1068 - Section 01.pdf

Operator's Manual

iSection 1 - Operating Instructions

Table Of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Operator's Cab 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Top Hatch Wiper 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield Washer Reservoir 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Cab Fuse Panel 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bubble Level 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gauge And Control Panel 1-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

ii Section 1 - Operating Instructions

Seat Console Control Switches 1-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab Heater 1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Conditioning (If Equipped) 1-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Column And Wheel 1-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Controls 1-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating The Transmission Shifter 1-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foot Operated Controls 1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Combination Steering 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conventional Steer Mode 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Wheel Steer Mode 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4‐Wheel Steer Mode 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crab Steer Mode 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Steering Modes 1-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Pump Control Unit 1-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Error Codes 1-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnostic Connector 1-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Seat 1-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Disconnect Switches 1-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Panel Circuit Breakers 1-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hour Meter 1-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outrigger Operation 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Extend Outrigger Beams 1-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Extend Outrigger Jacks - Raise The Crane 1-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Retract Outrigger Jacks - Lower The Crane 1-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Retract Outrigger Beams 1-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outrigger Removal System 1-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outrigger Box Removal 1-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outrigger Box Installation 1-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane System Controls 1-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Throttle 1-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Throttle Lock System 1-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing System 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

iiiSection 1 - Operating Instructions

Swing Brake Pedal 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Control Lever 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Swing Lock 1-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Park Brake 1-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

360° Swing Lock 1-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Rope Winch System 1-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warm‐Up Procedure 1-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Winch Control Lever 1-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Winch Control Lever (If Equipped) 1-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Operation 1-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Control Switch(es) 1-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Speed Hoist Or Lower 1-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Disable 1-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum Rotation Indicators 1-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

First Layer/Third Wrap Indicator (If Equipped) 1-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Hoist System 1-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Telescope System 1-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Telescope Control Pedal 1-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Telescope Override Switches 1-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fine Metering System 1-62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Cooler Fan Switch 1-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Monitoring System 1-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wind Speed Indicator 1-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Angle Indicator 1-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti‐Two Block Warning System 1-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lockout Pin And Flag 1-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rated Capacity Limiter Display 1-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MicroGuard 534 Rated Capacity Limiter 1-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Description 1-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Unit 1-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Operation 1-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Self‐Test 1-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

iv Section 1 - Operating Instructions

System Bypass 1-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Inoperative Or Malfunctioning 1-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuration Selection 1-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Select Rigging/Travel Mode 1-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cancel Audible Alarm And Reset Function Limiters 1-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Settable Alarms 1-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Angle, Length, And Height Operator Settable Alarms 1-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Operator Settable Alarm 1-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Defined Area Alarm 1-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Fault Codes 1-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration 1-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MicroGuard 434 Rated Capacity Limiter 1-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Description 1-85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Unit 1-85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Operation 1-86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Perform System Test 1-86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Bypass 1-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Inoperative Or Malfunctioning 1-87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuration Selection 1-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Select Rigging/Travel Mode 1-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Cancel Audible Alarm And Reset Function Limiters 1-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Settable Alarms 1-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Length/Angle/Height/Swing Operator Alarms 1-94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Set Operator Defined Area Alarm 1-96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering And Exiting The Operator's Cab 1-100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Break‐In Period 1-101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Starting Operations 1-101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Suspension 1-101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Distortion Due To Thermal Effects Of The Sun 1-101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Starting Procedure 1-102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Shutdown Procedure 1-102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jump Starting The Crane 1-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

vSection 1 - Operating Instructions

Electric Engine Block Preheater 1-104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ether Start (If Equipped) 1-105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Operation 1-106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

During Operation 1-107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Signals 1-108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Removal System 1-109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Removal 1-109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Installation 1-111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pick And Carry Operation 1-112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling The Crane 1-113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Highway Travel 1-113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel 1-114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel, No Load, Upper Over The Front, Boom Fully Retracted,

2.5 MPH (4km/h) Maximum 1-115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel, No Load, Upper Over The Rear, Boom Fully Retracted

2.5 MPH (4km/h) Maximum 1-115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing The Crane 1-116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting The Crane 1-116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caging The Park Brake 1-118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Uncaging The Park Brake 1-118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting The Crane 1-119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suspension Height Adjustment 1-120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Storage 1-122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Short Term Storage 1-122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Long Term Storage 1-122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator's Manual

vi Section 1 - Operating Instructions

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

Operator's Manual

1-1Section 1 - Operating Instructions

Figure 1-1Crane Nomenclature

1. Front Winch

2. Rear Winch

3. Counterweight

4. Rear Outrigger

5. Turntable Bearing

6. Front Outrigger

7. Boom Hoist Cylinder

8. Boom

9. Hook Block

10. Hook Ball

8

123

4 965 10

7

On DeliveryWhen a new crane is delivered, follow the instructions

outlined in the latest version of Technical Bulletin Gen

eral Series #213.

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

Safe operations of a hydraulic crane requires a well

trained, qualified operator. Crane operation is more in

volved than it may appear, and operation by a careless

or unqualified person can result in a serious accident.

When a hydraulic crane is maintained and used prop

erly it can be a safe, highly productive piece of equipment, but if not used properly, it can be dangerous.

Think Safety - You, the operator, are in charge of an

important piece of equipment. It is very important that

you know what it can do. It is also important that you

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

anticipate all of the situations you will encounter. Therules given here cover the general usage, and some of

the more common specific cases. If conditions arise

not covered by these rules, consult your nearest dis

tributor. A phone call could save someone's life.

Figure 1-2Read and understand all points covered in the

Operator's Manual before operating the crane.

Construction equipment can be dangerous ifimproperly operated or maintained. Thiscrane should be operated and maintainedonly by trained and experienced peoplewho have read, understood, and compliedwith the Operator's Manual.Before leaving operator's position, lowerload to the ground.Do not use swing brake for swing lock.When facing over rear some functionswill be reversed relative to operator.Raise the crane on outriggers, or block thewheels before working on the crane. Replaceall guards or panels before operating the crane.

Do not deface or remove this label from the crane.

WARNINGDo not lift, suspend, swing or lowerloads or attachments over anyone.Do not allow anyone to ride on anypart of load or attachment.

