HEAVY LIFT CRANE

ALASKAN MAR1NE

A WORD TO THE OWNER, OPERATOR, ANO MAINTENANCE PERSONNEL ABOUT SAFETY

FAIWRE TO READ THIS MANUAL IS A MISUSE OF THE EQUIPMENT. ANYONE WHO WILL OPERATE, SERVICE OR WORK AROUND THIS CRANE SHALL FIRST READ THIS MANUAL. DEATH OR SERIOUS INJURY CAN RESULT FROM IMPROPER OPERATION OR MAINTENANCE OF THIS EQUIPMENT.

Occupational safety and machine reliability is of prime concern to North American Crane and Equipment Company in the design and production of this crane. The intent of this manual Is to provide of the operator and others who work around this equipment a tool for safe operation of the equipment that will provide machine reliability.

It is the responsibility of the owner to know the specific requirements, governmental regulations, precautions, and work hazards which exist. The owner shall make these known to all personnel working with the equipment or in an area of known hazards, so that all personnel can take the necessary and required safety precautions. FAILURE TO HEED THESE INSTRUCTIONS CAN RESULT IN DEATH OR SERIOUS INJURY OR DAMAGE TO THE EQUIPMENT.

It is the responsibility of the operating and service personnel to use and maintain the crane and hydraulic power unit with caution, skill, and sound judgement. Following recognized safety and maintenance procedures will help prevent accidents and damage to the crane and its related components. Modification or Improper operation will create a safety hazard and therefore shall not be made without written approval by the owner and/or manufacturer. Safety covers, devices, and placards must remain installed and maintained in proper working condition. All manufacturer name plates and placards must remain on the equipment.

Disconnecting, removing, or otherwise disabling any safety device is a misuse of this equipment and will create a hazardous condition. Likewise, failure to perform routine maintenance and Inspections of the equipment can lead to premature failure of the crane and its components.

As an owner or employer, it is your responsibility to instruct the operator in the safe operation of your equipment and to provide the operator with a safe and properly maintained piece of equipment.

CRANE NOMENCLATURE

The operating and maintenance personnel should familiarize themselves with the various components of this crane and the names of its components. Knowing the correct terminology for the crane components is necessary In order to fully understand this manual. The following glossary of terms are supplied to further this endeavor. Common terms are shown In parentheses O:

Pedestal - The main support column for the crane. Most pedestals supplied by NACE are round and the outside diameter varies with crane capacity. Access openings are usually provided for maintenance of the valves. rotoseal, and drive gears.

Rotation bearing -- (Slew or Swing bearing). Shear ball or cross roller bearing Is mounted to the top of the pedestal column by either welding or bolting. Transfers moment and axial loading to the pedestal while and allowing the crane to smoothly rotated about its center axis.

Turret - The turret assembly provides attachment points for the main boom, boom cyllnder(s). and swing drive assembly{les).

Swing drive -- (slew drive). The swing drives are mounted on the turret base and drive against the rotation bearing gears. Our cranes can have up to four (4) drives but, one or two are more common. Each drive consists of: a pinion gear, a planetary gear drive (gearbox), swing brake, and hydraullc swing motor.

Roto-seal - A multi-ported hydraulic swivel that allows the crane to rotate 360° continuously in either direction. If a crane is supplied without a roto-seal, swing stops are installed to prevent 360° rotation.

Slip-ring -- Similar to a roto-seal but, conducts electricity Instead of hydraulic fluid. Slip-rings can be used alone, power pack on ride around, or In conjunction with a roto-seal, power pack below and operators cab on crane.

Main boom - The boom section that attaches to the turret and the lift cyllnder(s). The main boom anchors and pivots about the main hinge pin. The main boom provides mounting points for winch( es) and auxiliary padeyes depending on configuration of crane. Another function the main boom is to provide the housing support for the telescope boom, telescope cylinder, and wear pads.

Boom cylinder -- (lift or luff cylinders). Hydraulic cylinder(s) that anchor against the turret assembly and push on the main boom. The boom cylinders determine the lifting and rated capacities of the crane.

Telescope boom -- (Extension boom(s)) are the sections (stages) mounted inside one another and are hydraulically extended and retracted. Most of our cranes have either one or two stages and ride on replaceable wear pads.

Telescope cylinder - (Extension cylinder). Hydraulic cylinders that are anchored to the main boom and push against one (1) or more telescope boom sections. The extend cylinder are either single or double (piggyback) extension type.

Main Winch - (Hoist). Consist of hydraulic motor driving a cable storage drum. The torque (line pull) ot the winch is determined by the operating pressure of the hydraulic system and the layer of the wire rope on the winch drum at the time of lift. Load holding is provided by a multi-disk brake unit on the input shaft of the hydraulic motor. The main winch may be single parted or multi-parted, depending on capacity of crane.

Auxnlary winch - (Secondary hoist). One or more hoists Installed on main boom with different ratings. In multiple winch systems, usually are two parted and have three times the capacity or the fastline hoist.

Fastllne winch - (Whip hoist). A high speed/low capacity winch used to move fight loads when it is not desirable to use the Main Holst. Construction and operation Is Identical to the main hoist, except they are single parted.

Hose wlnch(es) - (Hose handling holst(s)). One or more hoists Installed on main boom with same ratings. Used to support long loads or hoses at multiple points. Operation and construction is Identical to the main hoist

Sheave head - The support structure and sheave group mounted on the end of the main, telescope. or knuckle boom - depending on the type of crane. The number of sheaves mounted In the sheave head Is determined by the crane capacity and the winch Installed on crane. Most cranes, except Knuckle boom, allow for two (2) or more parts of reeving.

Reeving -- The number of load fines between load block and sheave head. Normally an even number of 'parts' are used to prevent twisting or wrapping of load lines. As the number of parts increase, the greater the lifting capacity of the crane.

Two-blocking - Contact of the overhaul ball or load block with the sheave head. Anti-two blocking devices prevent contact with the sheave head and can be of the following types;

Mechanical - tube. stopper, or bars installed on cable or sheave head that prevent damage to sheaves. Usually Installed on fixed and knuckle boom cranes.

Hydraulic - Consists of boom tip valve controlling anti-two block system. When tip valve Is actuated, flow is shut of to winch and telescope functions.

Electro-hydraulic - Similar to hydraulic system. with switch on boom t ip controlllng the anti-two block system.

LMI -- Load Moment Indicating systems can range from a single pressure gauge tapped Into the blind end of lhe luff cylinder to a micro-processor based load-range-radius readout and control system.

Control valves -- The valves used to control the Individual functions of the crane and they can be controlled by the operator either manually, hydraulically, or electrically. Secondary valves Installed In the control valves are the main relief valves, used to limit maximum system operating pressures. and port relief valves, used to limit the operating pressure of the individual functions.

Cross port relief valve -- {Cushion valve}. A special type or relief valve package that relives the operating pressure to the opposite work port. Used in the swing circuit to protect the crane structure rrom damage during normal operation.

Counterbalance valve - (Load hold or Over center valve). Specialized hydraullc valves that are lnstalled on functions that are subject to over-hung or over-running loads. This valves are a pilot operated device that meters the amount of oil from the function, thus preventing the function to 'run' ahead of the pump, and stop all oil flow upon loss of pllot pressure.

Operators station - The location of the crane controls and load charts. The operators station can be located at the pedestal, on a ride-around, or remote from crane.

DEFINITIONS

The following list of definitions are Included to prevent any misunderstanding of terminology used throughout the text. This terminology Is in accordance with API Spec 2C and API RP 20 as well as ABS Certification of Cranes.

allowable load capacity - the "nominal" breaking strength of the wire rope divided by a design factor. Usually 5 for cranes up to 1 O tons or all cranes used offshore.

boom angle - the main boom or knuckle boom angle above or below horizontal of the longitudinal axis passing through the main hinge pin.

boom extension - Intermediate section of a telescope boom, between fully retracted and fully extended.

center of rotation - the vertical axis around which the crane superstructure rotates.

critical component - any component or structure that will cause uncontrollable load loss should a failure occur.

dynamic loading - loads Introduced into the crane and lifting systems by forces of acceleration and deceleration.

dynamic rating - rated load capacity of a crane when relative motion exists between crane and load to be lifted or stability of vessel is questionable.

falrlead sheave - sheave assembly used to minimize effects of sidelead on rope spooling.

floating crane - a crane and its associated equipment Install aboard a barge or pontoon vessel, or any vessel that exhibits the same seaworthiness.

foundation - supporting structure that the crane attaches to.

intended service - manufacturers rating of crane based on normal operating conditions supplied by the owner and/or operators.

lift capacity - the maximum lift capacity in pounds (kilograms), based on structural competency and the intended service of crane, and operating at design hydraulic pressure.

list - angle of inclination about longitudinal axis of the barge, pontoon, or ship.

load block - the assembly of hook, swivel, sheaves, pins, and frame suspended from the hoisting rope.

load hook - the primary attachment point for connecting load to load block or overhaul ball.

load ratings - rated load capacity at specific load radii or load reach.

normal operating conditions - conditions during which the crane is performing its' functions within the scope of the original or intended service. During these conditions, the operator is controlling the crane functions.

offlead - load angle that produces a horizontal shear load on crane structure.

offshore cranes - cranes mounted on bottom supported or floating structures used to move cargo, stores, drill and production equipment, and other material while at sea or unsheltered areas. Crane is subjected

to dynamic loadings.

personnel load rating - reduced load rating while handling personnel with crane.

radius, load - the horizontal distance from the center of rotation to the center of the load hook.

range - the theoretical volume of space the load hook can achieve based on radius and reach.

reach, load - the horizontal and vertical distances from the theoretical Intersection of the axis of rotation and main boom centerline, to the center of the load hook.

rated load capacity - the certified lift capacity In pounds (kilograms} based on structural competency, intended service. actual hydraulic system pressure, foundation competency, winch line pull capacity, wire rope strength, reeving, load hook capacity, dynamic factor, and upon stability and freeboard of mounting platform.

rope - refers to wire rope unless otherwise specified.

sale working load (SWL) - rated load capacity of crane independent of boom angle, hook reach, and load radius. This load Is generally the same as the load rating of the crane at maximum load radius.

seNice temperature - temperature range for which the crane is certified to operate as determined by the intended service.

shall - Indicates a rule or operation that must be followed or accomplished.

shipboard crane - crane mounted on vessel to be used for moving cargo. stores. and other material while the vessel is within a harbor or sheltered area. Vessels are sufficiently large to negate dynamic effects upon crane.

should - indicates that a rule or operation Is recommended but, the advisability depends upon the facts or conditions of each situation.

sidelead - load angle that produces a side loading on crane structure.

static load rating - rated load capacity of the crane when no relative motion exists between crane and the load to be lifted.

structural competency - the ability of the crane and Its components to withstand the stresses imposed by the applied loads.

tackle - an assembly of ropes, blocks, bars, hooks, grabs, etc., used for lifting, lowering, leveling, and pulling that are not part of the load block or hook.

ton - 2,000 pounds (907.2 Kg}, unless otherwise specified.

towing pad - pad eye to which a standing pendant (guy wire) Is attached during towing operations for reduction of sldelead forces on the boom.

trim - angle of inclination about transverse axis of barge, pontoon, or ship.

working load - the external load In pounds (kilograms) applied to the crane Including the weight of load block and any tackle.

CRANE SAFETY

SAFETY IN EQUIPMENT MAINTENANCE AND INSPECTION

Safe operation depends on you, the condition of your equipment, and your maintenance and inspection procedures.

The single most important factor in the prevention of equipment failure and accidents is a positive attitude towards safety. The habit of anticipating possible problems normally prevents many accidents from occurring.

The second most important factor is a structured preventative maintenance program that corrects wear and damage before they can lead to major repairs, and in worse case; catastrophic failures that can cause injury or death to personnel, or severe damage to the mounting structure and loss of revenues do to down time.

To this end, Inspection checks can not to be overlooked as a beginning of a comprehensive maintenance program. Below are listed several important inspections that must be performed before and during the operation of the crane. Further detailed inspection requirements are listed in the Maintenance Section.

• Hydraulic power unit -- check for proper oil level and leaks, condition of electrical starter and motor, condition of pump/motor coupling, and tightness of all mounting fasteners.

• Hydraulic components -- check for leaks or damage to valves, cylinders, and motors.

• Hose/fittings/lines - check for leaks, abrasion, damage, and loose connections and clamps.

• Structural -- visually inspect complete crane and accessories for damage; especially for cracks and corrosion in weldments, and bends or ripples in boom sections.

• Fasteners -- check all pins, retainers, bolts and nuts. Insure their presence and proper tightness.

• Sheaves -- Check for rope wear, cracks, and bearing condition.

• Lifting hook - check hook for safety latch, twisting and elongation of throat opening. Check shank for fatigue cracking.

• Wire rope -- check rope for broken wires, kinks, flat spots, and check end attachments for unsafe conditions.

• Covers and guards -- check for proper installation and presence.

• Safety devices -- insure proper operation and functioning.

• Operating placards and safety signs -- check for missing, illegible, and/or defaced signs and placards.

• Controls - check ror proper runctioning, response and self centering

• Fallsafe components - Insure that all brakes and load hold valves are operating correctly.

Make all necessary repairs and replacements prior to operating crane.

This safety checklist does not eliminate the prescribed detailed maintenahce requirements covered elsewhere in this or other manuals.

North American Crane and Equipment Company, and United States Coast Guard regulations require that a company shall perform dally and monthly inspections and maintain records of these Inspections for each crane, and that a thorough annual inspection of the crane shall be performed by a competent person, or by a government or private agency recognized by the USCG. The owner shall maintain a record of the dates and results of the inspections for each crane and Its optional equipment.

SAFETY IN EQUIPMENT OPERATION

Crane systems, such as the MCT-1565, are designed for; lifting heavy loads, reach with long distances, and rotating In a know working area. Furthermore. these cranes are installed aboard ships that operate In lnclementaJ weather and sea conditions, requiring further personnel safety awareness. As such, the object of the safety precautions is to allow trained personnel to operate and work around the lifting system safely. This means with no danger to operator. assisting personnel, material being handled, the environment surrounding the project, or the crane itself.

THE MATERIAL SET FORTH IN THIS SECTION. IS DONE SO PRESUMING THE OPERATORS AND ASSISTING PERSONNEL HAVE BEEN TRAINED IN OPERATION OF HEAVY LIFT SYSTEMS.

PERSONNEL

PRIMARY OPERATOR

The person at the operators station Is the primary safety operator for the system. This responsibility may be shared, in certain circumstances with other personnel; however. the person at the crane controls shall be responsible for insuring that; The readiness of the crane for operation, a safe working environment for assisting personnel. all schedule maintenance has been performed. the crane Is operated consistent with its Intended service, work loads remain with those values shown in the load chart, and that all safety and operating precautions are strictly adhered to.

The following operator qualifications have been extracted from OSHA 3100, API RP 20, ASME/ANSI 830.6 and NAVSEA chapter 569.

OPERATOR QUALIFICATIONS

Personnel who shall operate the crane and hydraulic power unit shall be limited to personnel with the following minimum qualifications:

1. Designated, competent, and experienced persons.

2. Trainees or untrained persons under direct supervision of a qualified person.

3. Maintenance and test personnel familiar with the operation of hydraulically operated cranes systems, only as necessary for performance of their duties.

4. Employees of North American Crane and Equipment Company or persons designated by NACE with appropriate experience.

5. Supervisor with a qualified person present.

Operators and trainees shall meet the following physical qualifications:

1. Have vision of at least 20/30 snellen in one eye, and 20/50 In the other - with or without corrective lenses.

2. Be able to distinguish colors regardless of their position.

3. Hearing, with or without hearing aid, must be able to distinguish differentiating sounds of 70 Db@ 10 feet from source(s).

4. A history of mental stability and not subject to seizures, dizziness, or any disability which may cause injury to self or to others present.

5. Shall not be under the influence of alcohol, drugs, or medication that impairs their judgement or abilities.

6. Shall disqualify themselves if they become mentally or physically unfit.

In addition to the above listed requirements, the operator shall :

1. Demonstrate the ability to read, comprehend, and interpret operator's manual, safety codes, placards, gauges, and other Information pertinent to correct and safe operation of cranes or similar equipment.

2. Demonstrate to the employer, the ability to operate this type of equipment or provide satisfactory evidence of experience.

3. Be familiar with relevant safety codes and regulations.

4. Recognize and be responsible for all maintenance requirements of the crane and its support equipment.

5. Be thoroughly familiar with the operation and function of the individual components that comprise the crane and hydraulic power unit.

SCOPE OF RESPONSIBILITIES

PRIMARY OPERATOR

The primary operator Is responsible ror four (4) major modes of crane movement; (1) Rotation (2} Boom elevation. {3) Telescopic boom travel. and (4) Load hook elevation. While at the control station, the primary operator must prevent the following:

1. System overload

2. Anti-two blocking

3. Injury to assisting

All loads and reaches must not exceed those allowed by the load/radius chart. located above of the operator's station.

Maintain a minimum distance of 1 FT. between load block and sheave head.

Never swing loads over other personnel, nor operate crane In unsafe manner. Never operate crane while other personnel are working on crane.

4. General danger to personnel and equipment

Before operating crane, check for any broken or damaged equipment Do not operate crane before damaged parts are repaired or replaced. Never attempt to operate crane In harsh weather and/ or sea states beyond the rated conditions of the dynamic load chart or the cranes intended service.

5. Head and foot Injury

6. Hand injury

ASSISTING PERSONNEL

Always wear hard hat and protective toe boo1s while working around lifting equipment.

Never operate crane while personnel have hands near any moving part.

Assisting personnel are any individuals assigned to help the primary operator during crane operation and Include, but not limited to; riggers, signallers, line handlers, and maintenance personnel. All assisting personnel should be familfar with lifting system operations and aware of the following hazards:

1. Injury to self Never allow lifting loads to travel overhead.

Never allow yourself to become "pinned" between the lifting load and an unmovable object

Stay clear of all moving parts.

Only stay In contact with the rigging and load as required perform required functions.

Never ride on the lifted material or object.

2. Slipping and falling Extreme caution should be exercised when work area is wet.

Keep work area and all crane surfaces clean and free of oil, grease, and like material.

MAINTENANCE SAFETY PRECAUTIONS

Proper maintenance will provide the operating personnel with a lifting system that can be safely and efficiently operated. The following precautions will reduce the possibility of injury during routine maintenance operations:

1. Before attempting to do any maintenance or repair of any crane system or component, isolate crane from hydraulic power unit.

2. Confirm that all pressure is removed from Individual components.

3. Before attempting any repair to the electrical system, disconnect all electrical power.

4. Support main boom and/or telescopic boom for attempting to remove or replace any hydraulic cylinder or swing drive(s).

5. Never attempt work on winch with a load attached to the load line.

6. Confirm that the swing control lever is secured in neutral position before attempting any repairs to the swing drive system.

7. While doing maintenance and repair, never allow oil and/or grease to accumulate in the work area.

8. Survey the repair to be accomplished and determine the correct tools, handling equipment, and parts required before you start the repair.

9. Always use safety harness when doing at sea maintenance or repairs.

1 o. Allow hydraulic system to cool before attempting to do maintenance or repair.

SAFETY TIPS - INTRODUCTION

This section of the safety manual is designed to present some of the daily work problems which may be encountered by the primary operator, assisting personnel, and maintenance personnel.

The primary operator and service mechanic are the key in any safety program. They must study all sections of the safety and operations manual to be aware of the safety tips which are presented to help prevent serious injury to themselves and assisting personnel.

Operation and Maintenance Safety Tips - Telescoping Boom Cranes

• Control lever movement should be slow and smooth to meter oil flow for safe operation. Sudden or jerky movement of the controls should be avoided to minimize shock loads to the hydraulic system, structural components, gear train, as well as side loading of the boom.

• Be constantly aware of the boom(s) position when operating the controls,

• Make certain the sheave head and load fine are centered directly over the load before lifting.

• Do not drag load with winch or boom(s).

Operator safety tips cont.

• Do not attempt to lift a fixed load. I.E. loads that are frozen to ground or deck.

• Do not sldelead or offl~ad boom(s) [Towing] without suitable guy wires or boom support structure.

• Know lhe weight of the load and rigging to avoid overloading the crane. Deduct the weight of load handling devices from the maximum load rating to determine how much weight can be lifted.

• Never rotate or extend a load over anyone. Use hand signals or horn to alert personnel of hazard.

• Keep load as close to ground whenever possible.

• Always use non-conductive tag lines.

• Do not leave loose objects on booms or loads. Remove any object that is not secured fastened to the booms or loads.

• When load is out of the primary operators' line of sight, a qualified assistant signal person shall be used and the primary operator must follow their signals.

• Obey the emergency stop signal from anyone.

• Do not operate crane during electrical storms. in sea states greater than 4-5. or when winds speeds are above 50 knots. Always use dynamic load chart when using offshore. Use extreme caution when operating In poor visibility conditions and always use assisting personnel.

• Stay clear of hydraulic leaks: High pressure and hot oil can cause serious Injury.

• Do not attempt to work on crane with hydraulic power unit on.

• Do not leave the crane unattended with a suspended load.

• Never move vessel with crane parked outboard nor when operating next to other vessels.

• Do not pull the overhaul ball or load block Into sheave head (two-blocking).

• Insure load hook safety latch is installed and operating.

• Payout load line before or during telescoping of booms to avoid two-blocking.

• Never allow personnel to ride the load line, load, or any non-personnel handling device attached to load line.

• Always maintain a 10:1 safety factor on wire rope when using crane tor personnel handling.

• Only use approved Personnel Handling Platforms.

• Use proper multi-part reeving for load to be lifted. Properly route cable for reeving.

Operator safety tips cont.

• Always maintain at least three full wraps on winch drum at all times.

• Know the lifting capacities of the boom and winch. The winch will normally have greater capacity at lower boom angles. Never use the winch to lift an unknown weight without first determining if crane boom cylinders can lift the weight.

• Never lift a load greater than the winch pull capacity by using luff or telescope cylinders.

• Do not drag load with winch.

• Always wind load line on winch with cable under tension.

• Never under-wind winch drum, winch brake becomes in-operative.

• Use sufficient load block or overhaul ball weights to help keep the proper rope lay on the winch.

• Do not use crane to scrape, hammer, or chisel ice from ships deck.

• When crane is not in use, always park crane in boom rest or lash to deck.

• When operating crane In dynamic conditions, use proper load charts or de-rate the crane accordingly. The same applies when operating crane in low temperature extremes.

• When working on the crane or hydraulic power unit, place warning tags or red tape on starter and crane controls. If isolation valves are installed in hydraulic system, close and wire in off position.

• Never start or operate crane while maintenance personnel are working the crane and its components. Get authorization from maintenance supervisor or lead mechanic before proceeding.

• If maintenance personnel have been working on crane or hydraulic power unit, never start crane or power unit without first contacting maintenance supervisor or lead mechanic to ascertain readiness of crane.

• If possible, always isolate crane from hydraulic system or electrical system when crane will be Idle for extended periods of time. This prevents unauthorized use of crane while away from unit.

• When working on crane or hydraulic power unit, do not allow oil to accumulate and clean up all oil spills immediately.

• Always wear approved safety harnesses when working on elevated structures or performing at sea repairs or maintenance.

• Always use at least two service personnel when performing major repairs.

OPERATION

TRAINING

All crew members must become thoroughly familiar with the operation or the crane controls, the correcting operating procedures, standard hand signals for cranes, maximum llftlng capacities. and all safety precautions before placing crane into service. Operator training Is essential. Always be prepared ror an emergency condition and know what actions are required by the crew. The following pages contain numerous safety precautions and information as well as detailed operating procedures and tips that must be observed while operating the crane. This section, like all of the manual, must be read carefully before operating the unit.

The health and safety of each crew member Is of primary Importance. Consequenlfy, each member has an obligation to himself and to their fellow crew members, to assure that all safe operating procedures are followed. All operating regulations recommended by the manufacturer, the employer, and required by local, state, and federal regulatory agencies must be observed. The operating procedures set fourth are North American Crane and Equipment Company's recommendations and do not necessarily cover the employer and governmental regulations. Each operator must know and follow these procedures.

Become thoroughly familiar with all equipment checks. You must be able to make complete inspection and capable of spotting any abnormality or malfunction before using equipment, while using crane, or after project is completed. There Is a high degree of reliability built into this unit, but there is always a possibility of mechanical or power failure due to incomplete servicing, improper operation, or abnormal wear. An operator must never take another's word. Always Inspect the unit yourself.

Each crew member must receive through instruct1ons on the care and maintenance of this crane and power unit, thus enabling him to Identify and anticipate any problems that may occur. Understanding how the equipment operates wnr help you recognize when it Is not functioning correctly and that repairs or adjustments are required.

90% of all crane failures can be attributed to untrained or unskilled operators. The skilled operator understands how the equipment operates and what the limitations of the equipment are. Most crane failures are do to ovenoadlng of the crane and its components. This manual , a load rating chart, and boom angle Indicator are provided to prevent overloading of the crane -- only It the operator reads and uses these items. It Is of utmost importance that the operator reads and understands the load chart, failure to do so places himself and all other personnel a1 risked and almost assures a crane or component failure.

An equally Important factor is the understanding what the limitations of the are. This requires that personnel operating the equlprnent1 fully comprehend how the crane works and what cranes are designed to do and what cranes are not designed to do. Never guess that the crane can do a certain job - always know!

CONTROLS

INTRODUCTION

The controls on the crane can be divided into two (2) categories; (1) primary and (2) secondary. Primary controls can be considered any device that the operator must use or check to operate crane. Secondary controls can be considered any device that the operator must be aware of and use should it become necessary. Below are listed both types of controls and their use. All crane primary controls are mounted at the operators station, except the boom angle indicator(s) ; which are mounted on either side of the main boom.

PRIMARY CONTROLS

Swing Control:

Extension Control:

Boom Control:

Winch Control:

Load Chart:

When facing the control station, is the first lever on the left. Pull lever to swing (slew) crane right (clockwise). Center (neutral) lever to hold crane position. Push lever to swing crane left (counter-clockwise).

Second lever from left. Push lever to extend booms. Center (neutral) lever to hold boom length. Pull lever to retract booms.

Third lever from left. Pull lever to raise boom (luff up). Center (neutral) lever to hold boom height. Push lever up to lower boom (luff down).

Forth lever from left. Pull lever to hoist load. Center (neutral) lever to hold load. Push lever to lower load.

This chart gives the crane capacities at differing boom angles, load radluses, and boom extension(s). Precautionary notes and general operating instructions are located below the main chart.

Boom Anale Indicator: Located on either side of main boom. Indicates relative boom angle from horizontal and when used with load chart - provides lift capacity of crane.

Load Moment Indicator: The LMI system provides the operator a constant readout of the loads, boom angle, and load radius. The system will also alert the operator, with and audible alarm, when an overload condition is approached. See LMI operators manual for complete details of system.

Motor Start/Stop:

Boom Lights:

Wiper Switch:

Warning Horn:

The power pack motor Start/Stop button is located to the left of the control console. Pull the button to start the power unit and push the button to stop the power unit. The button is illuminated when the power unit is operating.

The boom light control switch is located to the left of the control console and turns the boom lights ON or OFF.

The wiper switch is located to the left of the control console and turns the windshield wiper ON or OFF.

The warning horn push button Is located to the left of the control console and

• 3

•

1

•

D

HEATER

~-SWING

WINDSHIELD WIPER

PUMP PRESSURE GAGES

LMI READou:

BOOM EXTEND LUFF

/

c

LOOKING TOWARDS SHEAVE HEAD

D c

""SCM NUIJ~LR DRAv.ll'IG NUIABER 7R117 GA-5150

SIZE REV. B 0

DRAWING USED 0 REVISIONS

DATE CR;..NE S/N ZONE REV OESCR I PT I O:.J

12-20-95 MCT-1565-95-1019 I-A Lfu, OESCR I PT I Ot.J

12-20-95 MCT-1565-95-1020

2-20-95 IACT-1565-95-1021

2-20-95 MC~-1565-95-1022

12-20-95 MCT-1565--95-1023

12-2()-95 MCT-1565-95-102•

LOAD MOMEI T INDICATOR

CONTROL CO SOLE

- -0 0 LQtO 0

I ~B~BI mBDB

0

@ ..,,.

mm0m [!)[!)(!J[!J

mmos

SECTION A-A

CRANE CONTROL CO SOLE

A

APPROVALS

00-00-00

3

WARNING HORN

BOOM LIGHTS

WINDOW WIPERS

2

MOTOR START/STOP

1 ~-------~North American Alaska Marine crane _.,.,

WALT DAVIS

Ol.T!-•

~,...,....,,.,,.-------1Crane and Equipment Co. :~J:. 12-20-95 I S9.I: OATES 12-2()-95 Ql[Qt{J) fl'r

WA.LT DAV S CRANE OPERATOR CAB LAYOUT DAT'£ CHRXlll 12-2()-95 FOR MCT-1565 ~ .....

"AU D4VIS

DATJ: """"7\'m 12-2<>-95 ~--==------4 SlZE f"SCL! NUt.4BER

B 7R117 GA-5150 ~

0 c:o<TMCT- SCALE Wic GHT

NOIJE O.N.A.

B A

can be operated by pushing. The warning horn should be used to advise assisting personnel that a possible danger may exist.

Cab Light: The cab light provides illumination of the operating controls during night operations and is located above and behind the operators seat.

Sight Level gauge: The sight level gauge is located on the hydraulic reservoir and provides visual indication of the current fluid level In the reservoir.

Temperature Gauge: The temperature gauge is located at the bottom of the sight level gauge and provides visual indication of operating temperature.

SECONDARY CONTROLS

Relief Valves:

Port Relief Valves:

The main relief valves are located at the Inlet end of each valve bank and are used to limit the maximum pressure to the crane components.

Port relief valves are installed on the work ports of the telescope (out) and both ports of the boom cylinder valve. The valves are used to limit the operating pressure of these functions below the pressure of the main relief valves. See HS-7752 for settings.

Counterbalance Valves: Are located at the blind end of each boom cylinder and on the blind end of the telescope cylinder. They are used to adjust the maximum load holding capability of the cylinders and to prevent over-running the cylinders when retracting with full loads.

Pressure Gauges:

Unloader valve:

Anti-Two Block:

Filter Indicator:

The pressure gauges are located to the left of the LMI readout and provide an analog Indication of the current operating pressures of the hydraulic system. The operators can use the gauges as a backup to the LMI system and as a measuring tool for the condition of the hydraulic system.

The unloader valve is used to increase the speed of the boom and winch functions during light load operations. The operation the unloader can be monitored with the pressure gauges. This valve should be set @ 1700 - 1800 psig.

The anti-two block system prevents the load block from contacting the sheave head. The only adjustment is the reaction time of the system, which should be set at 1-3 sec.

The filter Indicator provides visual Indication when the filter elements needs to be changed. During cold start-ups, the Indicator may show that the filters are bypassing and should be ignored.

OPERATING PROCEDURES

EQUIPMENT FAMILIARIZATION

All personnel operating the crane and assisting the crane operators must become thoroughly familiar with location and operation of the crane and power unit controls, the correct operating procedures, maximum lifting capacity of the crane, and all relevant safety precautions before operating the crane. This crane is a complex piece of machinery and can be overloaded easily If not properly operated. All functions of the crane are hydraulically controlled and use standard industrial components. Hydraulic power is supplied to the crane by the platform mounted power unit. Carefully follow the operating procedures outlined below. The load ratings and support requirement of the crane during towing operations must be strictly adhered to.

PRE-OPERATIONAL EQUIPMENT CHECKS

Before operating the crane, the condition of the crane, hydraulic power unit, and their components must be verified tor operational readiness. Perform any routine or mandatory maintenance at this time. The following items should be checked each time the crane is placed in service and after each project is completed.

Electrical System

The electrical system Includes the slip-ring, inter-connecting wiring, cab controls, LMI system, boom lights, cable reel, and anti-two block switches. The operator and/or assisting personnel should perform the following inspection checks:

WARNING: THE ELECTRICAL SYSTEM CONSISTS OF BOTH HIGH AND LOW VOLTAGES; EXTREME CAUTION MUST BE USED WHEN INSPECTING THE ELECTRICAL SYSTEM.

• Inspect the all wiring harnesses for damage or chaffing.

• Inspect enclosures for adequate sealing and/or damage.

• Insure that the slip-ring torque arm bar is in place and retaining bolts are present.

• Insure that the slip-ring covers are in place and seals are intact.

• Inspect all boom appliances for operation and integrity.

• Insure operation of anti-two block switches.

• Insure integrity and operation of anti-two cable reel and wiring.

• Insure operation of LMI system.

• Insure integrity and operation of boom length reel and wiring.

• Insure operation of warning horn.

PRE-OPERATIONAL CHECKS cont.

Hydraulic Control System

The hydraulic control system Includes the hydraulic power unit. all Inter-connecting lfnes between power unit and crane control valves and their connections. There are no unusual or special components designed Into the system. The operator and/or assisting personnel should perform the follow checks:

• Inspect for any signs of leaking and pools of oil. Always determine and correct cause of leaking before placing crane Into service.

• Check hydraulic reservoir level and add correct grade of nuid If required. Determine why oil level was low before placing crane into service.

• Check all hose and fittings for signs of leaking. The hoses should be free of cuts or abrasions (chaffing) through the outer covering. Insure that all hoses are free of twisting or kinking.

• If suction valve at hydraulic power unit is not wired open. insure that valve is open prior to starting unit. Open any shut-off (isolation) valves between power unit and crane.

• Check crane control valves for binding or damage. DO NOT PLACE CRANE INTO SERVICE IF CRANE CONTROLS Will NOT SELF CENTER. Check for loose parts, corrosion, and proper alignment.

• Drain off any accumulation of water In pedestal base.

Lifting System

The lifting system consists of the main and telescope booms, the luff and extend cylinders, winch and rigging, and all associated mounting hardware. The crane operator and/or assisting personnel shall check the following before placing crane into service and after job is complete:

• Main and telescope booms for damage, excessive corrosion, cracked weJds, bends or ripples In boom sections, and misalignment.

• Check all cylinder, hinge, and boom pins for proper lubrication and for excessive wear. Insure that all pin retainer bolts are present.

• Check luff and extend cylinder hose and fittings for damage or leakage.

