

park brake and shift the transmission to neutral.2. Turn the ignition switch to the “LOCK” position.3. Remove ignition keys from both cabs and lock the

doors if the crane is to be left unattended.

Upper Engine Shutdown Procedure1. Lower any load to the ground and secure it prop­

erly.2. Check that the gate lock lever is in the “OFF” posi­

tion and all control levers are in the neutral positionto prevent inadvertent operation of the crane.

3. Check that the two position house lock is engagedand the swing park brake switch, on the top of theswing control lever, is in the “ON” position.

4. Ensure both drum brake pedals are latched in thefully applied position and all drum lock switchesare in the “ON” position.

5. Throttle the upper engine back to idle.6. Turn the starter key switch to the “OFF” position.7. Remove the ignition keys from both cabs and lock

the doors if the crane is to be left unattended.

Operator's Manual

1-84 Section 1 - Operating Instructions

Crane OperationCranes are used primarily for making heavy lifts. In or­der to do this properly, certain procedures must be fol­lowed. The following is a suggested procedure formaking typical lifts:1. Determine the weight to be lifted. Remember to

add the weight of the hook block, hook ball, slings,rigging, jib, etc. Determine height to which theload must be lifted.

2. Refer to the Crane Rating Manual. Find the short­est boom length and load radius that will accom­plish the job.

3. Do not swing the upper while on tires, use outrig­gers. Position the crane so a minimum swing isnecessary.

4. The crane must be supported by a firm, level sur­face before starting to lift. All capacities in theCrane Rating Manual are based on the crane beinglevel in all directions. If the crane is not level, outswing or side swing of the load will greatly reducelifting capacities and could cause crane damage oran accident. If the ground is soft, use mats.

5. If outriggers are used, the following points must beobserved:a. The outrigger beams must be fully extended to

lift the loads shown in the Crane Rating Manu­al. Serious reductions in lifting capacity will re­sult if beams are not fully extended, and thiscould lead to serious crane damage or an acci­dent. Do not operate with partially extendedoutrigger beams.

b. Outrigger pontoons must be on solid, smoothfooting, flush with the ground (no hills or val­leys under pontoons), otherwise pontoonsmay be damaged or destroyed. If there is anydoubt, use mats.

c. All capacities listed for the crane on outriggersare based on the outrigger jacks being used toraise the crane so that all tires are clear of theground and the crane level. A bubble level isprovided in the upper operator's cab to assistthe operator in determining when the crane islevel.

d. The bumper outrigger must be properly set af­ter setting the four main outriggers.

6. When making lifts on tires, all tires must be inflatedto pressures as listed on the Tire Inflation Label. Donot make lifts which exceed capacities listed in theCrane Rating Manual.

7. Raise the boom and swing over the load.8. Lower the hook block or hook ball and fasten it to

the load. The following points must be observed:

a. The boom peak must be directly above theload. Booms are made to lift and should neverbe used to drag a load sideways.

b. Always use chains, wire ropes, or slings of am­ple size and make periodic checks of their con­dition.

c. Always use sufficient parts of line. Refer to theWire Rope Capacity Chart in the Crane RatingManual for the number of parts of line neededfor a given lift.

d. When lifting loads, care should be taken to pre­vent sudden loading or unloading of the winchwire rope. Ease into the load. Lift the load afew inches (centimeters) off the ground andhold to check the brakes.

9. Lift the load to the desired height. Boom to the de­sired angle. Be careful when booming down orswinging the load, as these increase the load ra­dius and result in a decrease in capacity. Ensurethe load being lifted remains within the lifting ca­pacity of the crane at the boom length and radiusbeing used.

10. Control the load at all times. Use hand lines toguide the load. Do not guide loads into place withyour hands. Swing slowly and smoothly. Avoidjerks when starting or stopping swings.

During OperationThe operator must remain alert to possible malfunc­tioning of the crane while operating. If the crane doesmalfunction, lower the load and shutdown the craneuntil the problem is found and corrected. During op­eration, the operator must:1. Remain alert to any noise or loss of power or bad

response to control of the crane. Watch the servicemonitor, hydraulic oil temperature, and water tem­perature gauges for proper operating ranges.

2. Listen for any unusual noises in the hydraulic sys­tem or power train. If any, correct problem.

3. Watch for oil leaks or any loss of control. If any de­velop, correct before continuing operation.

4. Ensure all controls work freely and easily, with nosticking or binding. Lubricate or adjust as neces­sary.

5. If working on outriggers, periodically check theoutriggers to confirm that the crane is level and sta­ble. If working without outriggers, ensure the tiresare inflated to the proper pressure and the boom ispositioned directly over the rear of the carrier withthe two position house lock engaged. (Refer to theTire Inflation Label on the carrier for proper tirepressure.)

6. Heed all warning and caution labels. Observegood safety practices at all times.

Operator's Manual

1-85Section 1 - Operating Instructions

Upper Counterweight

Installation And RemovalThe upper counterweights consist of three individualpieces: a 22,730 lb (10 310kg) “A” counterweight, a19,200 lb (8 710kg) “B” counterweight, and a 27,070 lb(12 281kg)“C” counterweight. They can be installed tothe upper in various combinations depending upon thedesired capacities.

The counterweights can be assembled on the carrierdeck before raising them to the upper. Positioningpoints (frustums) on the carrier deck are used to spotthe counterweights for assembly and easy installationto the upper. Once the counterweights are assembledon the carrier deck the upper can be swung into themand the counterweight raised to the upper. The crane'slive mast or the 10 ft (3.05m) self assembly section withlifting sheaves (if equipped) can be used to perform allthe lifting required to install or remove the counter­weights to the carrier deck.

Two hydraulic cylinders at the rear of the upper frameare used to raise and lower the counterweights to andfrom the carrier deck. The controls which operate thecylinders are on the right side of the upper platform,

near the counterweight, behind an access door. Referto Figure 1-85.

Actuating the control lever operates both hydraulic cyl­inders simultaneously. Push the lever in to retract thehydraulic cylinders and lower the counterweight; pullthe lever to extend the cylinders and raise the counter­weight. The leveling control valves, on either side of thecontrol lever, are used to regulate the oil flow to the hy­draulic cylinders so the counterweight will remain levelduring removal or installation.