SAFETY INSTRUCTIONS

Operator's Manual

1-2 Section 1 - Operating Instructions

Figure 1-3Diesel exhaust fumes can be harmful.

Diesel exhaust fumes can beharmful. Start and operate engine ina well ventilated area. If it isnecessary to operate in an enclosedarea, vent the exhaust to the outside.Properly maintain the exhaustsystem to its original design.

General Safety Rules

The following is a list of safety rules which should be fol

lowed during all crane operations.

Operator Awareness1. Read this operator's manual and heed it. The man

ual contains important information.2. An operator must not eat, read, or otherwise divert

his attention while operating a crane. Remem

ber-operating is a full‐time job.

3. Don't smoke when fueling, or fuel up near an open

flame. Keep the nozzle in contact with the filler

neck to prevent static electric sparks. Shutdown

the engine when fueling.4. Start and operate the engine in a well ventilated

area. Diesel exhaust fumes can be harmful. If it is

necessary to operate in an enclosed area, vent the

exhaust to the outside. Properly maintain the ex

haust system to its original design.

5. Keep fingers, feet, and clothing away fromsheaves, drums, and ropes unless the crane is

shutdown and everyone knows what you are do

ing. Do not place a hand on wire ropes when

climbing on the crane. A sudden movement could

pull you into the drums or sheaves.

6. Keep your shoes clean. Before entering the opera

tor's cab, wipe clean any mud, gravel, snow, ice,moisture, or grease from your shoes. Slippery

shoes could cause momentary loss of control of

crucial foot operated controls.

Figure 1-4Keep hands and tools clear of moving parts.

Keep clear ofmoving parts toprevent seriousbodily injury.

7. Keep all walking surfaces (steps, ladders, plat

forms, etc.) and non‐skid materials on the crane

clean. Non‐skid materials are placed on the craneto assist operators and service personnel with safe

access/egress to/from the crane and to/from ad

justment and inspection areas. Do not allow non‐

skid materials to become contaminated with mud,

snow, ice, oil, paint, wax, etc. Any contamination

can cause the non‐skid materials to become slick,reducing their effectiveness for safety while walk

ing on the crane. If any non‐skid materials become

ineffective due to wear, age, or destroyed in any

way, they must be replaced.

8. To prevent movement of individual boom sections,

shutdown the engine and ensure that the operator

has properly vacated the operator's cab beforeputting hands or tools inside the boom. Unexpec

ted movement of the boom sections could sever

fingers, hands, arms, etc.

9. The operator, supervisor, or person in charge of the

load must observe the following rules:

a. Loads must be well secured before lifting. Besure that the rigging cannot slip off or pull away

from the load, or get out of position on the load.

Be sure the load is rigged so it will not turn over.

b. Chains and slings must be of adequate size, in

good condition, and not twisted around each

other.

Operator's Manual


Figure 1-5Level the crane.

A 3 Degree Side Tilt Can

Reduce Capacities

By Over 50%.

Grade Ground Level

Or Block Under Crane.

The Load Should Hang

Parallel With The Boom.

WrongRight

c. The load must not catch on an obstructionwhen lifting or swinging. Be sure the load, fall

lines, or any other parts of the crane do not

snag or strike any obstruction.

d. Do not allow the load to rotate out of control.

Personal injury to ground personnel, load

damage, crane damage, or damage to anti‐

two block system may occur.e. When hoisting with single part line, especially

in long falls applications, the design of wire

rope and hookball is crucial to minimize the po

tential for uncontrolled rope and/or load rota

tion. Rotation‐resistant wire rope is recom

mended for single part of line applications.See Wire Rope Capacity Chart in the Crane

Rating Manual for the specific types of rotation

resistant wire rope recommended for your

crane.

f. Avoid sudden starts and stops. Lift carefully,swing gently, brake smoothly, lower and set

loads carefully. Jerking the load, swinging and

engaging swing brake roughly, and lowering

the load rapidly and slamming on brakes, will

put shock loadings and possible side loadings

on the boom. Unnecessary abuse labels the

operator as a beginner. Be a professional.g. Do not wrap the winch rope around the load.

Do not use discarded, worn, or damaged wire

ropes for slings. They may fail and drop the

load.

h. The crane must be level on a firm supporting

surface before making a lift. Use the bubblelevel to level the crane. Check its accuracy fre

quently with a carpenter's level. Remember, a

three degree side tilt can reduce capacities by

50% or more.

Operator's Manual


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

Just A Little Bump

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

Can Cause This!

Wrong

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

Wrong

10. Operate the crane from the operator's seat only.Operating the crane from any other position, such asreaching in a window, constitutes a safety hazard.

11. Don't let the load or bucket hit the boom or fly. Don'tlet the boom or attachment rest on, or hit, a building

or any other object. A dent or other damage couldresult, which will weaken the boom or attachment. If

the damage is severe, the attachment could col

lapse. If a lattice or diagonal bracing member on the

fly is broken, cracked, or bent, contact your local dis

tributor for repair procedures. If the boom or fly is

struck, or damaged by anything, STOP. The loading

on a boom or attachments increases as they are lowered, therefore their suspension systems could col

lapse during lowering. Use another crane to lower a

damaged boom or attachment.

12. Watch the load or a signalman at all times. A suspended load must have your undivided attention.

13. Don't pull sideways on the boom or fly, not even a

little. Lift straight up on every load. Moving trucks,

rail cars, barges, or anything else pulling sideways

on the winch rope could buckle the boom or fly. Itcould also damage the swing mechanism. Pulling

sideways on a boom or fly can overturn the crane.

14. Heat from the sun only on one side of the boommay cause a temperature differential between thesides of the boom. The thermal effects may causeboom distortion (the boom to “deflect” to one side)creating a side load on the boom and/or fly. Sideloading is dangerous and shall be avoided.

15. Do not “two block” (pull the hook block into thehead machinery) as this can cause winch rope and

sheave breakage resulting in an accident.

Operator's Manual


16. After slack winch rope operation, make sure thewinch rope is properly seated in sheaves and on

drums before continuing to operate. Use a stick or

mallet to set the winch rope, not your hands.