• Missing or broken winch mounting bolts.

• Check that all bolts and fasteners are present and that retainers are In place.

• Check winch for leakage, loose parts, abnormal wear, proper alignment, and correct oil level.

• Check wire rope for proper spooling on winch drum.

• Check wire rope for damage. Such as; broken wires, Ratted wires. excessive corrosion, kinks and twists, and blrdcaging. See Lubrication and Maintenance section for complete wire rope Inspection instructions.

• Insure sheaves are free turning.

PRE-OPERATIONAL CHECKS cont.

• Inspect wire rope end connection signs for pullout or damage.

• Inspect load hook for cracking, throat separation, shank stretching, missing safety catch, and ability to swivel freely. REPLACE IF HOOK SHOWS ANY DAMAGE.

Swing Drive System

The swing drive system Includes the drive motor, planetary gear reduction drive and brake, pinion gear, and rotation bearing. The operator and/or assisting personnel should check the following:

• Ring and pinion gears for proper lubrication, loose or missing mounting bolts, excessive or abnormal wear, and mlsallgnment.

• Drive motors for loose or leaking fittings, damaged hoses, and loose or broken mounting bolts.

• Gear boxes for loose or broken mounting bolts.

• Rotational bearing for proper lubrication, integrity of seal, loose or broken mounting bolts, and excessive wear or "play".

CTD /EM SYSTEM

The CTD / EM system consists of the through bore slip-ring, EM sheave, EM guide rollers, main boom pad eye, towing padeyes. and owner furnished equipment that attaches to the main boom. The operator and/or assisting personnel shalt check the following before preforming any launching or towing operations:

• Perform system and maintenance inspection prior to handling any instrumentation package. Any deficiencies must be corrected before operation.

• Insure the towing guy wires are adequate for the towing operation and the correct tension is being maintained during towing operations.

• Insure the lower CTD /EM guide rollers turn freely and are not grooved.

• Insure the main CTD/EM sheave is turning freely.

• Inspect the main CTD/ EM sheave groove for wear and damage that could harm the EM cable.

• Inspect the upper seal area where the EM cable passes through the slip ring center bore. Apply water proof sealant as required to prevent leakage into the slip ring.

• Insure that EM cable has adequate clearance through the slip ring bore and dose not contact the seal tube.

• Inspect the boom padeyes for wear and cracking of welds. Repair before attempting a towing operation. Padeye bores can be built up with hard facing welding rod.

PRE-OPERATIONAL CHECKS cont.

CTO / EM SYSTEM cont.

• Inspect the EM over-boarding sheave block and shackle. owner furnished materials, for wear and/or damage. Repair or replace as required.

• Insure that EM cable does not contact the guide roller retainer bar.

• Inspect EM cable for damage as It Is played out. A severely damaged cable can cause loss of the Instrumentation package.

GENERAL OPERATING INSTRUCTIONS

1. Start power unit. If on temperature Is below 40°F, allow unit to idle for 10 - 15 Min. before operating crane. Power up the LMI system and allow unit to stabilize before attaching load to the load line. Select the correct number of parts of reeving for the current crane configuration.

2. Check functioning of all controls by operating each system through one (1) complete cycle. This Is especially Important if crane has been idle for long periods of time, serviced, or repaired. If any system does not function property, correct condition before continuing.

3. All crane control movements must be done with precise-controlled manipulations to prevent sudden starting and stopping of crane functions. This Increases the life of the crane by eliminating unnecessary shock loads whlle providing a safe working environment for the assisting personnel. The controls should be carefully actuated to began function and then slowly actuated further until the desired function speed Is achieved

4. When lifting loads, always monitor load and boom angle indlcator(s) to prevent overloading of the crane. Whenever possible, use the shortest possible retracted length required to achieve desired load radius. The LMI system Is calibrated for STATIC or SHIPBOARD operations only. The operator must use the load charts for offshore operations to preveht overloading of crane. Do not rely upon the overload indication feature during OFFSHORE operations.

5. When operating winch control, avoid •snapping• load line when hoisting. Always remove slack line before Increasing hoisting speed. NOTE: With multi-part reeving this is less of an concern because hooks speeds are relatively slow compared to single part reeving.

6. Use both winch and telescope controls to maintain load height when Increasing (decreasing) load radius without changing boom elevation.

7. When removing (placing) loads onto a moving deck or from (to) a moving deck to(from} a fixed platform, the operator should learn to time the deck movement to optimum time to hoist (lower) load. Under Ideal timing, the load is hoisted (lowered) when the crane (load) are essentially static. This occurs during two periods of wave action - at crest and trough.

8. When both the crane and load are on two separate moving platforms, The operator should learn to time deck movements of both vessels for the optimum moment to hoist (lower) load. Under ideal timing, the load Is hoisted (lowered) when the crane Ooad) are essentially at equal velocities. Thls occurs during two periods of wave action - when climbing a wave and when descending a wave.

GENERAL OPERATING INSTRUCTIONS cont.

9. If load is not visible to operator at all times, assisting personnel shall guide crane movements using approved hand signals.

1 O. When stopping movement of crane, slowly center control valve and do not cross over center position until crane function has stopped. Rapid reversal of crane function can impose undue shock loads on the equipment and shorten life of crane.

11. Always check operational area for obstructions within the boom(s) or load path. Allow at least 2 ft clearance from obstruction to boom(s) or load.

12. When operating crane as a shipboard unit, the crane must be derated if vessel list (or trim) exceeds 5° In either axis.

13. When using the LMI system, the following functions are provided; See operators manual for complete Information on LMI system.

A.

B.

c.

D.

WARNING:

E.

F.

G.

Hook load - "1" + "select". Provides current load on load block.

Boom Length - "2" + "select". Provides the current length of telescope boom extension.

Boom Angle - "3" + "select". Provides current boom angle.

Line Parts - "4" + "select". Provides current number of parts of line reeving the LMI system Is calibrated for.

IF THE ACTUAL NUMBER OF PARTS ARE DIFFERENT FROM THE CALIBRATED NUMBER OF PARTS, SEVERE OVERLOADING OF THE CRANE CAN OCCUR AND DAMAGE TO CRANE WILL ENSUE.

Load Radius - "5" + "select". Provides current load radius of the load hook.

Scan - •9• + "select". Provides continuous readout of Load, Boom Length, and Boom Angle In 2 second intervals.

Warning indicator.

1. 105% - Amber Indicator light. Increase boom angle or decrease boom length to prevent further overloading of crane.

2. 110% - Red indicator light with audible alarm. Immediately land load with winch or increase boom angle with luff cylinders, or reduce boom length with telescope cylinder.

14. When stopping crane always observe the following:

A. Land any attached load. If load must be suspended, tag crane control with notice of such and warning barricades should be placed beneath suspended load.

B. Place crane boom in boom rest or suitable secure boom to prevent crane from inadvertently swinging.

GENERAL OPERATING INSTRUCTIONS cont.

C. Place all controls In neutral position.

0 . Shut off power unit and lock disconnect switch in •otr position to prevent unauthorized operation of crane.

E. Perform crane Inspection and tag any abnormalities found. Operators and/or assisting personnel shall notify Maintenance personnel of any deficiency found.

15. When using crane for personnel handling.

WARNING: CRANE MUST BE APPROVED FOR PERSONNEL HANDLING AND REQUIRED ADDITIONAL SAFETY DEVICES AND SPECIALIZED EQUIPMENT. AT BOTTOM OF LOAD CHART IS INDICATION WHETHER CRANE IS APPROVED FOR PERSONNEL HANDLING OR NOT. - NEVER USE AN UNAPPROVED CRANE FOR PERSONNEL HANDLING-

A. Perform system and maintenance inspection prior to handling personnel and any deficiencies must be corrected before operation.

B. When handling personnel, all crane controls shall be operated In a precise-controlled manor. If control valves have adjustable travel stops, they should be adjusted to allow only 1 / 2 of normal travel.

C. Only agency approved Personnel Handling Platforms or Harnesses shall be used.

D. All crane safety devices must be operational before using crane for personnel handling.

E. When personnel platform ls stationary, all brakes and locking devices must be set

F. Never exceed the Rated Personnel Handling Capacity of crane or wire rope, whichever is less.

G. Only personnel handling approved load hooks shall be used during personnel handllng operations.

H. A trial lift must be accomplished before hoisting personnel.

I. At sea personnel handling operations are inherently dangerous, and operator shall use extreme caution during such operations. An assistant shall be assigned as spotter for crane operator and platform personal. The crane operator shall follow all directions of the spotter.

J. Whenever possible, all at sea operations should be performed leeward.

GENERAL OPERATING INSTRUCTIONS cont.

16. When using CTD operations and Instrumentation handling

WARNING: THIS CRANE HAS BEEN APPROVED FOR CTD AND INSTRUMENTATION HANDLING ONLY WHEN BOOMS ARE SUPPORTED IN THE TOWING BOOM RESTS. TOWING OF PACKAGES IS NOT ALLOWED WHEN BOOMS ARE NOT PROPERLY SUPPORTED, WITHOUT AUTHORIZATION.

A. Perform system and maintenance Inspection prior to handling any Instrumentation package. Any deficiencies must be corrected before operation.

B. Place boom In support before performing any towing operations. Insure the CTD or EM cable has sufficient clearance of boom rest and gunnels.

C. Install guide wires to 3rd stage telescope boom when towing or retrieving packages while the ship Is underway and the Induced loading is above the allowable side loading. , Tension the guy wires such that the boom has no side loading.

D. Insure the lower CTD/EM guide rollers are turning during haul in and pay out.

E. Insure the main CTO/EM sheave is turning during haul in and pay out.

F. Never exceed the Rated CTD / EM capacity of the crane or CTD / EM cable. Refer to load chart rated crane capacity.

G. To reduce stresses of the handling system, all towing operations should be performed over the stern and along axis of the crane boom.

H. Do not use main load block with CTD/EM sheave block attached to boom at boom angles greater than 65°. The CTD/EM sheave block can Interfere with the load block.

I. Monitor CTD /EM guide rollers for wear. Do not allow grooves to be worn Into rollers.

J. Shut off hydraulic power unit when performing towing operations for long periods of time to prevent inadvertent operation of handling system.

K. When connecting CTD /EM sheave block to boom, Insure the cable has at least 1" of clearance between cable and guide roller retainer bar.

L Insure that EM cable has adequate clearance through the slip ring bore and dose not contact the seal tube.

M. When using the crane to retrieve rhe inslrumentallon package. the operator shall use the Dynamic Load Chart to determine the crane rating.

N. During retrieval operations, the operator should use extreme care when operating the crane functions and strive to maintain smooth crane movements.

READING ANO UNDERSTANDING THE LOAD CAPACITY CHART.

The structures and components of the crane are designed to provide satisfactory service as long as the crane Is not loaded In excess of the maximum capacities specified on the load chans. Overloading can create serious potential safety hazards and as well as shorten the service life of the crane. It is Important that you know the weight of any load you are attempting to handle and the total weight or the load handling devices. This should be done by the use of a dynamometer or similar weighing device.

Overloading a crane can cause many types of failure depending on the configuration and working position of the crane at time of overloading. Failures can include, but are not limited to:

Structural -

Reeving -

Damage to boom(s), turret. pedestal, and foundation; bending cylinder and boom pins and/or rods: deformation of Winch drum and frame: breaking rotational bearing mounting bolts.

Damage to wire rope, sheaves, and/or load hook failure.

The Load Capacity Chart. located at the operators station, shows the rated load capacity of the crane at various load radii and boom angles. The working load must not exceed these values and should Include the load to be lifted as well as any load handling devices used. These Include but are not limited to; load block, slings, tag lines, pallet forks, grabs, etc., which can be handled by the crane and winch. The weight of the load handling devices, boom attachments, or any other device that Is not a crane structure must be deducted from the load chart rating to determine the payload which can be safely lifted. Additional reduction in load rating may be necessary to make allowance for dynamic loading factors Imposed on the crane. Factors that must be accounted for include: List and Trim of vessel, Seastate. wind velocity, temperature, and vessel stability. The amount of reduction Is a quantitative value based on previous experience and the weight of the work load. The de-ration of the crane shall be more for light loads than for heavy loads with all else being equal.

The ratings shown on the Static lift capacity charts are based on the structural integrity of the crane and winch, and represent a foundation efficiency factor of 100% when:

1. The vessel Is at o0 list and trim.

2. The proper amount of ballast has been added, If required.

3. The crane is mounted in accordance with the Installation instructions and the pedestal correctly welded or bolted to the foundation.

4. The weight of tackle has been considered as part of the load.

5. The seastate condition is o (zero)

6. The vessel remains stable during lift.

7. The operator controls the crane and load smoothly.

8. The crane has been Inspected and all deficiencies (If any) have been corrected.

9. The load does not exceed 2° maximum vertical and horizontal out of plane.

Reading and understanding load capacity chart cont.

Whenever a crane Is installed aboard a vessel, a stability test should been performed If the naval architect feels that the crane will cause significant vessel instability. If you are in doubt or have any hesitation about the vessels stability, you must perform a stability test as outlined In the Installation Section of this manual.

Using the Load Capacity Chart

The Load Capacity Chart located at the operators' station gives the rated crane capacities at various load radiuses and boom angles. (refer to chart). All load radiuses are measured from center of rotation of the crane. The load chart has three (3) columns under the two (2) recommended operating conditions - Fully Retracted and Fully extended. To use the chart, center the load hook over the working load, and read the boom angle Indicator.

WARNING: THE TELESCOPE BOOM MUST EITHER BE FULLY RETRACTED OR FULLY EXTENDED FOR THE ABOVE EXAMPLE.

Depending upon whether the boom is extended or retracted, read down the boom angle column until you find a corresponding angle closest boom current boom angle. Read both load radius and lift capacity from chart. If the boom angle is between two (2) values shown on chart, use the next lower boom angle to determine crane capacity and interpolate for load radius. To determine if the working load is within the rating of the crane, the payload and ending load radius must be known. If the working load (payload + tackle) is within the rated crane capacity for that load radius and the load radius will decrease for the final load radius, or the boom extension is between the two extremes and the final load radius can be achieved by Increasing boom angle, the crane can safely be operated.

The most important information in the load chart is the combination of load radius and load capacity. Whenever the radius Is between points on the chart, the next lower load capacity (smaller) shall become the rated crane capacity. Example;

At o0 boom angle, the crane has a higher rated capacity for Fully Retracted than it does for Fully Extended. The rated crane capacity for any load radius between Fully Retracted and Fully Extended is equal to the crane capacity in the Extended column.

When the load radius is decreasing, the beginning load radius capacity becomes the rated crane capacity for that lift. I.E.: You can not use a higher rated crane capacity just because the ending load radius will be less than the starting load radius.

EXAMPLES:

If the final load radius is greater than the starting load radius; reposition load hook over final load radius, without load attached, and read the new boom angle. Again read the load chart to determine the rated crane capacity and insure that the work load is less than this value. If the crane rating is greater than the work load. proceed with the operation.

If the final load radius is greater than the starting load radius and the working load is greater than the load chart value for the new boom angle, check the extended load capacities of the chart for the same boom angle. If the fully extended capacity is equal to or greater than the work load, then it is safe to extend telescope booms to achieve the desired load radius.

Reading and understanding load capacity chart cont.

The following procedure is the a correct method used to determine the cranes' ability to handle a known working load as shown In the preceding examples.

1. Determine the weight of the load handling equipment and add its weight to that of the payload to determine the work load.

2. Determine the distance from the centerline of rotation to the position of the load. {load radius)

3. Determine the load radius to where the load is to be moved.

4. Refer to the Load Capacity Chart for the crane configuration and determine what Is the optimum boom configuration that will to Insure that the load does not exceed the capacity of the crane for that load radius. When the load radius falls between points listed on the chart. the smallest load at the next load radius Interval Is to be used.

5. Refer to the winch capacity to Insure that load does not exceed winch capacity. If greater winch capacity Is required. See reeving diagrams on how to Increase winch capacity.

The following procedure is a typical method used to determine the cranes ability to handle an unknown working load.

WARNING: ONLY USE THIS METHOD IF THE MAIN BOOM ANGLE REQUIRE TO ACHIEVE THE FINAL LOAD RADIUS IS GREATER THAN OR EQUAL TO THE MAIN BOOM ANGLE REQUIRED FOR THE BEGINNING LOAD RADIUS ANO THE FINAL LOAD RADIUS IS LESS THAN THE BEGINNING LOAD RADIUS.

1. Perform steps 2 & 3 above.

2. Determine which load radius will require the least boom extension. Confirm that final main boom angle is greater than or equal to beginning boom angle.

3. Connect rigging to load and hoist up with winch to remove slack. DO NOT APPLY TENSION WITH WINCH.

4. Use boom up control. Depending on how the crane performs:

a. If load Is lifted easily with boom up cylinder, load Is within crane capacity tor that radius and can be safely moved.

b. If crane hesitates to lrtt load or load is lifted slowly, then load Is marginal for that load radius and it must be determined that the final load radius generates a better crane geometry. If It does, the load can be moved - but use caution to insure that the load radius Is always decreasing.

c. If the crane cannot lift the load, determine how to lighten load or to Increase main boom angle.

Reading and understanding load capacity chart cont.

A separate Dynamic Load Capacity Chart Is located at operators station for offshore operations. Use this Chart whenever performing offshore lifts or dynamic loads exist.

The ratings shown on the Dynamic load capacity charts are based on the structural integrity of the crane and winch, and represent a foundation efficiency factor of 100% when:

1. The crane meets all mounting conditions for the Static Load Rating.

2. The vessel is less than 15° list or trim, with or without rated load(s).

3. The weight of tackle has been considered as part of the load.

4. The seastate condition is less than 4-5, or amounted stated at bottom of chart.

6. The operator controls the crane and load smoothly, as much as possible.

7. The crane has been inspected and all deficiencies (if any) have been corrected.

8. The crane is operated above Its minimum temperature rating.

A separate chart is included for side towing operation. The ratings shown in the Side Towing chart are only to be used during CTD and instrumentation handling operations. The crane must be installed as required by the Static Load Rating Chart and is based on the following parameters:

1. The vessel is less than 15° list or trim, with or without rated load(s).

2. The weight of EM cable has been considered as part of the load.

3. The seastate condition is less than 3-4.

4. The crane has been inspected and all deficiencies {if any) have been corrected.

5. The crane ls supported as required in the load chart.

6. Booms are fully retracted.

The term direct side towing means the boom Is perpendicular to the side of the vessel and the EM wire is sideleading at 90° from the side of the boom. The boom does not require support in a towing crutch.

The Term 4s9- side towing means the boom is positioned toward the stern at a 45° angle to the side of the vessel. The boom does not require support in a towing crutch.

The Term guyed means one or more guy wires are attached to the 3rd stage boom towing eyes and the tension in the guy wires are set equal to the side pull loading. The boom must be supported by a towing crutch.

If load is between guyed and un-guyed capacities, guy wires must be installed and properly tensioned. The boom must be supported in a towing crutch

Summary

All else being equal, being able to fully understand a load chart and whether to use the Static Rated Load Chart or the Dynamic Rated Load Chart Is probably the greatest challenge of a crane operator. To prevent overloading a crane, keep In mind the following points when using the load charts:

• If any motion exists on either the platform the crane Is mounted on or the vessel the working load is on. always use the dynamic load chart.

• Whenever possible, always use Increasing boom angles to achieve the desired final load radius.

• Never Increase the load radius by booming down and/or extending out with a unknown working load. This will almost always guarantee overloading the crane.

• Bet ore performing any lift, insure that the rope and reeving are rated for the working load.

• Even If the working load is known. the operator should first test the capacity of the crane by using the luffing cylinders. If the crane struggles or fails to pick the load, this indicates that the hydraulic system may need servicing or the working load Is far greater than what the operator was told.

• There will always be Instances when the load chart does not cover the desired lift situation -only experience and sound judgement can be used In these instances - 'err to the side of caution'.

• A skilled crane operator can turn a dynamic lift into a quasi-static Ii~ An unskilled crane operator should always operate the crane using the Dynamic load Chart for rated loads.

• Because of the nature of towing operations and the Inherent danger of snagging, operation of the crane outside the support requirements is prohibited. Failure to correctly support the crane can lead to catastrophic failure of the handling system.

• The towing capacity of the crane is not the rated load capacity during retrieval operations and the Dynamic Load Capacity Chart must be Is used when retrieving instrumentation packages.

HOIST With lorearm ven1cal. lorehnger pointing up, move hand in small horizontal circles

LOWER BOOM Ar,,, extended. lingers closed, lhumb polnllng downward.

STOP Arm extended, >aim down. holding >0sltion rigidly .

tETRACT BOOM. Telescoping Booms.)

fists in front of ,.,Ith thumbs

oi toward each •lht.. .

LOWE.A With arm extended downward. forefinger pointing down. move hand in small hon2ontal circles

MOVE SLOWLY. Use one hand to give any motion signal and place o ther hand motionless in front of hand giving the motion signal. (Hoist S lowly shown as an example)

EMERGENCY STOP Arm extended. palm down, move hand rapidly right and let\.

EXTEND BOOM. (Telescoping Booms.) ONE HANO SIGNAL. One fist in front of chest w1lh lhumb tapping chest.

USE MAIN HOIST Tap list on head, lhen use regular signals

RAISE BOOM & LOWER LOAD Wllh arm ex1ended. lhumb po1nling up flex lingers in and out as long as load movement 1s desired.

• TRAVEL Arm extended forward. hand open and slightly raised. make pushing motion in dlrec11on ol travel.

RETRACT BOOM. (Teloscoping Booms.) ONE HAND S IGNAL One list In front of chest, lhumb pointing outward and heel of fist tapping chost.

USE WHIPLINE (Aux­lhary I to1st ) Tap elbOw with one hand, then use regular s ignals

LOWER BOOM & RAISE LOAD With arm extended. lhumb pointing down. flex lingers in and out as long as load movement 1s desired.

DOG EVERYTHING Clasp hands In lron1 of body

RAISE BOOM Arm exlended. fingers closed , thumb poinllng upward

SWING. A<m extended, point with finger in direction of swing of boom

EXTEND BOOM. (Telescoping Booms.) Both fists in front of body with thumbs pointing outward.

STANDARD HAND SIGNALS FOR

CONTROLLING CRANE OPERATIONS

EXTRACTED FROM ANSI STANDARD ADDENDUM -830.5-'1982 & 830.Sa-1984

3-652-00114

fNSTALLA TION

INSTALLATION INSTRUCTIONS

The foundation at point of crane placement must be designed to accommodate 2x the maximum tipping moment of crane as well as the axial load of the crane plus 2x live load. The crane pedestal Is designed to weld to a customer supplied foundation.

PLACING PEDESTAL

Use a suitable lifting device and rigging to handle 7,500 Lbs. Rig pedestal and turret (2) assemblies for level lift, and place on pedestal foundation. Secure pedestal assembly to foundation using acceptable welding procedures. North American Crane and Equipment Co. recommends using those found In AWS D1 .1-92. Use suitable shim stock to maintain a 1 /16" levelness. It Is advised that the crane controls are placed In such a positions that the operator will have an unobstructed view of the normal working side of the crane. This will require a survey of the crane site to determine which area the crane will generally operate in.

INSTALLING CRANE BOOM AND OPERATORS PLATFORM

Use suitable lifting device and rigging to handle 15,500 Lbs. Rig boom and operators platform assemblies for level pick using lifting eyes on boom. Align bolt holes on pedestal with bearing bolt holes and lower assemblies Into place. Install all bolts before removing rigging. Torque bolts to 1000 FT-LB In 250 FT-LB steps. Use a crossing pattern when torquing.

SLIP-RING INSTALLATION

Slide slip-ring assembly through pedestal access opening and use lifting sling to pull unit into place. Pull power feed and communications wires through conduit and into slip-ring housing. Install sealing gasket and fasten to bottom of turret with supplied bolts. Align torque arm bar with pedestal stop and Install supplied bolt to fasten in place.

ELECTRICAL CONNECTIONS (refer to ES-8102)

Connect 460v /60Hz/3¢> supply the appropriate terminal block. Repeat for 120v / 60Hz/ 1 tf> control power supply and communications circuit. Wire start, stop, and run circuits per schematic provided with starter panel. Connect anti-condensate heaters to starter N.C. auxiliary contactor. Re-Install access panels when wiring is complete. NOTE: Grounding wire must be bonded correctly al generators to prevent arcing across swing bearing and severe electrolysis.

STARTING CRANE

This crane was shipped with our standard factory settings and some adjustments will be required to optimize crane for service. These adjustments should only be done by qualified hydraulic service personnel.

Installation cont.

Observe that no obstacle is in the boom's path and operate Swing control function to bleed air from system. This may take 3 or 4 revolutions In both directions. Operate Boom, Telescope, and Winch controls functions in like manner until all air is bled from system; i.e. control is no longer "mushy" or "jumpy''. Check hydraulic system for leaks during and after each functional test. Confirm that crane controls operate as Indicated by placards.

It may be required to switch hydraulic hoses to achieve the desired function control. See rota-seal tree layout for correct hose connections. When operator is satisfied that system is operating correctly, check reservoir level and top to full mark with clean hydraulic oil. Operate crane unloaded for 20 cycles for operator familiarization and to practice controlled metering of each function. Always monitor hydraulic oil level and temperature during this practice session.

ADJUSTMENTS

Relief Valves

Loosen locknuts on control valve reliefs, located at the inlet and mid-inlet section. Install pressure 0-3000 psi gauges in line with the two (2) pressure lines. Start power unit and fully retract extension cylinder. Observe P2 gauge and adjust inlet relief valve for 1,300 psi. Lock jam nut. Repeat with boom cylinder and set P1 to 2,250 psi. Lock jam nut.

Counterbalance Valves

Assemble toad for 125% of Maximum rated load capacity for both retracted and extended (2 different loads). Insure booms are fully retracted and position hook over load for that radius and connect toad to hook. Pick load and boom up slightly. Shut off power unit and then loosen lock nut on boom cylinder counterbalance valve. With Allen wrench, turn adjusting screw CCW until it stops. Have assistant operate and hold the boom down function. Slowly turn adjusting screw CW until boom just starts to creep. Turn adjusting screw CCW to stop creeping and tighten lock nut without turning adjusting screw. Start power unit and test crane in both loaded and unloaded conditions. If boom tends to bounce in the loaded condition, turn adjusting screw CCW until bounce stops. Boom fully up and extend fully out. Connect lighter test load to crane and adjust telescope cylinder counterbalance valve In similar manor, except tighten lock nut when creeping is stopped.

LOAD TESTING

Perform load testing of crane to satisfaction of attending surveyor. Generally the load test consists of lifting 125% of load chart rating and holding this test toad for 5 min. This test is done at minimum, intermediate, and maximum load radiuses. The attending surveyor may require a vessel stability test to be performed in addition to the crane load test.

Crane is ready to be placed into service upon of successful completion of load testing.

STABILITY CHECK

Before the crane can be placed Into service, a vessel stability check must be performed ro determine if any areas of vessel lnstabllity occur with respect to crane slewing at rated load. The following procedure tests outlines the requirements for this test:

1. Install crane as previously described.

2. Trim vessel for o0 list and pitch, and laden vessel to its least operational weight.

3. To stability check vessel, assemble test load weights of 125% of rated capacity of crane at maximum load radius, Intermediate load radius, and minimum load radius for both fully retracted and fully extended boom conditions.

4. Starting with boom(s) Retracted, hoist Maximum Load Radius test weight 6" of deck. Increase load radius to maximum. Keep load 6" above deck by paying out with winch. Continue to Increase load radius untll telescope boom(s) are fully extended OR until vessel has a 5° pitch; whichever occurs first. If vessel produces a 5° pitch first, note load radius were this occurred. Trim vessel to o0 pitch before proceeding

5. Carefully slew crane athwart ship both directions until boom is perpendicular to ships' axis .QB. until vessel lists 5° either side; whichever occurs first. If vessel produces a s0

list first, note bearing and distance from ships' axis. If trimming is required to maintain 0° list, note amount of trim required.

6. If a list or pitch of 5° occurs, one of the corrective actions must be Implemented;

a. Re-test crane with lessor load until crane can be operated without Inducing any list or pitch. Divide the new test load by 1.25. This becomes the new maximum crane rating and a decal must be affixed to crane defining the areas of full stability {Instability).

b. Increase the operational weight of vessel or counter-weight (ballast) vessel

c. Note the amount of ballast required to maintain stability and affix a decal to the crane detailing this amount.

Repeat the Stability Tests for each load radius. 6 tests required, and take corrective action as required. If a vessel has more than one crane. each crane must be tested separately as well as together; If this is required by the Intended service for the cranes.

RECOMMENDED TORQUE VALUES

S.A.E. GRADE 8 BOLT CLAMP DRY TYPICAL USAGE SIZE LOAD 'TORQUE

(LBS) (FT-LBS)

1/4-20 2,850 12 CAB ACCESSORIES, PLAQUES,SMALL PARTS 1/4-28 3,250 14

5/16-18 4,700 24 CAB ACCESSORIES, SMALL PARTS, WEAR PAD RETAINERS, BEARING 5/16-24 5,200 27 RETAINERS

3/ 8-16 7,000 45 SHEAVE PIN, WEAR PAD, BEARING RETAINER, VALVE MOUNTING, 3/ 8-24 7,900 50 ROTO-SEAL HEAD, CAB ACCESSORIES

7 / 16-14 9,550 70 MOTOR, PUMP. VALVE MOUNTING, SMALL WINCHES, BOOM 7 / 16-20 10,650 78 ACCESSORIES

1 /2-13 12,750 105 MOTOR, PUMP, VALVE, RSERVOIR, SWING MOTOR/BRAKE 1/ 2-20 14,400 120 PIN LOCKING, SMALL WINCHES, BOOM ACCESSORIES

5/ 8-11 20,350 210 RIDE AROUND PLATFORM MOUNTING, WINCH, MOTOR, PUMP, 5/ 8-18 23,000 240 SWING DRIVE MOUNTING, SMALL ROTEK BEARINGS

3/4-10 30,100 375 RIDE AROUND PLATFORM MOUNTING, WINCH, ROTEK BEARING, 3/ 4-16 33,500 420 LARGE SWING DRIVES, DETACHABLE SHEAVE FRAMES

7/ 8-9 41 ,600 610 AIDE AROUND PLATFORM MOUNTING, WINCH, ROTEK BEARING, 7 / 8-14 45,800 675 TURRET MOUNTING, ENGINE MOUNTS

1-8 54,500 910 RIDE AROUND PLATFORM MOUNTING, TURRET MOUNTING, WINCH, 1-14 59,700 1000 ROTEK BEARINGS, ENGINE MOUNTS

1- t/ 4·7 87,200 1,820 TURRET MOUNTING, ROTEK BEARINGS, RIDE AROUND PLATFORM 1-t/ 4-12 96,600 2.000 MOUNTING

1-1/ 2..f> 126.500 3,160 TURRET MOUNTING, AOTEK BEARINGS, AIDE AROUND PLATFORM 1-1/2-12 142,200 3,560 MOUNTING

316SS BOLT CLAMP DRY TYPICAL USAGE SIZE LOAD TORQUE

(Lbs) (IN-Lbs) 1/ 4-20 1,570 78.8 CAB ACCESSORIES, PLAQUES, SMALL PARTS 1 / 4-28 1,980 99

5/16-18 2,210 138 CAB ACCESSORIES, SMALL PARTS, WEAR PAD RETAINERS, BEARING 5./L ,..i 2,350 147 RETAINERS

3/ 8-16 3,390 247 SHEAVE PIN, WEAR PAD, BEARING RETAINERS, VALVE MOUNTING, 3/8-24 3,600 271 ROTO-SEAL HEAD, CAB ACCESSORIES 7 / 16-14 4,490 393 MOTOR, PUMP, VALVE MOUNTING. BOOM ACCESSORIES 7/16 20 4,780 418

1/ 2-13 5,420 542 MOTOR, PUMP, VALVE, RESERVOIR, PIN LOCKJNG, BOOM 1/ 2-20 5,650 565 ACCESSORIES

NOTE:

(1) TORQUE VALUES ARE FOR ORY THREADS ONLY.

(2) FOR PLATED OR LUBRICATED THREADS, REDUCE TORQUE VALUES BY 25 - 35%

(3) S.A.E. GRADE 8 (UPPER) CHART IS VALID ONLY FOR J429/ASTM, 354BO/ASTM AND 490 MATERIALS.

(4) 31 6 SS (LOWER) CHART IS VALID ONLY FOR 304/ 316 STAINLESS STEEL

MAINTENANCE, LUBRICATION & SERVICE

MAINTENANCE

. A regular schedule of inspection and maintenance is essential to keep your unit In peak operating efficiency. Operators or service personnel responsible for the care of the unit must be completely familiar with the type and frequency of Inspections. maintenance and lubrication operations to be performed. The following pages oulline the maintenance, lubrication and service required.

INSPECTION

The following pages list Inspections which are to be conducted an your unit to help assure It Is operating properly and safely. Check all Items listed at the frequency listed. Any deficiencies found shall be carefully examined to determine If It creates an unsafe operating condition. If such a condition Is round, the crane shall be removed from service or warning tags shall be place at the operator control station and/ or power unit limiting its operation to prevent the unsafe condition from occurring. The condition shall be corrected as feasible. Any critical component deficiency found shall cause immediate removal of crane from service.

The inspections are separated into the following frequency classifications:

• Daily losoeqtions These items shall be visually Inspected each day by the operator prior to using the cranes.

• Weekly Inspections These items shall be visually Inspected weekly by the operator.

• Monthly Inspections These inspections are to be performed monthly by the personnel responsible for maintenance and service of the crane.

• Periodic Inspections This Inspection Is a thorough Inspection conducted at least every three months and Includes all Items listed under dally. weekly. and monthly inspection in addition to those items listed under periodic inspection. A written Inspection list and procedure should be developed by the Maintenance and Service personnel.

• Annual Inspections Federal Laws outlined In the CFA sections 46 and 29 require that an annual inspections be performed by an Authorized Inspector (Al) or Certified Machinery Inspector. Dated and signed records of these annual Inspections must be kept. The annual Inspection consists of NDE/NDT of all critical components of the crane as well as test loading crane to assure operation of all load holding devices. A written inspection plan and procedure shall be developed by the Al prior to the annual inspection. All crane repair and modifications records must be kept with the annual Inspection report and kept for two (2) years.