CAUTIONCounterweight must remain level at all times.If counterweight is not level during removal or

installation, it may cause damage to the

removal linkage or sheet metal areas adjacent

to the counterweight. Keep the counterweight

level by using the leveling control valves.

The leveling control valves must be at least partiallyopen for the control valve to operate during removaland installation procedures. During all other opera­tions the leveling control valves must remain com­pletely closed to ensure the counterweight remains inthe proper working position.

Operator's Manual

1-86 Section 1 - Operating Instructions

Figure 1-84Counterweight Assembly

1. “A” Counterweight Lifting Slot2. “A” Counterweight Lifting Pin*3. “A” Counterweight4. “AB” Counterweight Connecting Bolt5. “AB” Counterweight Lifting Pin*6. “AB” Counterweight Lifting Slot7. “C” Counterweight8. “C” Counterweight Connecting Link

9. “ABC” & “C” Counterweight Lifting Slot10. “B” Counterweight11. “B” Counterweight Lifting Slot12. “B” Counterweight Lifting Pin13. “AB” Counterweight Center Connecting Bolt

*Items 2 & 5 are the same pin used in two different locations based onlifting of “A” or “AB” counterweight.

8

12

10

5

4

2

3

9

7

13

1

6

11

10

3

7

12 5

4

8

Operator's Manual

1-87Section 1 - Operating Instructions

Counterweight Installation

Use the following procedures for handling, assem­bling, and raising the counterweight to the upper.

Counterweight Handling And Assembly1. With the crane parked on a firm, level surface, shift

the transmission to neutral and apply the parkbrake.

2. Fully extend all the outrigger beams and properlylevel the crane on the outriggers jacks.

3. Shutdown the carrier engine.4. Install two “A” counterweight lifting pins (2) into the

“A” counterweight (3). Secure each pin with twokeeper pins. Attach a sling to the pins from the “A”counterweight lifting slot (1).

WARNINGWhen using the live mast or the 10 ft (3.05m)self assembly section with lifting sheaves to

handle the counterweights, always refer to the

Crane Rating Manual to ensure lifting

capacities are not exceeded.

All personnel must stand clear while lifting the

“A” counterweight into position. Serious

personal injury may result.

5. Use the live mast reeved as a boom or the 10 ft(3.05m) self assembly section with lifting sheaves(if equipped) for lifting the counterweight.

6. Using the positioning blocks to locate the counter­weight, carefully place the counterweight on thecarrier deck. Refer to Figure 1-86.

7. Remove lifting sling and “A” counterweight liftingpins (2) from the “A” counterweight (3). Store pinsin tool box.

Note: If only the “A” counterweight (3) is to be

used, it can be installed to the upper at this time.

Refer to “Raising the Counterweight To Upper”

in this Section of this Operator's Manual.

8. Install two “B” counterweight lifting pins (12) in the“B” counterweight (10). Secure each pin with akeeper pin. Attach a sling to the pins from the “B”counterweight lifting slot (11).

9. Use the live mast reeved as a boom or the 10 ft(3.05m) self assembly section with lifting sheavesfor lifting the counterweight.

WARNINGWhen using the live mast or the 10 ft (3.05m)self assembly section with lifting sheaves to

handle the counterweights, always refer to the

Crane Rating Manual to ensure lifting

capacities are not exceeded.

All personnel must stand clear while lifting the

“B” counterweight into position. Serious

personal injury may result.

10. Lift the “B” counterweight (10) into place directly be­hind the “A” counterweight (3). Do not remove thelifting sling unless the “C” counterweight (7) is goingto be used.

11. Install the “AB” center counterweight bolt (13). Se­cure bolt with a washer, nut, and clamp.

12. If the “C” counterweight (7) is to be used, attach asling to the “C” counterweight lifting slot (9) in thetop of the “C” counterweight (7).

13. Use the live mast reeved as a boom or the 10 ft(3.05m) self assembly section with lifting sheavesfor lifting the counterweight.

WARNINGWhen using the live mast or the 10 ft (3.05m)self assembly section with lifting sheaves to

handle the counterweights, always refer to the

Crane Rating Manual to ensure lifting

capacities are not exceeded.

All personnel must stand clear while lifting the

“C” counterweight into position. Serious

personal injury may result.

14. Lift the “C” counterweight and place it on top of the“AB” counterweight assembly.

15. Install the “C” counterweight connecting links (8)in the slots on top of the “C” counterweight (7).They must go through the “C” counterweight andinto the “A” counterweight (3).

16. Install the two “AB” counterweight bolts (4). If the“C” counterweight (7) is to be used, the bolts mustgo through the “C” counterweight connecting links(8). Secure each bolt with a washer, nut, andclamp. Remove lifting sling if the “C” counter­weight is not used.

17. Install the counterweight assembly to the upperframe. Refer to “Raising the Counterweight To Up­per” in this Section of this Operator's Manual.

Operator's Manual

1-88 Section 1 - Operating Instructions

Figure 1-85Counterweight Removal Controls

1. Upper Platform 2. Control Levers 3. Leveling Control Valve

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

Lower(Retract)

Raise(Extend)

Neutral

1 2

3

Raising The Counterweight To Upper

All linkage must be properly adjusted before installingthe counterweight. See Section 3 of this Operator'sManual for the correct procedure.1. With crane parked on a firm, level surface, shift the

transmission to neutral and apply the park brake.2. Fully extend all the outrigger beams and properly

level the crane on the outriggers jacks.3. Shutdown the carrier engine.4. Place the counterweight(s) on the carrier deck.

Refer to “Counterweight Handling And Assembly”in this Section of this Operator's Manual.

5. Position the upper directly over the rear of the car­rier so the front portion of the indentions on the in­side of the counterweight align with the removallinkage on the upper frame. Refer to Figure 1-86.Engage the two position house lock.

Note: The positioning points (frustums) are po­

sitioned so the cones on the linkages will con­tact on the front portion of the indentions inside

the counterweights. This is by design to allow

enough clearance between the counterweight

stops and the counterweights when swinging

the upper into the counterweights. As the cylin­

ders are extended, the cones will slide fully intothe indentions and properly align the counter­

weights.

6. Open both of the leveling control valves one fullturn. (Ensure that both counterweight cylindersare still fully retracted.)