17. Do not lower the load beyond the point where less

than three full wraps of winch rope are left on the

drum. This condition could occur when lowering a

load beyond ground level. If all the winch rope runsoff the drum, the load will jerk which could break

the winch rope.

18. Make sure there is a safety latch on the hook, and

that it works properly. Without a latch, it is possible

for slings or chains to come off the hook, allowing

the load to fall.19. Don't alter any part of the crane. Additions to or

changes in any part of the equipment can create

loadings for which the crane was not designed.

Such changes may seriously affect the usable ca

pacities and make the entire Crane Rating Manual

invalid. Alterations can dangerously overload or

weaken critical parts and may cause disastrousfailure.

20. Do not exceed the rated capacities of the crane un

der any circumstances. While a crane has more

stability when lifting over a corner (as compared to

straight over the side) the crane capacity is not in

creased. Anytime the load exceeds the rated capacities listed in the Crane Rating Manual, the

crane is overloaded. Overloads can damage the

crane and such damage could cause failure and

accidents.

21. When operating on outriggers, all beams must be

equally extended; all fully retracted, all intermediate extended or all fully extended. All jacks must be

extended so all tires are clear of the ground, and

the crane must be level. Be sure that pontoons are

set on firm surface, adequate to support the block

ing, pontoon, crane and load without settling, slip

ping or collapsing. Blocking or matting under pon

toons must form a smooth level surface under theentire pontoon. Do not block under outrigger

beams inside the pontoons as this reduces stabil

ity. Blocking must be under pontoons only. Re

member-there are tremendous loadings on pon

toons and blocking - the weight of the entire crane

plus any load.

Figure 1-8Crane level, all beams extended equally (all

fully extended, intermediate extended or fully

retracted) and tires clear of the ground.

Right

When blocking or matting under pontoons, be

sure that each pontoon is supported fully - no un

supported pontoon area is permissible. Be surepontoons are on a smooth surface. Rough sur

face, rocks, etc., under pontoons will cause un

equal loadings, and can puncture them, causing

them to collapse.

Capacities are based on all outriggers being equal

ly extended: all fully retracted, all intermediate extended, or all fully extended. Working on outrig

gers that are not equally extended will reduce ca

pacities and crane stability considerably and could

cause an accident. Do not make any lifts while on

outriggers without the outrigger beams equally ex

tended.

Operator's Manual


Figure 1-9Watch that carrier!

Wrong

22. Cold weather operation requires some special at

tention by the operator to allow for changes in eve

ryday routines:a. Clean the crane, especially the boom, of accu

mulated amounts of ice or snow. Operating

the crane with an ice covered boom is danger

ous. The added weight of the ice or snow can

drastically reduce the capacity of the crane.

Also, falling ice may pose danger for groundpersonel.

b. Clean all snow and ice from steps, ladders,

platforms, etc. to eliminate slippery walking

surfaces.

c. If cold weather starting aids are provided on

the crane, use them. The use of aerosol start

ing sprays can be dangerous if the manufacturer's directions are not closely followed.

d. Pay close attention to the gauges in the opera

tor's cab when starting the engine. Normal

“warm up” times will be longer. Be sure pres

sures and temperatures are within normal

ranges before beginning operations.e. Always handle flammable materials according

to the manufacturer's instructions. Propane,

diesel, or other fuel for auxiliary heaters can be

dangerous if not properly handled. Do not

store such fuels on the crane.

Figure 1-10Fly Section Nomenclature

1. Head Sheave

2. Main Chord

3. Lattices

4. Picture Frame

5. Connecting Lugs

6. Head Machinery Cross Shaft

1

23

4

5

6

f. Use caution when lifting any load during freez

ing weather, as it may be frozen to the ground

or the supporting surface. The added tension,to break the load free, could cause an unsus

pected overload situation. Also, when the load

does finally break loose it could create an er

ratic motion causing damage or injury.

g. At the end of the work shift, park the crane where

it will not freeze to the ground. Major damage tothe drive mechanism could occur while trying to

free the crane from a frozen surface.

23. Before attempting to move the carrier, make sure

there is enough oil pressure to operate the brakes.

Always check the brake operation before traveling

the crane.

24. Brake firmly in one application. Avoid fanning thebrakes. This could exhaust oil pressure so fast that

the pump may not supply enough oil.

25. Do not coast downhill with the transmission shifter

in neutral. It makes control of the crane more diffi

cult and dangerous.

26. Position the transmission shifter to neutral beforeoperating the crane. When parking, shift to neutral

and engage the park brake. Block wheels if on an

unlevel surface.

27. When operating with the boom at a high angle, use

care not to let the load hit the carrier.

Operator's Manual


Figure 1-11Handling The Fly Section.

RightWrong

1. Use The Connecting Lugs And/Or Head Machinery Cross Shafts As

Lifting Points.

2. Use The Main Chords As Lifting Points With Nylon Straps Only

3. Do Not Attach Slings To Lattices, They Will Bend.

3

1

11

1

3

28. Use care handling the fly when loading, transporting, and unloading. Damage that occurs during

these operations can go undetected and could re

sult in failure of these components, once subjected

to loading. Do not attach slings to the lattices when

lifting the fly, as they will bend. Use the connecting

lugs and/or head machinery cross shaft as the lift

ing points. However, it is permissible to attach nylon straps around all four main chords.

29. Block under and between the fly sections when

loading them on a transport vehicle. When secur

ing the fly to a transport vehicle, it is best to use syn

thetic webs or slings. If using wire rope slings, pad

the fly to protect it from damage. Do not overtighten the tie downs or the fly may be damaged.

Do not use chain tie downs, as they may dent and

damage the fly section.

30. Thoroughly inspect all the elements of the fly sec

tion before installing it on the crane. Check each

main chord, picture frame, diagonal, lattice, and

connecting lug for bends, dents, and cracked orcorroded welds. Picture frames must be square.

Do not use any fly or jib section that is even slightly

damaged. Consult your local distributor for the

proper repair procedures.

Operator's Manual


Figure 1-12Stay Away From Power Lines.

Wrong

ELECTROCUTION HAZARD.Keep all parts of crane andload at least 15 ft (4.57m)from electrical lines or asstated in local code. ConsultOperator's Manual forminimum requiredclearances.