D c

JDB tio. lf..&.L NUMii:& .tr!At~ Sill UJCATION

t1.2SO 1358 1020 Af"T 8\ • M251 1416 1022 Afl

... .252 1417 !024 Af"T

3

•

1

• D c

~1)Q.t NUIJSE.R DRAW •iC N.., 1 "1 7Rl17 LS-7746 A sm: REV

B 0 REVISIONS

DATE CRANE S/ J ZONE' REV DESCP 0 TIO DATE APPROVA.LS

12-20-95 MCT-1565-94- 020

12-20-95 MCT-1565-94-1022

12-2(} 95 !CT-1565-94-102~

I-A & DESCR I PT I at~ OC>---00-00

r ,

DATl

12-'20-95 oc:xc..,

WAlT OA'lllS :l.A"!J: Cl£aC 12-20-95

~11'1. WAl..T DA'lllS

a..n:..-n 12- W- 95

liiDITllACT ~

B

3

2

1 • 0 rl}l . Il1 Cl i a 11 Alaska Marine Crane

Equipment Co. =-.~-:r,;,;i,

LUBRICATIO A :rn MAll.TE A{TCE SCHEDULE FOR MCT-1565

S1Z£ rscu :JMBER ORA "NG NlSl.'BER ~

B '{Rll 7 LS-7746 0 SCAU:

NON~ LISTED

A

DAILY INSPECTIONS

Check the following items:

1. Hydraullc oll level.

2. Loose parts or damage to structures or weld.

3. Cylinder movement due to leakage. Be sure oil temperature Is stabilized because heating or coollng of oil cause expansion and contraction.

4. Evidence of oil leak from hoses and fittings.

5. Evidence of oil leaks from pump, motor, and gearbox shaft seals.

6. Controls for binding and sticking.

7. All securing hardware such as cotter pins, snap rings, hairpins, and pin keepers for proper installation.

8. All safety covers for proper installation.

9. Cylinder holding valves for proper operation. Operate Boom Up and Telescope Out functions with hydraulic system off. Boom(s) should not move.

10. Condition of load line and end attachment for corrosion. severe kinking. crushing, cutting or slippage of cable clamps or wedge socket.

11. Positron of load line through guides and around sheaves.

12. Free turning of sheaves.

13. operation of LMI system and its components.

14. Operation of the anti-two blocking system and its components.

15. Operation of the electrical control system and all electrical components and enclosures.

16. Housekeeping of the operators cab and platform. Remove any condition that can cause slipping or falling from platform. Check glass for chips, cracking, or marks that poses a hazard to personnel or obstructs operators vision.

1 7. Operation of boom and cab llght(s).

18. Fire extinguisher charge.

WEEKLY INSPECTIONS

Check the following items:

1. Lubrication of points as required by lubrication chart.

2. Proper tightness of turret, winch, and swing drive mounting bolts during first month of operation of new machine and then quarterly thereafter.

3. Winch brake for proper operation at rated winch capacity.

4. Presence and proper operation of load hook safety latch.

5. Proper operation of all safety devices.

6. Check boom angle Indicator for range of travel.

7. Check load Indicating or LMI system for operation.

8. Check all electrical connections to/from crane for wear or damage.

MONTHLY INSPECTIONS

Check lhe following items:

l . All cylinders and valves for signs of leaks.

2. Lubrication of points required by lubrication chart.

3. Load hook for cracks or having more than 15 percent normal throat opening or 10 degree rwlst.

4. All structural members (pedestal, turret,boom, and sheave head attachments and connections) for bends, cracks, deformation, or broken members.

5. All welds for breaks or cracks.

6. All pins and keepers for proper Installation.

7. All control, safety and capacity placards for readability and secure attachment.

8. Inspect hydraulic hoses for twisting, chaffing, abrasion, and/ or deterioration of outer covering. Replace hose If wire braid Is showing. Thoroughly Inspect hose at crimp ends for annular cracking or separation.

9. Evidence of rusting. Abrasive clean effected area and repaint.

10. Electrical system for damage, moisture. and/or corroded wires, connections and components.

11 . Proper operation of electrical safety devices and auxlllary equipment.

12. Structural integrity of the slip-ring. Insure upper seal Is Intact.

13. CTD/EM cable sheave assembly for wear and/or damage. Insure sheave turns freely without draging or rubbing.

14. CTD/EM guide rollers for wear or grooves.

PERIODIC INSPECTION

Check the following Items:

1. All Items listed under daily, weekly, and monthly Inspections.

2. Loose bolts and fasteners in all areas.

3. All pins, bearings. shafts and gears for wear cracks or distortion.

4. Sheaves for excessive wear, damage, and cracks.

5. Hydraulic system for proper operating pressure.

6. Un-spool load line and check according to rope maintenance procedure.

7. Turret mounting bolts for proper torque (see torque chart) .

a. Boom and Telescope cylinders for drift caused by oil leaking around piston.

9. Cylinders for: a. Damaged rods b. Dented barrels c. Drift from oil leaking by piston d. Leaks at rod seals, welds. or holding valves.

10. Hydraulic hose and tubing for evidence of damage such as blistering, crushing, or abrasion.

11 . Check operation of overload system. if equipped.

12. Emergency stops and engine safety devices, If equipped.

13. Telescoping boom(s) wear pads for excessive wear, missing or loose fasteners, and damage.

ANNUAL INSPECTION

Perform the following inspections:

1. All items listed in the daily, weekly, monthly, and periodic inspections.

2. Perform non-destructive testing (NOT) to load hook. Inspect for hook and shank elongation, fatigue cracking, and laminar cracking.

3. Perform non-destructive examination (NOE) to the following critical components:

A Main boom hinge pins, bosses, and bushings. B All cylinder pins and connections. C. All boom sections. D. Sheaves; sheave pins, bosses, and bushings. E. Turret ears, bosses, and turret lo bearing mounting bolts. F. Winch mounting plate and bolts. Winch drum and wedge. G. Winch brake.

H. Rotational bearing. I. Pedestal to bearing interface:

1. Pedestal to bearing flange, bolts, and gussets, if equipped. 2. Pedestal to bearing weld, if equipped.

J. Pedestal to foundation interface K. Swing drive pinons, gearboxes, and brakes.

Any deficiency found may require further NOT as determined by the Al or the attending surveyor.

Any repair or modification to a critical component will require, a new load test of the complete crane.

The above list of Items required for annual Inspection is adopted from USCG, ABS, and API requirements. The regulatory body that has jurisdictional control for the region this crane is operated In may have additional Inspection requirements.

MAINTENANCE PROCEDURES

Before adjustments and repairs are started on a crane, the following precautions shall be taken as applicable:

1. Crane placed where it will cause the least Interference with other equipment or operations in the area.

2. All controls at the off position and all operating features secured from inadvertent motion by brakes or other means.

3. Starting means rendered inoperative.

4. Power plant stopped or disconnected at source.

5. Boom lowered Into boom rest, if possible, or otherwise secured against dropping.

6. Lower load block lowered to ground or otherwise secured against dropping. Always remove load from load line when servicing winch.

7. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic components.

8. The cylinder load hold valves in the back of the Boom and Extend cylinder(s) are connected directly into the bore side of the cylinder and must not be removed unless all hydraulic pressure is released from both bore and rod side of cylinder. To remove all pressure, insure that main boom is supported by boom rest and extend cylinder is .!YJ!y retracted. NEVER REMOVE CARTRIDGES WITH BOOM(S) ELEVATED OR EXTENDED.

9. The swing brake is a hydraulic release - spring set device and is mounted on the input side of the swing drive gearbox. As such, removal of the swing brake for servicing will allow crane to inadvertently slew if crane is not secured. NEVER REMOVE BRAKE WITHOUT PLACING BOOM(S) IN BOOM REST OR TYING CRANE DOWN.

After adjustments and repairs have been made, the crane shall not be returned to service until all guards have been reinstalled, trapped air removed from hydraulic system if required, safety devices reactivated, and maintenance equipment removed.

ADJUSTMENTS AND REPAIRS

Any hazardous conditions disclosed by the inspection requirements listed above shall be corrected before operation of the crane ls resumed. Adjustments and repairs shall be done only by designated personnel.

Adjustments shall be maintained to assure correct functioning of components, The following are examples:

• Functional operating mechanisms

• Safety devices

• Controls systems

• Power plants

• Braking systems

Repairs or replacements shall be provided as needed for operation.

To ensure that parts meet original specifications and avoid premature failure which could result in death or serious injury, use only OEM parts in repair of crane.

Refer to the repair section of the manual tor information relating to removal and replacement of assemblies, and individual repair manuals for component repair.

CARE OF WIRE ROPE

Care is required in the handling of wire rope to prevent damage to the rope or the individual wires which will affect the overall strength and performance of the rope. The formation of kinks must always be prevented as this displaces the strands of wire form their original position and relation to each other causing severe bending and unequal tension In the strands. This distortion and wire displacement cannot be corrected even under high tension and a permanent weak point remains in the rope. Displaced or raised wires indicate a previous kink, but will not show the damaged condition of the inner rope wires.

Wire rope must never be pulled over a non-rotating support such as a spindle bar, a pin or an inoperative sheave. This practice causes severe abrasion to the outer strand wires. A properly operating sheave or snatch block is essential to safety and long service life of the rope.

The use of worn sheaves or sheaves with flat grooves shall be avoided since they do not provide sufficient support to prevent the distortion and flattening of the rope as it passes over the sheave. Sheaves having nicked or broken flanges are likely to cut or otherwise damage the rope and must not be used.

An even distribution of wire rope coils over the hoist drum is essential to smooth operation and to prevent rope from either cutting down through or crushing other coils on the drum with resultant damage to the rope and difficulty in unreeling rope.

ROPE CONSTRUCTION

The following table lists the nominal breaking strength requirements by rope size.

CONSTRUCTION

6 x 25 IWRC

6 x 37 IWRC

18 x 7 IWRC

8 x 19 IWRC

DIAMETER NOMINAL BREAKING STRENGTH

5/8" 45,400 Lbs.

5/8" 41,200 Lbs.

5/8" 42,000 Lbs

5/8" 36,200 Lbs

CLASSIFICATION

DYPAC 6HS

EIPS - BRIGHT

DYPAC 18HS

NON-ROTATIONAL

If wire rope replacement is required for crane load line, care should be taken in selecting a wire rope suitable for crane use. Wire rope strength are used determine the rated crane capacity and should be matched to the winch line pull and application. Standard rope construction required is 6 x 37 for multi­part reeving and 8 x 19 for non-rotating. High strength abrasion resistant ropes are preferred, such as DYPAC 6HS, and are supplied as standard. If a rotation resistant - high strength rope is required, DYPAC 18HS is recommended. Any wire rope replacement must use a 5:1 safety factor to determine crane capacity. Non-rotating wire rope is recommended for use with odd numbered - multiple part reeving with locked swivel on dead end, and for single part requirements. However, under no conditions are rotation resistant ropes to be used with a swivel end connection on a single part line and allowing load to spin.

Handling and Care of Wire Rope

Installation

To properly install a rope on a machine winding drum or winch, the reel containing the rope should first be set up on a shall supported on two jacks or other suilable stands A sim­ple braking device such as a plank or strip or sheet metal should be rigged to bear down on one or both al the reel flanges so that ample tension can be maintained throughout the winding of the rope.

The position of the anchorage point of the rope to the drum should be

located in relation to the direction of lay of the rope. A right hand laid rope under tension tends to unlay or rotate 1n a counter·clockwise direction. with the observer standing behind the winch drum. This forces a right hand laid rope, overwindlng on the drum, toward the left hand flange. For this reason it is good practice to start win­ding a right hand laid rope from the lefl hand I lange of the wincl1 drum, the rope over winding and the observer standing behind the drum.

The opposite 1s true for a tell hand laid rope; that is, the anchorage

' + L- -R I

r==i

s rf 'l --INN+~ ~G __ ~j I

t="1

should be at the right hand flange of the winch drum, with the observer standing behind the drum. This prac· lice results in the turns winding tightly together

In the lnitial windmg 11 is important that all turns or the first layer on the drum be Light and true. parllcularly those turns which will not be otl the drum with the rope fully payed out under load Open or wavy windlng will result in serious damage to multiple layer wound rope. Adjacent turns should be tapped against each other with a sort metal or wooden hammer .

I

r:· I I Ltrf 1 ttAf'IO

- :i I _l J _../ : b.J~llJ Overwind

Right to Left Use Left Lay Rope

l\ :l: I : I I I I

~ -----· -l

·~ ~21¥: I~ _y I

I J' Underwind ~ ----- J Left to Right • \ / 1 R

Use Left Lay Rope LCrr L'-• -uNocnwovNo

L I t f I

L£"1 LAY- OVCRWDUNO

use the right fist ror R1gl11 Lay Rcpe, tef1 fist ra< Left Lay Rcpe. For overwound rcpe keep ya.ir fist baek up For unde!WOUnd rcpe. palm up Index finger ponted to the drum will 1nd1cate hcMi the rcpe sh:luld lead from the drum and from which flange

•

• Handling and Care

( ,f Wire Rope

Overwinding and Crosswindlng •

WI ,;:t:; the ideal w1nd1ng cond111on wOJld be a single layer of rope on the d!um. this is not always possible Where 11 cannot be avoided the sue· coed1ng laye1 s should not cross-wind but should wind regularly 1n Iha groove rormed between successive turns of the preceding layer of rope.

Initial Operation After 1nstalhng a nf!V'I rope 11 1s ad· visable to run through its normal operating cycle for a number of trips under light load and at reduced speed ThtS permits the new rope to ad1usl 1tsell gradually to wor1<ing conditions and enables the strands to become seated and some stretch to occur. the rr,pe then being less liable lo damage t en the full load is applied.

Shock Loading NeVer hft or stop a load with a jerk; the load so imposed may equal several times the static working load and such practice may break a rope. Jerks which do not break lhe rope cause rapid detertorat1on resulting in reduced rope llf e.

Rope Speed Experience indicates that rope wear in· creases with speed Rope economy resullS from moderately increasing the

. load and reducing rope speed Some author1t.es suggest that when ropes are 1unning light, rope speed should not ex· ceed 60 fUsec. whether hoishng or ~ring

In-Service Lubrication Wlle1her stationary 01 1n motion, steel wire ropes must be protected from corrosion, and when in motion must be lubricated to minimize wear between the metal·to-rnetal (wire-to-wire) sur· rounding surf aces During manufacture a lubricant which will satisfy both these requirements at least for a time is 00111 into the strands of wire and into the COfe. ExpostJre to the elements. normal rope operation CJ11er sheaves and on and off drums will gradually deplete and contaminate the lubricant.

A rew ropes, fOI' instance scraper ropes and small excavator drag ropes, which are continually working through dirt and grit may not show improved results through relubrication in service. Most ropes ho.vever should be lubricated at Intervals depending on the type or service to minimize corro­sion and wear and extend rope hfe

'A used rope shOUld be cleaned with ~re brushes. scrapers. compressed air, or superheated steam In some in· stances ii may be necessary to soften lhe Old lubricant and accumulahon or

dirt with a penetrating orl or a gooo grade of kerosene

A lubricant suited to the cood1t1ons under which the rope as operating shOuld then be apphed Several methods are suggested. and the one most suited to l11e 1nstallat1on and lubricant being used may be chosen tt is better to lub11ca1e hghlly and Ire· quenlly than heavily and infrequently.

A suitable rope lubricant should have the following properties·

1) Freedom from acids and alkalies 2) Sullicient adhesive strength to stay

on the rope without lhr()N-Off at maximum rope speed.

3) Ability to penetrate between strands and reach the core.

4) Non·solubiltty under conditions ot rope use.

5) Resistance to oxidation. 6) High him strength an adval'llage

When a wire rope is taken out or ser· vice IOI storage against pos.sible future use 11 should ftrst be cleaned. then lubricated. The rope should then be covered and stored in a dry locahor1 and protected against mechanical damage.

Handling and Care 'f Wire Rope

Lubricating Methods

Below are illustrated some simple methods of lubricating ropes externally while in use There arc or course otller

lubricators and cleaning devices available commercially, and still others which can readily be f abncated in a

Drip and Swab Application

Sphl wcxxien or metal bOxes

plant or local woo.-shop. For details or these contact your Wire Rope In· dustr1cs Ltd sales representative or our engineering Depanment

nope passes tllrough t.>urlap or similar wiper at oulfel ml<J of L>ox

•

••

•

•• •• •

)

Engineering 1formation

Multiple Part Lines

When a load Is suspended on a single part of rope the whole load is sup­ported by one rope When the load 1s suspended vertically on two ropes then each part of rope supports half the load, similarly ror three parts, etc. Ir however the rope is continuous over sheaves or pulleys so that the load ls not only supported but is also raised then 11 is necessary lo Lake into ac· count forces required Lo overcome fnctton in the sheave bearings and the resistance to bendmg of the rope as n passes over the sheaves. The factor for these forces is called the ··emc1P.n· cy lactor" and differs for sheaves with

plain bearings and sheaves with roller bearings.

The maximum Load which will be im­posed on the "fast" or "lead" line, that is the rope passing from the last sheave directly lo the drum, can be determined by the following formula:

w P=-­NxE

Where P = Maximum load on "lead" line in lbs.

W = load being hoisted in tbs. N = number of parts of line E = efficiency factor

One-Part Line (single block)

Two-part Line (2 singles)

Three-part Line (double & single)

P= P=

'

~,

w 2xE

Suggested Efficiency Factors

P= w 3xE

LOAD ON "LEAD" LINE

The following efficiency factors are based upon the number of sheaves being equal to the number or parts of line. When there are additional idler or deflection sheaves on the "lead" line. reduce the efficiency factors as follows:

For plain bearing sheaves, 8 % lor each additional sheave

For roller bearing sheaves, 4 % for each additional sheave.

Four-par! Line (2 doubles)

P= w

4xE

Five-part Line (treble & double)

P=

t I

E (Efficiency Factor) Parts of Line Plain Bearing Roller Bearing

Sheaves Sheaves

1 .926 .962

2 880 943 3 844 .925 4 810 .908

5 776 .890 6 748 .874 7 719 .857

8 692 .842

9 666 .826 10 642 .811 11 619 796 12 597 782

CABLE INSTALLATION

Unwind the cable by rolling it out along the ground to prevent kinking. Securely wrap the cable end. opposite hook, with tape to prevent fraying.

2. Insert the cable end, opposite hook end, into the hole In the drum. Secure the cable to the drum using cable wedge furnished with the winch. See winch manual for further Inf ormatlon.

3. Carefully run the winch In the "reel-In" direction, keeping tension on the end of the cable, spooling all the cable onto the cable drum. Take care to form neatly wrapped layers.

4. A wire rope must be "broken In" if It is to perform properly. Operate winch with 1 /4 load and 1 /2 speed for 30 cycles. Every 1 o cycles, remove wire rope from drum and re-spool. This will remove most of the torsional loading within the wire rope and will allow it to wear In.

5. Use a swivel end during breaking period and then either remove or lock for multi-part reeving.

LUBRICATION

Following the designated lubrication procedures are Important in ensuring maximum crane lifetime and utilization. The procedures and lubrication charts in this section include information on the types of lubricants used, the location of the lubrication points, the frequency of lubrication, and other information.

The service intervals specified are for normal operation where moderate temperature, humidity and atmospheric conditions prevail. In areas of extreme conditions, the service periods and lubrication specifications shall be altered to meet existing conditions. For Information on extreme condition lubrication, contact your local lubricant representative or the North American Crane Service Department.

See Lubrication Schedule drawing (LS-7745) for lubrication and inspection points specific to your crane.

LUBRICANTS

Specific brand recommendations of lubricants are not made here due to regional avallabillty. Where specific grades of lubricants are recommended, consider these as minimum requirements and select your lubricants based on operating conditions, availability, and your current usage. Where questions arise, refer to the component manufacturer's manual and reliable supplier.

Extreme Pressure General Purpose Grease (EP-2).

EP-2 lubricating grease of proper consistency is to be applied periodically at relatively frequent intervals with grease guns through grease fittings. Minimum apparent viscosity of 300 SUS (Saybolt Universal Seconds) at 100°F (38°C) is recommended. We recommend that all EP-2 greases used be fortified with molybdenum disulfide (MoS2) and be Lithium base. Never use Aluminum base greases for items that will come in direct contact with salt water (sea water.)

Extreme Pressure Multipurpose Gear Lubricant (EPGL).

This gear lubricant is compounded to achieve high load carrying capacity and meet the requirements of either APl-GL-5 or MIL-L-2105C. Unless otherwise specified, SAE 90W viscosity is recommended for year round service in swing drive planetary gearboxes and multi-drive PTO drives. Low temperature usage is restricted as follows:

SAE VISCOSITY AMBIENT TEMPERATURE NUMBER RANGE - °F (°C)

75W -40 to +50 (-40 to +10)

sow -15 to +80 (-26 to +27)

90W o to 100 (-7 to 38)

140W 40 to 120 (5 to 49)

250W 70 to 130 (10 to 54}

Open Gear Lubricant.

This is a special adhesive lubricant of heavy consistency for protection of wire rope and exposed swing drive gears where provision is not made for continuous lubricant replenishment. Select the viscosity that gives best protection and lubrication without peeling, scaling, or excessive throw off.

Winch lubricant

This is a standard enclosed gear lubricant without large quantities of extreme pressure and anti-friction additives that will effect the operation of the winch clutching and braking components. Use only lubricants that conform to API GL-2/GL-3 specifications or as amended below:

NAME AMBIENT TEMPERATURE RANGE - °F (°C)

MOBIL SCH630 (synthetic) -40 to -10 (-40 to -23)

TEXACO MEROPA 150 -10 to 100 (-23 to +38)

TEXACO MEROPA 220 50 to 130 (10 to 54)

NOTE: Use MEROPA 220 (or equal) for offshore cranes and high duty cycle shipboard cranes operating above so°F (27°C).

Hvdraullc Oil.

Oil in a hydraulic system serves as the power transmission medium, system lubricant. and coolant. Selection of the proper oil is essential to ensure satisfactory system performance and life. The following types of oil are suitable under most operating conditions:

1. Good quality antiwear hydraulic oils.

The most important factors in selecting an oil for hydraulic service are:

1. Viscosity

2. Antiwear additives

Viscosity. The oil must have proper viscosity to provide a lubricating film at system operating temperature.

Oil viscosity is important because it has a direct bearing on efficient transmission of power. An oil must flow readily through the system with a minimum of pressure and flow loss. Positive lubrication depends on viscosity. The oil must be sufficiently light to get between the components machined surfaces and maintain a lubricating film at system operating temperatures. Oil too light may cause the following conditions in the system.

1. Excessive leakage.

2. Lower volumetric efficiency of the pump.

3. Increased component wear.

4. Loss of system pressure.

5. Lack of positive hydraulic control.

6. Lower overall efficiency.

Oil too heavy may cause the following conditions In the systems:

1. System pressure drop.

2. Increases system temperature.

3. Sluggish system operation.

4. Low mechanical eHiciency.

5. Higher power consumption.

The followlng oil viscosity characteristics are recommended:

• 100 to 180 SUS optimum at system operating temperature.

• 60 SUS minimum at maximum system operating temperature.

• 7500 to 10,000 SUS maximum at starting temperature.

When an hydraulic all Is selected, the following grades wlll usually meet the above viscosity requirements, depending on ambient operating temperature.

GRADE/CALLOUT SYSTEM OPERATING TEMPERATURE RANGE ° F (°C)

AW22 -20 TO 80 (-29 TO 27)

AW32 -10 TO 110 (-23 TO 43)

AW46 10 TO 130 (-12 TO 54)

AW68 20 TO 150 (-7 TO 66)

AW100 40 TO 150 (4 TO 66)

AW150 50 TO 180 (10 TO 82)

AW220 80 TO 180 (27 TO 82)

Arctic Condition Below -20°F (-29°C).

In general. petroleum based fluids developed especially for low temperature service may be used with satisfactory results. However, certain fluids, such as halogenated hydrocarbons. nitro hydrocarbons, and phosphate ester hydraulic fluids, might not be compatible with hydraulic system seaJs and wear bands. Fluid must be compatible with Buna-N, Nltrile, and Vlton seal material. AJways check with your petroleum products distributor or the North American Crane Service Department

Regardless of temperature and oil viscosity, always use suitable start-up procedures to ensure adequate lubrication during system warmup.

Antlwear Additives. Excessive wear In the system may cause a loss In volumetric efficiency, and may cause shutdowns for maintenance. An efficient antlwear oil protects the components against rusting, resists oxidation, and helps prevent wear. However. anti-wear additives are not an substitute for maintaining a "clean" hydraulic system.

LUBRICATIONS POINTS

A regular lubrication schedule must be established for all lubrication points. Normally, this is based on component time and usage. For high duty cycle operation and offshore cranes, the frequency of the lubrication schedule will need to be increased. Conversely, lightly loaded and Intermittent duty cycle cranes will require less frequent lubrication. The most efficient method of keeping track of lube requirements Is to maintain a job log Indicating crane usage and duty cycle.

All oil levels are to be checked with the crane parked on a level surface in transport position, and while the oil is cold unless otherwise specified.

LUBRICATION .AND MAINTENANCE SCHEDULE

REFERENCE NUMBER OF ITEM MAINTENANCE RECOMMENDED COMMENTS NUMBER LOCATIONS DESCRIPTION INTERVAL LUBRICANT

1 9 HINGE PIN EVERY 40 EP-2 GREASE MORE FREQUENT MAINTENANCE BUSHINGS HRS. W/ MoSOz INTERVALS WILL BE REQUIRED IN

ABRASIVE ENVIRONMENTS.

2 4 ROTATION EVERY 40 EP-2 GREASE ADJUST MAINTENANCE INTERVAL TO BEARING HRS. W/ MoSOz OPERATING ENVIRONMENT.CHECK

WEAR ANNUALLY

3 2 SWING DRIVE EVERY 80 TEXACO CRATER HIGH PRESSURE CLEAN AND RE-LUBE GEARS HRS . 2X OR EQUAL EVERY 6 MONTHS WITH CODE 948

GREASE.

4 2 SWING MOTOR CHECK LEVEL GEAR LUBE TO REPLACE GEAR OIL IF GEAR BOXES EVERY MONTH API GL-5 CONTAMINATED. REMOVAL OF GEAR

SPECS. BOX REQUIRED TO CHANGE OIL. TYPE SAE 90 llt

5 1 WINCH GEAR CHECK LEVEL GEAR LUBE TO REPLACE GEAR OIL ONCE A YEAR. . BOX EVERY MONTH API GL-5 -SPECS . TlPE SAE 90 wt

6 60 TURRET BOLTS EVERY 6 ------------- CHECK BOLTS FOR PROPER TORQUE. PED. BOLTS MONTHS ---

7 1 WIRE ROPE ONCE A YEAR ULTRA DUTY CHECK ROPE FOR BROKEN AND EP-0 DAMAGED WIRES. REPLACE AS

REQUIRED WITH 9/16 11 DYFORM 6

8 16 WEAR PADS ANNUALLY --------- CHECK FOR EXCESSIVE PAD ----- CLEARANCE. (1/4" TOTAL

CLEARANCE) . REPLACE AS REQUIRED

9 2 SHEAVE PINS EVERY 40 EP-2 LITHIUMN CHECK FOR EXCESSIVE WEAR EVERY HRS. BASE GREASE. 6 MONTHS.

10 3 SHEAVES ANNUALLY -------- CHECK FOR DAMAGE AND/OR WEAR. REPLACE AS NEEDED

REFERENCE NUMBER OF ITEM MAINTENANCE RECOMMENDED COMMENTS NUMBER LOCATIONS DESCRIPTION INTERVAL LUBRICANT

11 1 LOAD BLOCK ANNUALLY ------------- CHECK FOR DAMAGE AND WEAR. --- NOT OF HOOK FOR STRESS CRACKS.

12 VARIOUS HYDRAULIC EVERY 6 ------------- CHECK HOSES FOR WEAR AND/OR HOSES MONTHS --- DAMAGE. REPLACE AS REQUIRED.

13 1 CONTROL ANNUALLY ------------- CHECK FOR WEAR AND/OR VALVES --- CORROSION, CHECK CONTROL

LINKAGE FOR BINDING, LUBRICATE AS REQUIRED.

14 VARIOUS FASTENERS ANNUALLY ------------- CHECK ALL BOLTS AND SCREWS FOR DAMAGE, CORROSION, AND/OR

PROPER TORQUE. REPLACE AND TORQUE AS REQUIRED.

15 1 WIRING ANNUALLY ---·--- CHECK WIRING FOR CORROSION AND/OR DAMAGE.

16 1 SUCTION ANNUALLY ------------- REMOVE AND CLEAN STRAINER WITH STRAINER CLEAN DIESEL FUEL OR KEROSENE.

17 1 FLUID LEVEL DAILY ------------- CHECK LEVEL DAILY WITH ALL CYLINDERS RETRACTED . DETERMINE

WHERE LEAKAGE IS IF OIL LEVEL IS LOW. FILL WITH CLEAN OIL ONLY . REPLACE OIL EVERY TWO

. YEARS WITH NEW AW- 32 FLUID .

18 1 MOTOR ANNUALLY EP-2 APPLY 2 PUMPS OF GREASE TO EACH BEARING. CHECK INSULATION FOR

DAMAGE.

19 1 FILLER/ EVERY 6 ------ INSURE THAT BREATHER IS NOT BREATHER MONTHS PLUGGED. CHECK DAILY WHEN

OPERATING CRANE IN TEMP . BELOW 32 °F

20 l FILTER EVERY 6 ------ REPLACE ELEMENTS EVERY 6 MONTHS MONTHS.

REFERENCE NUMBER OF ITEM MAINTENANCE RECOMMENDED COMMENTS NUMBER LOCATIONS DESCRIPTION INTERVAL LUBRICANT

21 1 PUMP/MOTOR EVERY 6 ----- INSURE JAWS HAVE NOT MOVED AND COUPLING MONTHS INSERT IS INTACT.

22 1 PUMP EVERY 6 ----- CHECK HOSE CONNECTIONS TO/FROM MONTHS PUMPS.

23 1 WINDSHIELD WEEKLY ----- INSURE OPERATION. CHECK BLADES WIPER FOR WEAR OR STREAKING.

24 1 LOAD MOMENT MONTHLY EP-2 LITHIUMN INSURE SYSTEM IS OPERATING INDICATOR BASE GREASE PROPERLY. CHECK LINE RIDER

FOR BINDING AND CORROSION .

25 2 BOOM ANGLE DAILY DRY FILM INSURE INDICATOR IS OPERATING INDICATORS LUBRICANT PROPERLY

26 1 HYDRAULIC ANNUALLY AW32 CHECK FOR CONTAMINATION. FILTER FLUID OR REPLACE AS REQUIRED.

27 1 SLIP-RING MONTHLY NON- INSURE BRUSH HOLDERS AND CONDUCTIVE BRUSHES ARE TRACKING CORRECTLY.

DRY FILM CHECK BRUSHES FOR OXIDATION AND LUBRICANT CLEAN AS REQUIRED .

28 1 ANTI-TWO DAILY ------ CHECK FUNCTIONING OF ANTI-TWO BLOCK BLOCK SYSTEM. CHECK CABLE EVERY

6 MONTHS FOR DAMAGE .

-- VARIOUS STRUCTURE ANNUALLY ------------ CHECK FOR DAMAGE, ABNORMAL WEAR, BROKEN PARTS, CHIPPED PAINT, AND CORROSION. REPAIR

AND/OR REPLACE AS REQUIRED.

SERVICE AND CRANE REPAIR

REPAIR INFORMATION

This section is divided into separate sub-sections that deal with the removal, repair. and Installation of major sub·component assemblies associated with this crane. Refer to each sub·sectlon for each component or related sub-assembly.

Sub-section #

.1

.2

.3

.4

.5

.6

.7

.8

.9

.10

.11

.12

.13

.14

.15

.16

.17

.18

.19

.20

.21

Title

Boom cylinder removal and repair

Telescope cylinder removal and repair

Boom/telescope counterbalance valve removal and replacement

Swing motor removal and repair

Swing motor brake removal and repair

Swing motor gear box removal and repair

Swing motor cushion valve service

Control valve repair

Retek bearing

Winch removal

Pinion gear removal and replacement

Sheave removal and replacement

Telescope boom wear pad replacement

Pump removal and repair

Pump insert replacement

Pump drive motor service and repair

Slip-ring repair

Anti-two block system repair

Unloader Valve

Return filter element replacement

Suction strainer replacement

REPAIR INFORMATION

Sub-sect ion #

.22

.23

Title

CTD /EM sheave removal and repair

CTD / EM guide roller removal and repair

.1 BOOM CYLINDER REMOVAL AND REPAIR

REMOVAL

STEP 1: Position boom cradle or simjlar support object such that boom cylinders are extended 2-3 inches with boom resting in cradle.

WARNING: Do not place cradle under boom cylinder(s).

STEP 2: With boom safely blocked in this position, shut off hydraulic system to crane, and jiggle valve handle to remove any load on cylinder pins.

STEP 3: Slowly loosed hose fittings at cylinder to be repaired to release any residual pressure.

STEP 4 : Loosen locknut on counterbalance valve at butt end of cyllnder and turn adjusting screw clockwise until adjusting screw bottoms: Do not force screw in. Tighten locknut and wire down number of turns required to bottom adjusting screw.

STEP 5: Remove and cap hoses with steel JIC plug. It is advisable to tag hoses and ports for relnstallation.

STEP 6: Rig cylinder that Is to be removed with another crane or some other liftlng device.

WARNING: Do not use chain or cable on cylinder rod without proper rod protection.

STEP 7: Remove pin from rod end. Use soft mallet or similar Item to drive pin out If necessary. lower rigging so cylinder is approximately horizontal and clear of rod end pin bosses.

STEP 8: Remove pin from butt end of cylinder and lower cylinder to deck.

CYLINDER REPAIR

DISASSEMBLY

STEP 1: Secure cylinder In suitable fixtures.

STEP 2: Remove head retainer nut with suitable spanner wrench.

STEP 3: Slide rod, piston. and rod gland from cylinder bore;

CAUTION: Use care to prevent damage to rod sealing surface.