7. Pull the control lever to the “RAISE” position andhold. As the counterweight is raised, regulate boththe leveling control valves, as required, to keep thecounterweight level as it moves upward. Continueraising the counterweight until both sets of coun­terweight removal linkages toggle over center. Re­turn the control lever to the “NEUTRAL” positionand fully close both leveling control valves.

DANGERStay clear of the counterweight during theraising procedure. Failure to do so could

result in serious personal injury if the

counterweight was to fall or move suddenly.

All personnel and equipment must be out of

the path of the counterweight.

Do not swing the upper until the outriggers are

properly set. Counterweighted crane will tip ifoutriggers are not used. Swing while on

outriggers only.

8. Shutdown the upper engine.

Operator's Manual

1-89Section 1 - Operating Instructions

Figure 1-86Counterweight Raising/Lowering

1. Indention On the Inside‐Top of Counter­weight

2. Removal Linkage3. Indention On the Inside‐Bottom of

Counterweight

4. Counterweight5. Positioning Points (Frustums)6. Carrier Deck

7. Counterweight Stop8. Indention In Bottom of Counterweight9. Counterweight Cylinder

Counterweight Lowered (Cylinders Retracted) Counterweight Raised (Cylinders Extended)

1

2

4

5

6

9

1

2

5

4

9

87 7

3

6

2

2

Counterweight Removal

Use the following procedures for lowering, disassem­bling, and handling the counterweight to the upper.

Lowering The Counterweight From Upper1. With the crane parked on a firm, level surface, shift

the transmission to neutral and apply the parkbrake.

2. Fully extend all the outrigger beams and properlylevel the crane on the outriggers jacks.

3. Swing the upper directly over the rear of the carrierso the rear portion of the the indention in the bot­tom of the counterweight is aligned with the posi­tioning blocks on the carrier deck. Refer toFigure 1-86.

Note: The positioning points (frustums) are po­sitioned so the front portion of the blocks will

catch on the back portion of the indentions on

the bottom of the counterweights. As the cylin­

ders are retracted, the counterweight will slide

slightly away from the upper and fully onto the

positioning points (frustums). This will allow

enough clearance between the counterweightstop and the counterweights while swinging the

upper out of the counterweights.

Operator's Manual

1-90 Section 1 - Operating Instructions

DANGERDo not swing the upper until the outriggers areproperly set. Counterweighted crane will tip if

outriggers are not used. Swing while on

outriggers only.

4. Engage the two position house lock.5. Check that both the leveling control valves are fully

closed.6. Open left leveling control valves one full turn.

DANGERStay clear of the counterweight during thelowering procedure. Failure to do so could

result in serious personal injury if the

counterweight was to fall or move suddenly.

All personnel and equipment must be out of

the path of the counterweight.

7. Push the control lever to the “LOWER” position andhold until the counterweight removal linkage, onthe left side of the counterweight, just toggles overcenter.

8. Fully close left leveling control valve and open theright leveling control valve one full turn.

9. Push the control lever to the “LOWER” position andhold until the counterweight removal linkage, onthe right side of the counterweight, just togglesover center.

10. Open the left leveling control valve one full turn.(Both leveling control valves should be openedequally at this point.)

11. Push the control lever to the “LOWER” position andhold. As the counterweight lowers, regulate boththe leveling controls valves, as required, to keepthe counterweight level as it moves downward.Slowly lower the counterweight until it is supportedby the positioning blocks on the carrier deck andthe linkage is clear of the counterweight. Returnthe control lever to the “NEUTRAL” position.

12. Fully close both leveling control valves.13. Disengage the two position house lock and rotate

the upper away from the counterweight.14. Disassemble the counterweights and remove

them from the carrier deck. Refer to “Counter­weight Disassembly And Handling” in this Sectionof this Operator's Manual.

Operator's Manual

1-91Section 1 - Operating Instructions

Counterweight Disassembly And Handling1. If the “C” counterweight (7) was used, remove the

two “AB” counterweight bolts (4). Remove the “C”counterweight connecting links (8) from the slotson top of the “C” counterweight (7).

2. Attach a sling to the “C” counterweight lifting slot(9) in the top of the “C” counterweight (7).

WARNINGWhen using the live mast or the 10 ft (3.05m)self assembly section with lifting sheaves to

handle the counterweights, always refer to the

Crane Rating Manual to ensure lifting

capacities are not exceeded.

All personnel must stand clear while lifting the

counterweight(s). Serious personal injury

may result.

3. Using the live mast or the 10 ft (3.05m) self assem­bly section with lifting sheaves, lift the “C” counter­weight (7) off the carrier deck and onto the trans­port vehicle.

Note: The upper counterweights may be re­

moved while bolted together in the “ABC” con­

figuration using the “ABC” counterweight lifting

slots (9).4. Install two “B” counterweight lifting pins (12) in the

“B” counterweight (10). Secure each pin with akeeper pin. Attach a sling to the pins from the “B”counterweight lifting slot (11).

5. Remove the “AB” center counterweight bolt (13).

WARNINGWhen using the live mast or the 10 ft (3.05m)self assembly section with lifting sheaves to

handle the counterweights, always refer to the

Crane Rating Manual to ensure lifting

capacities are not exceeded.

All personnel must stand clear while lifting the

counterweight(s). Serious personal injury

may result.

6. Using the live mast or the 10 ft (3.05m) self assem­bly section with lifting sheaves, lift the “B” counter­weight (10) off the carrier deck and onto the trans­port vehicle.

Note: The upper counterweights may be re­

moved while bolted together in the “AB” config­

uration using the “AB” counterweight lifting

slots (6).

7. Install two “A” counterweight lifting pins (2) into the“A” counterweight (3). Secure each pin with twokeeper pins. Attach a sling to the pins from the “A”counterweight lifting slot (1).

WARNINGWhen using the live mast or the 10 ft (3.05m)self assembly section with lifting sheaves to

handle the counterweights, always refer to the

Crane Rating Manual to ensure lifting

capacities are not exceeded.

All personnel must stand clear while lifting the

counterweight(s). Serious personal injury

may result.

8. Using the live mast or the 10 ft (3.05m) self assem­bly section with lifting sheaves, lift the “A” counter­weight (3) off the carrier deck and onto the trans­port vehicle.