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

Electrical Dangers1. All Electrical Power Lines Are Dangerous. Contact

with them, whether insulated or not, can cause

death or injury. When operating near power lines,

the best rule is to have the power company turn off

the power and ground the lines. However, in some

cases, the operator may be unable to have the

power turned off. Follow these rules whether thepower is turned off or not.

a. Be alert. You are working around conditions

which can cause death.

b. Keep all parts of the crane, fall lines, hook

block, and load, at least 15 ft (4.57m) away

from the electrical lines or as specified in the“High Voltage Power Line Clearance Chart” or

other distance specified by applicable codes.

Slow down crane operation.

Minimum Required Clearance For NormalVoltage In Operation Near High Voltage PowerLines And Operation In Transit With No Load

And Boom Or Mast Lowered.

Normal Voltage, kV(Phase to Phase

Minimum RequiredClearance, ft (m)

See Note 1

Operation Near High Voltage Power Lines

To 200 15 (4.57)

Over 200 To 350 20 (6.10)

Over 350 To 500 25 (7.62)

Over 500 To 750 35 (10.67)

Over 750 To 1000 45 (13.72)

Operation in Transit with no Load and Boom orMast Lowered

To 345 15 (4.57)

Over 345 To 750 16 (4.87)

Over 750 To 1000 20 (6.10)

Note 1: Environmental conditions such as fog,smoke, or precipitation may require increasedclearances.

High Voltage Power Line Clearance Chart

Operator's Manual


Figure 1-13Crane equipped with proximity warning device

on the entire boom.

Shaded area shows “sensitivity zone” with full boom length

sensor used, and adjusted for 15 ft. (4.57m) clearance. Contact

can be made outside this zone by the fall lines, winch rope, cab,

etc. In such cases, the alarm will not sound, but the crane will be

electrified and deadly.

Wrong

c. Assume that every line is “Hot”.

d. Appoint a reliable person equipped with a loud

signal (whistle or horn) to warn the operatorwhen any part of the crane is working around

the power line. This person should have no

other duties while the crane is working around

the power line.

e. Warn all personnel of the potential danger.

Don't allow unnecessary persons in the area.Don't allow anyone to lean against or touch the

crane. Don't allow ground workers to hold

load lines, or rigging gear unless absolutely

necessary. In these cases use dry plastic

ropes as tether lines. Make certain everyone

stays at least 15 ft (4.57m) away from the load,

or as specified in the “High Voltage Power LineClearance Chart” or such distance as required

by applicable codes.

f. The use of boom point guards, proximity de

vices, insulated hooks or swing limit stops do

not assure safety. Even if codes or regulations

require the use of such devices, you must follow rules listed here. If you do not follow them,

the result could be serious injury or death.

Figure 1-14Crane equipped with proximity warning device

on boom tip.

Shaded area shows “sensitivity zone” with the probe near the

boom peak and adjusted for 15 ft. (4.57m) clearance. Contact

can be made outside this zone by the fall lines, winch rope, cab,

etc. In such cases, the alarm will not sound, but the crane will be

electrified and deadly.

Wrong

g. Grounding the crane can increase the danger.

Poor grounding such as a pipe driven into the

ground, will give little or no protection. In addition, a grounded crane may strike an arc so

heavy that a live line may be burned down.

This could cause the crane and the area

around it to be electrified.

h. When operating near radio or T.V. transmitting

stations, high voltage can be induced in metalparts of the crane, or in the load. This can oc

cur even if the crane is some distance from the

transmitter or antenna. Painful, dangerous

shocks could occur. Consult trained electronic

personnel before operating the crane to deter

mine how to avoid electrical hazards.

2. What do you do if a power line is touched by acrane or load?

a. Remain calm - think - a mistake can kill

someone.

b. Warn all personnel to keep clear.

c. If crane will still operate, try to move it away

from contact. You, the operator are reasonablysafe in the cab unless the crane is on fire or an

arc is cutting through the cab.

Operator's Manual


Figure 1-15Crane equipped with insulated link.

1

1. Insulated Link

This Man Is Not Protected

Wrong

d. Move away from contact in the reverse direc

tion to that which caused the contact. Exam

ple: If you swing left to the wire, swing to theright to break contact. Remember - once an

arc has been struck, it will stretch out much far

ther than you think before it breaks. Keep mov

ing until the arc has been broken.

e. When the arc breaks, continue moving away

until you are at least 15 ft (4.57m) away (or asspecified in the “High Voltage Power Line

Clearance Chart” or as specified by local

codes). Stop the crane. Make a thorough in

spection for crane damage before further use.

f. If you cannot disengage from the electrical

line, and the crane is not on fire or no arc is cut

ting through the cab, stay in your seat untilpower line can be turned off.

g. If you must leave the crane, don't step off.

Leap from the crane as far as you can, landing

with feet together, then hop away from the

crane with feet together, or shuffle feet to keep

them close together. This could help preventpersonal injury.

3. When using a magnet:

a. Lifting magnet generators produce voltage in

excess of 200 volts and present an electrical

shock hazard. Only trained personnel should

work on the magnet, controller, or wiring.Don't open the controller door with the genera

tor running.

b. Do not let workmen touch magnet or load.

Figure 1-16Crane equipped with insulated link and boom

point guard.

1

1. Insulated Link

Wrong

Figure 1-17If you must leave the crane, do not step off.

Leap as far as you can with feet together and

hop or shuffle away from the crane.

c. Do not let workmen get between magnet and a

metal object.

d. If necessary to position a load, use a dry,

wooden stick.e. Open magnet disconnect switch at magnet

control panel before connecting or discon

necting leads.

Operator's Manual


Figure 1-18No hook riders!

Wrong

Radio Frequency Or Electro MagneticInterference (RFI Or EMI)

Certain areas may contain high Radio Frequency Or

Electro Magnetic Interference (RFI or EMI). In these

areas the boom can act like an antenna and produce an

electrical current that may cause electrical shocks and/or

the crane to malfunction. If operating in an area wherethese conditions may exist, test the crane or have the

area tested for the magnitude of this interference before

operating the crane. Operation may not be possible or

boom length may be limited. Comply with all local, state,

and federal laws when operating in high RFI/EMI areas.