STEP 4: Secure rod assembly ls suitable fixture without scoring or marring rod surface. Remove piston retaining nut retainer and piston nut. Use spanner wrench to remove piston from rod. Remove rod gland retainer capscrews.

STEP 5: Slide rod gland and cylinder head from rod.

STEP 6: Clean and inspect cylinder bore and rod for obvious signs of damage or excessive wear. Repair or replace parts as required.

Boom Cylinder repair cont.

STEP 7: Clean and inspect cylinder piston and rod gland for obvious signs of damage or excessive war. Replace parts as required.

STEP 8: Remove all packing and seals from assemblies and thoroughly clean parts to remove all rust and foreign material. Clean and dry parts with lint free material. If assembly is not to be reassembled immediately, coat all Internal parts and wear surface with lithium base grease. Store In clean dry area.

RE-ASSEMBLY

STEP 1: Install new packing, seals, and bearing materlal In rod gland. Lubricate rod with assembly lubricant or clean hydraulic oil. Carefully slide rod gland retainer over rod. Slowly Install cylinder head on rod. do not force or damage to rod seals can occur.

STEP 2: Install new piston o-ring and thread piston to rod until piston is tight at rod shoulder. Use mallet to strike spanner wrench to tighten piston. Install piston lock nut and torque to 600 ft. lbs.

STEP 3: Install new piston seals and wear bands. Lubricate piston seals with clean hydraulic oil or assemble lube. Carefully install piston and rod assembly Into cylinder barrel, keeping it concentric with barrel untll piston bottoms In barrel; Tighten rod gland retainer nut until retainer contacts cylinder barrel. Tighten cylinder head retainer with spanner wrench.

STEP 4 : Remove cylinder from fixture and stand cylinder on bun end. With suitable device, fill rod end with clean hydraulic oil and plug ports.

Cylinder is ready for Installation.

CYLINDER INSTALLATION

STEP 1: Check cylinder pins bores and crane pin bosses for excessive wear or damage. Repair or replace bushings and/or pins as required.

STEP 2: With suitable rigging, hoist butt end of cylinder Into place and install pin and retainer.

STEP 3: Connect hydraulic hoses to correct ports; as tagged previously.

STEP 4: Use hydraulic system to align rod end pin bores to bosses. Insert pin and retainer

STEP 5: Loosen lock nut on counterbalance valve, and tum adjusting screw counter clockwise same number of turns as previously recorded. Tighten lock nut.

STEP 6: Lubricate pins with recommended grease.

Crane Is now fully operational.

.2 TELESCOPE CYLINDER REMOVAL AND REPAIR

CYLINDER REMOVAL

STEP 1: Position boom cradle or similar support object such that the main boom Is supported and the telescope boom(s) free while crane Is resting on cradle. Extend telescope cylinder until rod end pin is visible.

WARNING: Do not use main boom cylinder to rest or position telescope boom on cradle.

STEP 2: With crane safely blocked In this position, shut off electrical system to power unit and jiggle valve handles to relieve any hydraulic pressure.

STEP 3: Slowly loosen hose fittings at cylinder to vent any residua! pressure.

STEP 4 : Loosen lock nut on counterbalance valve at butt end of cylinder to be removed; turn adjusting screw clockwise until screw bottom: Do not force screw In. Tighten locknut and record number of turns required to bottom screw.

STEP 5: Remove and cap hoses with steel JIC plugs. It Is advisable to tag hoses and ports for relnstallat ion.

STEP 6: Remove spilt boss caps from anchor end of telescope cylinder. Place wood blocks under butt plate of cylinder for support.

STEP 7: Remove all main boom wear pads. Rig telescope booms for pulling and slide telescope booms out of main boom section until 2' is left in main boom. Adjust rigging for level lift and finish removing telescope boom(s). Place boom(s) on suitable support structure.

STEP 8: Remove pin from rod end. Use sort mallet or sJmilar device to drive pin out if necessary.

STEP 9: Remove trunnion split blocks from 2ND stage section and sllde cylinder from booms.

CYLINDER REPAIR:

DISASSEMBLY

STEP 1: Place cylinder In suitable holding device that supports the cylinder In three places, center and both ends, and leaves rods unsupported.

STEP 2: Remove rod gland retaining bolts from lower cylinder assembly and slide retainer away from cylinder head.

STEP 3: Rig rod with nylon sling or some other non·metalllc device.

STEP 4: Slide rod assembly from cylinder bore.

STEP 5: Repeat steps 1 through 4 for upper rod assembly

CAUTION: Use care to prevent damage to rod sealing surfaces

STEP 6: Clean and Inspect cylinder rods and bores for obvious signs of excessive wear and/ or damage. Repair or replace parts as required.

Telescope Cylinder Repair cont.

STEP 7: Secure rod assembly in suitable without scoring or marring rod surface. Remove piston retaining nut, and piston from rod. Slide rod packing head and rod gland retainer from rod.

STEP 8: Clean and Inspect piston and rod gland for obvious signs of damage and/or excessive wear. Replace parts as required.

STEP 9: Remove all packing and seals from assemblies and thoroughly clean parts to remove all rust and foreign material. Clean and dry parts with lint free cloth. If cylinder is not to be re­assembled immediately, coat all internal parts and surfaces with lithium based grease and store in dry area.

RE-ASSEMBLY

STEP 1: Install rod gland retainer plate on rod. Install new packing, seals and bearing material in rod gland head. Lubricate rod with assembly lube or clean hydraulic. Carefully slide assembly onto rod, with bolt holes facing rod eye.

DO NOT FORCE OR DAMAGE TO SEALS CAN OCCUR

STEP 2: Install new piston o-ring and thread piston onto rod until piston is tight at rod shoulder. Install piston locknut and torque to 600 Ft-Lbs.

STEP 3: Install new piston seals and wear bands. Lubricate piston assembly with clean hydraulic oil. Carefully install piston and rod assembly into cylinder barrel, keeping it concentric with the bore until piston bottoms In cylinder. Torque rod gland retainer bolts to 45-60 Ft-Lbs.

STEP 4: Repeat above steps for upper cylinder assembly.

STEP 5: Remove and replace cylinder rod bushing before installing cylinder.

CYLINDER INSTALLATION

STEP 1: Check pin bores and pin bosses for excessive wear or damage. Repair or replace bushings as required.

STEP 2: With suitable rigging, slide cylinder into place and install trunnion split boss caps. Torque capscrews to 375 Ft-Lb (dry)

STEP 3: Connect hydraulic hoses to correct ports as tagged previously.

STEP 4: Use hydraulic system to align rod pin bushing to 3RD stage bosses; install pin and retainer.

STEP 6: Rig boom(s) for level lift. Install new wear pads on 2nd and 3rd stages It required. Carefully slide telescope sections into main boom. Align anchor pin bushing to main boom split boss and install split boss caps. Torque capscrews to 375 Ft-Lb (dry).

Telescope Cylinder Repair Cont.

STEP 7: Install new main boom wear pads.

STEP 8: Loosen lock nut on counterbalance valve and turn adjusting screw counter clockwise same number of turns as previously recorded. Tighten lock nut.

STEP 9: Lubricate pins with recommended grease.

STEP 10: Test crane for proper operation and functioning of load hold valve.

Crane Is now fully operatlonal .

.3 BOOM/TELESCOPE COUNTERBALANCE VALVE REMOVAL AND REPLACEMENT

REMOVAL

STEP 1: Secure boom assemblies in suitable support fixture.

WARNING: DO NOT PLACE SUPPORTS UNDER BOOM CYLINDER ROD.

STEP 2: Secure power supply to power unit in off position.

STEP 3: Place drip tray under valve(s) to be removed. Loosen and remove defective counterbalance valve.

REPLACEMENT

STEP 1: Install new counterbalance valve.

STEP 2: Loosen jam nut on adjusting screw and tum adjusting screw CW until It bottoms. NOTE: IF A MAIN BOOM COUNTERBALANCE VALVE WAS REPLACED, BOTH COUNTERBALANCE VALVES WILL HAVE TO BE RE-ADJUSTED.

STEP 3: Start system and operate crane function that valve was removed from. Raise main boom to approximately 30 degrees. If telescoplc cylinder counterbalance valve needs to be adjusted. extend cylinder out half travel and raise main boom to maximum extent.

STEP 4: Hoist maximum rated load per suitable load moment Indicator and adjust counterbalance valve is held by turning adjusting screw CCW. Tighten jam nut.

Crane is now ready to place In service.

.4 SWING MOTOR REMOVAL AND REPAIR

REMOVAL

STEP 1:

STEP 2:

STEP 3:

STEP 4:

STEP 5:

Shut off and secure electrical system to crane.

Remove and tag hydraulic hoses to defective motor.

Loosen and remove mounting bolts between motor and brake.

Lift motor from brake and Install suitable protective cover on brake mounting surface.

Repair motor per Oanfoss Service and Repair Manual.

INSTALLATION

STEP 1:

STEP 2:

STEP 3:

STEP 4:

STEP 5.

Grease motor shaft with high quality EP-2 lubricant.

Remove brake mounting protective cover and install motor.

Torque mounting bolts to 130-140 Ft-Lbs(dry).

Re-connect hoses per tag.

Start hydraulic system and test for leaks.

SPARE PARTS Hydraulic Motor OMPA - SAE Version

Vederlagsf ri reparation

Cost-free repairs

Kostenlose Reparatur

Reparation gratuite

HN.11.FA.93 is new

Vi 90r opm~rksom pA at den vederlagsfrie reparation som er omtalt i oanfoss Almindelige Leveringsbetingel­ser kun udf0res hos Danf oss Nordborg eller hos Danfoss autoriserede service shops (side 7).

We would point out that cost-free repairs as mentioned in Danfoss General Conditions of Sale, are carried out only at Danfoss Nordborg or at service shops autho­rized by Danfoss (page 7).

Wir machen darauf aufmerksam, dass die in den "Allge­meinen Lieferbedingungen" von Danfoss erwahnte kosten­lose Reparatur nur bei Danfoss Nordborg oder bei den von Danfoss autorisierten Kundendienstwerkstatten aus­gefilhrt wird (Seite 7).

Nous faisons observer que la reparation gratuite men­tionnee dans Les Conditions generales de Vente de Danfoss ne devra etre effectuee que dans Les ateliers Danfoss ~ Nordborg ou dans Les ateliers de depannage agrees par Danfoss (page 7).

hploded

lilspending&lllO!llent Tightening torque Anzuga1110111ent Couple de serrage

Itm deNnt

l 0,5 - 0,8

la 0,5 - 1,0

16 J,O - J,5

16s J,O - J,5

l9 1 ,o - 2,0

in-lbs (lbr in)

45 - 70

45 - 90

270 - 315

270 - J15

90 - 180

12

11

I Motor '!"'tl'I mounting flange A-4

) . 10

Item Spare Parts

1 Screw {Motor with mounting flange A-2 and A-4) M6; l = 20 mm

1a Screw (Motor with mounting flange C) MS; 1 = 20 mm

2 Dust seal rin9 Cyl. 01 1/4 in shaft: 42x35,1x3,S mm Cyl. 01 in and splined shaft: 27,Sx3S,1x4

3 SEigot f lan9e (Motor with mounting flange A-4} Cyl. 01 1/4 in shaft Cyl. 01 in and splined shaft

3a SEigot flange (Motor with mounting flange C}

3b SEi9ot flange (Motor with mounting flange A-2)

4 Shaft seal (Motor with mounting flange A-2 and A-4} Cyl. 01 1/4 in shaft: 48x3SxS,5 mm NBR Cyl. 01 in and splined shaft: 48x28,6x6 mm NBR 48x28,6x6 mm FPM

4a Shaft seal (Motor with mounting flange C} 42x28,6x5,5 mm NBR

s o-rin9 (Motor with mounting flange A-2 and A-4) Cyl. 01 1/4 in shaft: 53x2 mm NBR Cyl. 01 in and splined shaft: 47,6x3,5 mm

Sa 0-ring (Motor with mounting flange C) 48x2 mm NBR

6 Bearin9 race Cyl. 01 1/4 in shaft: 52x3Sx3,S mm Cyl. 01 in and splined shaft: 47,5x29,Sx3

NBR: Buna N, Perbunan PPM: Viton

Stock per 1000 motors **

Number per motor

Code No.

681X1989 6 105

681X1962 6 10S

63383198 1 * mm 151-1313 1 *

151-1734 1 10 1S1-1690 1 10

1S1-1827 1 10

1S1-1902 1 10

63383273 1 * 63383209 1 * 63383271 1 30

633B338S 1 *

63381528 1 * NBR 63381191 1 *

63381333 1 *

lSl-1701 2 30 mm 151-1608 1 1S

Item Spare Parts

7 Axial needle bearing Cyl. 01 1/4 in shaft: 52x35x2 mm Cyl. 01 in and splined shaft: 45x28,6x3 mm

8 Parallel kei 01 1/4 in shaft: 5/16x5/16x1 1/4 in, B. S. 01 in shaft: 1/4x1/4x1 1/4 in,

9 Housing + output shaft

10 Cardan shaft OMPA 50; 1 = OMPA 80; 1 = OMPA 100; 1 = OMPA 160; 1 = OMPA 200; 1 = OMPA 250; 1 = OMPA 315: 1 = OMPA 400; l =

11 0-ring 75,9x1 ,8 mm NBR

12 Distributor plate

13 Gear wheel set OMPA 50; w = OMPA 80; w = 0.MPA 100; w = OMPA 160; w = OMPA 200; w = OMPA 250; w = OMPA 315; w = OMPA 400; w =

14 End cover (Side port motor) 7/16-20 UNF thread

14a End cover (End port motor) 7/8-14 and 7/16-20 ONF thread

15 Washer Side port motor End port motor

NBR: Buna N, Perbunan PPM: Viton

B.S . 46

94 mm 98 mm

100,5 mm 108,5 mm 113,5 mm 120 mm 128,5 mm 139,5 mm

6,5 mm 10,4 mm 13,0 mm 20,8 mm 26,0 mm 32,5 mm 40,9 mm 52,0 mm

Stock per 1000 motors **

Number per motor

Code No.

981X3198 1 50 151-1458 1 50

46 151-4109 1 so 151-1467 1 50

Not sold seperately

151-1787 1 10 151-1788 1 10 151-1789 1 10 151-1790 1 10 151-1791 1 10 151-1861 1 10 151-1792 1 10 151-1793 1 10

63381173 3 * 151-1713 1 10

151-1126 1 10 151-1127 1 10 151-1128 1 10 151-1129 1 10 151-1185 1 10 151-1193 1 10 151-1186 1 10 151-1187 1 10

151-1730 1 10

I

151-1836 1 10

684X2481 7 * 684X2481 5 *

Item Spare Parts

16 Screw M8x1 (Side port motor) OMPA 50; 1 = OMPA 80; 1 = OMPA 100; 1 = OMPA 160; 1 = OMPA 200; 1 = OMPA 250; 1 = OMPA 315; 1 = OMPA 400; 1 =

16a Screw M8x1 (End port motor) OMPA 50; 1 = OMPA 80; 1 = OMPA 100; 1 = OMPA 160; 1 = OMPA 200; 1 = OMPA 250; 1 = OMPA 315; 1 = OMPA 400; 1 =

17 Name Elate (Side port motor) Aluminium Brass

17a Name Elate {End port motor) Aluminium

18 Drive screw

19 Drain 12lu9 7716-20 UNF thread (incl. o-ring)

20 Check valve (incl. item 21)

21 0-ring 5x1 ,5 mm NBR

22 Seal Elu9 778-14 UNF ports

22a Seal 121u9 (End port motor)

NBR: Buna N, Perbunan PPM: Viton

Stock per 1000 motors **

Number per motor

Code No.

35 mm 681X1578 7 42 35 mm 681X1578 7 42 40 mm 681X1579 7 42 50 mm 681X1581 7 42 55 mm 681X1898 7 42 60 mm 681X1834 7 42 70 mm 681X1546 7 42 BO mm 681X1583 7 42

40 mm 681X1579 5 30 45 mm 681X1580 5 30 45 mm 681X1580 5 30 55 mm 681X1898 5 30 60 mm 681X1834 5 30 65 mm 681X1582 5 30 75 mm 681X1900 5 30 85 mm 681X1105 5 30

151A0308 1 10 151A0305 1 10

151A0313 1 10

681Z1011 2 100

631X2013 1 5

151-1076 2 30

63381324 4 60

633X1021 2 100

631X2050 2 10

Item Spare Parts

Spare parts bag A

(Motor with mounting flange A-2 and A-4 with cyl. 01 in and splined shaft)

2 Oust seal ring 4 Shaft seal NBR 5 0-ring N8R

11 0-ring NBR (3 pcs.) 15 Washer (7 pcs.)

Additional contents

Washer Spring washer (6 pcs.) X-ring N8R

Spare parts bag B

(Motor with mounting flange A-4 and 01 1/4 in shaft)

2 Dust seal ring 4 Shaft seal NBR 5 0-ring NBR

11 0-ring NBR (3 pcs.) 15 Washer (7 pcs.)

Additional contents

Washer

Spare parts bag C

(Motor with mounting flange C)

2 Dust seal ring 4a Shaft seal N8R Sa 0-ring NBR

11 0-ring NBR (3 pcs.) 15 Washer (7 pcs.)

Additional contents

Washer

NBR: Buna N, Perbunan PPM: Viton

151-1313 63383209 63381191 63381173 684X2481

684X2120 684X9008 63389003

63383198 63383273 63381528 63381173 684X2481

684X2120

151-1313 63383385 63381333 63381173 684X2481

684X2120

Stock per 1000 motors **

Number per motor

Code No.

151-1154

151-1179

151-1177

1

1

1

30

30

30

* Indeholdt i reservedelsposen A, B eller c

Contained in spare parts bag A, B or C Im Ersatzbeutel A, B oder C enthalten

Contenu dans Le sachet de pieces de rechange A, 8 ou C

** Antallet af reservedele som De b0r have pa lager for hver 1000 motorer der er i brug i Deres omrAde.

** The number of spare parts to be hold in stock for each 1000 motors being in service in your district.

** Die Anzahl von Ersatzteilen, die Sie fur je 1000 Motoren, die in Ihrem Gebiet verwendet werden, auf Lager haben sollten.

** Les quantites de piece de rechange que vous devez prevoir en stock pour chaque 1000 moteurs a ctuellement en service dans votre secteur.

Service Shops I Kundendienstwerkstatten / Ateliers de depannage

Asean: Australia: Austria: Belgium: Denmark: Finland: France: FRG: Great Britain: Italy: Netherlands: Norway: Spain: Sweden: U.S.A.:

Danfoss Industries Pte. Ltd., Singapore Russel Armstrong, Melbourne Hainzl Industriesysteme, G.m.b.H., Linz N.V. Danfoss S.A., Bruxelles B. S0ndergaard A/ S, MAl0v OY oanfoss AB, Espoo Danfoss S.A.R.L., Trappes (Paris) Danfoss GmbH, Offenbach/Main Danfoss Limited, Greenford Sardella & C. Oleodinamica s.r.l., Torino ITRO B.V., Schiedam Danfoss Norge, Rud (Oslo) Danfoss S.A., Madrid Transventor Bydraulik AB, Vastra Frolunda Danfoss Inc., Mahwah, New Jersey

SEP 15 ' 95 13 : 40 FR DANFOSS CUSTOMER sue TO 9 12063954322 P.02/02

f 1me: 61 : 2 4 P1'1 B..-r1 EXPLOSION RE?ORt: · SIN~Il­

rent ! teen:, 151- 5 134 0 0 Q-:' Od

~A 125 A-4 ~ Cat : l.: ~ 1"' D~ r :

*'*~SERIES 7***

O~T!OSS -------...,----------··,....-··--··-·-------..,..--,..--------COM?ONENT CCHPONEMT

..,:;::::=..;. ___ __;I:....1.;..:rt=-::..:......:NUM:S~,:...=..:ER~----..:Ci::...T:....v.:....· ......:...P..;;;E::;,·~-=--V:-1..;;...;..:' DESCRIPTION

1~1-107600 2. 0000 EA CHECK VALVE 151- 111200 l . OOOv EA GEAR WHEEL S:T 151-131300 1.0000 EA SPcCIAL SHAFT SEAL. 151-!~7800 1 . 0000 EA INSTRUCTION OMP

_;;;_ ___ _;;;i_s_1_-_l:....4...:...;;;.5..:900~~-----..:1..:-~o:....o~oo EA AXIAL NEEDLE BEARING 151-160900 1. 0000 EA BEARING RAC E 151-171300 1. 0000 EA DISTRIBUTOR PLATE 151- 173000 1. 0000 :A END COVER 151- 178900 L 0000 EA CARDAN SHAFT 151-543900 1 .00 00 c A DRAI N P[LIG

DN P-:-odu c ts St lc : S Ctl : C

0 0 0 0 0 0 0 0 0 0

151-543800.-,-------1--0000--~EA--SP--I-GO---,-FLA--NG--E,,..---------- 0 RE?LACE S 151- 16'YO

? / l"i ,

SG

0

0 0 0 0 0 0 0 0 0 0

1 . 0000 EA HOUS ING A-4 SIDE?ORT 7/S- 14UNF o o 1 . 0000 cA OUTPUT SHAFT 1 ~ ~3 S?LINEO 0 0

151A041100 L 0000 EA NAMEPLATE OMP/OMR o 0

==~=========6:~:::s~1~1:7::300:~::=========::3~=-.~o~~o~-=~o~o::_-:_-=EA.:_;:..,_.:...._~...;;o~-R~-=-..;.~..;;,1:NS:~~~~~-=--=--=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=.-=._:_--:_:o:_-=.-:_-=.-=.~o,.._ 6338119100 1. 0000 EA 0-RING 0 0

~-----6~33~B~33-=-"'·-:a:_soo=:,:_::_-::_-::_-::_-::_-::_-::_-::_-::_-::_-=_~1~=-. .,:-o:......:o~~..;;,o~o;;.-.:EA;;;..:_;;:s~-~rt~l~NG~-------~~~__;;.;;._ ____ ~o=----::o=--633X0017oo 2. 0000 'EA PLASTIC PLUG . o o 681X018100 7 . 0000 EA SCREW O O 6B1X198900 6 _ 0000 EA SCREW O 0

_..,:;_ ____ 6_B4 __ x_2_1_2_ooo _______ l.'"".~oooo E.A LJASHER o o 684X248100:,_ _______ 7:....:....· ~o~o~oo:..=.....:EA:=...;.._W:..::.:;..;A~S~HER;;:=;,,:_ ___________________ ~~o=------=o:--E 10S01 . 0000 EA CAaTON 0 0

SAME AS D993i11o92 E10503 . 0000 EA S? AC!:R 0 0

S A."'tE AS 0993X0514

--------· ·-------- ----

.. ---···-------. , ... , .. _ ........ .... -~--

.5 SWING MOTOR BRAKE REMOVAL AND REPAIR

REMOVAL

• STEP 1: Secure crane In boom rest or tle to deck.

STEP 2: Remove hydraulic drive motor as outline In 7.4.

STEP 3: Disconnect brake llne(s) and plug fittings.

STEP 4: Loosen and remove 4ea. mounting bolts;

service per MICO Service and repair manual.

INSTALLATION

STEP 1: Grease shaft splines on brake.

STEP 2: Install new gasket and bolt brake to gear box.

STEP 3: Connect brake line.

STEP 4: Install motor as described In 7.4.

STEP 5: Loosen brake bleed screw 1 /4 turn. Start hydraulic system and have primary operator slowly operate swing mode. Open bleed screw untll oll trickles from fitting. Purge air and tighten bleed screw. Test unit for leaks.

Modular

MULTIPLE DISC BRAKE

(SAE C size)

__ s_E_R_V_IC_E_IN_S_T_R_uc_T_ro_N_s_--.,MJU----'

NOTE: This service sheet covers both 545 Series and 547 Series "C" mount Brakes.

Mill l >I CO ll PO llA T[O

REPAIR KITS (Refer to Page 3 for item numbers)

NUMBEF1 DESCRIPTION INCLUDES 12-501-002 0-ring and Back-up Case Gaskets (13)

Ring Krt 011 Seal (5) 0 -rings (18 & 20) Back-up Rings (17 & 19) Loctite

12-501-004 Standard Torque Case Gaskets (13) Lining Kit Primary Oise (9}

Stator Discs (11) Rotor Discs (1 O) Loctite

12-501..006 Bearing Kit Case Gaskets (13) Oil Seal (5) Bearing (4) Loctite

12-501-008 Spring Kit Case Gaskets (13) Springs - red (15) Springs - blue {15} Loctite

12-501-014 High Torque Case Gaskets (13) lining Kit Primary Disc (9)

Stator Discs (11) Rotor Discs· thick (10) Rotor Discs· thin {10) Loctite

NOTE: All repair kits f nclude mounting face gaskets and face soals. Some motors and gearboxes allow for the use of o-rings to seal the mounting faces on either side of the brake.

Do not use the o-ring and face gasket together to seal a mounting face.

ftl1D W IS T OIV l ~IO >I

1911 Lee Boulevard I P.O. Box 2118 North Mankato, Minnesota U.S.A . 56002-2118 Phone: (507) 625-6426 / Fax: (507) 625-3212

701 East Francis Street / P.O. Box 9058 Ontario, California U.S.A. 91761-9058

Phone: (714) 947-4077 / Fax: (714) 947-6054

Form No 81 -547-001 8/92 ® ~~ Printed In U S.A

DISASSEMBLY 1. Remove 2 socket head assembly

bolts (1). A suitable holding fix­ture is useful to keep brake In position.

2. Tap female end of spline shaft assembly (7) and spring plate (14) with soft mallet to separate cover. If sections will not separate, use a screwdriver to carefully pry sections apart.

3 Remove retaining ring (3) from spline shaft assembly (7).

4. Remove spline shaft assembly (7) from cover {6) by tapping male end of spline shaft assembly with soft mallet.

5. Remove retaining ring (2) from cover (6) and press out oil seal (5) and bearing (4) if required.

6. Remove four socket head shoulder bolts (8). A sultable holding fixture is useful to hold brake In position.

CAUTION Do not remove shoulder bolts without pressurization of brake (approx. 300 psi) or damage may result.

7. Before removing primary disc (9), rotor discs (10) and stator discs (11), note pattern for reas­sembly purposes.

8. Release the pressure to brake before removing the 4 socket head cap screws (12).

9. Remove spring plate (14). 1 o. Remove case gasket (13) from

spring plate (14). 11 . Before removing springs (15),

note pattern and color for reas­sembly purposes.

12. Remove piston (16) by carefully exerting hydraulic pressure through brake release port on pressure plate (21).

13. Remove o-rings (18 & 20) and back-up rings (17 & 19) from piston (16). NOTE: Care must be taken so as not to scratch or mar piston.

14. Remove case gasket (13) from pressure plate (21).

ASSEMBLY LUBRICATE ALL RUBBER COM­PONENTS FROM REPAIR KIT WITH CLEAN TYPE FWID USED IN THE SYSTEM. 1. Clean all parts thoroughly before

assembling. 2. Press oil seal (5) Into bore until It

is ftush with bearing shoulder. DRY DESIGN BRAKE; oil seal (5) must be installed with open side facing pilot end of cover (6). LIQUID COOLED BRAKE; oil seal (5) must be Installed with closed side facing pilot end ot cover (6).

3. Press bearing (4) into position until It bottoms out on oil seal borestep.

4. Install retaining ring (2) into cover (6).

5. Press spline shaft assembly (7) Into bearing (4} until shaft bottoms on shaft shoulder. Bearing Inner race must be supported during this operation.

6. Install retaining ring (3) on spline shaft assembly (7).

7. Install back-up rings (17 & 19) on piston (16) toward spring pockets.

8. Install a-rings (18 & 20) on piston (16}. Be sure a-rings are flat and all twists removed. NOTE: Care must be taken ao as not to scratch or mar piston.

9. Lubricate piston (16) with type fluid used In the system. Carefully press piston into pressure plate (21) . Be sure piston is oriented such that threaded holes In piston are In alignment with thru holes in spring plate (14) when Installed.

10. Install springs (15) according to pattern and color noted during disassembly. Different colored springs must be alternated.

11 . Affix case gaskets (13) to pressure plate (21) and spring plate (14).

12. Place unit on a press. Using fix­ture, depress and Install four socket head assembly bolts {12). SEE NOTE BELOW. '"forque bolts to 35 - 40 ~ lbs. A suitable holding fixture Is useful to hold brake in position.

13. Install stator discs (11} and rotor discs (1 O} In same sequence as noted during disassembly.

14. Install primary disc {9). 15. Align discs and partially screw in

four socket head shoulder bolts (8). SEE NOTE BELOW. Inspect for free movement of stack. Pres­surize brake release port (approx. 300 psi) to release discs. Torque shoulder bolts to 15 - 18 ft. lbs. and release pressure. A suitable holding fooure Is useful to hold brake In position.

16. Install cover (6) using socket head assembly bolts (1). SEE NOTE BELOW. Torque bolts to 9 - 11 ft. lbs.

NOTE; Bolts should have one or two drops of Loctite # 242 applied to threads.

CAUTION If hydrostatic bench testing is performed on the brake assem­bly, release pressure should not exceed 1 ooo psi unless four additional bolts are used for supplemental clamping.

Special Notes for Oil Cooled ("Z Option") Brakes 1. Flow Thru Cooling

Range = 1 to 7 GPM Note: Maximum brake case pressure not to exceed 15 PSI

2. Sump Cooling For sump oil cooling contact factory for recommended fluid levels at specified rpm and mounting orientation.

3. Brakes are shipped dry and customer Is responsible for adding proper type and volume of cooling oil.

( '

(

( ;,,

NOTES . •ts contain two • All Repair Ki gaskets {13).

types of case e the correct ~ Be sure to us model: ,.- ~ ~ gaskets for your -----

- 547 Series Brakes use this gasket ~

- 545 Series Brakes use ---~ this gasket

ries Brakes .._ Some 545 Soe 3/8 - 16 flat head

required tw . s to be bolts and °;'~~93o ft. lbs. torqued to

S ries Brakes • Some 545 e 7116

_ 14 to required only ~~o-

60 ft. lbs.

be torqued to

FIGURE 2

FIGURE 1

BLEEDING Install brake in system and con­nect pressure If nes.

2 Bleed pressure release section of brake by pressurizing side inlet

port and allowing air to escape trom top port. Pressure should not exceed 100 psi during bleeding.

3 Apply sufficient pressure to re­lease brake and check for proper operation in system.

SERVICE DIAGNOSIS

PROBLEM CAUSE EXPLANATION ACTION

Brake slips A. Excesshte pressure in If there Is back pressure In the actu- Check filters, hose size. hydraulic system atlon line of the brake, holding torque restrictions In other

will be reduced. hydraulic components

B. 011 in brake if designed Wet linings generate 67% of the dry Replace oil seal in brake for dry use torque rating If the brake has oil in it, Check motor seal

check the type of oil hydraulic or Check piston seals gearbox Note: Internal compon-

1. Gearbox oil ents will need to be in-2. Hydraulic oil spected, cleaned and

replaced as required.

C Disc plates worn The thickness of the disc stack sets Check disc 1 hickness the torque level. A thin stack reduces torque.

D. Springs broken or have Broken or set springs can cause re- Check release pressure taken a permanent set duced torque - a rare occurrence.

Brake drags or A. Low actuation pressure The brake should be pressurrzed to Place pressure gauge runs hot minimum of 20 psi over the full in bleed port & check

release pressure under normal oper- pressure with system on ating conditions Lower pressures will cause the brake to drag thus gener-ating heat.

B. Bearing failure If the bearing should fail, a large Replace bearing amount ol drag can be generated.

C. Oil In brake Excess fill or oil in sump condition thru Drain oil and refill as wet brakes can cause the unit to run specified for brakes hot. Also excessive rpm In sump Switch to flow thru condition. cooling.

Brake will not A. Stuck valve or clogged Brakes are designed to come on when Place pressure gauge release system pressure drops below stated tn bleed port - check

release pressure. If pressure cannot for adequate pressure -get to brake, the brake will not release. Replace defective line

or component

B Bad o-rlngs If release piston will not hold pressure, Replace a-rings brake will not release.

C. Discs frozen These brakes are designed for only Replace disc slack limited dynamic braking. A severe emergency stop or prolonged reduced release pressure operation may result in this type of damage.

13-547-190

-ORDER INFORMATION (See NOTE on the top ot page 5) NOTE: On oil cooled models (Z option) actual torque is 67% of value shown on torque

code chart. Recommended sump oil fluid volume when mounted: Horizontal - 118.3 ml (4 oz), Vertical - Contact MICO West

3 c -

OUTPUT FACE ----3C • SAE C-Mount

+Boll

OUTPUT SPLINE I INPUT SPLINE --~ 04 Qnternal)/14 SAE De19>ttion 14/00 00• Uledwith 'R0 only 14/06 04a 14Tl2124 14/13 06•25.4mm(l.00')01U8 14114 13a 13T 8118

13 • 13T 181:12 17/17 14 • 14T 12/24 21/00 17a 17Tl2/24 21/21 21•21T1&'32 ___ __.

Other configurations consult MICO West.