Operator's Manual

1-92 Section 1 - Operating Instructions

Figure 1-87Using the live mast or the 10 ft (3.05m) self assembly section with lifting sheaves to handle the

counterweights.

1. Mounting Lug2. “A” Bumper Counterweight3. Pin

4. Lock Pin5. Upper Counterweights6. Positioning Blocks

7. Live Mast Reeved As A Boom8. 10 ft (3.05m) Self Assembly Section

With Lifting Sheaves

A

A

A

1

2

3 4

56

7

8

65

Operator's Manual

1-93Section 1 - Operating Instructions

Bumper Counterweight

Installation1. Park the crane on a firm, level surface, shift the

transmission to neutral, and apply the park brake.2. Fully extend all the outrigger beams and properly

level the crane on the outriggers jacks.3. Shutdown the carrier engine.4. Use 10 ft (3.05m) self assembly section with lifting

sheaves for lifting the counterweight, or if an auxil­iary lifting device is to be used, refer to the “Coun­terweighting Instructions” plate for the specificweight of the bumper counterweight, to determinethe capacity required from the device being used.

WARNINGWhen using the 10 ft (3.05m) self assemblysection with lifting sheaves to handle the

counterweights, always refer to the Crane

Rating Manual to ensure lifting capacities are

not exceeded.

5. Carefully lift the “A” bumper counterweight andplace it on the mounting lugs on the front bumper.Refer to Figure 1-87.

6. Install the pins and lock pins to secure the counter­weight to the carrier.

Removal

The boom may be removed from the crane before re­moving the counterweights if no other lifting device isavailable for crane disassembly. Refer to “Boom As­sembly And Disassembly” in Section 4 of this Opera­tor's Manual for specific instructions.1. Park the crane on a firm, level surface, shift the

transmission to neutral, and apply the park brake.2. Fully extend all the outrigger beams and properly

level the crane on the outriggers jacks.3. Shutdown the carrier engine.4. Use 10 ft (3.05m) self assembly section with lifting

sheaves for lifting the counterweight, or if an auxil­iary lifting device is to be used, refer to the “Coun­terweighting Instructions” plate for the specificweight of the bumper counterweight, to determinethe capacity required from the device being used.

WARNINGWhen using the 10 ft (3.05m) self assemblysection with lifting sheaves to handle the

counterweights, always refer to the Crane

Rating Manual to ensure lifting capacities are

not exceeded.

5. Remove the lock pins and pins which secure thecounterweight to the carrier. Refer to Figure 1-87.

6. Carefully lift the bumper counterweight off themounting lugs.

Operator's Manual

1-94 Section 1 - Operating Instructions

permission of the Publisher the American Society of Mechanical Engineers, 345 E. 47th Street, New York, New York 10017.

USE WHIP LINE

MOVE SLOWLY

TRAVEL

RAISE BOOM

LOWER THE LOAD

DOG EVERYTHING

LOWER

LOWER BOOM

RAISE THE LOAD

EMERGENCY STOP

USE MAIN HOIST

SWING

(Telescoping booms)

(One track)

STOP

(Both tracks)TRAVEL TRAVEL

EXTEND BOOM

(Telescoping booms)EXTEND BOOM

(Telescoping booms)RETRACT BOOM

(Telescoping booms)RETRACT BOOMRAISE THE BOOM AND LOWER THE BOOM AND

HOIST

Extracted from the American National Standard, Crawler, Locomotive and Truck Cranes, ANSI B30.5b-1985, with the

Figure 1-88Hand Signals

Hand SignalsHand Signals are important for communications be­tween the designated signal person and the operator.A Hand Signal Chart, Figure 1-88, is included in thisSection of this Operator's Manual. A copy is also on therear exterior of the carrier cab.

These signals should be used at all times unless voiceinstructions with a radio or telephone are being used.One person should be designated as a signal personand their signals obeyed by the operator. Obey a stopsignal from anyone.

Operator's Manual

1-95Section 1 - Operating Instructions

Traveling The CraneTruck cranes are designed for highway travel and jobsite travel, with or without a load. Certain conditionsmust be met for safe travel. Refer to the following out­lined procedures before traveling the crane.

Job Site Travel

Job site travel is considered to be any travel off a pavedsurface. Job site travel can be performed either with orwithout a load. Traveling with a load is considered to bea “Pick And Carry” operation. Refer to “Pick And CarryOperation”.

Job Site Travel Without A Load

The crane may be traveled on the job site with theboom installed and no load or with a partially assem­bled boom supported with the boom assembly link.Refer to the following procedure for proper job sitetravel instructions:1. Level the crane on fully extended outriggers.

2. Position the upper directly over the front or rear ofthe carrier and engage the two position houselock.

3. Cranes with fully assembled booms: Refer tothe appropriate “Job site Travel” charts shown onthe following pages for allowable boom configura­tion, maximum travel speeds, and boom angle.

Cranes with partially assembled booms: Referto “Boom Assembly Link” or “10 ft (3.05m) Self As­sembly Section With Lifting Sheaves” in this Sec­tion of this Operator's Manual for more information.

4. Inflate the tires to pressure listed on the Tire Infla­tion Label based on maximum allowable speed.

5. Retract all outrigger jacks just clear of the groundbut leave the outrigger beams fully extended.

6. Limit travel speed to the values stated on the ap­propriate “Job Site Travel” chart. Maintain a safedistance from all obstructions, structures, andpower lines.