Protective Equipment1. Always replace protective guards and panels be

fore operating the crane.

2. Always wear hard hats, safety glasses, steel toe

shoes, hearing protection, and any other safety

equipment required by local job conditions,

OSHA, or regulations.3. Always wear safety glasses when drilling, grinding

or hammering. Flying chips could injure the eyes.

4. Always wear a mask to prevent breathing any dust,

smoke, fumes, etc. while cleaning, drilling, weld

ing, grinding, sanding, etc. on any part of the

crane. Breathing dust, smoke, fumes, etc. can be

very hazardous.5. The crane is equipped with a fire extinguisher in the

operator's cab. Make sure all personnel know that

one is available and where it is located. It must be

kept in the crane at all times (except when need

ed). Instruct all operating and maintenance per

sonnel in proper use of the extinguisher. Check periodically to make sure it is fully charged and in

working order. Replace immediately if required.

Figure 1-19Use a signalman, back safely.

Wrong

6. Do not tamper with safety devices. Keep them in

good repair and properly adjusted. They were put

on the crane for your protection.7. When operating a crane equipped with any form

of load indicating mechanism, overload warning

system, or any automatic safety device, remem

ber that such devices cannot replace the skill and

judgment of a good operator. For instance, such

devices cannot tell when a crane is located on asupporting surface that will give away, that too

few parts of line are being used to lift a load, can

not correct for the effects of wind, warn that the de

vice may be improperly adjusted, correct for side

pulls on the boom, or for many conditions which

could occur and create hazards. It requires all the

skill, experience, judgment, and safety consciousness that a good operator can develop to attain safe

operation. Many safety devices can assist the op

erator in performing his duties, but he should not

rely on them to keep him out of trouble.

Signalmen And Bystanders1. Don't allow crane boom or loads to pass over peo

ple, or endanger their safety. Remove all loose ob

jects from load. All unnecessary personnel should

leave the immediate area when crane is operating.

2. Do not allow anyone to ride on the hook ball, hook

block or any part of the load or attachment for

construction work or recreational activities. (This applies to recreational activities such as “bungee jump

ing” or “bungee cord jumping”). Cranes are intended

to lift objects, not people. They are not elevators.

3. Do not carry passengers! There is only one seat

and it is for the operator. Do not allow personnel to

ride on the carrier deck during operation or while

traveling the crane. A fall from the crane can causedeath or serious injury.

Operator's Manual


Figure 1-20Remove the keys from the ignition and post asign to make others aware of repair activity.

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

OUT OF SERVICE

Signed:

Do not operate the crane or start the engine without

first notifying this mechanic. Personnel within the

crane could be hurt or killed. Crane damage may

also result from premature operation of systems

which are under repair.

DANGER

4. Always look before you back up, or better yet, posta signalman to guide you. Make sure the back up

alarm is working properly. Use the horn as a signal.

Use a code such as one beep - stop, two beeps -

forward, and three beeps - backward. Make sure

everyone on the job site knows the code.

5. Do not make a lift which is not in plain sight withouta signalman. This can lead to an accident or crane

damage.

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

poorly maintained crane. Pay particular attention

to the clutches, brakes, attachments, and wireropes. If a component is worn or damaged, re

place it before operating.

2. Labels, plates, decals, etc. should be periodically

inspected and cleaned as necessary to maintain

good legibility for safe viewing. If any instruction,

caution, warning, or danger labels, decals, or

plates become lost, damaged, or unreadable, theymust be replaced.

3. When performing repetitive lift applications, espe

cially at or near maximum strength limited capaci

ties, an inspection of the major structural areas of

the crane, for cracks or other damage, should be

conducted on a regular basis. (A non‐destructivetest such as magnetic particle or dye penetrant

may even be considered.) Along with inspection

for cracks and damage, frequently check the criti

cally loaded fasteners, such as the turntable bear

ing mounting capscrews, to ensure they have not

been stretched. Not only does frequent inspectionpromote safety, but it is also much easier and less

expensive to perform a repair when a crack is

small, before it has a chance to traverse through a

structural member. Any sign of cracks or damage

must be repaired before continuing operations.

Consult your distributor for repairs.

4. When performing maintenance on the crane, dothe following:

Figure 1-21Allow engine to cool before removing radiator cap.

a. Fully retract the boom. Lower the boom to the

limit of the boom hoist cylinder. Be sure boomor cylinder does not hit the carrier.

b. Shutdown the engine, but leave the key in the

“ON” position, disengage the main pump, and

work all control levers back and forth to relieve

pressure and relax the attachment.

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

not move.

d. Bleed any precharge off the hydraulic reservoir

before opening it or disconnecting a line.

e. Hydraulic oil becomes hot during operation. In

some cases it becomes hot enough to causesevere burns. Be careful not to let hydraulic oil

come in contact with skin.

f. Disconnect battery cables and remove ignition

key so crane can't be started. Post warningsigns in cab so no one will try to start the engine. Never adjust, maintain or repair a crane

while it is in operation.5. When making repairs, which require welding, use

proper welding procedures. Also the following

precautions must be taken:

a. All paint in the area should be removed to pre

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

b. Turn the battery disconnect switches to the

“OFF” position to protect any electronic equip

ment on the crane which may be affected by

electric arc welding.

c. The welding ground cable should be attachedto the portion of the crane being welded. If

welding on the upper, ground on the upper. If

welding on the carrier, ground on the carrier.

Failure to take this precaution may result in

electrical arcs in the turntable bearing.

d. The welding ground cable should always be

connected as close as possible to the area being welded. This minimizes the distance that

electricity must travel.

Operator's Manual


Figure 1-22Use a guard when inflating tires.

Right

e. Disconnect computers and other electronic

equipment (such as rated capacity limiters and

engine computers) to prevent damage. Contact the distributor for proper procedures.

f. Remove all flammables from the proximity of

the welding area.

6. Use extreme caution when removing radiator

caps, hydraulic pressure caps, etc. They can fly off

and hit you, or you could be burned by hot oil,water, or steam.

7. Keep the crane clean, in good repair, and in proper

adjustment. Oil or grease on the decks may cause

falls. Improper adjustments can lead to crane

damage, load dropping, or other malfunctions.