ASSIGNED NUMBERS CATALOG PROOUC'llOH CATALOG

COOE ORO ER COOE HUMBER HUMBER HUMBER

JC-041412-C 13·547·282 30·141412-CDZ 30-041498-C 13-547-324 3C-141412·CZ 3C·140012·R 13-547·272 3C-141412·K4 SC-140098-R 13-547-268 30·141412-K4Z 3C-140612·MZ 13-547-370 30-141412-M 3C· 140645-M 13-547·264 30-141445-C 30·140655-M 13-547·232 30·141445-K4 3C· 140655·MZ 13-547-006 30-141445-M 3C·140680·MD 13·547·210 30·141445·C2 3C·140685-M 13-547-246 30-141445-0Z 30·140698·M 13·547-190 30·141454-C 3C-141356·B 13·547·290 30· 141455-B 3C·141380-D 13-547-410 30-141455-BZ 30·14 1398·0 13·547-016 3C·141455-C 3C·141410-CZ 13-547-024 30· 141455-CO 3C-t41410-K4 13-547-16'1 3C·141455-CZ 3C-t41412-C 13-547-030 30-141455-M 3C·14f412-CD 13-547-316 30-141486-C

PROOUC'llOH OROER

HUMBER

13·547-288 13-547-034 13-547-296 13-547-038 13-547·038 13·547-072 13-547-384 13·547·352 13-547·208 13-547-362 13-547-074 13·547·354 13-547-298 13-547-076 13·547-344 13-547-078 13·547-364 13-547-082

OPTIONS (Available separately or In comblnatlon) 0 - Double Bearing z -Oil Cooled - see note above S · Speed Sensor

INPUT FACE C - SAE C-Mount 4-Boll M 4-Boll and SAE

A-Mount 2·Bolt R - Closed B SAE 8-Mount 2-Bolt K4 - Eaton

Standard 4000

C2 · SAE C·Mount 2-Bolt Thru

C24 • 2-Boll and 4-Bolt O·Mount

TORQUE Torque lnltlal Full

Code Rei.He Releau A.Ung PtHI UB Preuu,. N-m (lb-In) blf (p1I) bar (pal)

98 1107 (9800l 14.5 (210! 20.0 g:> 85 960 (8500 11.0 (160 15.2 ! 80 9().4 (8000) 12.4 1180) 17.2 (250 70 791 (7000) 11.0 160) 14.S (210) 66 746 (8600) llO (130! 12.4 (180) 55 622 (5500) 9.0 (130 11.7 1170) s. 610 (5400! 78 ~10!

11.0 ISO) 45 506 (4500 7.8 10 lo.3 (150) 12 1356 112,000) 14.5 10) 21.• (1110! 10 1130 10.000) 12.4 IO) 17,2 (250

Other (orques available on request.

CATAl.00 PROOUC'llOH CATAlDG PAOOUCTION COOE OROEA COOE ORO ER

HUMBER HUMBER HUMBER HUMBER

3C·141466-C24 13-547-358 3C·141498·MO 13·547-378 3C-141466·M 13-547-204 3C-171780-C 13-547-124 3C·141466-MZ 13-547·226 30-171785-C 13-547-278 JC-141470-C 13·547-08.4 SC-171785-CZ 13-547·126 JC-141470-CZ 13-547-066 3C·171798-C 13·547-212 30-141480-8 13·547-342 3C·212145-C 13-547-332 3C-141480-C 13-547-090 3C-212166-C 13-547-130 30·141480·C2 13-547-092 3C-212180-C 13-547·132 30· 141480·K4 13·547-094 3C·212180·0Z 13-547-170 3C·141480-K4Z 13-547-254 30·212185-0 13-547·220 3C·141480·M 13-547·098 3C·212198·0 13·547-134 3C·141485·C 13·547·096 3C·141498·C 13-547-102 3C-141498-C2 13-547-104 3C-1414S8-CS 13-547-106 3C·141498-CZ 13-547-108 3C·1414S8-K4 13-547-110 30·141498-M 13-547-116

12

m1D C-Mount Modular Brakes

• More retarding torque than competitive models

• Numerous mounting configurations available

• Low release pressures, ideal for use with closed-loop hydrostatic systems

• Rugged heavy duty construction with torques to 1356 N-m (12,000 lb-in)

• Heat treated 8620 shafts for high strength and long life

• Compact modular package simplifies mounting

• Unique balanced piston design

TYPICAL MODEL SHOWN For detailed information on other models, contact MICO West 13·547-078 (3C-141455-CZ)

INPUT END

22, 9 J ~ . 90 ~ (2 Pt.ACES)

14 SA£ 0-R I NC PORT 7 /16-20IJNF" -28

{ 1 PRESSURE PORT) { 1 BlEEOER PORT)

SPECIFICATIONS Torque range at Obar {O psi)

JO" I NYOWTE Sl't. INE~XTERHAl 14 TOOTH 12/24 PITCH

Ft.AT ROOT. SIDE FIT. Ct.ASS 5 PER AHSI 892. 1-1970

l u35, 1 .. IN. FUl.l I. 38 SPLINE

40, l/l . 58 COOLING PORT lOCATIOH (2 Pl.ACES) l OPTION ~y

back pressure .•. .. . . 509 • 1356 N·m (4500 • 12,000 lb·in) Release pressure range .. . .... 10.3 • 21.4 bar (150 • 310 psi) Maximum operating pressure. . . . . . . . . . . 207 bar {3000 psi) Maximum speed . . . . . . . . . . . . . . . . . . . . . • 4000 rpm Volume of oil

to release brake ..•...... . .. . . . . 16.4 cm3 (1.0 ln3) Maximum operating temperature . . . . . • • • • . 132 •c ( 270 °F) Maximum energy Input . ...... .. 542,400 joule (400,000 ft·lb)

(one stop, no damage)

11

114. 76/114, 25 4. 5111/4. 498

mllllmeters inches

j 114, 76/114. 25

4 518/4. 498

14, 28/. 562 DIA. T~ OH 161. 93/6. 375 DIA. 8. C. (REF) { 4 PLACES)

OUTPUT FACE

Approximate weight. . ...••..... . ... .. . 18 kg (40 lb) Fluid type . . . . • . . • . • . • . . • • . Mineral base hydraulic oil

.6 SWING MOTOR GEAR BOX REMOVAL AND REPAIR

REMOVAL

STEP 1: Remove hydraulic drive motor described In 7.4.

STEP 2: Loosen and remove gear box mounting bolts gear box.

STEP 3: With suitable rigging, hoist gear box from turret and lower to deck.

STEP 4: Remove pinion retaining bolts and washer; slide pinion gear from output shaft.

STEP 5: Repair gear box per Fairfield Service and Repair manual.

INSTALL.A TION

STEP 1: Grease output shaft with high quality EP-2 lubricant and install pinion gear on output shaft. Install retaining washer and bolts; torque bolt to 100 Ft-Lbs(dry).

STEP 2: Grease pinion gear with Texaco Crater 2X or equal.

STEP 3: With suitable rigging, hoist gear box Into place. Use pry-bar to align bolt holes.

STEP 4: Torque mounting bolts to 750 Ft-Lbs(dry).

STEP 5: Fill gear case with SAE 90wt EP oil.

STEP 6: Install motor per 7.4.

.5 SWING MOTOR BRAKE REMOVAL AND REPAIR

REMOVAL

STEP 1: Secure crane In boom rest or tie to deck.

STEP 2: Remove hydraulic drive motor as outline In 7.4.

STEP 3: Disconnect brake llne(s) and plug fittings.

STEP 4: Loosen and remove 4ea. mounting bolts;

service per MICO Service and repair manual.

INSTALLATION

STEP 1 : Grease shaft splines on brake.

STEP 2: Install new gasket and bolt brake to gear box.

STEP 3: Connect brake line.

STEP 4: Install motor as described In 7.4.

STEP 5: Loosen brake bleed screw 1/ 4 turn. Start hydraulic system and have primary operator slowly operate swing mode. Open bleed screw until oil trickles from fining. Purge air and tighten bleed screw. Test unit for leaks.

Modular

MULTIPLE DISC BRAKE

(SAE C size)

____ s_E_R_v_1c_e_1_N_s_TR_u_c_T_1_o_N_s __ Jll1D __ NOTE: This service sheet covers both 545 Series and 547 Series "C" mount Brakes.

REPAIR KITS (Refer to Page 3 for item numbers)

NUMBER DESCRIPTION 12-501-002 0-ring and Back-up

Ring Ktt

12-501-004 Standard Torque Lining Kit

12-501-006 Bearing Kit

12-501-008 Spring Kit

12-501-014 High Torque UningKrt

I

INCLUDES Case Gaskets (13) Oil Seal (5) 0-rings (18 & 20) Back-up Rings (17 & 19) Lociite

Case Gaskets (13) I

Primary Disc (9) Stator Discs (11) Rotor Discs (10) Loctite

Case Gaskets (13) Oil Seal (5) Bearing (4) Loctite

. Case Gaskets (13) Springs - reef (15) Springs- blue (15) Loctite

Case Gaskets (13) Primary Disc (9) Stator Discs (11) Rotor Discs - thick (10) Rotor Discs - thin (10) Loctite

NOTE: All repair kits include mounting face gaskets and face saals. Some motors and gearboxes allow for the use of <Hings to seal the mounting fa.ces on either side of the brake.

Do not use the <>-ring and face gasket together to seal a mounting face.

Mill w e st D•Y•SIOI<

1911 Lee Boulevard I P.O. Box 2118 North Mankato, Minnesota U.S.A. 56002-2118 Phone: (507) 625-6426 / Fax: (507) 625-3212

701 East Francis Street / P.O. Box 9058 Ontario, California U.S.A. 91761-9058

Phone: (714) 947-4077 I Fax: (71 4) 947-6054

Form No 81 -547-001 8/92 ® ~:~IN_K_ ~~ Printed In U.S.A.

DISASSEMBL V 1. Remove 2 socket head assembly

bolts (1 ). A suitable holding fix­ture Is useful to keep brake in posltion.

2. Tap female end of spline shaft assembly (7) and spring plate (14) with soft mallet to separate cover. If sections wlll not separate, use a screwdriver to carefully pry sections apart.

3. Remove retaining ring (3) from spline shaft assembly (7).

4. Remove spline shaft assembly (7) from cover (6) by tapping male end of spline shaft assembly with soft mallet.

5. Remove retaining ring (2) from cover (6) and press out oil seal (5) and bearing (4) if required.

6. Remove four socket head shoulder bolts (8). A suitable holding fixture is usefuJ to hold brake in position.

CAUTION Do not remove shoulder bolts without pressurization of brake (approx. 300 psi) or damage may result

7. Before removing primary disc (9), rotor discs (10) and stator discs (11), note pattern for reas~ sembly purposes.

8. Release the p ressure to brake before removing the 4 socket head cap screws (12) .

9. Remove spring plate (1 4). 10. Remove case gasket (13) from

spring plate (14). 11. Before removing springs (15),

note pattern and color for reas­sembly purposes.

12. Remove piston (16) by carefully exerting hydraulic pressure through brake release port on pressure plate (21) .

13. Remove o-rings (18 & 20) and back-up rings (17 & 19) from piston (16). NOTE: Care must be taken so as not to scratch or mar p iston.

14. Remove case gasket (13) from pressure plate (21 ).

ASSEMBLY LUBRICATE ALL RUBBER COM· PONENTS FROM REPAIR KIT WITH CLEAN TYPE FLUID USED IN THE SYSTEM. 1. Clean all parts thoroughly before

assembling. 2. Press o il seal (5) Into bore until it

is flush with bearing shoulder. ORY DESIGN BRAKE; oil seal (5) must be installed with open side facing pilot end of cover (6). LIQUID COOLED BRAKE; oil seal (5) must be installed with closed side facing pilot end of cover (6).

3. Press bearing (4) Into position until It bottoms out on oil seal borestep.

4. Install retaining ring (2) into cover (6).

5. Press spline shaft assembly (7) Into bearing (4) until shaft bottoms on shaft shoulder. Bearing inner race must be supported during this operation.

6. Install retaining ring (3) on spline shaft assembly (7).

7. lnsta.11 back~up rings (17 & 19) on p iston (16) toward spring pockets.

8. Install a-rings (18 & 20) on piston (16). Be sure a-rings are flat and all twists removed. NOTE: Care must be taken so as not to scratch or mar piston.

9. Lubricate p iston (16) with type fluid used In the system. Carefully press piston into pressure plate (21 ). Be sure piston is oriented such that threaded holes In piston are In alignment with thru holes in spring plate (14) when installed.

10. Install springs (15) according to pattern and color noted during disassembly. Different colored springs must be alternated.

11. AfflX case gaskets (13) to pressure plate (21) and spring plate (14).

12. Place unit on a press. Using fix­ture, depress and Install four socket head assembly bolts (12). SEE NOTE BELOW. "forque bolts to 35 - 40 ft. lbs. A suitable holding fixture Is useful to hold brake in poslUon.

13. Install stator discs (11 ) and rotor discs (1 O) in same sequence as noted during disassembly.

14. Install primary disc (9). 15. Align d iscs and partially sc rew in

four socket head shoulder bolts (8). SEE NOTE BELOW. Inspect for free movement of stack. Pres­surize brake release port (approx. 300 psQ to release discs. Torque shoulder bolts to 15 • 18 ft lbs. and release pressure. A suitable holding fixture Is useful to hold brake In position.

16. Install cover (6) using socket head assembly bolts (1). SEE NOTE BELOW. Torque bolts to 9 - 11 ~lbs.

NOTE: Bolts should have one or two dropa of Loctite #242 applied to threads.

CAUTION If hydrostatic bench testing Is perlormed on the brake assem­bly, release pressure should not exceed 1000 psi un less four additional bolts are used for supplemental clamping.

Special Notes for Oil Cooled ("Z Option") Brakes 1. Flow Thru Cooling

Range = 1 to 7 GPM Note: Maximum brake case pressure not to exceed 15 PSI

2. Sump Cooling For sump oil cooling contact factory for recommended fluid levels at specified rpm and mounting orientation.

3. Brakes are shipped dry and customer is responsible for adding proper type and volume of coollng oil.

(

(

mm C-Mount Modular Brakes

• More retarding torque than competitive models

• Numerous mounting configurations available

• Low release pressures, ideal for use with closed-loop hydrostatic systems

• Rugged heavy duty construction with torques to 1356 N-m (12,000 lb-in)

• Heat treated 8620 shafts for high strength and long life

• Compact modular package simplifies mounting

• Unique balanced piston design

TYPICAL MODEL SHOWN For detailed infonnation on other models, contact MICO West 13·547-078 (3C· 141455·CZ)

INPUT END

n.vj ~ tO ~ (l Pl4CCS)

I• SAE <>-4tlHG POii! 7 / 16-20\MF-29

(I PRESSUR£ PORT) ( I 111.EEOCll PORT)

SPECIFICATIONS Torque range at o bar (O psi)

30' INYOl.Ul£ 5Pl. IN£-€Xll;llHAl 1' TOOTH 12/2• PIJCH

Fl.U AOOl, SIDE: FIT, Ct.o\SS !I P[R AHSI 892. 1-1910

».• 1 z 1a

112. 70/12. 19

SOO/r

I

l Ul~.l WIN. f'Ul.l I Ja Sl'l.11€

•0. 1/L 55 COOL I HG POllT LOCo\ JI OH (2 Pt.ACES) l OPl IOH Olt. T

back pressure • • • . . 509 • 1356 N·m (4500 • 12,000 lb-In) Release pressure range .•••..• 10.3 • 21.4 bar (150 • 310 psi) Maximum operabng pressure. . • 207 bar (3000 psi) Ma.iumum speed • • • • • • • • • • • . • . • • • • • . • 4000 rpm Volume of oil

to release brake • 16.4 cm3 ( 1.0 1n3) Maximum operating temperature. • • • 132 ~ ( 270 "F) Maximum energy Input. • • • • • . , 542,400 joule (400,000 lt·lb)

(one stop, no damage)

11

millimeters Inches

i 11• . 16/114, l' • )18/• •9&

14, 2&/. '62 014. TlllU OH 1&1. 93/6. 37) Olo\ 9 C. (llff') ( • Pl.ACU)

OUTPUT FACE

Appr9ximate weight. •. ••••••••••.•• .•. 18 kg (40 lb) Fluid cype . • • • • . • • • • . • . • • Mineral base hydraulic oil

.6 SWING MOTOR GEAR BOX REMOVAL ANO REPAIR

REMOVAL

STEP 1: Remove hydraulic drive motor described In 7.4.

STEP 2: Loosen and remove gear box mounting bolls gear box.

STEP 3: With suitable rigging, hoist gear box from turret and lower to deck.

STEP 4: Remove pinion retaining botts and washer: slide pinion gear from output shalt.

STEP 5: Repair gear box per Fairfield Service and Repair manual.

INSTALLATION

STEP 1: Grease output shaft with high quality EP-2 lubricant and Install pinion gear on output shaft. Install retaining washer and bolts: torque bolt to 100 Ft-Lbs(dry) .

STEP 2: Grease pinion gear with Texaco Crater 2X or equal.

STEP 3· With suitable rigging, hoist gear box Into place. Use pry-bar to align bolt holes.

STEP 4 : Torque mounting bolts to 750 Ft·Lbs(dry).

STEP 5: Fill gear case with SAE 90wt EP oil.

STEP 6: Install motor per 7.4

~ \

.7 SWING MOTOR CUSHION VALVE SERVICE

STEP 1:

STEP 2:

STEP 3:

Install 0-2500 PSI pressure gauges through tee connections at ports C1 and C2.

Rig lifting system for maximum safe working load at maximum work radius; platform should be level and stable for accurate testing.

Operate swing mode in both directions and record pressure.

NOTE: If pressure fluctuates more than 150 PSlg during swing mode, remove load from lifting system and retest. If pressure still fluctuates more than 50 PSlg; inspect for: Excessive ring and pinion gear wear, loose pinion gears, binding in gear reduction boxes, physical damage to turret assembly, swing motor failure, or Rotek bearing damage. Do not proceed until problem has been corrected.

STEP 4:

STEP 5:

STEP 6:

Loosen lock nut on cross port relief valves and turn adjusting screw counter-clockwise 5 full turns or until screw tops out. Remove lines from swing motor ports and cap. Start system and operate swing valve. adjust cross port relief pressure to 1450 - 1500 PSlg on both work ports. Turning adjusting screw clockwise increases pressure and counter-clockwise reduces pressure.

Tighten locknut when correct pressure is achieved and re-connect hoses to swing motors.

Operate swing and check for oil leaks; repair as required.

Crane is now ready for service.

.8 CONTROL VALVE REMOVAL AND REPAIR

REMOVAL

STEP 1: Shut off and secure electrical system to crane.

STEP 2: Move control handles to release residual pressure.

STEP 3: Tag and plug hoses at control valve.

STEP 4: Remove the valve mounting capscrews and lower valve to deck.

Repair per valve Gresen Service and Repair manual.

INSTALLATION

STEP 1:

STEP 2:

STEP 3:

STEP 4:

STEP 5:

STEP 6:

Place control valve under platform and install capscrews.

Connect hoses per tags. Plug one function.

Open suction valve and start system.

Loosen main relief valve locknut and turn adjusting screw 5 turns ccw.

Operate disabled function and observe pressure reading at gauge. Adjust main relief pressure to 2250 PSlg by turning adjusting screw cw to increase pressure or ccw to reduce pressure. Tighten locknut, while holding adjusting screw, when correct pressure has been achieved.

Remove plug(s) from work port(s) , and connect hoses per tags. Operate system and check for leaks.

Crane is ready for use

;

SECTION II DESCRIPTION

Gresen's Model V42 Directional Conlrof Valves are available wtlh live different types of work sections, plus various options to meet specific job speci­fications

The following paragraphs describe the five work sections and options with reference to the parts il­lustrations in Section IV in this manual.

3-WAY, 3-POSITION WORK SECTION (Refer to Figure 4-2) Provides conlrol of single acting cylinders or start and stop of non-reversible hydraulic motors whe(e free-wheeling or motor is NOT required: The cylinder port 1s blocked m neutral position.

4-WAY, 3-POSITION WORK SECTION (Refer to Figure 4-3) Provides control of double acting cylinders without the floating action plus hydraulic motor start. stop. and reverse control where free-wheeling is NOT required. Cylinder ports are blocked in neutral position.

4-WAY, 4-POSITION FLOAT WORK SECTION (Refer to Figure 4-4) Provides control of double-acting cylinders requir­mg a floating action such as: loaders, dozers, snow plows, etc. Incorporated into the work section is a 4-position float positioner. Three positions are standard double-acting with spring return to neutral. The fourth position is detented to hold in

float position (both cylinder ports open to tank) .

4-WAY, 4-POSITION REGENERATIVE WORK SECTION (Refer to Figure 4-5) . Same as 4-way, 3-position work section except that the fourth "regeneration" position provides a large volume of oil for fast cylinder action, but with little force.

4-WAY, 3-POSITION WORK SECTION WITH PRESSURE OETENT RELEASE (Refer to Figure 4-6). Provides automatic return to neutral position as soon as work cycle is completed. The spool is held in either power position by a detent assembly until re­leased by predetermined pressure setting in the power circuit. Spool returns 10 neutral.

2-0

MID-INLET CONVERSION SECTION (Refer to Figure 4-7 thru 4-9) Provides an inlet port ror a secondary pump down­stream in the valve assembly Conversion sections are available in split flow, combined flow, and a two­posilron section for two-speed split or combined flow application.

SPOOL ACTION OPTIONS

SPRING RETURN TO NEUTRAL (Standard) (Refer to Figure 4-12). Spool will return to neutral position from A or B power position when handle is released.

SPRING EXTENDED SPOOL, "A" Option (Refer to Figure 4-13) Eliminates spring return to neutral Spring returns to the spool "OUT" position only Usually used for cam operation of spool

INTERNAL HYDRAULIC OETENT RELEASE, "KO" Option (Refer to Figure 4-17) Automatically returns spool to a neutral position as soon as work cycle is completed.

ROTARY SPOOL ACTUATOR, " W" Option (Refer to Figure 4-16) Movement of spool is controlled by a rotary movement of the handle. Allows 90° rotation of spool in each direction from center.

3-POSITION DETENT, "O" Option (Refer to Figure 4-14). Valve spool remains in any of three detented positions. No spring return to neutral.

1-POSITION SPOOL .. IN" OETENT, .. R" Option (Refer to Figure 4-18). Work port "B" remains open to tank In detent position. Allows a single-acting cylinder to float. Spring returns spool to neutral.

REGENERATIVE SPOOL (Refer to Figure 4-19). Regeneration position provides a large volume of hydraulic oil to cylinders for fast action, but with little force.

SOLENOID CONTROL (Refer to Gresen's Service and Parts Manual No. SC-1252).

HYDRAULIC CONTROL, " HR" , " HAO" or " HRH" Op­tion (Refer to Gresen's Service and Parts Manual No. SC-1253).

HANDLE ASSEMBLIES (Refer to Figures 4-20 thru 4-24). Provides a choice of either horizontal or ve rtical handle assemblies and coated with either red or black plastic or plain.

2- 1

INLET and OUTLET COVERS (Refer to Section 111, Parts Ordering Information).

RELIEF VALVES and WORK PORT CHECKS (Refer to Figures 4-25 thru 4-34).

SECTION Ill MAINTENANCE

REPLACING, ADDING OR REMOVING WORK SECTION ASSEMBLIES

NOTE For clarification. the side containing the inlet cover (the cover containing the main relief valve) will be called the left end or the valve assembly. Refer to Figure 3-1 .

Before disassembly, it is suggested that each work section be marked numerically to ~void rncorrect reassembly.

SPOOL POSITIONERS

MAIN ""' RELIEF "',,,_..,.,. ....

LEFT ENO

1

2 Remove four hex nuts (Item 29. Figure 4-1) from the right end of the valve assembly using a 9/16'' socket wrench If the valve assembly consists of only one or two work sections. bolts and lock washers must be removed instead.

3. Remove the outlet cover and each section by slid ­ing from assembly studs (Item 29. Figure 4-1 ).

4. If work sections are to be added or subtracted from the valve assembly. lhe four studs must be removed from the inlet cover and replaced with studs of proper length Refer to Table 3-1

REAR WORK PORTS

2

FRONT

WORK SECTIONS

TURN AROUND OR

OUTLET COVER

RIGHT ENO

~HANDLE 3 ASSEMBLY

Figure 3-1. Schematic View of a Typical Model V42 Control Valve Assembly.

3-0

Table 3-1. Bolt and Stud Part Numbers

OUTLET COVERS NO. OF (RIGHT SIDE) WORK

SECTIONS PART NO. PART NO. 8090- 8091-

TOP OUTLET END OUTLET

1 3732-127 3732-122 2 3732-130 3732-128 3 3493-001 1672-001 4 3493-002 1673-001 5 3493-003 1674-001 6 3493-004 1675-001 7 3493-005 1755-001 8 3493-006 1756-001 9 3493-007 3493-008

NOTE Use lock nuts. part no. 1665--001. four required, with all assembly studs. Except for valve assemblies containing only one or two work sections. NO LOCK WASHERS required . Studs are of stress-proof material and should be replaced only with original equipment replacement parts. If the valve assembly contains on ly one or two work sections, assembly bolts with lock washers, part no. 1039-001, are used.

5. Thoroughly clean 0-ring counterbores and ground surtaces of each section.

6. Replace the three 0-ring seals, two part no. 1621-001 and one part no. 1622-001. Buna-N seals are standard. For optional Viton Seals, see Cross Reference Chart on page 4-31.

7. Replace work sections on assembly studs in the same o~er In which they were removed. 0-ring countert>ores (with 0-rings in place) should be to your left when facing the "A" port or front side of the valve assembly.

NOTE Use care In replacing work section to avoid dlslodglng 0-rings from counter­bores.

8. When all work sections and the outlet cover are po­sitioned on the assembly studs, replace stud nuts

. and tighten evenly to 24-26 foot pounds [33-35 Nm].

3-1

DESCRIPTION

Boll } Use Lock Washers Bolt Part No. 1039-001 Stud Stud Stud Use Stud Nuts

Stud Part No. 1665-001

Stud Nuts are lock nuts,

Stud no lock washers required

Stud

.------CAUTION----­lf stud nuts are not tightened to the proper torque, valve spools may bind or stick. or cause section seals to extrude.

REPLACING SPOOL SEALS

Figure 3-2 shows spool assembly - less the complete handle assembly. When the handle bracket is furnished, retainer plate and retainer screws are not used. Seal assembly is retained by handle bracket and its attaching parts.

REAR

SPOOL POSITION ER ASSEMBLY

SPOOL SEAL

SEAL PLATE

QUAD SEAL

SCREW AND

LOCK WASHER

RETAINER OR

HANDLE BRACKET

Figure 3-2. Spool Seal Assembly.

1. Remove spool positioner assembly from rear of work section. Keep In order of disassembly

2 Remove complete handle bracket assembly or retainer and retainer screws from front of work section.

3 Remove seal plate from each end of work section

4 Remove quad seals and spool seals from seal plates and thoroughly clean plates.

5. Lightly 011 new seals . Insert them into grooves in seal plate.

6. Slide the seal plates over each end of the spool into the counterbore in the work section.

7 Reassemble parts in reverse order or disas­sembly.

8 Torque bonnet screws and handle bracket or seal retainer screws to 8-10 fool pounds [11-14 Nm).

PARTS ORDERING INFORMATION

INLET COVER Part No. 8089·

All inlet covers are machined to accept Models KC, RP60 or NA plug. If the outlet port is not machined, then the outlet port In the right or outlet cover must be used for a tank return line. The Inlet cover may be machined with several different combinations of port sizes and locations.

Use the following porting chart to determine the proper machining modification number. NPT and SAE threads cannot be intermixed in the same casting .

PORT LOCATION NPT"•

End in• 1-1/4" Top in• 1-1/4" End Out 1-1/4" Top out• 1-1/4" Machining Modlflcaiion -030 Number

16 16 16 16 - -16 20

-001 -004

CORED OPENINGS

I ~ - -- . t. ... _1 ' ., ' ' .

SAE

20 16 20 20 16 20 - 20 20 20 20 20

-005 -007 -oos

VALVE NAMEPLATE PART NO. 3555-001

/ NAMEPLATE SCREW

..---::". (2 USED) PART NO. 3392-001 ..

t I I

' . t I . '

"These port locations are cored and will be plugged If not required .

··ports with NPT pipe threads are limited to 2000 PSI (136 bar) max.

3-2

Ordering Example For Inlet Covers

8089 - 030 - KC 2000 PSI CRACK•

J [138 bar]

Basic Casting Part No.

Machining Modification ----' Number

Relief Valve _________ __J

Details

· specify: 1. Model number of relief valve to be used. (See

Figures 4-25 and 4-26). 2. Relief setting required. Crack pressure is setting

when relief is passing 1 GPM [3.8 lltres/min.). Full flow is pressure setting when relief Is passing specified G PM (litres/min].

3. "NR" (no relief) if plug is to be Installed. 4. If "With no relief assemblyor"NR" plug installed"

is specified. relief cavity will be plugged with only a plastic shipping plug.

OUTLET COVERS

A choice of two outlet covers for the Model V42 1s available: lop outlet. part no. 8090-: and end outlet. part no 8091-

Top Oullet Cover, Part No. 8090-

Standard machining provides a top outlet port for open center applications. When the tc;>P outlet port is plugged to provide a turnaround outlet flow, the outlet port must be localed in the inlet cover.

Two options are available for the no. 8090 top outlet cover ... power beyond and c losed center applica­tions. For power beyond, the core between the open

3-3

center and exhaust passages is tapped and plugged The top outlet port becomes lhe power beyond port The tank outlet port must be located in the inlet cover.

When the top power beyond port is plugged, the Valve Assembly may be used in a closed center application. For future conversion from standard open center to either power beyond or closed center applications. the outlet cover may be ordered with the core tapped but not plugged (for field conversion machining) .

Options For The No. 8090 Outlet Cover

0-RING PART NO. SAE 16 - No. 2710-001

Turnaround plug option.

PLUG PART NO. 1282-001

Power beyond option.

Use the following porting chart to determine the proper machining modification number for the no. 8090 outlet cover. NPT and SAE threads cannot be intermixed In the same casting.

PORT LOCATION NPT SAE

Top Outlet 16 -Power Beyond

or 1"-11-1/2 - 16 Closed Center

Option Machining

Modification -005 -006 -002 Number

End Outlet Cover. Part No. 8091 -

I

I I I I I I

'--t.-4--J._T"~-~----'-/~~--t-L:.J_i..~

LOWER INTERNAL 13/ 16 HOLE

Standard machining provides an end outlet port for open center applications. When the end port is plugged to provide for a turnaround outlet flow, the outlet port must be located in the Inlet cover .•

Two options are available for the no 8091 end outlet cover . . . power beyond and closed center applications. When the lower 13/16 inch hole (located on the inside) connecting the open center and exhaust passage is eliminated. the outlet port may be used for power beyond When the power beyond port 1s plugged, the cover may be used ror c losed center applications,

Options For The No. 8091 - Outlet Cover

CLOSED CENTER

TURNAROUND

RIGHT END OUTLET

POWER BEYOND

3-4

When the lower internal 13/ 16 inch hole is provided, the cover will operate in open center hydraulic circuits as a standard end port. or as a turnaround section when the outlet port is plugged

When the power beyond or the closed center option is used, an outlet to tank must be provided on the left end section of the valve.

Use the following porting chart to determine the proper machining modification number for the no. 8091 outlet cover.

PORT LOCATION NPT SAE

Standard Outlet or , .. 1-1/4" 16 20 - -

Turnaround Power Beyond

or - - - - 16 20 Closed Center

Machining Modification -008 -002 -006 -004 -007 -035

Number

Ordering Example For Outlet Covers

Basic Casting Part No.

_j-006 - Plug Outlet Por1

Machining Modification Number

Option Details -----------'

WORK SECTIONS

The following information is necessary for proper specification for each Model V42 work section:

1. Function of section 2. Options 3. Work port sizes 4. Work port "A" options 5. Work port "B" options 6. Handle end options

The chart shown on the following page will help in identifying options available and the information needed for proper ordering, Refer to Catalog No. PC-1201 for complete Information on available options.

FUNCTION OF SECTIOW

OPTIONAL FEATURES

WORK PORT SIZES

"A" and "B" WORK PORTS

WORK PORT OPTIONS

HANDLE-END OPTIONS ..

Check one for each section D 3-Way, Casting No. 8045, see Figure 4-2. D 4-Way, Casting No. 8045, see Figure 4-3. D 4-Way Float, Casting No. 8046, see Figure 4-4. D 4-Way Regenerative. Casting No 8138, see Figure 4-5.

0 3-Way, Free Flow D 4-Way, Free Flow o ______ _

0 SAE 12 (1-1/16" - 12 UN) Standard 0 SAE 16 (1-15/16" - 12 UN) 0 3/4" - 14 NPT 0 1 " - 11-1 /2 NPT Ports with NPT threads are limited to 2000 PSI [136 bar) max.

Specify for "A'' and "8'' work ports D Anti-Cavitation Check. A-C D Upper Option Plug D Lower Option Plug D Work Port Relief, Model WH --------0 Work Port Relief, M<>C1el RP51 -------

Specify relief setting

D Standard Steel Retainer Assembly, LCHA 0 Vertical Handle, CVHA 0 Horizontal Handle. CHHA 0 Spool Boot Assembly 0 Less Handle Only, includes link assembly, LHO 0 Handle Bracket Only, less link assembly, HBO

·Each spool is fitted to 11s work section housing at the factory and neither part can be purchased separately. 0-ring grooves are machined on the left side (when viewed from the "A" work port end) of each work section housing.

MID-INLET CONVERSION SECTIONS

The following information is necessary for proper specification when ordering a mid-inlet conversion section:

1. Type of section 2. Port size 3. Relief valve type and setting

FUNCTION OF

SECTION

PORT SIZES

RELIEF VALVE

OPTIONS

0 Combined Flow D Split Flow D 2-Posltlon, combined or split flow

0 SAE·16"(1-15/16 .. . - ·12 UN) Standard 'O ~·1 .::J 1·1-'1/2 NPT Ports with NPT .pipe threads are limited to 2000 PSI ·1136 bar) max.

For split or combined flow sections only 0 Model KC,--------0 Model RP60, -------­For 2-posltlon selective sections only 0 Model WH, --------0 Model AP51. --------

Specify relief setting

3-5

SECTION IV PARTS LISTING

MAIN RELIEF

SPOOL ACTION OPTIONS

ANTI CAVITATION CHECK AND/OR CYLINDER

PORT RELIEF VALVES

2,3,4

INLET COVER

1

38 THAU 42 WORK

SECTIONS

1 THRU 17

36,37 BRACKETS

OR RETAINERS

18 THRU 24

MAIN RELIEF

2,3,20,21

I

0

\ 31. 32.33 MID-INLET

CONVERSION SECTIONS

34, 35 HANDLES

30 BOOT

Figure 4-1. Model V42 Directional Control Valve, Typical Main Assembly.