7. Once the desired destination is reached, shift themain transmission to neutral and apply the parkbrake.

Operator's Manual

1-96 Section 1 - Operating Instructions

Job Site Travel, Boom Only (No Load)

BoomLength

Permissible Boom Angles - Degrees From Horizontal

Counterweight Combinations Upper + Bumper

ABC +A ABC + 0 AB + A AB + 0 A + 0 0 + 0

ft m 1 mph 1 mph 1 mph 1 mph 1 mph 1 mph

None None NO YES YES YES YES YES

20' Base Only NO YES YES YES YES YES

50 15.3 0-58 0-80 0-80 0-80 0-80 0-80

60 18.3 0-62 0-80 0-80 0-80 0-80 0-80

70 21.4 0-64 0-80 0-80 0-80 0-80 0-80

80 24.4 0-68 0-80 0-80 0-80 0-80 0-80

90 27.5 0-70 0-80 0-80 0-80 0-80 28-80

100 30.5 0-74 0-80 0-80 0-80 0-80 40-80

110 33.6 0-76 0-80 0-80 0-80 0-80 48-80

120 36.6 0-76 0-80 0-80 0-80 24-80 54-80

130 39.7 0-78 0-80 0-80 0-80 36-80 58-80

140 42.7 0-80 0-80 0-80 14-80 44-80 62-80

150 45.8 0-80 0-80 0-80 30-80 50-80 66-80

160 48.8 0-80 10-80 0-80 38-80 54-80 -

170 51.9 0-80 26-80 24-80 42-80 58-80 -

180 54.9 0-80 36-80 34-80 50-80 62-80 -

190 58.0 24-80 42-80 40-80 54-80 64-80 -

200 61.0 32-80 48-80 46-80 58-80 - -

210 64.1 40-80 52-80 50-80 60-80 - -

220 67.1 44-80 56-80 54-80 - - -

230 70.2 50-80 58-80 - - - -

240 73.2 52-80 60-80 - - - -

250 76.2 56-80 - - - - -

260 79.2 58-80 - - - - -

Notes1. Position upper directly over rear of carrier and engage two posi­

tion house lock.2. Remove hook block/hook ball or place them on carrier deck.3. Crane travel path to be firm and level surface. Gradability of path

1% side to side maximum.4. Fully extend all outrigger beams and position outrigger jacks so

pontoons just clear ground.5. The front axle is limited to a minimum of 15% of the total crane

weight.

6. Boom length not to exceed the liftoff capability on outriggers overrear for the specified counterweight. Refer to “Liftoff Capabilities”chart in Section 4 of this Operator's Manual.

7. Inflate tires to proper pressure per the Tire Inflation Label on thecarrier.

8. Maximum travel speed is 1 mph (1.6km/h).9. Values represent crane equipped with Heavy Duty 1024 AG pick

& carry rims.

Operator's Manual

1-97Section 1 - Operating Instructions

Job Site Travel,

Boom With Jib (No Load),Maximum 1 mph (1.6km/h)

Boom Length Jib Length

Permissible Boom Angle

Counterweight RequiredUpper + Bumper

ft m ft m ABC + A ABC + 0

50 15.4 30-75 9.1-22.9 0-66 0-80

60 18.3 30-75 9.1-22.9 0-68 0-80

70 21.3 30-75 9.1-22.9 0-70 0-80

80 24.4 30-75 9.1-22.9 0-72 0-80

90 27.5 30-75 9.1-22.9 0-76 0-80

100 30.5 30-75 9.1-22.9 0-76 0-80

110 33.6 30-75 9.1-22.9 0-78 0-80

120 36.6 30-75 9.1-22.9 0-80 0-80

130 39.7 30-75 9.1-22.9 0-80 20-80

140 42.7 30-75 9.1-22.9 0-80 32-80

150 45.8 30-75 9.1-22.9 16-80 40-80

160 48.8 30-75 9.1-22.9 28-80 44-80

170 51.9 30-75 9.1-22.9 36-80 50-80

180 54.9 30-75 9.1-22.9 42-80 54-80

190 58.0 30-75 9.1-22.9 48-80 58-80

200 61.0 30-75 9.1-22.9 52-80 60-80

210 64.1 30-75 9.1-22.9 54-80 62-80

220 67.1 30-75 9.1-22.9 58-80 -

230 70.2 30-75 9.1-22.9 60-80 -

Notes:1. Boom With Jib job site travel chart applies for all jib lengths. Con­

firm main boom length installed in crane, then adjust main boomangle within permissible range before adjusting outrigger jacks.

2. Position upper directly over rear of carrier and engage two posi­tion house lock.

3. Remove boom and jib hook blocks/hook balls or place them oncarrier deck.

4. Crane travel path to be firm and level surface. Gradability of path1% side to side maximum.

5. Fully extend all outrigger beams and position outrigger jacks sopontoons just clear ground.

6. The front axle is limited to a minimum of 15% of the total craneweight.

7. Boom + Jib length not to exceed the liftoff capability on outrig­gers over rear for the specified counterweight. Refer to “LiftoffCapabilities” chart in Section 4 of this Operator's Manual.

8. Jib head machinery must remain above the boom foot.9. Inflate tires to proper pressure per the Tire Inflation Label on the

carrier.10. Maximum travel speed is 1 mph (1.6km/h).11. Jib offset angle can be 5, 15, or 25 degrees.

Operator's Manual

1-98 Section 1 - Operating Instructions

TravelHeight

6.76 ft(2.06 m)

Job Site Travel,

Boom Only (No Load),Maximum 1 mph (1.6km/h), Boom Horizontal

BoomLength

TravelHeight

Counterweight Combinations Upper + Bumper

ft m ft m 0 + 0 A + 0 AB + 0 AB + A ABC + 0 ABC + A

50 15.3 23.55 7.18 Yes Yes Yes Yes Yes Yes

60 18.3 23.75 7.24 Yes Yes Yes Yes Yes Yes

70 21.4 28.61 8.72 Yes Yes Yes Yes Yes Yes

80 24.4 29.04 8.85 Yes Yes Yes Yes Yes Yes

90 27.5 29.36 8.95 No Yes Yes Yes Yes Yes

100 30.5 29.62 9.03 No Yes Yes Yes Yes Yes

110 33.6 29.82 9.09 No Yes Yes Yes Yes Yes

120 36.6 29.98 9.14 No No Yes Yes Yes Yes

130 39.7 30.12 9.18 No No Yes Yes Yes Yes

140 42.7 30.24 9.23 No No No Yes Yes Yes

150 45.8 30.33 9.25 No No No Yes Yes Yes

160 48.8 30.41 9.27 No No No Yes No Yes

170 51.9 30.51 9.30 No No No No No Yes

180 54.9 30.58 9.32 No No No No No Yes

190 58.0 30.61 9.33 No No No No No No

Notes:1. Position upper directly over rear of carrier and engage two posi­

tion house lock.2. Remove hook block/hook ball or place them on carrier deck.3. Crane travel path to be firm and level surface. Gradability of path

1% side to side maximum.4. Fully extend all outrigger beams and position outrigger jacks so

pontoons just clear ground.5. The front axle is limited to a minimum of 15% of the total crane

weight.