8. Keep all walking surfaces (steps, ladders, plat

forms, etc.) and non‐skid materials on the craneclean. Non‐skid materials are placed on the crane

to assist operators and service personnel with safe

access/egress to/from the crane and to/from ad

justment and inspection areas. Do not allow non‐

skid materials to become contaminated with mud,

snow, ice, oil, paint, wax, etc. Any contaminationcan cause the non‐skid materials to become slick,

reducing their effectiveness for safety while walk

ing on the crane. If any non‐skid materials become

ineffective due to wear, age, or destroyed in any

way, they must be replaced.

9. Check tires daily for correct pressure. Do not standin front of a tire when inflating it. The lock ring can

fly off and injure you. Use a clip‐on inflator, and

stand aside. Use a guard in front of the tire.

10. When checking battery fluid level, use a flashlight,

not an open flame. If the battery explodes, you can

get acid in your eyes, which could cause blind

ness. Don't check battery charge by shortingacross posts. The resulting spark could cause the

battery to explode. Check with a tester or hy

drometer. Don't smoke near batteries.

Figure 1-23Do not use an open flame near the battery.

Wrong

WARNINGBattery posts, terminals, and related accessories contain lead and lead compounds. Wash

hands after handling.

11. When using jumper cables to start an engine, be

sure to connect negative post to a ground stud,

and positive post to positive post. Any spark couldcause the battery to explode. Refer to “Jump Start

ing the Crane” found later in this section of the Op

erator's Manual for the proper procedure.

12. Test the automatic winch brake by raising the load

a few inches and holding. It should hold without

slipping. It takes more braking power to hold a loadin the air when the drum is full of rope than when it

is a few inches above the ground with only a few

wraps on the drum.

13. Always reduce pressure in hydraulic system to

zero before working on any part of the system.

14. Use extreme care when working with circuits with

accumulators. Check that hydraulic pressure is relieved before opening the circuit for repairs.

15. When setting pressures, never exceed the manufac

turer's ratings. Always follow instructions exactly.

Over pressurization can cause hydraulic component

damage or failure of mechanical parts on the crane.

Any of the above can lead to an accident.

Operator's Manual


Figure 1-24Do not operate the crane with worn or

damaged wire rope.

Thursday. . . . .

“I thought I could savemoney by running this

rope until Friday”.

Wrong

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

tional Safety And Health Act) regulations state “athorough inspection of all ropes shall be made

once a month and a full written, dated, and signed

report of the rope condition be kept on file where

readily available.” A visual inspection must also be

performed daily. Replace any worn or damaged

rope. Pay particular attention to winch ropes.Check end connections (pins, sockets, wedges,

etc.) for wear or damage.

2. Use at least the number or parts of winch line

specified on the Wire Rope Capacity chart located

in the Crane Rating Manual to handle the load. Lo

cal codes may require more parts of line than isshown. Check code requirements and use them

where applicable.

3. Non‐rotating, rotation‐resistant, or spin‐resistant wire

ropes are recommended for single part of line ap

plications. This is of utmost importance for long fall

hoist line applications. Only if certain criteria are met

may a swivel hook ball be used with rotation resistantrope. Refer to “Single Part Line Hoisting' and “Hook

Ball Usage With Rotation Resistant Rope” found inSection 5 of this Operator's Manual.

4. Do not handle wire rope with bare hands. Always

use gloves to prevent possible injury from frayed or

damaged spots in the rope.

5. Inspect head machinery and hook block often as

damaged or deteriorating sheaves can cause

undo wear of the wire rope.6. A swivel hook ball may be used with rotation resist

ant rope only if certain criteria are met . Refer to

“Hook Ball Usage With Rotation Resistant Rope”

found in section 5 of this Operator's Manual.

7. When reeving wire rope on the crane, do not stand,

walk, or climb on the boom or attachment. Use aladder or similar device to reach necessary areas.

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

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

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

3. Be sure the work area is clear. Make sure to haveproper clearance for the crane, boom, and load.Don't swing, travel, lift, or lower loads, raise orlower jacks, without first making sure no one is inthe way. If your vision is obscured, locate a signalman so you can see him, and he can see all areasyou can't. Follow his signals. Be sure you and thesignalman understand each other's signals. Seehand signal chart Figure 1-99. Use the horn tosignal or warn. Make sure everyone on the job siteunderstands signals before starting operations.

4. When working inside a building, check overheadclearance to avoid a collision. Check load limits onfloors or ramps so as not to crash through.

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

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

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

Operator's Manual


Figure 1-25Know your load.

Wrong

“It looks likeabout 15 tons”

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

load. Use a scale or a load indicating system to determine exact weight. Remember the weight beinglifted includes the weight of any lifting slings or gear,the hook block, and any other weight on the hook. Iflifting off the boom with the fly erected, the weight ofthe fly must also be considered as part of the load.(The Rated Capacity Limiter will automatically deduct the weight of the stowed fly to obtain the totalallowable load.) The total load weight must neverexceed the rated capacity of the crane, as listed inthe Crane Rating Manual, for the position, boomlength, load radius, and condition of operation being used. Remember - capacities in the Crane Rating Manual are based on ideal conditions:a. Standing on firm, level surface.

b. Calm wind.

c. No side loads or out swing of load.

d. Good visibility.

e. Crane in top condition and equipped as whenleaving the factory.

When such conditions cannot be attained, loads

being handled must be reduced to compensate.

The amount loads are reduced depends upon how

good or how poor actual operating conditions are. It

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

Wrong

is a matter of judgment and experience. Some fac

tors which may require reduction of capacities are:

a. Soft or unpredictable supporting surfaces.b. Wind.

c. Hazardous surroundings.

d. Inexperienced personnel.

e. Poor visibility.

f. Fragile loads.

g. Crane in poor condition.h. Condition and inflation of tires.

When in doubt, do not take a chance. Reduce rat

ings more than you think you need. Avoid working

a crane in high winds. If you must work in a wind,

reduce capacities as shown on the “Wind Speed

Restrictions” chart in the Crane Rating Manual.

Wind blowing against the load and the boom produces a side load on the boom and reduces its ca

pacity.