0

OUTLET COVER

25,26

1W1

--- '\! 29

TORQUE SECTION STUDS TO

24-26 FT. LBS. (33·35 Nm)

MODEL V42 OIRECTtONAL CONTROL VALVE ASSEMBLY, TYPICAL MAIN ASSEMBLY

Item Par1 Oea<:rfpUon Quantity No. No. Per Assembly

1 8089 COVER, Inlet (Refer to page 3-2) 1 2 RELIEF, RP60 (See Figure 4-25) AIR 3 RELIEF, KC (See Agure 4-26) AIR 4 K-7014 PLUG, No Relief, (NR) (See Figure 4-27) AIR 5 1622-001· 0-RING, Large 1 plus

1 per section 6 1621-001· 0-RING, Small 2 plus

2 per section 7 K-28060 POSITIONER. Spring Return to Neutral (See Figure 4-12) AIR 8 POSITIONER, Spring Extended Spool (See Figure 4-13) AIR 9 K-28025 POSITIONER, 3-Position Detent, "D." (See Figure 4-14) AIR

10 K-28061 POSITIONER, Float, (See Figure 4-15) AJA 11 K-28103 POSITIONER, Rotary, 'W" (See Figure 4-16) AJA 12 POSITIONER, Internal Pressure Detent Release. ··KO" (See Figure 4-17) AJR

4-0

MODEL V42 DIRECTIONAL CONTROL VALVE ASSEMBLY, TYPICAL MAIN ASSEMBLY (Continued)

Item Parl Description No. No.

13 K-28027 POSITIONER, Spool "IN" Detent Spring Return to Neutral "R'' (See Figure 4-18)

14 K-28059 POSITIONER, Regenerative (See Figure 4-19) 15 POSITIONER, Hydraulic Remote (Refer to Catalog No. SC-1253) 16 POSITIONER, Hydraulic Remote (Refer to Catalog No. SC-1253) 17 POSITIONER, Solenoid Control (Refer to Catalog No. SC-1252) 18 K-28065 CHECK, Anti-Cavitation, Upper, (See Figure 4-28) 19 K-28064 CHECK. Anti-Cavitation, Lower, (See Figure 4-29) 20 RELIEF, Model RP51 (See Figure 4-30) 21 RELIEF, Model WHA (See Figure 4-31) 22 RELIEF, Model WH (See Figure 4-32) 23 PLUG. Lower Anti-Cavitation (See Figure 4-33) 24 PLUG, Upper Anti-Cavitation (See Figure 4-34) 25 8090- COVER, Top Outlet (See Page 3-3) 26 8091- COVER, End Outlet (See Page 3-4) 27 1039-001 WASHER. Lock (for 1 or 2 work sections only) 28 BOLT, (See Table 3-1) 29 STUD and STUD NUT ASSEMBLY, (See Table 3-1) 30 BOOT ASSEMBLY (See Figure 4-24) 31 MID-INLET SECTION. Split Flow (See Figure 4-7) 32 MID-INLET SECTION, Combined Flow (See Figure 4-8) 33 MID-INLET SECTION. 2 Position (See Figure 4-9) 34 HANDLE ASSEMBLY, Vertical (See Figure 4-20) 35 HANDLE ASS EMBLY. Horizontal (See Figure 4-21) 36 RETAINER , Standard (See Figure 4-22) 37 BRACKET, Handle (See Figure 4-23) 38 WORK SECTION, 3-Way, 3-Position (See Figure 4-2) 39 WORK SECTION, 4-Way, 3-Position (See Figure 4-3) 40 WORK SECTION, 4-Way, 4-Posltion Float (See Figure 4-4) 41 WORK SECTION. 4-Way. 4-Position Regenerative (See Figure 4-5) 42 WORK SECTION, 4-Way, 3-Position With Pressure Detent Release

(See Figure 4-6)

Quanllty Per Assembly

AIR

AIR AIR AIR AIR AIR AIR AIR AIR A/A AIR AIR

1

1 4 4 4

AIR AIR A/A AIR AIR AIR AIR AIR A/ R A/A AIR AIR A/ R

• Buna-N seals are standard for all Gresen valve assemblies. Optional Viton seals are available. See Cross Reference Tables on page 4-31 .

4- 1

LOCATION OF UPPER ANTl·CAVITA.TION CHECKS OR WORK PORT RELIEFS

(2 PLACES) SEE FIGURES 4-28, 4-30,

4-31 AND 4-34

1 3 \

LOCATION OF LOWER ANTI-CAVITATION

CHECK (2 PLACES) SEE FIGURES 4-29

AND 4.33

4 6 7

13 12 11

Figure 4-3. 4-Way, 3-Posltlon Work Section

Item No.

1 2 3 4 5 6 7 8 9

10 11 12 13

P1r1 No.

K-28029° K-7018' K-28060 20153-001· 20164·-0()1 • 2709--001' n90-001 2796--001 7791-001 12172-001 1039--001 8351--001