6. Boom length not to exceed the liftoff capability on outriggers overrear for the specified counterweight. Refer to “Liftoff Capabilities”chart in Section 4 of this Operator's Manual.

7. Inflate tires to proper pressure per the Tire Inflation Label on thecarrier.

8. Do not swing the upper with the “A”, “AB”, or “ABC” upper coun­terweights.

9. Maximum travel speed is 1 mph (1.6km/h).

Operator's Manual

1-99Section 1 - Operating Instructions

6.76 ft(2.06m)

Assist Crane(See Note 8)

Minimum TravelHeight

12'-9”(3.89m)

Job Site Travel,

Boom Only (No Load),Maximum 1 mph (1.6 km/h), Boom Horizontal

With Assist Crane or Dolly

Boom Length Assist Crane Force Boom Length Assist Crane Force

ft m lb kN ft m lb kN

50 15.3 4,272 19.002 160 48.8 8,173 36.355

60 18.3 4,595 20.434 170 51.9 8,540 37.988

70 21.4 4,947 22.005 180 54.9 8,907 39.620

80 24.4 5,291 23.535 190 58.0 9,276 41.262

90 27.5 5,641 25.092 200 61.0 9,644 42.899

100 30.5 5,996 26.671 210 64.1 10,014 44.544

110 33.6 6,354 28.264 220 67.1 10,383 46.186

120 36.6 6,714 29.865 230 70.2 10,753 47.832

130 39.7 7,077 31.480 240 73.2 11,123 49.477

140 42.7 7,441 33.099 250 76.2 11,453 50.945

150 45.8 7,806 34.723 260 79.2 11,815 52.555

Notes:1. Position upper directly over rear of carrier and engage two posi­

tion house lock.2. Remove hook block/hook ball or place them on carrier deck.3. Crane travel path to be firm and level surface. Gradability of path

1% side to side maximum.4. Fully extend all outrigger beams and position outrigger jacks so

pontoons just clear ground.5. The front axle is limited to a minimum of 15% of the total crane

weight.6. Boom length not to exceed the liftoff capability on outriggers over

rear for the specified counterweight. Refer to “Liftoff Capabilities”chart in Section 4 of this Operator's Manual.

7. Inflate tires to proper pressure per the Tire Inflation Label on thecarrier.

8. Use assist crane or dolly to support end of boom.9. Do not swing the upper with the “A”, “AB”, or “AB” upper counter­

weights. The upper may be allowed to swing only when the up­per counterweights are lowered onto the carrier deck frustumsand tied down to prevent tipping and when the swing brake islocked out. Refer to “Swing Brake Lock Out” in this Section of thisOperator's Manual.

10. Maximum travel speed is 1 mph (1.6km/h).

Operator's Manual

1-100 Section 1 - Operating Instructions

Pick And Carry Operation

Travel during pick and carry operations is restricted tospeeds of 1 mph (1.6km/h) or less on a firm, level sur­face. Lifts are to be made with the main boom only, withthe crane prepared as follows:1. Inflate the tires to the pressure listed on the Tire In­

flation Label for 1 mph (1.6km/h) maximum speed.2. Level the crane on fully extended outriggers with

the tires clear of the ground.3. Refer to Crane Rating Manual for boom combina­

tions and counterweight configurations for pickand carry operations.

4. Remove the jib, if equipped.5. Retract all outrigger jacks just clear of the ground

but leave the outrigger beams fully extended.

6. Attach as many hand lines as necessary to preventthe load from swinging during travel.

7. Carefully attach the load to the winch wire rope andlift it only as high as necessary.

8. Carefully travel at no more than 1 mph (1.6km/h).Take extra care due to the increased overall widthcaused by the extended outrigger beams. The out­riggers or pontoons must not be allowed to hit anyobstructions. Maintain a safe distance from all per­sonnel and obstructions. Travel only on a firm,level surface.

9. Once the desired destination is reached, shift themain transmission to neutral, apply the park brake,and lower the load into position.

Operator's Manual

1-101Section 1 - Operating Instructions

Figure 1-89Boom Assembly Link

A

1. Pin With Hitch Pins2. Assembly Link - Working Position

3. Live Mast4. Pin With Hitch Pins

5. Assembly Link - Stored Position6. Boom Base Section

CAUTIONDo not lower the live mast below the minimum travel clearance shown above. Boom hoist wire ropeswill contact the live mast cross member and may damage it. The maximum boom angle is 50�. The

above assembly is for transport of the base section only. Do not use the assembly link without the 10 ft

(3.05m), 20 ft (6.1m), or 30 ft (9.15m) pendant during boom assembly (a 22 ft {6.7m} pendant can be

used with the link). Do not cantilever or assemble boom with this arrangement.

12' - 9''(3.89m)

Minimum TravelHeight

24.78”Minimum Travel

A

Clearance

(629.4mm)

4

3

1

25

6

Boom Assembly Link

The boom assembly link is used along with a 10 ft(3.05m), 20 ft (6.1m), or 30 ft (9.15m) pendant to lift theboom base section during self assembly operations ofthe attachment. When job site conditions or highwayload limitations permit, the assembly link can be usedto support the boom base section while traveling thecrane. Use of the boom assembly link while travelingon highway eliminates the need to remove the basesection and store the live mast. Check local road re­

strictions before roading the crane in this configurationto ensure compliance.

Figure 1-89 illustrates two minimum dimensionswhich must be observed when utilizing the boom as­sembly link. When the live mast and base section arelowered, the boom hoist wire ropes will contact the livemast cross member. Wear on the live mast may occurduring transportation of the base section if these mini­mums are not observed.

Operator's Manual

1-102 Section 1 - Operating Instructions

(0.56m)

Figure 1-9010 ft (3.05m) Self Assembly Section With Lifting Sheaves

CAUTIONDo not lower the live mast below the maximum travelclearance shown above. Boom hoist wire ropes will

contact the live mast cross member and may

damage it. The above assembly is for transport of

the 10 ft (3.05m) self assembly section with lifting

sheaves and base section only. Do not use the link

without the 8 ft (2.4m) pendant during self assembly.