When lifting loads, in a wind, which have large sur

face areas, such as building panels, the movement

of the load may pose a danger to workmen or

building structures. Out swing of a load will increase the load radius, and may overload the

crane. This could lead to boom failure or the crane

tipping.

2. Do not lift two loads at the same time, even if the

total load weight is within crane capacity. Loads on

the boom and fly at the same time, stress the boomand drastically reduce its ability to handle loads.

Your full attention cannot be given to both loads,

creating a dangerous situation.

Operator's Manual


Figure 1-27Do not push with the boom.

Wrong

3. Lifts where two or more cranes work together can

be hazardous and should be avoided. Such lifts

should be made only under the direction of a qualified engineer. If a multiple crane lift is unavoidable,

observe the following rules:

a. The cranes must be level and located on firm

surfaces.

b. The cranes should be the same size and ca

pacity, use the same boom length and bereeved similarly.

c. Cranes must be positioned so that each boom

point is directly over its load attaching point.

The winch lines must be vertical during all

phases of the lift.

d. The rigging must be placed so each crane lifts

a share of the load well within the crane's capacity.

e. Be sure that during handling more load is not

transferred to any crane than it can handle.

f. Don't attempt to travel when making multiple

crane lifts.

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

h. Use only one signalman.

i. Use of an operable load and angle indicating

system is desirable.

4. When operating off the main boom with the fly

erected, deductions must be made for the flyweight. (The Rated Capacity Limiter will automati

cally deduct the weight of the stowed fly to obtain

the total allowable load.) The weight of the fly, etc.,

must be subtracted to obtain a “NET” capacity.

Failure to do so could result in an overloading con

dition and cause boom failure. Refer to the Crane

Rating Manual for amounts to be deducted.5. When operating off the main boom with the auxil

iary lifting sheave installed, the weight of the auxil

iary lifting sheave must be deducted. Refer to the

Crane Rating Manual for amount to be deducted.

Figure 1-28Safety Instruction Label

Operation under conditions which

exceed listed capacities may result inoverturning.

Swinging, extending or lowering boom

to radii where no capacities are listed

may result in overturning even without

a load.

6. Some capacities on hydraulic cranes are based on

strength of materials. In these cases, overloads

will cause something on the crane to break, beforeit will tip. Do not use signs of tipping as a warning of

overload.

7. Don't lash a crane down. Lashing a crane down

encourages overloading. Crane damage or injury

could result.

8. Do not shock load and/or overload the crane atanytime. Shock loading or overloading the crane

will reduce the fatigue life of crane components

and could result in component failure.

9. When performing repetitive lift applications, espe

cially at or near maximum strength limited capaci

ties, be aware that these applications may reduce

component life. These applications include repeated lifting (or lifting and swinging) of near 100%

strength limited capacities and repeated lifting

maximum moment loads. These applications may

fatigue the major structural portions of the crane.

Although the crane may not break during these ap

plications, they can reduce the fatigue life andshorten the service life of the crane. To improve the

service life, while performing repetitive lift applica

tions, consider reducing the capacities to 70% of

maximum strength limited capacities to reduce fa

tigue cracking. Frequently perform a thorough in

spection of all the structural areas of the crane.Any sign of cracks or damage must be repaired be

fore continuing operations. Consult your distribu

tor for repairs.

10. Always refer to the Crane Rating Manual after

changing the arrangement of the attachments for

the correct lifting capacities.

11. The boom must be extended in the correct mannerbefore making a lift. The capacities listed in the Crane

Rating Manual for this crane are based on the boom

sections being extended in accordance with boom

mode “AMax1”, “AMax2”, or “Standard”.

Operator's Manual


12. Do not use the boom to push or pull. It is not designed for this purpose. Such action can damage

the boom and lead to an accident.

13. Know the load radius. Don't guess at it. Determine

the load radius by using the boom angle indicator,

the boom length indicator, and the Crane Rating

Manual, or measure it with a steel tape. Remember

- Radius is the horizontal distance from the centerline of rotation of the upper to the center of gravity

of the load, when the load is hanging free.

14. Do not operate a hydraulic crane at radii or boom

lengths where the capacity charts in the Crane Rat

ing Manual show no capacity. Don't use a fly not

designed with or for your crane. Either of the abovecan tip the crane over or cause attachment failure.

In some cases, the crane can tip over with no load

on the hook, forward or backward! Also, if the

boom is fully extended at a low angle, the crane

may tip until the boom touches the ground. In any

of these cases, injury or crane damage could re

sult.15. When lifting a load with any crane, the load may

swing out, or sideways. The load radius will in

crease. Due to the design of hydraulic crane

booms, (cantilever boom, supported by cylinders

and overlapping sections) this increase is much

more pronounced. The increase or out swing ofthe load can overload the boom, and lead to boom

failure or tipping. Also, movement of the load can

cause it to hit something. Make sure the load being

lifted will remain within capacity as it is lifted and the

boom deflects.

16. When extending or lowering a boom with a load,the load radius increases. As the load radius in

creases, capacity decreases. If capacity is ex

ceeded, the boom may bend or the crane may tip

over. Sometimes at low angles, a hydraulic crane

boom can be extended with a load, but cannot be

retracted. This is because more power is available

in the boom telescoping cylinders to extend than toretract. If an operator extends the boom under

load, he may not be able to retract the boom and

may get into a dangerous situation.

Figure 1-29Pinch Point Label

DANGER

17. Know the boom length. Don't guess. Use of an in

correct boom length can cause an accident.

18. When lowering or retracting the boom, the load willlower. To compensate for this, the operator must

hoist up on the winch rope. Otherwise, movement

of the load may cause an accident. When extend

ing the boom, the load will raise. The operator

must hoist down the winch rope to keep the load in

place. Extending the boom without winchingdown, can lead to “two blocking”. This is when the

hook block or the hook ball contacts the head ma

chinery. Two blocking can lead to sheave or wire

rope damage.

19. Pinch points, which result from relative motion be

tween mechanical parts, can cause injury. Keep

clear of the rotating upper or moving parts.20. Lifting heavy loads can cause the crane to tilt or

lean toward the load. When swinging a load from

over the end to over the side, the tilt of the crane will

increase. Since tilt acts to increase load radius, it

must be compensated for when swinging the load.