12351--001 8045-XXX

4-WAY, 3-POSITION WORK SECTION

Descrfpllon

SEAL KIT (Contains Items 2, 3. 4 and 8 plus section seats) SERVICE KIT (Contains items 4 thru 7) POSITIONEA, Standard (See Agure 4-12)

~~~: ~~~=re-cut } Not Sold Separately. Order K-281 os• SEAL, 0-Ring } PLUG. Load Check • SPRING Not Sold Separately. Order K-7018

POPPET PLATE. SeaJ WASH ER, Lock ADAPTER, Clevis HANDLE. BRACKET or RETAINER (See Figure 4-20 thru 4-24) SPOOL. 4-Way } HOUSING, 4-Way See Note

8 A

Quantity Per Section

1 2 2 1 1 1 1 2 1 1 1 1 1

~OTE: These are matched parts and are not sold separately. See page 3-2 for ordering information.

• Buna-N seals are standard for all Gresen valve assembltes. Optional Vi ton seals are available. See Cross Reference Tables on page 4-31.

4-2

Figure 4-7. Spilt Flow Mid-Inlet Section

llem No.

1 2 3 4 5 6

Part No.

0947-001 8011-001 3731-111 8012-001 3953-XXX

SPLIT FLOW MID-INLET SECTION

Description

RELIEF VALVE (See Figures 4-25 thru 4-27) PLUG ADAPTER SCREW PLUG, Split Flow HOUSING

ouanllty

1 , 1 ,

NOTE: Mid-Inlet Sections may be changed from split flow to combined flow in the field by replacing items 3, 4 and 5. Order:

K-7026 Combined Flow Conversion Kit

4-3

, _ UllUIUUll.I

TORQUE TO 66·66 IN . LBS.

(6·7 Nm]

6 3 5 4

Figure 4-21. Horizontal Handle

Item P•rt No. No.

K-28083 K-28085

1 1620-001 2 1857-001 3 0086-001 4 3249-001

3249-003 5 11393-001

11392-001 6 11824-001

HORIZONTAL HANDLE

Description

REPLACEMENT KITS (Contains all items listed below) Replacement Kit with Black Plastic Coated Handle (Standard) Replacement Kit with Plain Handle SCREW. Fii. Hd., 1/4-20 by 3/4 inch long PIN, Clevis PIN, Cotter, 0.078 by 0.50 inch long HANDLE, Horizontal , Black Plastic Coated (Standard) HANDLE. Horizontal, Plain (Optional) PIN, Link } SIDE PLATE, Link Not Sold Separately Order 928-001

BRACKET, Handle

TORQUE TO 66·66 IN. LBS.

(6-7 Nm)

Figure 4·22. Standard Seal Retainer

Item Part No. No.

K-2802.2 1 0562-001 2 11825-001 3 1857-001 4 0086-001

STANDARD SEAL RETAINER

Dncr1ption

REPLACEMENT KIT (Contains items 1, 2, 3 and 4) SCREW, Button Hd .• 1/4-20 UNC by 5/8 inch long PLATE, Retainer PIN, Clevis PIN, Cotter, 0.078 by 0.50 inch long

4-4

Quanllty

4 1 3 1

1 1 1

Quantity

4 1 1 1

TORQUE TO 66-66 IN . LBS .

(6·7 Nm)

1

I

6 5

Figure 4-20. Vertie.al Handle

VERTICAL HANDLE

Item Part Descrlptlon No. No.

K-28080 REPLACEMENT KITS (Contains all Items listed below) Replacement Kit With Black Plastic Coated Handle (Standard)

K-28082 Replacement Kit With Plain Handle 1 1620-001 SCREW, Fii. Hd., 1/4-20 by 3/4 Inch long 2 0086-001 PIN, Cotter, 0.078 by 0.50 Inch long 3 8349-001 HANDLE, Vertical, Black Plastic Coated (Standard)

8349-003 HANDLE, Vertical, Plain (Optlonar) 4 1857-001 PIN, Clevis 5 11393-001 PIN, Link } 0 92 00

11392-001 SIDE PLATE, Unk Not Sold Separately. rder 8· 1.

6 11824-001 BRACKET, Handle

4-5

Quantity

4 3

1 1 1 1 1

TORQUE TO 66 ·66 IN LBS

[6· 7 Nm)

Figure 4·23. Handle Bracket

llem No.

1 2

Pert No.

K-28086 1620-001 11824·001

HANDLE BRACKET

Description

REPLACEMENT KIT (Contains items 1 and 2) SCREW. Fil Hd .. 1/4-20 by 3/ 4 inch long BRACKET. Handle

TORQUE TO 65· 65 IN. LBS.

(6·7 Nm!

2 3

! I .

Figure 4·24. Spool Protective Boot

Item No.

1 2 3

Pert No.

K-7021 K-28104 0562-001 11825-001 12118-002

SPOOL PROTECTIVE BOOT

DescrlpUon

REPLACEMENT KIT (Contains items 1 thru 3) SPOOL BOOT /HANDLE BRACKET KIT (Contains Boot. Bracket and 4 Screws) SCREW, Fil. Head, 1/4-20 x 5/ 8 lnch long RETAINER, Boot BOOT, Dust

4-6

Ouenllty

4 l

Ouanlfty

4 1 1

2

7

3 4

6 TORQUE TO 10 n LBS (13, 6 Nm)

5 TORQUE TO

6 n LBS (8 Nm)

Figure 4-12. Spring Return to Neutral Posltloner

Item No.

1 2 3 4 5 6 7

Part No.

K-28060 3481--001 1608-001 1609--001 1291--001 2673--001 3731-196 3533--001

SPRING RETURN TO NEUTRAL POSITIONER

OescrtpUon

REPLACEMENT KIT (Contains all items listed below) BONNET SPRING COLLAR, Stop WASHER, Lock SCREW, Flt. Hd., 1/4-20 by 1 inch long SCREW, Hex. Soc. Hd., 3/8- 16 by 3/4 Inch long COLLAR, Spool

4-7

Ouanllty

1 1 2 1 4 1 1

TORQUE TO 15· 18 FT. LBS

[20· 24 Nm]

18

19

./"'-.. 17 15

16 14 13 12

Figure 4·25. Model RPSO Pilot-Operated Main Relief Valve.

11 10 9

6

TORQUE RELIEF CARTRIDGE TO

20 FT. LBS. (27 Nm]

MODEL RPSO PILOT-OPERATED MAIN RELIEF VALVE

Item Part No. No.

K-19004" 1 6884-001 " 2 6814-002" 3 2709-001· 4 9020-019 5 1660-001 " 6 1783-001 7 1698-001" 8 12675-001 9 10298-001

10 12676-001 11 12674-001 12 8475-001 13 10071-001 14 10059-001 15 11059-001 16 10034-001 17 9302-006 18 8956-001 19 10035-001

10852-005

Oeecription

SEAL KIT (Contains items 1 thru 7) SEAL, 0-Aing SEAL, 0-Ring SEAL. 0-Rang RING, Back-Up No1 Sold Separately SEAL, O-Ring Order K-19004'

RING, Back-Up SEAL, 0-Ring FILTER RING, Retaining POPPET, Main SPRING POPPET, Relief BODY, Relief SPRING BODY, Pilot Assembly COVER, Tamperproof (RP60N only) NUT, Hex Jam, 3/8" - 24 SCREW, Adjustment WASHER, RPGON (Shown) WASHER, ID, RP60A (Not Shown)

NOTE

Due to close tolerances on working parts. Model RP60 is not field serviceable. If service other than seal re­placement is required, con­tact the factory.

Quantity

, 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

·suna-N seals are standard for ell Gresen valve assemblies. Optional Viton seals are available. See Cross Refer­ence Tables on page 4-31 .

4-8

3 4

I I~

Figure 4-27. No Relief "NA" Plug (Main Relief)

Item Pert No. No.

K-7014 1 2952--001 2 2109-001· 3 1783-001 4 1698-001 .

NO RELIEF "NA" PLUG (MAIN RELIEF)

Description Ouanllty

REPLACEMENT KIT (Contains all Items listed below) PLUG, Relief SEAL. 0-Rlng WASHER. Backup SEAL, 0-Ring

1 , 2

• Buna-N seals are standard for all Gresen valve assemblies Optional Viton seals are available. See Cross Reference Tables on page 4-31 .

FROM ¢ TO EXHAUST--+---<1 '----CYLINDER

CORE PORT

Figure 4-28. Upper AntJ-CavltaUon Check Valve

Item Ho.

1 2 3 4 5 6

Patt Ho.

K-28064 K-28062 6529-001 1661-001 21055-001 1718-001 9020-022 1616-001"

UPPER ANTI-CAVITATION CHECK VALVE

REPLACEMENT KIT (Contains all Items listed below) SEAL KIT (Contains Items 4, 5 and 6) BODY RETAINER, Ball BALL SEAL, 0 -R lng } WASHER, Backup Not Sold Separately. Order K-28062 SEAL, 0-Ring

Ou.nllty

1 1 1 1 1

· s una-N seals are standard for all Gresen valve assemblies. Optional Vlton seals are available. See Cros Reference Tables on page 4-31.

4- 9

FROM -EB TO EXHAUST CYLINDER CORE PORT

3

Figure 4-29. Lower Anti-Cavitation Check Valve

Item No.

1 2 3 4 5 6

Part No.

K-28065 K-28063 6526-001 1659-001 21054-001 1660-001 6527-001 1698-001°

LOWER ANTI-CAVITATION CHECK VALVE

OflCripllon

REPLACEMENT KIT (Contains all items listed below) SEAL KIT (Contains items 4, 5 and 6) BODY RETAINER, Ball SALL SEAL, 0-Rlng Not } WASHER, Backup Sold Separately. Order K-28063 SEAL, 0-Rlng

Quantity

1 1 , , 2 1

·euna-N seals are standard for all Gresen valve assemblies. Optional Vlton seals are available. See Cross Reference Tables on page 4-31 .

4-10

20 19 18 11 16 15 14

Figure 4-30. Model RP51 Pilot Operated Work Port Relief Valve.

TORQUE TO 1S- 18 FT. LBS.

(20- 24 Nm)

1~ 8

tO

TORQUE RELIEF VALVE ASSEMBLY TO 20 FT. LBS. (27 ,2 Nm]

MODEL RP51 PILOT OPERATED WORK PORT RELIEF VALVE

Item Pen Description Ou entity No. No. Per Relief

K-19005' SEAL KIT (Contains items 12 thru 20) 1 12675-001 FILTER 1 2 10298·001 RING, Retaining 1 3 20254-001 SPRING 1 4 10209-001 POPPET, Main 1 5 8475-001 POPPET, Relief 1 6 8954-001 BODY, Relief Valve 1 7 11059-001 BODY, Pilot Assembly

NOTE 1

8 9302-006 NUT, Hex Jam 1 9 8956-001 SCREW, Adjustment Due to close tolerances on 1

10 10059-001 SPRING, Pilot working parts. Model RP51 1 11 10035-001 WASHER, RP51-N (Shown) is not field serviceable. If 1

10852-001 WASHER, ID, RP51-A (Not Shown) service other than seal re- 1 12 6884-001" SEAL, 0-Rlng placement Is required, con- 1 13 6814-002' SEAL. 0-Rlng tact the factory. 1 14 1615-001" SEAL. 0-Rlng 1 15 9020-019 RING, Back-Up Not sold 1 16 1660-001" SEAL. 0-Rlng separately. 1 17 9000-113" SEAL, 0-Rlng Order K-19005 1 18 9021-113 RING, Back-Up 1 19 9020-022 RING, Back-Up 20 1110-001· SEAL, 0-Rlng 21 10034-001 COVER. Tamperproof (RP51 ·N only)

·euna-N seals are standard for all Gresen valve assemblies. Optional Viton seals are available. See Cross Refer­ence Tables on page 4-31 .

2 3 4 5 6 7 8

12 9 10

Figure 4-32. Model WH Olfferential Poppet Work Port Relief Valve (Non-Adjustable).

Item No.

1 2 3

4 5 6 7 8 9

10 11 12

MODEL WH DIFFERENTIAL POPPET WORK POAT RELIEF VALVE (Non-Adjustable)

K-19002 K-19003 1880-001 6533-001 1450-001 1864-001 1451-001 1865-001 1870-001 7497--001 0458--001 0459-001 0462-001 1883-001 1881-001 9020--022 1718-001 1615-001 • 2707-001 •

Descrfpllon

SERVICE KIT (Contains items 7 and 8) SEAL KIT (Contains items 9 thru 12) CAP, Relief BODY SPRING, 500-1350 PSI (34-93 bar] SPRING, 1351-1750 PSI [94-121 bar) SPRING, 1751-2000 PSI [122-138 bar] SPRING, 2001-2600 PSI [138-179 bar) SPRING, S.S., 2001-2600 PSI [138-179 bar) SPRING, S.S., 2601-3200 PSI [180-221 bar] SHIM, (.040 Inch) [1,02mm) SHIM, (.020 inch) [0,51 mm) SHIM, (.010 Inch) [0,25mm) RING, Piston } POPPET, Relief Not Sold Separately. Order K-19002

WASHER, Backup} SEAL, 0-Ring SEAL, O-Ring Not Sold Separately Order K-19003

SEAL, 0-Ring

Ou1nllly

1 1

1 1 1 1 ,

AIR AIR AIR

1 1 1

1 1

"Buna-N seals are standard for all Gresen valve assemblies Optional Viton seals are available See Cross Reference Tables on page 4-31 .

4-12

Figure 4-33. Lower Anti-Cavitation Plug

Item No.

1 2 3 4

Par1 No.

K-28087 K-28063 6759--001 1698-001" 6527-001 1660-001

LOWER ANTI -CAVITATION PLUG

Description

REPLACEMENT KIT (Contains all items listed below) SEAL KIT, (Contains Items 2, 3 and 4) PLUG SEAL, 0-Aing ) WASHER, Backup Not Sold Separately. Order K-28063 SEAL. 0-Ring

Quantity

, 2

"Buna-N seals are standard for all Gresen valve assemblies Optional Viton seals are available. See Cross Reference Tables on page 4-31 .

4

Figure 4-34. Upper Anti-Cavitation Plug

Item No.

1 2 3 4

Part Ho.

K~132 K-28062 6760-001 1615-001° 9020--022 1718--001

UPPER ANTI-CAVITATION PLUG

DetatpUon

REPLACEMENT KIT (Contains all Items listed below) SEAL KIT (Contains Items 2, 3 and 4) PLUG SEAL, 0-Rlng } WASHER, Backup Not Sold Separately. Order K-28062 SEAL, 0-Ring

1 1 1 1

·auna-N seals ere standard on all Gresen valve assemblies. Optional Vlton seals are available. See Cross Reference Tables on page 4-31.

4-l3

Standard Buna-N Seals and 0-Rlngs

All standard Gresen products utilize Buna-N seals which are compatible with petroleum base, water­in-oil emulsions, and water-glycol fluids. Phosphate ester type fire-resistant fluids will cause Buna-N seals to swell. This swelling is not normally detrimental to static seals, but will be a problem ror dynamic seals such as valve spool seals. Swelling or these seals can result in binding. The temperature range or Buna-N seals is -40° F to +200°F [-40°C to +93°C].

Table 4-1. Cross Reference for Seals and 0 -Rlngs Buna-N to Vlton

Buna·N VII on Application Part No. Part No.

0926-001 6273-001 Relief Seal 1615-001 7447-001 Relief and Check Seal 1621-001 6274-001 Large Section Seal 1622-001 6275-001 Small Section Seal 1660-001 None Check Seal 1698-001 6276-001 Relief and Check Seal 1718-001 None Relief and Check Seal 2707-001 7448-001 Relief Seal 2709-001 6277-001 Relief Plug Seal 6814-001 7450-001 Reher Seal 7877-001 None Piston Seal 7951-001 None Piston Seal

Optional Vlton Seals and 0-Rlngs

Vi ton seals are recommended for most applications that use phosphate-ester type fluids. Vi ton seals are also recommended for applications that have a con­tinuous operating temperature of f-200°F [+93°CJ or more Viton seals are available for Gresen Model V42 Valves.

Table 4-2 Cross Reference For Seal Kits. Buna-N to Vi ton

Buna-N Vllon Appllcallon Part No. Part No.

K-7014 K-28033 No Relief "NA" Plug Kit K-7018 K-7020 Check Plug Kit K-28029 K-28032 Spool and Section Seals

Table 4-3. Cylinder Port Plugs and Seals for 3-Way Work Sections

Part No.

1282-001 1288-001 1726-001 1629-001 2708-001 2710-001

4-14

OescrlpUon

Cylinder Port Plug (3/4" NPTF) Cylinder Port Plug (1" NPTF) Cylinder Port Plug (SAE 12) Cylinder Port Plug {SAE 16) 0-Ring for SAE 12 Plug 0-Ring for SAE 16 Plug

·.

•I

•" • I

l · ,. .. . .. ..

•' ..

• I

.,

,. . .. . .. ' . ... . '

• • • r . . .

lMIOIUO

""'"" ONLY'

'~o . -

. ,\•

' . ..

..

...

. ....... · ... . ,. -•I ':. • .... :. t "' t!'

:.• ·' ,. . \ . '.

·.; ..

, .. . " . '•

..

TOLfllAhCl \JHUSS OTHEHW1SE Sl'fCtfttQ

otc x. • !:::::: WAit ®.,,.._.:. r •·!I

. . . . ·~:'

....... ,..

•.

. " ' . .. ·

r.

·/ "+ SllE ~,e1N~ Po~T • I '. '

...

:

. - · ..... , . .. . ·. ... • I ·· .. -

.. !· ..

' • r

••• •:t ' •

' . . . ... -:

... T : ; • I I .. ,

t I.:

..

,.

. " I•

~·~· ~-.co. ". flf~f ,_, ·-· _,....._,_ l!llfllHl»OUI .° • · - ·· .. ,. ' ¥111tfUQT4 '

. RELIE~ RP-53 -~ -·-·---·-.. OJC JIU a~ \I :;:.:,n....:,":n:.=:a---==:=.'=::._•:,:.:

MA~lilNE ~.....,......._......, ft.':1:°'..,:''-=r'...::C-.:=:=:.:-..:.---REMaT~ V~NT/_FuoT, Co~L AS.SY · . · ·· .'

•'' ----·--- - . ·--11.$~6-< J

~c;uVJ1 • !:::::' '''l'Sri liiiii -.;::..,_ ... .,_,.,.._.,... •• ';:'t;v"

"''-' '*"""'°"' ··-· l it, !'· t.,._·1""' ,.... c B 't'•• I : • • . .. ~· ·~ .

GRESEN MANUFACTURING ENGINEERI j PARTS LIST DATE 11/01/89 ~ ' E 09.05.29

PARENT ITEM NO. DESCRIPTION ERO NO REV TEST SPEC PAGE I OF I ll56600l REl1EftRP53 3501017 /I / f'"q E RE L SEQ. COMPONENT

DESCR IPTION OTY. PER LEVEL NO. ITEM NUMBER

l 04242001 RELIEFtRP53 SUB- AS SY i.ooo

.2 IJ 01615001 SEALtO RING-AS023,90 OUR 1.000

.2 5 01660001 SElLtO RING-AS0l9,QO OUR i.ooo

.2 I I 09000113 SE~L,O-RING-AS~ll3t70 OU t.ooo

.z I 'L 09020019 Rl~GtBACK UP-ASOl9tCONT i.ooo

.2 )_ 10298001 RI~G,RETAINlNG 1.000

.z I 12675001 FILTERtRELlEF RP 1.000

.z if 20209001 POPP ETtMAIN RP5l i.ooo

.2 R 202 54001 SP,ING,.418 OD X .049 WO 1.000

.z } () zoqo3001 Rl~GtBACK-UP-SCARF-CUT l.ooo

.2 0006 06954001 BOJYtRP51 1.000

.z 0007 11576001 PILOT HEAO,RP-53 ASSY t.ooo J? ./"? , ~,.,,.

l 0003 09020022 RI~GtBACKUP-AS022t C ONT. 1.000

l 0009 01716001 SE~LtO RING-AS022e90 DUR i.ooo

.9 ROTEK BEARING REMOVAL AND REPLACEMENT

REMOVAL

STEP 1: Place crane boom lh suitable support structure.

STEP 2: Shut off and secure electrical system to crane.

STEP 3: Disconnect and tag all electrical wiring from slip-ring to operators cab and platform. Disconnect and tag all electrical wiring between operators cab/platform and crane booms.

STEP 4: Remove torque arm from slip-ring. Lower slip-ring to bottom of pedestal and protect from damage.

STEP 5: Rig operators cab ahd platform for level pick. Remove the platform to turret mounting bolts and lift platform away.

STEP 6: Rig boom and turret assembly for level pick. Use suitable heavy lift crane with at least 15,000 Lbs capacity. Pull slack from rigging without applying tension to bearing bolts.

STEP 7: Remove turret to bearing bolts and remove turret/ boom assembly from bearing.

STEP 8: Rig bearing for lift and remove bearing to pedestal flange bolts. Remove bearing from pedestal and discard all bearing/turret mountfng bolts, washers. and nuts.

STEP 9: Inspect the turret and pedestal flange mounting surfaces. It excess pitting or corrosion exists. surface should be sand blasted and a suitable bedding compound should be used to set the new bearing.

STEP 10: Inspect pinion drive gears for excess wear or damage. Service as required.

INSTALLATION

STEP 1: Hoist new Rotek bearing In place on pedestal. See Step 9 above. If bedding Is required go to Step 2 below. Otherwise, bolt bearing to pedestal flange with new bolts. washers, and nuts. Torque bolts to proper setting with a crossing pattern In 200 Ft-Lb steps.

STEP 2: Mix metal filler, DEVCON or equal. per manufacturer recommendations and apply a 1 / 8" layer to bearing surface. Use care to prevent filler from entering bolt holes.

STEP 3: Rig turret and boom assembly for level pick and lower assembly into place; align mounting holes and tighten turret to bearing. Torque to all bolts to 200 Ft-Lb.

NOTE: For ease of installation and alignment of pinion gears to ring gear, disconnect brake line at shuttle valve and use hydraulic hand pump to release brakes.

STEP 4: Allow metal tiller material to cure per manufacturer's recommendation. Support of boom during curing ls recommended, but not required. Attach slip-ring to the turret and re­connect all wiring below turret. Connect torque arm to slip-ring.

STEP 5. After metal filler has cured, 12 hrs to 24 hrs, torque turret to bearing mounting bolts to proper torque in 200 Ft-Lbs steps.

Bearing service cont.

STEP 6: Rig operators cab/platform for level pick and lower Into place on turret. Install the platform to turret bolts and torque to the correct amount as outlined above.

STEP 7: Connect all wiring from the slip-ring to the boom and operators cab. Check wiring for grounding before powering circuit. Insure that the main grounding lead is installed.

STEP 8: Bump start electric motor and check for correct rotation. Change motor leads if required. Open suction valve and start motor. Allow unit to operate unloaded for a few minutes. This Is the Ideal time to check for leaks and correct function of the rest of the electrical system.

STEP 9: Carefully operate each crane function and insure correct operation. If all systems and controls seem to be operating correctly, proceed to next step.

STEP 10: Lubricate Rotek bearing with high quality EP-2 MoSo2 grease. Start hydraulic system to crane and make five (5) complete revolutions with swing. Inspect for alignment and/ or binding. Correct as required. While slowly rotating, < 1 RPM, apply 10 pumps with grease gun for every 90 degrees of rotation.

Crane is ready for service.

.10 WINCH REMOVAL

STEP 1: Remove wire rope from load block.

STEP 2: Unspool wire rope from drum and store in safe place.

STEP 3: Shut off and secure electrical system to crane.

STEP 4: Remove and tag hydraulic hoses to winch.

STEP 5: Remove and discard eight (8) mounting capscrews. With suitable lifting device, remove winch from crane.

Service winch per Braden Service and Repair manual

INSTALLATION

STEP 1: Position winch over mounting holes and Install new mounting capscrews. (ASTM 490 Gr 8). Torque to correct setting in 50 Ft-Lb steps.

STEP 2: Install hoses per tags.

STEP 3: Start hydraulic system and check for correct rotation and leaks.

STEP 4: Reeve wire on winch and reconnect load block.

STEP 5: Connect test load, 100% of winch rated load, and test operation of winch. Remove test load and connect proof load, 125% winch rated load, use boom up to test operation of holding capacity.

Crane Is ready for service

CH I

CONSTRUCTION HOIST

EXPLANATION OF MODEL NUMBER 150 A - 23 090 - 01

I MAX

RATING

"'T -,-- I -.-DESIGN GEAR MOTOR DRUM MODEL RATIO SIZE SIZE

CH DESIGNATES CONSTRUCTION HOIST (C2H DESIGNATES TWO SPEED) 150 DESIGNATES 15,000 LB FIRST LAYER LINE PULL A DESIGNATES THE MODEL SERIES RELATING TO DESIGN CHANGES 23 DESIGNATES TOTAL GEAR REDUCTION

- 1 T API

090 DESIGNATES HYDRAULIC MOTOR DISPLACEMENT IN CU IN/REV (DECIMAL POINT ELIMINATED). EXAMPLE 090 = 9.0 CU IN/REV)

01 DESIGNATES THE DRUM OPTION 1 MEETS API 2C RECOMMENDATION

TO ORDER PARTS -(1) List model and serial numbers of the winch. (2) Refer to exploded view and select the component(s) needed and note item number. (3) Find item number on material list, show part number, description and quantity required on your order. (4) Refer to Parts Price list and show price for each component or assembly.

RECOMMENDED f)LANETARY GEAR OIL We have published the following specification to help you determine which lubricant is best suited to

your application. Your lubricant supplier should assure you that his product meets these specifications. If there is still any doubt as to the suitability of a lubricant, contact the Braden Service Department.

°F-40 -30 -20 -10

MOBIL SHC 630 SYNTHETIC

0

' .

RECOMMENDED GEAR OIL

PREVAILING AMBIENT TEMPERATURE 10 20 30 40 50 60 70 80 90 100 110 120 130°F

TEXACO MEROPA 150 OR EQUIVALENT API GL-2/3

TEXACO MEROPA 220 OR EQUIVALENT API GL-2/3

NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS: OFFSHORE CRANES, SUSTAINED FAST DUTY CYCLES OR FREQUENT LIFTING.-----~

WINCH MODEL NUMBER

WINCH SERIAL NUMBER

The winch model number and serial number are stamped into the top of the motor side end plate. Both of these numbers are extremely important in the shipment of the proper replace­ment parts, and your order should always reference them.

(

BRAKE CYLINDER ASSEMBLY NO. 81614 BASIC MATERIAL LIST

ITEM NO. QTY. PART NO. DESCRIPTION ITEM NO. QTY. PART NO. DESCRIPTION 2 1 24448 Brake Cylinder 31 3 24113 Spiral Pin

3 1 24439 Brake Piston 41 1 244S3 Bearing Support

4 1 24438 Brake Piston Plate 42 8 13413 Capscrew (1/2 - 13 x 1'/2 GS) s 1 24463 Backup Plate 44 1 18066 Reducer Bushing

6 8 244S6 Belleville Spring 4S 1 10074 Relief Valve

7 1 244S4 Spring Guide 46 1 22374 Pipe Plug

8 1 24474 Retaining Ring 49 1 24466 Motor Adapter

9 1 13031 Snap Ring so 1 24484 O·Ring

10 1 23486 Snap Ring S1 8 244SS Brake Cylinder Capscrew

11 1 2447S 0-Ring 64 1 24486 Ball Bearing

12 1 24476 O·Ring 6S 1 24487 Ball Bearing

13 1 24477 Backup Ring 66 10 24490 Brake Disc

14 1 24478 Backup Ring 67 9 2SS30 Friction Disc

1S 1 13709 Street-Elbow - 4S 0 69 1 23834 Oil Seal

OVERRIDING BRAKE CLUTCH 70 1 10427 . Oil Seal 72 1 1904S Plug

ASSEMBLY NO. 81644 73 1 24489 Brake Plate Spacer

ITEM NO. QTY. PART NO. DESCRIPTION 76 1 2S038 Nipple

17 1 NSS Outer Brake Race t 97 .. 1 2S1S9 Adapter

18 1 NSS Inner Brake Race t 98 .. 1 25160 Sight Glass

19 2 24866 Snap Ring 99•• 1 19034 Pipe Plug

20 2 24862 Sprag Bearing Retainer 100 ... 1 223S1 Bearing Race (.092 " thick)

21 1 NSS Sprag Clutch t 101 .. . 1 180SO Thrust Bearing

24 2 2486S Sprag Bearing 102· .. 1 26291 Bearing Race (.063 " thick)

74 1 24S06 Retaining Ring .. Used on API winches

t NSS - Not serviced separately, order entire brake clutch assembly no. . .. Design revision , not in all models. Also requires revised items 26 & 28. 81644.

MATERIAL LIST VARIABLES CH150 & CH175 & CH185 & CH230 &

ITEM C2H150 C2H17S C2H185 C2H230 NO. DESCRIPTION QTY. PART NO. QTY. PART NO. QTY. PART NO. QTY. PART NO. 26 Primary Planet Carrier (Revised) 1 26292 1 26292 1 26293 1 26293

Primary Planet Carrier (Old) 1 24447 1 24447 1 24567 1 24S67 27 Primary Planet Gear 3 24442 3 24442 3 24575 3 24S75 28 Primary Planet Gear Shaft (Revised) 3 26294 3 26294 3 26295 3 2629S

Primary Planet Gear Shaft (Old) 3 24461 3 24461 3 24S72 3 24S72 29 Thrust Washer 6 24479 6 24479 6 24167 6 24167 30 Roller Bearing 3 24480 3 24480 3 24579 3 24S79 32 Thrust Washer 1 24481 1 24481 1 24581 1 24581 34 Output Planet Carrier 1 24S68 1 24568

S/N Below 8401827 1 24441 1 24441 S/N Above 8401826 1 2S291 1 2S291

35 Output Planet Gear 3 24S76 3 24576 S/N Below 8401827 3 24443 3 24443 S/N Above 8401826 3 2S288 3 25288

36 Output Planet Gear Shaft 3 24S73 3 24S73 S/N Below 8401827 3 24462 3 24462 S/N Above 8401826 3 25289 3 2S289

37 Thrust Washer 6 11894 6 11894 S/N Below 8401827 6 24482 6 24482 S/N Above 8401826 6 11932 6 11932

38 Roller Bearing 6 24S80 6 24S80 S/N Below 8401827 6 24483 6 24483 S/N Above 8401826 6 25292 6 25292

39 Spiral Pin 3 24113 3 24113 3 24S82 3 24S82 40 Support End Plate 1 24468 1 244S2 1 24S91 1 24468 43 Lockwasher ('h ) 32 11026 36 11026 36 11026 32 11026 48 Motor End Plate 1 24467 1 24451 1 24590 1 24467 S3 Ring Gear 1 24446 1 24446 1 24574 1 24S74 54 Ring Gear Adapter 1 29391 1 29391 1 24S69 1 24S69 SS Primary Sun Gear 1 24445 1 2444S 1 24577 1 24S77 S6 Cable Drum Closur~ 1 24464 1 2446S 1 24S87 1 24464 S7 Output Sun Gear 1 24444 1 24444 1 24S71 1 24571 S8 Thrust Washer 1 2448S 1 2448S 1 2448S 1 2448S S9 ' Cable Drum 1 24460 1 24SOS 1 24S86 1 24S78. 60 Base Capscrew 16 24130 16 24130 20 24130 16 24130 61 ' Tie Plate 2 24471 2 24472 2 24S84 2 24471 62 Bearing Spacer

S/N Below 8401827 3 244S7 3 244S7 S/N Above 8401826 3 25290 3 25290

68 0-Ring 1 24773 1 24772 1 24S92 1 24473 71 Cable Wedge 1 24493 1 24492 1 24493 1 24494

' CH 185A-02, USE # 2S177 CABLE DRUM AND # 2S174 TIE PLATES.

STANDARD MOTOR INSTALLATION

SINGLE SPEED MOTOR HYDRAULIC SUB ASSEMBLIES CH150, CH175, CH185 & CH230

ITEM PART NO. DESCRIPTION QTY. NO. 77 11 cu . in. Hydraulic Motor 1 61660

12 cu. in. Hydraulic Motor 61661 9 cu . in. Hydraulic Motor 61662

78 Brake Valve 1 81609 79 Capscrew (1/2 - 13 x 41/2 GS) 4 23690 80 0-Ring 1 10330 81 0-Ring 1 13S42 82 Tee-Male Branch 1 22934 83 Hose Assembly - 16 in. 3 13706

8S Elbow 2 21163 86 Elbow 1 25302 87 Reducer-Elbow 1 24236

88 Capscrew (112 - 13 x 1'/2 GS) 4 13413 89 Lockwasher ('h ) 4 11026

Note: Item 86 is included in Item 77 Motor Kit to insure assembly .

TWO SPEED MOTOR HYDRAULIC SUB ASSEMBLIES

C2H150. C2H175 C2H185 ITEM NO. DESCRIPTION 77 Hydraulic Motor - 2 speed 78 Brake Valve 79 0-Ring 81 0 -Ring 82 Elbow Tpg. Ftg. 84 Tee-Male Branch 85 Hose Assembly - 17 in. 86 Hose Assembly - 10 in. 87 Capscrew (112 - 13 x 1'/2 GS) 88 Lockwasher (112) 89 Elbow 90 Capscrew (7/, 6 - 14 x 3% GS) 91 Elbow Fitting

REFER TO BACK PAGE FOR API MOTOR INSTALLATION

0-RING AND SEAL KITS WINCH MODEL KIT PART NO. CH1SO, C2H1SO 61611 CH230, C2H230 61611 CH17S, C2H175 61612 CH18S, C2H18S 61613

All kits contain item numbers 11 , 12, 13, 14, 50, 68, 69 & 70.

C2H230 PART

QTY. NO. 1 2S337 1 81586 1 211SO 1 10330 2 21163 1 22934 2 13707 1 13711 4 13413 4 11026 1 24236 4 24012 1 2S302

> J

BRADEN 2nd GENERATION

CH SERIES COIVIPONENTS

ON API WINCHES, THESE PARTS REPLACE ITEM 46.

~

tL

NOTE: Serial numbers 8203197 and 8203198 (CH 150) and 8203199, 8203200, 8203201, 8203202, 8203195, 8203196 and 8203193, (CH 175) are equipped with brake/clutch assembly 81615. All other serial numbers are equipped with brake/clutch assembly 81644 (item number~ 17, 18, 19, 20, 21, 24 and 74). ·contact Braden Winch Co. for repair parts if you have one of the above listed serial numbers.

t i

API MOTOR l,NSTALLATION

SINGLE SPEED MOTOR HYDRAULIC SUB ASSEMBLIES. CH150, CH175, CH185 & CH230

ITEM PART NO. DESCRIPTION QTY. NO. 77 11 cu. in. Hydraulic Motor 1 61660

12 cu. in Hydraulic Motor 1 61661 9 cu. in. Hydraulic Motor 1 61662

78 Brake Valve 1 81609 . 79 Capscrew('h -13x41h G5Socket Hd.) 4 23690 80 0-Ring 1 10330 81 0-Ring 1 13542 82 Tee - Male Branch 1 22934 83 Hose Assembly - 16 in . 3 13706 85 Elbow 1 21163 86 Elbow 1 25302 87 Reducer - Elbow 1 24236 88 Capscrew (112 - 13 x 11/2 G5) 4 13413 89 Lockwasher (112) 4 11026 92 Tee 1 23769 93 Needle Valve 1 25258 94 Male Connector 1 21219 95 Warning Tag 1 25257 96 Pipe Plug 1 22374

TWO $PEED MOTOR HYDRAULIC SUB ASSEMBLIES

C2H150, C2H175, C2H185 & C2H230 ITEM PART NO. DESCRIPTION QTY. NO. 77 Hydraulic Motor - 2 speed 1 25337 78 Brake Valve 1 81586 79 0-Ring 1 21150 81 0-Ring 1 . 10330 82 Elbow Tpg. Fig. 1 .. ,. .. 2·1163 84 Tee - Male Branch 1 i 122934 85 Hose Assembly - 17 in . . 2 13707 86 Hose Assembly - 10 in . 1 13711 87 Capscrew (112 - 13 x 1'/2 G5) 4 13413 88 Lockwasher (112) 4 11026 89 Elbow 1 24236 90 Capscrew ('/,6 - 14 x 3V. G5 Socket Hd.) 4 24012 91 Elbow Fitting 1 25302 92 Tee 1 23769 93 Needle Valve 1 25258 94 Male Connector 1 21219 95 Warning Tag 1 25257 96 Pipe Plug 1 22374

:,r-.

The Braden HVSOA Brake Valve was designed ex­pressly for use on Braden planetary gear winches with maximum flow rates up to 80 GPM. It acts in conjunc­tion with the hydraulic motor, winch brake, overrunning clutch, gear train and drum to provide precise load con­trol under varying load conditions and hydraulic oil temperatures.

THEORY OF OPERATION The brake valve mounts on the hydraulic motor and con­trols the flow of fluid out of the motor when a load is be­ing lowered, thereby controlling the speed of the motor and load .

Basically, the control portion of the valve consists of a spring-loaded spool which blocks the oil's passage out of the motor until enough pilot pressure is applied to the end of the spool to shift it - against the spring pressure - to a position that opens a passageway. Once the valve begins to open, the size of the opening is directly propor­tional to the distance the spool moves. A poppet-type check valve located inside the brake valve permits fluid to bypass the valve's control function and flow directly to the motor when the flow is reversed to raise a load .

The winch brake is a spring-applied, hydraulically­released, multiple-disc type located inside the winch . When engaged, it locks the outer part of the overrunning clutch to the winch housing. The inner part of the over­running clutch is a part of the power train and is located between the motor and the planetary-gear reduction. The overrunning clutch is constructed in such a way that the inner part can be rotated freely in one direction, but automatically locks itself to the outer part when rota­tion in the opposite direction is attempted. The power · train components, including the motor and drum, are constantly engaged during all winching operations.

When the directional control valve handle is moved to a position to raise a load, oil is directed to the brake valve where it lifts the check valve poppet off its seat, and oil flows to the motor. The winch brake release port and the brake valve pilot port are connected to a manifold at­tached to the side of the motor which is the low pres­sure side during hoisting operations; therefore, the brake remains engaged and the control passageway in the valve remains closed. The overrunning clutch is

BRADEN

HVBOA BRAKE VAL VE* positioned in the winch in such a way that its inner part will turn freely relative to the outer part when the motor rotates in the direction to raise a load. When fluid pressure at the motor inlet increases to the point where the motor torque is sufficient to raise the load, the motor will begin to turn, and the winch will raise the load. The rate of flow to the motor, and consequently the speed of the motor and the load, is established by the position of the directional control valve handle within the " raise" portion of its travel.

When the directional control valve handle is returned to neutral, both motor ports are connected to tank through the directional control valve ; consequently, the pres­sure at the motor inlet drops to zero, and the load stops and attempts to reverse its direction. The load cannot drive the power train backward, however, since the in­ner part of the overrunning clutch, which is a part of the power train, locks itself to the outer part when rotation is attempted in this direction, and the outer part is locked to the winch housing by the winch brake. The load, therefore, is supported by the winch brake when the directional control valve is in neutral.

When the directional control valve handle is moved to a position to lower a load, oil is directed to the motor through the manifold. The motor cannot turn, however, because the winch brake is engaged, locking the outer part of the overrunning clutch to the winch housing; and the inner part, which is a part of the power train , cannot rotate in this direction relative to the outer part. Since the brake release port and brake valve pilot port are connected to the manifold, as pressure to the motor in­creases, pressure on these ports also increases. The brake release piston and springs, and the brake valve spool and spring, are sized so that the brake will com­pletely release before the brake valve spool begins to move. When the pressure is high enough to release only the brake, the load begins to turn the motor. Except for internal leakage, the motor would not be able to turn, because the oil's passageways through the brake valve are closed : one by the spool which has not yet moved, and the other by the poppet-type check valve. Internal leakage in the motor does, however, allow it to turn very slowly, permitting the precise positioning of a load. The fact that internal leakage does occur is the reason a winch brake is necessary. Without a brake , a load would slowly drift downward whenever the directional control valve is in neutral. When the pressure increases to a point where the brake valve spool begins to open a passageway through the valve, the motor begins to rotate more rapidly, and the load begins to move faster. As the load accelerates, the pressure on the inlet side of the motor decreases, because the motor is now ac­ting as a pump. Since the brake valve pilot port is con­nected to this side of the motor, the pilot pressure drops; the spring moves the brake valve spool in the

*Patent Number 4,404,891

--·------- - ------------------

direction to reduce the valve opening ; the flow out of the motor decreases, slowing the motor and the des­cent of the load . The pressure on the inlet side of the motor will then increase , causing the valve opening to again increase , speeding up the descent of the load . With a given flow rate to the motor - which is controlled by the position of the directional control valve handle within the " lower" portion of its travel - the brake valve will automatically establish a balance between spring pressure trying to close it and pilot pressure trying to open it, and the load will be controlled at a constant rate of descent. Adjustment of the control handle position will cause the brake valve to establish a different con­stant rate of descent. To stop a load during a lowering operation, the direc­tional control valve handle is moved to neutral ; the motor inlet pressure and brake valve pilot pressure drop; the brake valve closes, reducing the speed of the load to near zero; then , the winch brake automatically engages to stop and hold the load .

BRAKE PISTON

MULTIPLE DISC BRAKE

The small ball check valve located inside the brake housing is a part of the motor drain system and has nothing to do with the control function of the valve . The motor is internally drained to the low pressure port of the motor during a raising operation and externally drained through the check valve to the low pressure side of the brake valve during a lowering operation. By providing low pressure paths to drain fluid which leaks past the high pressure seal inside the motor, the low pressure motor shaft seal is subjected only to system back pressure. The check valve closes during a raising operation to isolate the drain system from the raise pressure.

The small piston inside the brake valve spool is the damper piston . This piston acts to retard the motion of the spool when it shifts to open the valve , thereby reducing flow surges and resultant erratic load action which could otherwise be quite severe when the direc­tional control valve is opened too quickly.

TO TANK

SUGGESTIONS FOR TROUBLE SHOOTING

If the winch will not lower a load , or not lower it smoothly, the problem is likely a plugged or loose orifice. There are two .020 " diameter orifices in the brake valve . They are described in the following assem­bly/disassembly procedure . To correct this problem, clean the orifices and be sure to tighten the pilot orifice in the valve body.

If the winch allows the load to creep down when the control valve is in neutral , the problem is not in the brake valve, for it does not function when the control valve is in neutral. The problem is usually caused by high back pressure or malfunction of the winch brake. Refer to the winch service manual.

1 PROCEDURE FOR DISASSEMBLY

5

Clean the outside surfaces of the valve. Select a clean , dust free work area, as cleanliness is of utmost importance when servicing any hydraulic equipment .

Remove the spring retainer and spool spring as shown . Measure the overall free length of the spool spring . Replace it if it is less than 1 15

/ 15" long .

DAMPER PISTON

Remove the damper piston from the spool as shown . The piston will come out slowly , because of a partial vacuum formed as it is removed . Take care not to damage the polished surfaces on the piston or spool.

Remove the pilot orifice as shown, using a %2 " alien wrench.

SLIDE SPOOL IN OR OUT FROM THIS END OF VALVE BODY ONLY

Remove the plug and spool as shown . The spool should always be removed from this end of the valve housing to minimize the possibility of damaging the o-ring . Take care not to damage the polished sur­faces on the spool.

Remove the check valve spring retainer, check valve spring and check valve poppet as shown. Measure the overall free length of the check valve spring . Replace it if it is less than 1 1/2 " long.

7

Remove the plug , drain check valve spring and ball as shown . Measure the overall free length of the drain check valve spring . Replace it if it is less than 1 '!.. " long .

9 ASSEMBLY PROCEDURE

ooo Install new o-rings on the plug and spring retainers , being careful not to damage the o-rings.

11

ORIFICE

Inspect the . 020" diameter orifice in the end of the spool to make certain it is open.

Discard all o-rings and back-up rings. Clean all parts in a good grade of cleaning solvent. Inspect the ex­ternal polished surfaces on the spool and damper piston for damage that might result in fluid leakage. Inspect the bore the spool slides in and the bore in the spool for damage that might result in leakage . In­spect both check valve seats , the ball and the pop­pet sealing surfaces for damage that might result in fluid leakage. Replace parts as required .

Install new o-rings and back-up rings on the spool and damper piston as shown . It is important that each back-up ring is on the correct side of it's o-ring. Take care not to cut the o-rings during assembly . Let the spool and damper piston set for ten minutes before installing them in their respective bores. This will allow the o-rings to return to their original size after being stretched .

12

Lubricate the o-ring on the damper piston and install the piston in the spool as shown .

-----

13

r

SLIDE SPOOL IN OR OUT FROM

THIS END OF VALVE BODY ONLY

Lubricate the o-ring on the spool and slide the spool into the valve body as shown. Always install the spool from the end shown to minimize the possibility of damaging the o-ring . Install the plug .

Inspect the . 020 " diameter hole in the orifice to make certain it is clean . Install the orifice tightly in the valve body.

17 SPRING RETAINER

SPRING

POPPET

Install the check valve poppet, check valve spring and check valve spring retainer as shown .

Install the spool spring and the spring retainer.

16 .'' i

J 'J' ' , PLUG-j' . ,. •

;, .. ,--. .. !'· .

Install the ball, drain check valve spring and plug as shown . Use a good grade of thread sealant on the plug .

18 TO MOTOR DRAIN AND BRAKE BALANCE PORT (BP) IF SO EQUIPPED

TO BRAKE RELEASE AND MOTOR MANIFOLD

Hydraulic hook-up is as shown . Note: not all winches are equipped with a balance port.

Item

0-Ring Kit Part Number 61567 Consists of the Following:

Part No. Quantity No. Description

7 1 24186 0-Ring 12 2 23601 0-Ring 13 24193 0-Ring 14 24194 0 -Ring 15 24195 Back-up Ring 16 24196 Back-up Ring

HV80A BRAKE VALVE PART NO. 81586 PARTS BREAKDOWN

Item No.

1 2 3 4 5 6 7 8 9

10

11-15 4188

Quantity

Printed in U.S.A.

Part No. Description Item No. Quantity Part No. Description

24199 Valve Housing 11 24192 Spool Spring 24182 Check Valve Spring Retainer 12 23601 0-Ring 24183 Spring Retainer 13 24193 0 -Ring 22450 Plug 14 24194 0-Ring 24184 Spool 15 24195 Back-up Ring 24185 Damper Piston 16 24196 Back-up Ring 24186 0-Ring 17 24197 Ball 24187 Check Valve Poppet 18 24198 Drain Check Valve Spring 24200 Pilot Orifice 19 22374 Plug 24190 Check Valve Spring

PACOIR WINCH DIVISIONS P.O. BOX 547 • BROKEN ARROW, OK 74013

PHONE: (918) 251-8511 • TELEX: 492340 • FAX: (918) 258-4822

.11 PINION GEAR REPLACEMENT

STEP 1: Place main boom in suitable support structure and secure electrical system from further operation.

"' STEP 2: Remove pinion retainer capscrews and pinion retainer plate from output shaft of planetary gear box.

STEP 3: Remove pinion gear from output shaft; use pry bars if necessary.

STEP 4: Clean and inspect pinion gear for abnormal wear and/or damage. If gear teeth are damaged, inspect rotational bearing ring gear for extent of damage. Inspect internal splines of pinion for excessive wear. Service as components as required.

INSTALLATION

STEP 1: Coat internal gear splines with anti-seize compound and install on output shaft of gear box.

STEP 2: Remove brake line from gear box, and release brake with hand pump.

STEP 3: With suitable feeler gauges or other type of measuring tool, check pinion gear backlash. Backlash must be between .005" and .012".

STEP 4: Coat gears with TEXACO CRATER 2X or equal.

Crane is now ready for use

.12 SHEAVE REMOVAL AND REPLACEMENT

REMOVAL

STEP 1 : Remove load block and reeve wire rope past sheaves.

STEP 2: Secure crane from electrical system to prevent operation.

STEP 3: Remove self-locking nut from sheave pin(s) and remove locking bolt from pin boss(es) .

STEP 4: With suitable device, remove sheave pin(s). Support sheave from falling to deck.

STEP 5: Inspect sheave pin(s) and bores for excessive wear. Replace pin(s) and bushings as required.

STEP 6: Inspect sheave groove for excessive wear. Clean and repair groove as required.

Perform NOT to assure sheave(s) are serviceable.

REPAIR

NOTE: THE ONLY REPLACEABLE PARTS ARE THE BUSHINGS AND THRUST WASHERS. USE CARE WHEN PRESSING BUSHING TO PREVENT CRACKING OF SHEAVE HUB.

INSTALLATION

STEP 1: Install new UMHW thrust washers in sheave counter-bores.