Do not cantilever or assemble boom with thisarrangement.

22”

12'-9”(3.89m)

MAX

MIN(0.74m)29”

10 ft (3.05m) Self Assembly SectionWith Lifting Sheaves

WARNINGThe 10 ft (3.05m) self assembly section withlifting sheaves is used only for self assembly

operations of the crane. Do not use as an

auxiliary lifting device.

The 10 ft self assembly section with lifting sheaves isused during self assembly operations of the crane.When job site conditions or highway load limitationspermit, the 10 ft (3.05m) self assembly section with lift­ing sheaves and base section can remain on the cranewhile transporting the crane. Leaving the base sectionand 10 ft (3.05m) self assembly section with liftingsheaves on the crane while transporting decreases selfassembly time when reaching the job site. Check localroad restrictions before transporting the crane in thisconfiguration to ensure compliance.

Figure 1-90 illustrates a 12 ft 9 in (3.89m) maximum di­mension which must be observed when transportingthe base section and the 10 ft (3.05m) self assemblysection with lifting sheaves. When the base sectionand the 10 ft (3.05m) self assembly section with liftingsheaves are lowered, the boom hoist wire ropes willcontact the live mast cross member. Wear on the livemast may occur during transportation of the 10 ft(3.05m) self assembly section with lifting sheaves andbase section if this minimum is not observed.

Before performing self assembly operations, the 8 ft(2.4m) pendant must be installed. When installing the8 ft (2.4m) pendant, the 10 ft (3.05m) self assembly sec­tion with lifting sheaves must be lowered onto a mini­mum of 22 in (0.56m) of blocking to prevent live mastfrom contacting the 10 ft (3.05m) self assembly sectionwith lifting sheaves and boom hoist wire rope from con­tacting the live mast cross member. Refer toFigure 1-90. Refer to “10 ft (3.05m) Self AssemblySection With Lifting Sheaves” in Section 4 of this Oper­ator's Manual for 8 ft (2.4m) pendant installation.

Operator's Manual

1-103Section 1 - Operating Instructions

Highway Travel

Highway travel is considered to be any travel of thecrane over 5 mph (8km/h). The following conditionsand precautions must be met for any highway travel.For specific instructions on crane disassembly, refer tothe appropriate Section of this Operator's Manual.1. The boom and jib, if equipped, must be disassem­

bled and removed from the crane.

Note: The boom base section and 10 ft (3.05m)

self assembly section with lifting sheaves (if

equipped) may remain installed if local codes

and road weight limitations will allow the use of

the boom assembly link to carry it over the rear

of the carrier. Refer to “Boom Assembly Link” or“10 ft (3.05m) Self Assembly Section With Lift­

ing Sheaves” in this Section of this Operator's

Manual.

2. Remove the upper and bumper counterweights,as required, to meet road weight limitations. Theoutrigger boxes may also need to be removed inorder to meet local weight restrictions.

3. The upper can be over the front or rear of the carrierfor travel with the two position house lock en­gaged.

4. Store the live mast, as required.5. If the outrigger boxes remain installed on the car­

rier, all outriggers must be fully retracted (jacks andbeams) with all pontoons removed from jacks andstored properly.

6. All upper control levers must be in the neutral posi­tion. The upper ignition key must be turned off, keyremoved, and all doors and windows locked.

7. Check all tires for correct pressure, adjust if re­quired.

8. Obey all local codes and other “Rules of the Road”and travel carefully.

Towing The CraneAlways use good judgment and reliable equipmentwhen towing the crane. Use extra caution when towingthe crane on the highway and in traffic. When makingconnections between the crane and towing vehicle,check that none of the connections will cause damageto either vehicle. Pay particular attention to tie rods,brake lines, power steering cylinders, and power steer­ing lines.

Always exercise safety and follow all local codes whentowing the crane. Prepare the crane as follows beforetowing it.

1. Properly disassemble the attachment and movethe live mast to the stored position.

2. The upper must be positioned directly over the rearof the carrier with the two position house lock en­gaged.

3. All outriggers must be fully retracted (jacks andbeams) with all pontoons removed from jacks andstored properly.

4. All control levers in the upper operator's cab mustbe in the neutral position with the control lockoutswitch “OFF”.

5. Unlock the steering column by turning the ignitionswitch to the “OFF” position. Turn on the hazardflashers.

6. Shift the transmission to neutral.7. Release the park brake when the crane is attached

to the towing vehicle and ready to be towed.

Transporting The CraneWhen transporting the crane, precautions should betaken in securing the crane to the trailer, barge, or othermeans of conveyance. The towing shackles are therecommended tie down points. If the crane is notequipped with towing shackles, chains may be loopedaround the outrigger boxes or the axle housings andused to secure the crane down.

CAUTIONIf chains are wrapped around the axlehousing, be certain the chains will not damage

the tie rods, brake lines, power steering

cylinders, or power steering lines.

If chains are wrapped around the outrigger box collar,be certain the chains will not damage the hydrauliclines and fittings. The chains should be wrappedaround the outrigger box, not the outrigger beam.

Always exercise safety, and follow all local codes whenloading, unloading, or transporting the crane.

WARNINGDo not use the towing shackles as a means oflifting the crane. These shackles are not

intended to be used to lift the crane and may

break if subjected to the entire weight of the

crane. Serious personal injury or extensive

equipment damage may result from this

practice.

Operator's Manual

1-104 Section 1 - Operating Instructions

Prepare crane as follows before transporting it:1. Properly disassemble the attachment and move

the live mast to the stored position.2. The upper must be positioned directly over the

front or rear of the carrier with the two positionhouse lock engaged.

3. All outriggers must be fully retracted (jacks andbeams) with all pontoons removed from jacks andstored properly.

4. All control levers in the upper operator's cab mustbe in the neutral position with the control lockoutswitch “OFF”.

5. Engage the park brake and shift the transmissionto neutral.

6. Lock all windows and doors. Remove the keysfrom the crane.

7. Depending on the specific situations, furtherpreparations may be needed to protect the cranefrom the environment or vandalism. See “CraneStorage” for further suggestions.

Transporting The Tubular

BoomWhen transporting the tubular boom sections, precau­tions should be taken in securing the sections to thetrailer. The following is the suggested method of tubu­lar boom tiedown for transport. When transporting tu­bular boom sections, the following conditions must bemet:

CAUTIONIf tubular boom sections are improperlysecured to the trailer, damage could occur

which may weaken the structural integrity of

the boom.

1. Spread‐axle trailers are recommended for trans­porting boom sections. Locate rear blocking be­tween, or forward of, the rear axles. Refer toFigure 1-91, Detail 1.

2. On close‐group axle trailers, rear blocking must bepositioned forward of the rear axle group. Refer toFigure 1-91, Detail 2.

3. Do not tie down in mid span.4. Do not strap over top of boom.5. Secure boom to the trailer with 4” (10cm) nylon

straps over bottom boom chords as shown.6. Wood blocking should be positioned directly un­

der nylon straps in two (2) places.7. Nylon straps must be kept very tight. Check strap

tightness often. Straps must be twisted to preventvibration.

8. Boom Length = 10', 20', 30', 40', or 50' (3.05m,

6.1m, 9.1m, 12.2m, or 15.2m) boom extensions.9. Boom extensions stacked together on a trailer

should be of equal length. If extensions cannot beof equal length, refer to Figure 1-91, Detail 3 foradditional tiedown instructions.

10. Counterweights, rigging items, etc. are allowedunder boom sections. Transport boom sectionson trailers with other crane components wheneverpossible. Do not tie boom directly to these otherloads. Do not stack loads on top of boom sections.

11. Pendants should be secured to top panel of boomsection during transport. Locate pendants alongthe centerline of the boom and secure each pen­dant to the top lattice in a minimum of four (4) loca­tions.

Operator's Manual

1-105Section 1 - Operating Instructions

Figure 1-91Boom Tiedown For Transport

1. Recommended Nylon Tie‐Down Strap Locations (Approximate).

2. Counterweights, Rigging Items, Etc. Are Allowed, And Recommended, Under Single Boom Sections.

3. Do Not Locate Rear Blocking In This Area Of The Trailer.

4. Secure Pendants To Top Plane Of Boom Section (Minimum 4 Places Per Pendant).

5. Twist Nylon Straps6. Wood Blocking - 2” X 4” (5cm x 10cm) Minimum7. Trailer

5 5

6 7 67

Transporting Boom Sections

VIEW A-A VIEW B-B

Boom LengthBoom Length � 2

1 2

B

B

A

A

3' (.91m) To 5' (1.5m)

1

4

3' (.91m) To 5' (1.5m)

3' (.91m) To 5' (1.5m)

B

B

Boom Length

Boom Length � 2

A

A

4

Boom Length “A”

Boom Length “B”“A” � 2

1 1

4 6

Detail 1

Detail 2

Detail 3

1 2 1

3

3

4 4

3

Operator's Manual

1-106 Section 1 - Operating Instructions

Crane StorageAnytime the crane is going to be left unattended, itshould be prepared so that it will not be damaged bythe elements, be an attraction to vandals, or a playthingfor children.

Short Term Storage1. Do not leave the crane where it will be a traffic haz­

ard.2. Lower all loads to the ground.3. Ensure both drum brake pedals are latched in the

fully applied position and all drum lock switchesare “ON”.

4. The two position house lock must be engaged.5. All control levers must be in the neutral position

with the gate lock lever in the “OFF” position.6. The attachment can be left in the air provided that

guidelines in the Wind Restrictions Guide in theCrane Rating Manual are adhered to. If the windvelocity exceeds the these guide lines any timeduring crane storage, position the attachment onthe ground Refer to the Crane Rating Manual forwind speed and other applicable restrictions. Donot take chances. If possible store the attachmenton the ground.

7. Tie off the hook block and/or hook ball. Winch linesshould be snug.

8. Shift the transmission to neutral, engage the parkbrake, and shutdown the engine(s). Block thewheels to prevent the crane from rolling if on tires.

9. If the crane is on outriggers, the outriggers must beproperly set and supported so the crane will re­main level.

10. In cold weather, locate the crane where it will notfreeze to the ground.

11. To preserve battery life, move the battery discon­nect switches to the off position.

12. Remove the keys from the crane and lock all win­dows and doors.

Long Term Storage1. Store the crane inside a building if possible.2. Thoroughly clean the crane.3. Touch up any spots where paint has chipped. This

will prevent rusting.4. Lubricate the entire crane as per the lubrication

chart. Ensure all gear cases are filled to theirproper oil level.

5. Inflate tires to pressures shown on the Tire InflationLabel. Check tire pressures periodically duringstorage to ensure they do not go flat. If possibleblock the crane up so the tires are clear of theground. Ensure the blocking is placed so thecrane cannot fall off it. If this is not possible, set thecrane on planks so the tires will not sink into theground. Block the tires to prevent the crane fromrolling.

6. Fully retract all hydraulic cylinders. Cover all cylin­der rods, craned and unpainted surfaces with acoat of grease.

7. All control levers must be in the neutral positionwith the gate lock lever in the “OFF” position.

8. Engage the park brake and shift the transmissionto neutral.

9. Tie off the hook block and/or hook ball. Winch linesshould be snug.

10. Cover all open areas around the engines, cabs,etc. to prevent entry of water. Cover the entire areaaround the engine(s) with a tarp if possible.

11. Prepare the engines as per the engine manufactur­er's manual(s). Ensure antifreeze protection is suf­ficient to prevent the engines from freezing. If anti­freeze protection is not adequate, completely drainthe engine blocks.

12. If in a location where vandalism may occur, removethe keys and lock the doors on the cabs. Cover allglass in the cabs with plywood or boards to preventglass breakage. Provide a means of locking theaccess doors to the engines, fuel tanks, and hy­draulic reservoirs.

13. Drain all moisture from the air reservoirs to preventrust and deterioration.

14. To preserve battery life, move the battery discon­nect switches to the off position.

15. Store the crane so it does not provide a playthingfor children. Such a unit can be an “attractive nui­sance” for children to play on. If they fall off it or getentangled, serious injury may result.

16. While in storage, the crane should be “exercised”every 60 days to ensure the working condition ofthe crane. Start the engines and operate allswitches, control cables, and hydraulic functionsseveral times to circulate lubricants and to keep allmechanisms and linkages operative.