STEP 2: With suitable device, install pin(s). Assure that lock bolt hole aligns with hole in boss. Install lock bolt.

STEP 3: Install new self-locking retaining nut. DO NOT OVER TIGHTEN NUT. THIS CAN CAUSE DISTORTION OF SHEAVE PLATES.

STEP 4: Check sheave for free rotation and minimal radial run-out.

STEP 5: Grease bushings and re-connect load block to wire rope.

crane is ready for service

.13 WEAR PAD REPLACEMENT

STEP 1: Place main boom in suitable support structure with telescope boom fully retracted.

STEP 2: Shutoff power unit and install 30 ft jumper hoses between cylinder ports and existing work <

lines.

STEP 3: Secure 2nd boom stage to 3rd boom stage such that 3rd stage cannot extend. Restart power unit, remove split block caps from main boom, and extend cylinder out. The 3rd stage should still be inside the 2nd stage boom. Fully retract the cylinder and shutoff power unit. Secure electrical system from operation.

STEP 4: Remove upper /lower and side wear pads from main boom.

STEP 5: Rig 2nd/3rd stage booms for lift and pulling. Disconnect jumper hose and plug hose ends. Lift and pull extension boom from main boom. Rest booms on suitable cribbing.

STEP 7: With suitable lifting/pulling device, rig telescope cylinder for removal from boom assembly. Reconnect hydraulic system to cylinder and extend 3rd stage until pin boss is accessible. Remove locking bolt and pin, and retract the cylinder. Remove split block from 2nd stage and pull cylinder from booms. Support cylinder in three (3) places.

STEP 8: Remove side and lower wear pads from 2nd stage boom. Pull 3rd stage boom from 2nd stage boom.

STEP 9: Remove and replace 3rd stage wear pads. Check 3rd stage boom for damage and/or bending.

STEP 10: Re-install 3rd stage boom into 2nd stage boom. Remove and replace the 2nd stage rear wear pads. Install new side and lower front 2nd stage wear pads.

STEP 11: Re-install telescope cylinder. Connect jumper hose to cylinder ports and Re-install telescope booms into main boom.

STEP 12: Connect jumper hose to hydraulic system extend cylinder while preventing 3rd stage boom from extending. Install split boss caps and new bolts. Torque to correct setting.

STEP 13: Lift telescope booms such the main boom front lower wear pad can be installed. Re-install bearing retainer bar and capscrews.

STEP 14: Lower telescopic boom and remove cribbing. Fully retract telescope booms into main boom. Remove jumper hose and connect work lines to cylinder ports. Install new top and side wear pads in main boom.

NOTE: BEARING GROOVE MUST CLEAR WELD BEAD ON TELESCOPE BOOM. INSTALL BEARING WITH GROOVE TOWARD TELESCOPE BOOM.

Re-install bearing box cover plate.

STEP 15: Re-connect hydraulic hoses as tagged. Start crane and operate extend function to check for binding. Trim wear pads if excessive binding occurs.

~ crane is ready for service

.14 PUMP REMOVAL AND REPAIR.

REMOVAL

STEP 1: Shut off and secure electrical system to crane.

STEP 2: Close suction valve and tag with warning label. Place oil absorbers under and around pump.

STEP 3: Tag and plug four (4) bolt flange fittings pump inlet and outlet ports.

STEP 4: Remove the two (2) pump mounting capscrews and lower pump to deck.

STEP 5: Remove pump coupling from pump shaft. Inspect insert for excessive tooth wear.

Repair per Denison Service and Repair manual.

INSTALLATION

STEP 1: Install coupling and insert onto pump shaft.

STEP 2: Connect pump to pump/motor adaptor. Insure that suction and pressure ports are pointing in the same direction as before.

STEP 3: Install new o-rings on the 4 bit. flanges and re-install the flanges.

STEP 4: Open suction valve and start system.

STEP 4: Loosen the main relief valve locknuts on both valve banks and turn each adjusting screw 5 turns ccw. Remove and plug one (1) work line, on each valve bank.

STEP 5: Operate disabled function and observe pressure reading at gauge. Adjust the main relief valves until a pressure reading of 2250 PSlg is indicated by turning each adjusting screw cw to increase pressure or ccw to reduce pressure. Tighten locknut, while holding adjusting screw, when correct pressure has been achieved.

STEP 6: Remove plug(s) from work port(s) , and connect hoses per tags. Operate system and check for leaks. Check operation of the unloading valve. See below if valve is not operating correctly.

Crane is ready for service

.17 SLIP-RING REPAIR

WARNING: THE CRANE OPERATES ON HIGH VOLTAGE AND EXTRA SAFETY PRECAUTIONS MUST BE FOLLOWED TO PREVENT ELECTROCUTION. ALWAYS REMOVE POWER TO CRANE AT THE PRIMARY POWER SUPPLY DISCONNECT BEFORE SERVICING ANY HIGH VOLTAGE APPARATUS.

Most repairs on the slip ring can be made without removal of unit from crane pedestal. To gain access to internal parts of slip ring, loosen lower cover bolts before attempting to remove the side access panels. See Cavotec manual for complete slip ring maintenance and repair details.

NORTH AMERICAN CRANE & EQUIPMENT CO.

P.O. NO. 34057 CAVOTEC JOB NO. 7001

OPERATION, MAINTENANCE AND INSTRUCTION MANUAL

REVOLVING UNIT TYPE KK13580-440.86.53S/RISPEC/MPT

CAVOTEC INC. 1174 FINDLAY ST.

WASHINGTON, PA 15301

TEL.: (412)-228-4520 FAX: (412)-228-5678

DESCRIPTION

The revolving unit has a slipring assembly which is a uni-block construction built on a robust base-bearing. The ring pack is connected to the inner ring of this base-bearing while the brushgear assembly is mounted on an internal structure bolted to a base plate fixed onto the outer ring of the base bearing. The modular design of the housing, fastened to the same internal structure, allows removal not only of the two larger rectangular doors, but also, if required, the removal of the two side panels which are normally frtted with the cable glands. This revolving unit is equipped with a plastic tube located on the central axis. This tube allows the end user to pass cables or hoses through the center of the revolving unit during operation.

~ ,1 "' :;; -:tO

~

~ <

~

,,.,...:; .,., ,,. !JO. ltK JJf IP ... ,.;._

'k) A1!r1 · • ~ !!lalfrt•er It Uq" .. ,,,

0111 I /. ·

,.,.,

_J y;;iJT ,;;.RT NQ. lml ocsc•1PnON I MATERIAL IT

r------------------------, r--, ---------------------------F.F.=L--~---1 ,--f · I -+- ---------- ---t-1- -t--

1 I I I

--~------------------------~--~---L------------------------~ L--~

On'llhe. NE.1U8A

JCSCRIA: loti R£,VI DATE

PARTS LIST

Customer:_North American Crane & Equipment Co., LLC._ Type:_KK135BD-440.86.53S/R/SPEC/MPT

ITEMNO. QTY. DESCIUPl10N PART NO.

24 1 Through terminal S90-97002-000

25 1 Cover S90-97002- l 00

26 2 Gasket SRl-01256-001

27 2 Side panel SRl-01197-00D

27 2 Side panel SRl-01197-00A

27 2 Side panel SRl-01197-00B

28 8 Screw 840-73908-016

29 8 Plain washer S47-6592G-008

30 2 Door SRl-01195-00A

30 2 Door SR2-01195-00B

30 2 Door SRl-01195-00C

31 4 Neoprene gasket SRl-00200-000

32 8 Socket head cap screw S42-93108-016

33 8 Special washer SR2-01400-000

34 2 Aluminum label SR2-01081-000

35 8 Push-on terminal 898-00000-002

36 l Cover SRl-01194-001

37 2 Eye bolt S57-30010-000

38 I Driving arm SRl-01190-000

39 2 S.s. screw 842-73910-020

40 4 S.s. plain washer S47-6592X-010

41 2 S.s. lock washer S48-8842X-010

42 2 S.s. nut S49-5588X-O 10

43 I Flange assembly B-100056

44 1 Sna~ring 5100-306

45 2 V-ring seal 400750

46 4 Hex head bolt 3/8-16NC S.S. x I 1/4 LG

MISC.

8.4 x 17

A2507FLP

A 10

Date: 8-23-95 Sheet2 of-3 . -

REF.DWG.

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

IOOOOlP

IOOOOIP

lOOOOlP

lOOOOIP

PARTS LIST

Customer:_ North American Crane & Equipment Co., L.L.C. __ Type:_ KI< I 35BD-440.86.53S/R/SPECIMPT

ITEM NO. QTY. DESCR.JPl'ION

1 I Base ball bearing

2 1 Baseplate

3 4 Screw

4 7 Lock washer

5 10 Plain washer

6 I Cap

7 6 Nut

8 3 Tie-rod

9 3 PVC Insulating tube

10 3 Fiberglass tube

11 I Triangle

12 2 Structure

12 2 Structure

12 2 Structure

13 S.s. screw

14 8 Nylon washer

15 Internal carrier arm

16 2 Screw

17 4 Plain washer

18 2 Lock washer

19 2 Nut

20

21 2 Heat shrink tube

22 2 Heat shrink tube

23 6 Plastic strap

PART NO.

SR2-SO 173-00 I

SR2-0l 189-001

840-73910-025

S48-8842F-O 10

S47-6592G-010

860-20000-000

S40-5588G-010

S45-IOOOG-165

S92-1014P-122

S92-1520W-124

SR2-01201-000

SR2-01582-00A

SR2-01582-00B

SR2-01582-00C

S42-73910-016

S47-6592N-010

SR2-01198--001

840-73908-035

S47-6592G-008

S48-8842F-008

S49-5588G-008

S9l-50001-000

S9I-50005-000

891-50005-001

891-40000--003

Date: 8-24-95 Sheet I of3

MISC. REF.DWG.

AS-196

AS-196

AS-196

A 10 AS-196

10.5x 21 AS-196

AS-196

A~-!9§

AS-196

10.2xl4.5xl22 AS-196

15.5x20xl24 AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

AS-196

8.4 x 17 AS-196

AS AS-196

AS-196

AS-196

AS-196

AS-196

200x4.8 AS-196

MAINTENANCE

Environmental conditions affect slip ring performance; therefore periodic inspection is essential maintenance of the revolving unit. The fiist inspection should be ·made shortly after installation and before operation. Continuing inspections should be made on a regular basis after every 200-400 hours of operation under normal conditions. An inspection should include opening up the enclosure and checking for condensation, water and dust collection. If contaminants are found, the enclosure and slip ring assembly should be wiped down with a lint free cloth. If the problem appears persistant, steps should be taken to correct the leakage or conden­sation problem. Note: always disconnect power before opening enclosure!

SLIP RING INSPECTION

a) Brush Holders Inspect brush holders for proper alignment. Brush holders should be located so that the entire brush contact surface rides squarely on the ring . Brush holder clamps should be checked for tightness. Loose clamps will allow the brush holder to rotate, causing the brush to lift from the surface of the ring. Brush lift will cause arcing and excessive heat concentration.

b) Brushes Inspect brush contact surface by removing the brush and checking the surface for dirt.oxidation, pitting or other contaminants. Remove any large particles .

c) Rings Inspect the ring surface for dirt, oxidation or other contaminants. A properly operating ring will have a film that appears burnished in color where the brushes track with a darker surrounding color. If this condition does not exist, cleaning will be necessary. The ring should be cleaned with an abrasive that is non-conductive such as Ideal Industries Flexible Abrasive for slip rings. Caution: Do not use emery paper or cloth since emery is conductive. Hold the flexible abrasive against the the ring with a medium amount of pressure while turning the core. If the core can't be turned, the abrasive must be rubbed over the ring. Continue cleaning until the ring surface is polished without any dirt or contaminants left on the surface. To prevent abrasive from being embedded in the brushes, they should be lifted off the ring. · · Inspect ring surfaces for pitting. Pitting of the surface must be corrected since pits will produce arcing which leads to development of more and larger pits. Small pits can be eliminated by hand stoning of the area. If there are large and/or excessive amount of pits present on the surface, the surface will have to be machined. Machining is also necessary if concentricity of the surface is questionable. When machining or hand-stoning the rings, remove only enough material to eliminate the pits. The brushes should be lifted from the surface when machining or stoning. The ring surface should be finished to 16-32 microfinish.

d) Electrical Connections Inspect all electrical connections for tightness and any corrosion. Clean corroded parts with wire brush and/or muriatic acid. Loose and/or corroded terminations will cause excessive heat concentrations.

100001

<2> ACCESS PANELS @ 180' APART

SLIP RING TORQUE: ARM

V-R!NG SEAL

-uP

BALL BEARING

ll.i!2

r--------~----d---------, ~--, -r----------------- -------r-:=r--1--1- - -- - -- - -- - -1-1---f

I I I I

--~------------------------~--~-L------------------------~ ~--J

l 1/2 NPT CONDUIT HUB

--1'1---- 10.56 _--J

3/4 NPT CONDUIT HUB

------------32.60------------401

~~ ------:$:.----------, r--, 3.00 --~---------------r·---~--..l---1 I I I

T -~-~-~- --+-~--+-' I I I

--.-------------------3.oo----~--.,---L __________________ =r=~~ ~--J

UNIT DESCRIPTIVE DATA

4.00

TMIS IS TD CDl:Tlf'T "* T

0.75

3.00

1. HEAVY DUTY \/ATERT!UHT, DUST TIGHT STAINLESS STEEL CONSTRUCTION \/ITH CORROSION RESISTANT FASTENERS.

2. RINGS tl-51 20 N'F. 750VAC, SIL VER PLATED BRASS RINGS \/ITH V-SHAPED uRODVES, EQUIPPED \/!TH MUL Tl­CONTACT SIL VER GRAPHITE BRUSHES g. VtTH L5,.,,.A2 SHIELDED \/IRE LEADS EXTENDING TD TERMINAL BLOCKS.

nt'E m= er·=Nmtpt CIM"lllOCS TD lllOSlOllS Sl«MI ""11 *-CD IJN TNIS DAM.llNG.

J, RINGS 16-13' 40 AMP. 750VAC BRASS RINGS \/(TH V-SHAPED GROOVES, EQUIPPED \/!TH MUL Tl-CONTACT COPPER GRAPHITE BRUSHES g. \/ITH l°""'A2 \/IRE LEADS EXTENDING TD TERMINAL BLOCKS.

4. RINGS 114-17• 200 AMP. 750 VAC BRASS RINGS \/ITH V-SHAPED GROOVES. EQUIPPED V!TH MULTI-CONTACT COPPER GRAPHITE BRUSHES L IJITH 7°""'A2 VIRE LEADS EXTENDING TO TERMINAL BLOO<S.

5. UNIT \/EIGHT• APPROX. 180 LBS. 6. UNIT EQUIPPED VITH 120VAC, 40 \/ATT SELF-REGULATING HEATER.

SIGl£D --------lllO Oo\Tt•

,,..,........... ........ =--­:r::: ~ ....=:::• ~ _., :-..:::%' .. ~

NO.I PART ICl. Ian DCSCIUPTllJ<

<3> tl.56 MOLES @ 120' APART CJ.I 12.50 B.C.

I 1/2 NPT CONDUIT HUB

<3> 3/8-16NC SE:TSCREVS @ 120' APART

3/4 NPT CONDUIT HUB

HATIJllAL

l NPT CONDUIT HUB

VIRE LEADS TO EXTEND 36' F'OR

VT

40 g. 200 AMP. RINGS

APPROVAL

O ..an VITM MlJU'ICNIE as l5GW

o-•vrn<-- I DETAIL .,. . D-• SCALE• l.5X ,_. .. ro

ow«EI MlTU " MOIAIT C 2121/9'

11£1111\nl JUICTllJI lllX • 2111'5 •DOED JUNCTION IOX A llt91'95

DESCRIPTDlN lt!CV I ll"'Tt

CUSTOMER• NORTH AMERICAN CRANE L EQUIPMENT CO. CUSTCMER'S ORDER NO.• 34~7

INSTALLATION

Note: Make certain that all electrical power has been disconnected before proceeding with installation.

The revolving unit is installed in a vertical position with the base-bearing downwards in the crane column. The ring pack is connected to the fixed part of the crane through (3) 9/16 dia. holes equidistant on a diameter of 12.50 dia. on the mounting flange. The base plate, supporting the brushgear assembly, is provided with a driving-arm which drives the rotating part of the collector through a non-rigid system in order to compensate for possible mounting misalignments between revolving and crane structure. It is important therefore to maintain this flexibility also in case a different driving system is adopted.

Installation Procedures

1. Move unit into position for mounting.

2. Bolt revolving unit flange to structure.

3. Fasten revolving unit's torque arm.

4. Thread conduits onto revolving unit's flange couplings.

5. Remove side panels from revolving unit.

6. Fish customer's wire leads through conduits and connect them to the appropriate terminal blocks.

7. Check to be sure all connections are tight.

8. Thread customer's conduits onto revolving unit's side panel hubs.

9. Fish customer's wire leads through and connect them to the appropriate slip ring brush.

10. Check to be sure all connections are tight.

11 . Reattach side panels.

12. Final check should be made to assure that all bolts have been tightened and that there are no objects interfering with unit rotation.

SAFETY

ELECTRICAL PRECAUTIONS

The revolving unit should be interfaced with the unit on which it is installed and the entire assembly grounded in accordance with local codes, ordinances, and the National Electric Code.

Always disconnect and lockout electrical power from this unit before attempting to maintain or repair it. -

Do not use this revolving unit with electrical loads greater than the rated current and voltage.

PARTS LIST

Customer:_North American Crane & Equipment Co., L.L.C._ tYJ>e:_KK l 35BD-440.86.53S/R/SPEC/MPT

.,

1lTEMNO. QTY. DESCRIPTION PART NO.

47 4 Hex nut 3/8-16NC S.S.

48 4 Lockwasher 3/81.D.

49 1 Plastic tube A-100063

50 1 Gasket A-100067

51 ] Bearing housing A-100066

52 3 Hex head bolt l/2-13NC S.S. x 1 Yi LG

53 3 Hex nut l/2-13NC S.S.

54 3 Lockwasher Yi I.D.

55 1 Spacer A-100068

56 3 Hollow cup point setscrew 3/8-16NC S.S. x 1 LG

57 1 Conduit hub ST-2

58 1 Conduit hub ST-3

59 1 Conduit hub ST-5

60 1 Ball bearing JA030XPO

61 1 Gasket A-100069

62 2 Plug 3/4NPT

63 2 Plug 1 NPT

64 2 Plug 1 YiNPT

65 1 Nameplate A-100073

MISC.

Date: 8-23-95 SheeC3 of3

REF.DWG.

100001P

100001P

100001P

100001P

100001P

100001P

100001P

100001P

lOOOOIP

IOOOOIP

lOOOOlP

lOOOOIP

lOOOOlP

IOOOOIP

lOOOOIP

lOOOOlP

lOOOOIP

IOOOOlP

lOOOOIP

WIRING

The power rings of the collectors series KK135 and all other rings are pre-wired onto a numbered solderless compression type terminal block. Particular care must be taken during wiring in order to ensure the following points:

-a perfect electrical contact between conductors and relevant rings and brushgears.

-an adequate insulating distance, especially at the fixing points of the cable terminals between phase-to-phase and phase-to-ground.

-an accurate positioning and fixing of the conductors; in particular to and from the brushgear to avoid interference and/or entanglement of the cables with the rotating parts of the slip ring assembly.

-once the wiring is completed, check that all of the brushes are well positioned in their corresponding groove on the slipring, and perfectly ali~ned with it.

-.19 UNLOADER VALVE

Most of the internal components of the unloader valve can be serviced without removal of the entire valve from the system.

WARNING: INSURE THAT THE HYDRAULIC AND ELECTRICAL SYSTEMS ARE SECURE FROM OPERATION BEFORE REMOVING ANY COMPONENT OF THE UNLOADING SYSTEM.

STEP 1: Close the suction valve to the pump.

STEP 2: See denison service manual for component parts and service.

ADJUSTMENT

STEP 1: Loosen locknut on adjusting knob and turn knob CCW until spring pressure is relieved.

STEP 2: Open suction valve and start hydraulic system. Open junction box on motor and place clamp on ammeter on a motor lead.

STEP 3: Operate the boom down function and note pressure gauge readings. P 2 should be showing the main system relief on the winch circuit and the P 1 gauge should show the current unloading pressure. Note current reading from ammeter.

STEP 4: Turn adjusting knob CW j_ turn. Repeat step 3 and note greatest reading on the P 1 gauge. The pressure recorded on the gauge is the adjustable pressure/turn. Calculate the number of turns required to achieve 1700 psi peak pressure on the P 1 gauge. Turn adjuster the required number of turns, less 1 turn, and repeat step 3. Note: the pressure on the P 1 gauge will increase to the current setting and then drop to near O psi. The objective of the operation is to achieve the greatest peak pressure while staying at or below the Full Load Amperage (FLA) rating of the motor.

STEP 5: Continue the adjustment procedure in 1 /8 CW turns once 1700 psi on P 1 is reached. From this point on, monitor the ammeter until FLA + 5% is reached.

STEP 6: Tighten locknut and test unloading system with load to confirm operation.

I DENISON I Hydraulics I Pilot Operated Unloading Valves Series R4U 3-EN 250-B

Sizes - 3/a", 314", 1114"

Outstanding design: Denison Pressure Controls, Serie R4, are exceptional - both in function and design - even under high flow conditions. Pacemaking in design, these valves offer improved features within a reduced envelope.

High Per;formance: R4 valves are designed for a maximum adjustable pressure of 350 bars and a flow capacity ranging from 90 I/min (3/e") to 600 I/min (1 W'). The pilot stage design reduces pressure overtravel and cracking flow to a minimum, thus reducing heating, power and production losses at high pressure operation.

Fast Response: Due to the Denison design, which combines a poppet type seat valve with the pilot control, precise adjustment and quick response eliminate pressure variation and system shocks. For sensitive control three spring settings are available.

Optional Versatility: R4 valves can be used as threaded or subplate body type units or cartridges for manifold application. A solenoid vent valve is available. Integrally mounted, it requires no additional piping and can be vented in energized or de­energized condition. More details on additional equipment can be obtained from the model code.

Standardized Mounting: Mounting configuration of Pressure Controls R4 are in accordance to international standards, such as CETOP, DIN, ISO or NFPA. Subplate mounting, L-body or flow­through T-body are standard. Vent porting allows remote pressure control and adjustment.

1. Description Denison Unloading Valves are pilot operated controls consisting of two valve sections: high flow, poppet type seat valve section controlled by the low-flow, adjustable pilot section mounted on top.

R4U valves are used to unload a circuit at low pressure when a pilot signal (Port X) is maintained at a pressure that is higher than that of the pilot section. A typical application for an R4U is to unload a pump that is connected to an accumulator circuit. Another use for the R4U is to unload the low pressure side of a double pump. Pressure setting is achieved by means of a knurled knob or by an acorn nut with a lead seal, if a tamperproof setting is required. The R4U can be vented by means of an optional vent valve, W01. This valve can be sandwiched between the pilot valve and main body.

2. Characteristics

Due to the precise ratio between the main piston area and its mass, an exceptionally fast response can be obtained. The outstanding design features of the pilot allow the R4U to function as a relief valve at the adjusted pressure setting, even when no

external pilot signal is applied. All the valve components are ·qual ity controlled based on international standards, thus ensuring worldwide interchangeability and replacement. Every valve is subject to an accurately monitored functional test before despatch.

R4U03

3. Operation Flow entering the inlet Port A is blocked by the poppet at low pressures. The pressure at A passes through an orifice in the main poppet and through a second orifice to the pilot section. There is no flow through the valve until the pressure at A exceeds the spring setting load of the pilot section. The degree in which the pilot spring is preloaded corresponds to the operating pressure of the unloading valve. When pressure exceeds the setting of the valve, the ball in the pilot section is lifted from its seat, reieasing a small pilot flow to tank, this results in a pressure drop across the main poppet. The main poppet, therefore, opens and flow is allowed from Port A to Port 8, Port B being normally connected to tank. The external pilot pressure, when applied at Port X (sustained by another part of the system), causes a small overide piston to act against the ball pushing it further off its seat. This creates a very low pressure drop, as long as pilot pressure at X is main­tained. As soon as the pilot pressure at X drops approximately 150/o below the pilot section setting, the main poppet closes with a snap action which causes the pump flow to be diverted back into the hydraulic system. In order to ensure the correct functioning of the R4U excessive restriction in the tank line or the pilot pressure signal at Port X should be avoided. The spring cavity of the pilot section drains internally as standard, external drain being optional.

R4U - threaded body R4U - subplate mounting R4U +Vent Valve W01

3-62

Hydraulics . Service-Information

Pilot Operated Unloading Valves Series R4U

Vorgesteuerte Druckentlastungsventile Baureihe R4U

Valves de mise a vide a commande pilote Serie R4U

S 10-T610-D

R4U 03

2

17 13 14 15 16 16A 17A 18 19 20 21 22

11

10

9

~ ===-=-=t7'~~mtt 6 ----V7t-r-t71:1mJ

s ~m 4 3

2

29

Subplate Body I Plattenaufbau I Plaque de base

27 28 19A

0

Threaded Body with Vent Valve VV01

Gewindekorper mit Entlastungsventil VV01

Corps taraude avec valve de mise a vide VV01

22

22

23 Knob 50 mm Dia.

24 Handrad 50 mm Rf

Bouton molete d 50 mm.

(Not for version with VV01)

(Nie ht !Ur Austuhrung mit VV01) (Incompatible avec W01)

~.

0

[ '

~ : . v

' '

R4U 06

17 12 13 14 15 16 16A 17A 18 19 20 21 22

11

10

9-=:);~~~~~~ 8 7

6

5

4

3

29

2

1

25

Subplate Body I Plattenaufbau I Plaque de base

27 28 19A

0

Threaded Body with Vent Valve VV01

Gewindekorper mit Entlastungsventil VV01

Corps taraude avec valve de mlse a vlde VV01

22

23

24

3

R4U 10

29

4

17 12 13 14 151616A17A 18 19 2021 22

11

10

9----=~~D~~~~ 8 7

6

5

4

3

x

2

Subplate Body I Plattenaufbau I Plaque de base

27 28

0

-Y 1: 11

A

I I

I /

19A

23

24

26 25

22

Threaded Body with Vent Valve VV01

Gewindekorper mit Entlastungsventil VV01

Corps taraude avec valve de mise a vide VV01

,. '

/ . ·\ .

' ;

-, I

Item Part No. Quantity Pos. Description Benennung Description Tei I Nr. Stlick Ref. Code No. Quantile

R4U

03 06 10

) 1 Body R4U 03 Gehiiuse R4U 03 Corps R4U 03

Subplate Type Plattenaufbau Sur embase 036-38563 1 - -Threaded Type l/i' NPTF GewindeanschluB 'Ii' NPTF Taraude l/i' NPTF 036-38631 1 - -Threaded Type 'Ii' B.S.P.P. GewindeanschluB .R 'h" Taraude l/i' B.S.P.P. 036-38632 1 - -

Body R4U 06 Gehiiuse R4U 06 Corps R4U 06

Subp late Type Plattenaufbau Sur embase 036-38907 - 1 -

Threaded Type - 1" NPTF GewindeanschluB - 1" NPTF Taraude - 1" NPTF 036-39844 - 1 -

\ (T-Design) (T-AusfUhrung) CT-Construction)

Threaded Type - 1" B.S.P.P. GewindeanschluB - R 1" Taraude - 1" B.S.P.P. 036-39845 - 1 -(T-Design) (T·AusfUhrung) (T-Construction)

Threaded Type - 3//' NPTF GewindeanschluB - 3//' NPTF Taraude - 3//' NPTF 036-39923 - 1 -(l-Design) (l-AusfUhrung) (l-Construction)

Threaded Type - 31/' B.S.P.P. GewindeanschluB - R 3/l' Taraude - 3//' B.S.P.P. 036-39926 - 1 -(l-Design) (l-AusfUhrung) (L -Construction)

Body R4U 10 Gehiiuse R4U 1 O Corps R4U 10

Subplate Type Plattenaufbau Sur embase 036-39889 - - 1

Threaded Type - 1 W ' NPTF GewindeanschluB - 11//' NPTF Taraude - 1 W' NPTF 036-39947 - - 1 (l-Design) (l-AusfUhrung) (l-Construction)

Threaded Type - 1 W ' B.S.P.P. GewindeanschluB - R 11//' Taraude - 1 'I/' B.S.P.P. 036-39950 - - 1 (l-Design) (l-AusfUhrung) (l-Construction)

2 Plug Stopfen Bouchon 431-90104 1 1 1

3 Plug 1/e" NPTF Stopfen Bouchon 'le'' NPTF 431-90204 2 2 2 Subplate body only nur bei Plattenaufbau Plaque de base seulement

4 Spring Feder Ressort 036-38448 1 - -Spring Feder Ressort 036-27547 - 1 1

(~ ~. ;.

5 Piston Kolben Clap et 036-38466 1 - -Piston Kolben Clapet 036-32902 - 1 1

6 Sleeve HUise Chemise 036-3&442 1 - -Sleeve HUise Chemise 036-27549 - 1 1

7 0-Ring Runddichtring Joint torique 691-00018 2 - -0-Ring Runddichtring Joint torique 691-00125 - 2 2

8 0-Ring Runddichtring Joint torique 691-00022 1 - -

0-Ring Runddichtring Joint torique 691-00026 - 1 1

9 0-Ring Runddichtring Joint torique 691-00013 4 4 4 (subplate body) (Plattenaufbau) (sur embase)

0-Ring Runddichtring Joint torique 691-00013 2 2 2 (threaded body) (GewindeanschluB) (corps taraude)

' \ \ . \_ ;

10 Cap '!/ ' NPTF Vorsteuergehause W' NPTF Chapeau I//' NPTF 036-27545 1 1 1

Cap I//' B.S.P.P. Vorsteuergehause R •ti ' Chapeau '!/ ' B.S.P.P. 036-35245 1 1 1

Cap lnterne und externe Steuerol- Drainage interne et externe a partir 036-36318 1 1 1 (Int. & Ext. Drain from Subplate) fUhrung aus der AnschluBplatte de l'embase

\ 11 Set screw Gewindestift Vis 312-35051 1 1 1

12 Spacer Distanzbuchse Entretoise 036-27548 1 1 1

13 Control Bloc KolbenfUhrung Bloc de contr61e 036-11710 1 1 1

14 Control Piston Ventilko lben Fourrure 036-14679 1 1 1

15 Seat Ventilsitz Siege 036-1 1692 1 1 1

16 Ball Stahlkugel Bille 201-08001 1 1 1

16A Ball-Support Kuge ltrager Siege de bille 036-11697 1 1 1

17 Plug Stopfen Bouchon

'//' NPTF W' NPTF W' NPTF 431-90404 1 1 1

I//' B.S.P.P. RI//' I//' B.S.P.P. 446-01004-2 1 1 1

17A Gasket Dichtring Joint

For Plug I//' BSP FUr Stopfen RI//' Pour Bouchon •// ' BSP 635-01004-2 1 1 1

18 Spring 105 bar Feder 105 bar Ressort 105 bars 036-13244 1 1 1

Spring 210 bar Feder 210 bar Ressort 210 bars 036-13245 1 1 1

Spring 350 bar Feder 350 bar Ressort 350 bars 036-12289 1 1 1

5

- --------------------------- -

1jem Part No. Quantity

Pos. Description Benennung Description Teil Nr. Stiick

RH Code No. Quantile

R4U

03 06 10

19 S.H.C. Screw 3/e"-24 NF x 1.75" lg. Schraube Vis 359-15220 4 4 4

S.H.C. Screw 3/e"-24 NF x 1. 75" lg . Schraube Vis 359-15220 3 3 3 (on valves with acorn nut) (bei Ventilen mil Hutmutter) {sur valves avec ecrou borgne)

S.H.C. Screw 3/e"-24 NF x 3.50" lg. Schraube Vis 359-15340 4 4 4 (on valves with W01) (bei Ventilen mit WOt) (sur valves avec W01)

S.H.C. Screw 3/e"-24 NF x 3.50" lg . Schraube Vis 359-t5340 3 3 3 (on valves with acom nut & W01) (bei Ventilen mil Hutmutter und W01) (sur valves avec ecrou borgne et W01)

19A S.H.C. Screw 3/e"-24 NF x 1.75" lg. Schraube Vis 036-36749 1 1 1 (on valves with acorn nut) (bei Ventilen mit Hutmutter) (sur valves avec ecrou borgne)

S.H.C. Screw 3/e"-24 NF x 3.50'' lg . Schraube Vis 036-36751 1 1 1 (on valves with acorn nut & W01) (bei Ventilen mit Hutmutter und W01) (sur valves avec ecrou borgne et W01)

20 0-Ring Runddichtring Joint torique 671-00012 1 1 1

21 Seal Piston Dichtkolben Poussoir 036- 21767 1 1 1

22 Control Devices: Verstelleinrichtungen : Dispositif de reglage :

Knob (32 mm dia.) Handrad (32 mm Ill) Bouton molete {Ill 32 mm) S16- 39147 1 1 1

Knob (50 mm dia.) Handrad (50 mm Ill) Bouton molete (Ill 50 mm) S16-39148 1 1 1

Acorn Nut with Lead Seal Hutmutter plombierbar Ecrou avec verrouillage S16-39149 1 1 1

Lock SchloB Reglage par verrouillage S16-34509 1 1 1

23 Plug '/ "" NPTF Stopfen •/ 10" NPTF Bouchon 1/ 10" NPTF 431-90104 1 1 1 {on models with external pilot oil {nur bei Geraten mil externer {seulement sur modeles avec discharge on ly) SteuerolabfUhrung) drain externe)

24 Orifice Plug Drosselstopfen Vis diaphragme 036-25528 1 1 1

25 0-Ring Runddichtring Joint torique 691-00116 2 - -0-Ring Runddichtring Joint torique 691-00216 - 2 -0-Ring Runddichtring Joint torique 69 1-0022 1 - - 2

26 Roll pin Spannstift Pied de positionnement 325-16100 1 1 1

27 Rivet Kerbnagel Rivet 320-10203 4 4 4

28 Symbol Plate Symbolschild Plaque de symbol isation - 1 1 1

29 Vent Valve W01 Entlastungsventil W01 Valve pilote de mise a vide W01 6 1 1 1

Not shown: Nlcht gezelchnet: Non represente :

Name Plate Typenschild Plaque d'identification 036-38883 1 1 1

Subp late 'h'' NPTF AnschluBplatte 'h'' NPTF Plaque de base W' NPTF S16-63123 1 - -Subplate W' B.S.P.P. AnschluBplatte R 1h" Plaque de base W' B.S.P.P. S16-63 124 1 - -Subplate 1" NPTF AnschluBplatte 1" NPTF Plaque de base 1" NPTF S16-39165 - 1 -Subplate 1" B.S.P.P. AnschluBplatte R 1" Plaque de base 1" B.S.P.P. S16-39168 - 1 -Subplate 1 W' NPTF AnschluBplatte 1 'h'' NPTF Plaque de base 1 'h'' NPTF 816-39194 - - 1

Subplate 1 'h'' B.S.P.P. AnschluBplatte R 1 W' Plaque de base 1 W' B.S.P.P. 8 16-39197 - - 1

Repair kits Austausch-Baugruppe Jeu de pieces detachees

Main Body Gehause Corps s 16-82990-0 1 - -s 16-82896-0 - 1 1

Top Cap 105 bar Vorsteuergehause 105 bar Couvercle superieur 105 bar s 16-82888-0 1 1 1

Top Cap 21 Obar Vorsteuergehause 210 bar Couvercle superieur 210 bar s 16-82889-0 1 1 1

Top Cap 350 bar Vo rsteuergehause 350 bar Couvercle superieur 350 bar s 16-82890-0 1 1 1

Seal Kits Dlchtrlngsiitze Pochettes de jo ints

Subplate Body Type Plattenaufbau Corps a embase 816-39211 -0 1 - -

s 16-39213-0 - 1 -

816-39217-0 - - 1

Threaded Body Type Leitungseinbau Corps a ori fices taraudes s 16-39212-0 1 - -

s 16-39214-0 - 1 1

•Pilot head external drain connection plugged. •Orifice de drain externe sur la t8te pilote for subp late body with drain obtur pour les co rps a montage thru subplate. sur embase avec drain par l'embase.

• Bei Plattenaufbauventilen mit extern er 6 Spares for Vent Valve W01 see information S 10-Q 493. Steuero labtuhrung aus der Platte ist 6 Ersatzteile fUr Entlastungsventil W01 siehe Information S 10-Q 493. der Y-AnschluB im Vorsteuerkopf verschlossen. 6 Pieces detachees pour valve pilote W01 voir information S 10--0 493.

6

r.

·, ,l

Model Code

r--- ·----- - ---, 1 omit for version 1

' ' : w ithout VVOt

'

Model Number R4U -l ···:- A

Series--------------'' R4U = Pressure Unloading Valve

I

Size-------- -- -- - --- - --- - -- - -- - _ _, 03 = 3/if' 06 = 3/4'' 10 = 1114''

Max.pressure---------------~

0 = for cartridges only l 350 bar 5 = for body valves only

Body mounting--- - --- - -------------------G = Cartridge 8.S.P.P. . 0 = Cartridge NPTF 1 =Threaded body - R4U03 = 112'' NPTF; R4U06 = 1" NPTF

(2 A-Ports, 1 8-Port) ; X, Y-Port = 1/4'' NPTF 3 = Subplate mounting - R4U03/06/10

Y-Port = 1/4'' NPTF (Drain line code 2) 6 =Threaded body - R4U03 = 112'' 8 .S.P.P.; R4U06 = 1" 8.S.P.P.

(2 A-Ports, 1 8-Port) ; X, Y-Port = 1/4'' 8.S.P.P. 9 = Subplate mounting - R4U03/06/10

Y-Port = 1/4'' 8.S.P.P. Ext. drain from pilot head only (code 2) A = Threaded body - R4U06 = 3/4" NPTF; R4U10 = 11/4'' NPTF

(1 A-Port, 1 8-Port); X, Y-Port = 1/4'' NPTF D =Threaded body - R4U06 = 3/4'' 8.S.P.P.; R4U10 = 11/4'' 8.S.P.P.

(1 A-Port, 1 8-Port); X, Y-Port = 1/4'' B.S.P.P.

Pressure setting range-------------------' 1 = 7-105 bar 3 = 7-210 bar 5 = 7-350 bar

-, I

I

I I I I

Type of control- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J

1 = Hand knob 32 mm dia. 2 = Hand knob 50 mm dia. (not for version with vent valve W01) 3 = Acorn nut with lead seal 4 =Adjusting device with key lock, key order no. 700-70619

Drain line---------------------------~ 0 =internal 1 = external from the subplate 2 = external from the pilot head

~T-- - --=-~~

I

3-way vent valve W01---------- ------------------- ---------' 09 = with manual override j Solenoid de-energized: open to tank 10 = without manual override Solenoid energized: vent line blocked 11 = with manual override j Solenoid de-energized: vent line blocked 12 = without manual override Solenoid energized: open to tank

Solenoid voltage and current--------------------------~

W01 = 115 VI 60 CY } W02 = 230 V I 60 CY W06 = 115 V I 50 CY AC WO? = 230 V I 50 CY W54 = 110 VI 50 CY W57 = 220 VI 50 CY

GOR = 12V GOO= 24 V GOH= 48V

} DC

-, I I I I I I I I I I I I

I

I I I I I

Design letter-- - -- - - - - - --- - - - ------ - -- - -- - - - - - - --- - - - --- ---- _ _J

1

Seal class---------------------------------------~ 1 = Standard (for special fluids consulting of Hagglunds Denison is recommended)

Modifications- -- --------- - - ----- ---- ---- ----- -- -- - --- -- -- - - - -- - - _____ ...J

Rights o f alteration reserved I Anderung vorbehalten I Sous reserve d'eventuelles modifications. 7

.20 RETURN FILTER

Most of the internal components of the return filter can be serviced without removal of the entire filter from the system.

The Filter element can be changed without disassembly of the filter head or disturbing the hydraulic piping.

WARNING: INSURE THAT THE HYDRAULIC AND ELECTRICAL SYSTEMS ARE SECURE FROM OPERATION BEFORE REMOVING ANY COMPONENT OF THE FILTER.

ELEMENT SERVICE

STEP 1: Place 5 gallon pail under filter bowl and absorbent wipers around pail.

STEP 2: Remove drain plug from bottom of filter bowl. While the bowl is draining, loosen the four (4) bowl retaining bolts.

STEP 3: Remove the bowl from the filter body once drained. Clean inside of bowl with clean - lint free cloth and set aside. Pull elements from filter and remove element spacer from element set.place used elements in pail.

STEP 4: Install new (576366) into filter head. Install element spacer and lower element (676366) .

STEP 5: Install new bowl gasket and bowl. Torque retain bolts to correct setting. Install drain plug.

STEP 6: Start hydraulic power unit and check for leaks.

,..---...\

.21 SUCTION STRAINER SERVICE

WARNING: INSURE THAT THE HYDRAULIC AND ELECTRICAL SYSTEMS ARE SECURE FROM OPERATION BEFORE REMOVING SERVICING SUCTION STRAINER.

REMOVAL

STEP 1: Place five (5) clean 55 gallon drums below crane platform.

STEP 2: Connect jumper hose to drain valve and insert hose into one of the drums. Open drain valve. Open fill/spill containment box on reservoir and remove fill cap. Monitor oil level in drum and change drums, as required , until reservoir is drained.

STEP 3: Remove side access cover plate. Remove strain from pipe with strap wrench.

STEP 4: Clean suction strainer with diesel fuel and compressed air, or send unit out for ultra-sonic cleaning. If strainer shows indication of collapse; replace.

INSTALLATION

STEP 1: Install strainer on pipe fitting. Do not over tighten or crush strainer pleats.

STEP 2: Clean gasket surface of reservoir and cover plate. Coat surface with high quality gasket sealant and install gasket on plate. Place cover on reservoir and install retaining bolts. Torque to 25 Ft-Lb.

STEP 3: Close drain valve and remove jumper hose. Install pipe plug in end of drain valve.

STEP 4: Use transfer pump with a 1 O Micron Absolute filter to transfer hydraulic fluid from drums to reservoir. Do not completely drain each drum to avoid introducing contaminants to the hydraulic system. Top off reservoir with new hydraulic fluid .

STEP 5: Start hydraulic power unit and check for leaks.

.22 CTD/EM SHEAVE REMOVAL AND REPAIR

REMOVAL

STEP 1: Remove and discard ENSA nut.

STEP 2: Remove pin locking capscrew.

STEP 3: With soft mallet, drive sheave pin through bosses.

STEP 4: Remove CTD /EM sheave for assembly.

STEP 5: Remove and discard trust washers.

Repair or replace sheave as required .

INSTALLATION

STEP 1: Install new thrust washer in their bores. Use grease to hold washers in place while positioning sheave. Align sheave to sheave pin bosses.

STEP 2: Carefully drive sheave pin through bosses and roller bearing.

STEP 3: Install pin locking capscrew and nut.

STEP 4: Install new ENSA nut and torque to 150 Ft-Lb.

STEP 5: Grease sheave roller bearing while slowly turning sheave.

Crane is now ready for operation

.23 CTD/EM GUIDE ROLLER REMOVAL AND REPLACEMENT

STEP 1: Remove retaining bar nuts.

STEP 2: Remove retaining bar and guide rollers.

STEP 3: Install new guide rollers.

STEP 4: Install retaining bar and nuts. Torque to 100 Ft-Lb. Insure rollers do not contact bar. Trim rollers if necessary.

Crane is ready for operation.

I I / n \

BILL OF MATERIAL MCJL-1565-94-l0l9/l02U

ITEM QNI'Y MANUF1\CIURE OODEL NUMBER DESCRIPI'ICN

1 1 NACE AY-3415 RESERVOIR

2 1 DENISON T6CC-025-012-1ROO-Al [X)UBIE VANE RJMP

3 l BSF 1202-345-7.6 RJMP /MOIDR ADAPl'ER

- 1 IDVEJOY L225-2.875/L225-.875 RJMP jMO'IDR CDUPLING

4 1 MARATHON 364'ITFC8026-R47 60HP MOIDR

- 2 POI CF-lP-210-E 0-3000 PSI GAUGE

5 1 GRES EN V42-RP60A-F4-04-PB SWING AND TEI.ESCDPE CONTROL VALVE WITH MAIN & FORI' RELIEF I AND FOWER BEYOND

6 1 DENISON R4U06-5A31 UNIDADER VALVE

7 1 PARKER C1200-S CHECK VALVE -8 l GRES EN V42-RP60A-G4-F4-TR B'.)()M AND WlliCH CDNTROL VALVE WITH MAIN

RELIEF AND STD. TANK REIURN

9 1 NACE AY-4826 ANTI -'ThO BLOCK MANIFOID ASSEMBLY

10 1 GRES EN DXV-12-1800 CROSS FORI' RELIEF

ll 2 DA.NFOSS OMPA-125 SWING MJ.l'OR

12 2 MICD 13-547-190 SWING BRAKE

- 2 FAIRFIEID S3AB-5523-XAl PI..ANEI'ARY GEAR OOX

13 l NACE AY-5653 511 x 36' EXTENSION CYLINDER

14 2 NACE AY-4783 811 x 45" B'.XM CYLINDER

- 3 SUN CBEA-IAN CDUNrERBAIANCE VALVE

15 1 BRADEN CH185A-36120-0l-1 API WlliCH

•

•

FSCM NUMBER DRA'MNG NUIABER SIZE REV.

1' 22 FPS

1' 22 FPS .- -· -- ,... - ·-- ·--, \/INCH

~[ll: ~IX I "

;

I I 1' 15 FPS

r--.

I 1 6

BOOM 2000 PSI7 I

•• ..--, • 6

I 1' 15 FPS

2250 Ps17 I IlL JX I

? r.:b

I - I

L_ SET I! 2500 PSI w - · --- · - -·--·

® 1' 10 FPS

.... .:!:,SET @ 1800 PSI

- ...,,

0 I ... 0

3/4' 13 FPS 3 / 4' 13 FPS

, -- - - t~)f ··n

,,

,.~ ,. ....

l't'\ ,. ....

1-1/4' 10 FPS

..... .....

7R117

DRAWING USED ON

DATE CRANE S/ N

12-12- 94 MCT-1565-94-1019

THROUGH

12-12-94 MCT-1565-94-1024

r--.

! ~ I

: ~!1$1-+-'·. ~ ! ---., 1 GPM

' I -B-t- l 1/2'

I I i 3 FPS I,.

I l__J I

L~_.J ANTl-T\JO BLOCK

VALVE

r I I I

f I I

I I I I

I

HS-7752 B 0

REVI S IONS

ZONE REV JESCR IPT ION DATE APPROVALS

I-A £

1'

2000 PSI 1' r=- ·- - ·=-i . II I @ I iCJ

L------------------~"t'\ 1/ 2 ' 2250 PSI 1'

1/::>• I l I

112· I BQOH CYLINDERS I

1/2' I : . Il I ! ll :=========;:J L_ ___ __ =._J @

2250 PSI

I I

EXTEND 1r . ~,..,..,,,.....[ rr"T"ri l.T. J~l

I I I

• I I I I

I I I I,.

314• I ~~~ ni-

1

- · ExITNsioNcYUNDER - · :J L--~~~~------~~~--1~~~: ~+-i· I .. I

t I I I I t---~? ...._~~~

I 1· 15 FPS

I . S\IING

•

I @L __ _ _

,-·--·-- ·-' 0-3000 PSI ~

60HP I 460V /30 Lr-

SET I! 2000 PSI

3/4' 13 FPS

I I

,, I I I

LJ

u=~,,.1

3/ 4' 13 FPS '" .....

3/4' 13 FPS

'

1-114' 10 FPS

-3/4' 13 FPS

-

2'

CD ~ 8 FPS

r-· -- ·-- ·-- · - 1 I 280 GALLON 10 Ille. I RESERVOIR NOKINAL •

t\A ~~ I I I 1v1 i~® I I

USE A\146 I I

, ..

I

... I I I I I I I I I I I I

t I I I I I ... r I I I ... ... I I I

I I I

I I I I I I I I I I

l I I I I I I I I I I I 10 @) I

1750 RPM 3' I J:. I I i 1----....-------~---·-J I L----~2-F_P_S_:.. _____ --1'<..>"~xa-+;--+-< I

L·--·--·--·----~ 100 MESH

L ___________ _J

1850 PSI 3/4' L. _ - · _ - · _ - ·- _ . ~ =-__J

® I

·--...... 1v•· !@

C~S~N_:o:~L~S _j112'

@@ SIJlNU HOUJRS AND BRAKES

..... -__ ..,._. _ _ _ G_. __ A_DA!_MS __ --1N ortn American Alaska Marine Cr an e !MR - · E . t C ~ Porter Yay

02-12-95 Crane and qu1pmen o. w ton. .... ~ - ---1

01-15-95 rnTLE G. ADAMS HYDRAULlC SCHEMATIC FOR 02-12-95 MCT-1565 I AGOR 24,25,26

SIZE

rsCM7Rii 7 I DRA'MNG NUMBER REV.

B HS- 7752 0 SCALE WEIGHT SHEET NUMBER

NONE N.A. I OF I