Swing slowly. Change boom angle (raise theboom) while swinging, to maintain a constant ra

dius, and prevent in swing or out swing of load. If

not, a dangerous condition could result.

Operator's Manual


Figure 1-30Watch that side tilt!

Wrong

A little sidetilt whileworking overthe end......

....Increases loadradius when swungover the side

21. The winch rope must be vertical when starting to

lift. If not, the load will swing in, out, or sideways

when lifted from the ground. The crane will lean toward the load when lifting heavy loads. This is

caused by elasticity of the crane and the boom.

This lean will increase operating radius so the load

will swing outward when it clears the ground. This

out swing is dangerous to anything in the path of

the load, and because of the increase in load radius may overload the crane. To overcome this out

swing, boom up as the load is lifted so winch ropes

remain vertical. When setting the load on the

ground, lower boom after the load touches down to

avoid hook block swing when it is unhooked from

load.

Figure 1-31Watch that centrifugal force!

1. Load Radius at Rest

2. Load Radius Increases Due To Centrifugal Force

1

2

Wrong

22. Watch out for centrifugal force when swinging a

load. Swing gently. Centrifugal force tends to in

crease load radius. This increase in radius couldoverload the crane and cause crane damage or tip

ping. When stopping the swing, over swing of the

load can side load the boom.

23. Keep the winch ropes as short as possible to pre

vent excessive swinging. Always use the shortest

boom length which will do the job. Remember -the shorter the boom, the better the capacity.

24. Due to inertia (weight), a load will momentarily tend

to stay in position when the crane starts to move.

For this reason do not back the crane away from a

suspended load when handling near capacity

loads. The inertia effect will tend to increase load

radius and decrease stability. Use hand lines as required to control the load.

25. Don't increase the counterweight. Don't add any

thing to the crane that will act as additional counter

weight. Remember that anything which has

weight, if carried behind the crane's center of grav

ity, acts as counterweight. Adding counterweightaffects backward stability of the crane, particularly

when working over the side. It also encourages

overloading of the crane.

26. Working areas for cranes are defined per the workingareas chart in the Crane Rating Manual. Permissibleloads, per the Crane Rating Manual, will vary from lifting quadrant to lifting quadrant. The operator must

Operator's Manual


make sure capacity ratings are not exceeded regardless of which quadrant he is operating in, or whenswinging from one quadrant to another.

27. When working on tires, the tires must be inflated topressures shown on the Tire Inflation label located

on the left rear fender of the carrier.

28. Prior to lifting any loads, inspect the boom or boom

and fly combination to ensure they are straight. The

heat from the sun may distort the boom due to tem

perature differential on the sides of the boom. Re

position the boom to allow the thermal effects fromthe sun to equalize the temperatures of the side walls

of the boom to eliminate the distortion before lifting a

load. Refer to “Boom Distortion Due To Thermal Ef

fects Of The Sun“ found in Section 1 of this Operat

or's Manual for additional information.

Traveling1. Traveling with a suspended load should be

avoided if possible. It is especially hazardous

when terrain is rough or irregular, on a side slope,

or in a hilly area. When traveling with a load, ob

serve the following rules:

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

b. Travel by the smoothest, most level route. If a

smooth, level route is not available, don't travel

with a suspended load. Grade the route to pro

vide a smooth, level path. If it is not possible to

grade the route, move the load by stepping.

Level the crane on outriggers, lift the load andset it down ahead of the crane. Travel the un

loaded crane beyond the load, level the crane

on outriggers, lift the load, swing and set it

down farther along the route. Continue this

procedure until the load is at its destination.

c. Carry loads as close to the ground as possible.d. Do not allow side swing of the load.

e. Don't attempt to carry loads which exceed the

crane's rating.

f. Don't travel with a load on soft ground. If the

crane sinks into ground, stability can be af

fected to the point of tipping the crane.

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

h. Fully extend outrigger beams. Extend or re

tract jacks until pontoons just clear the ground.

i. Check clearance for the extra width of the

crane with the outriggers extended. Outrigger

beams or pontoons must not hang on any obstruction.

j. When making lifts on tires, inflate tires as

shown on the Tire Inflation label located on the

left rear fender of the carrier.

2. When traveling on the highway, road the cranesafely. Watch for narrow bridges and low clear

ances. Check load limits, heights, width and

length restrictions in the area you are traveling.

Make sure your crane complies with all regula

tions.

3. When roading the crane, note the following:

a. Operate with lights on. Use proper warningsigns, flags and other devices. Use an escort

service if required.

b. Engage travel swing lock. Release the swing

park brake and 360� swing lock (if equipped).

c. Lash down or otherwise restrain the hook

block.d. Check for maximum allowable travel speed

and any other travel limitations. Don't exceed

these maximums. Crane damage or an acci

dent could result.

e. Inflate tires as listed on the Tire Inflation Label

located on the left rear fender of the carrier.

f. Fully retract all outriggers.g. Remove all pontoons from the outrigger jacks

and store them properly.

4. If the crane must be towed, refer to “Towing The

Crane” found later in this Section of the Operator's

Manual for specific instructions.

Operator's Manual


Figure 1-32Do not leave crane while a load is suspended.

Wrong

Leaving The Operator's Cab1. Do not get on or off a crane in motion. Use the grab

handles and ladders when climbing on or off the

crane. Remain in three point contact with the crane

at all times (two hands and one foot or two feet and

one hand).

2. Whenever an operator leaves the control station for

any reason, the following must be done:a. Lower the load to the ground.

b. Engage swing lock. Engage the park brake.

Shutdown the engine and remove the keys.

c. Do not depend on a brake to suspend a load

unless the operator is at the controls, alert and

ready to handle the load. Brake slippage, vandalism, or mechanical malfunctions could

cause the load to drop.

3. Do not leave crane unattended with engine running.

4. When changing work shifts be sure to notify the next

operator of any changes or problems with the

crane.5. Hydraulic cylinders, left extended under load, often

times have a tendency to drift in (retract) due to in

ternal fluid passage in the cylinders and/or control

valves. Do not shutdown the crane and leave it unat

tended for extended periods of time, i.e. overnight,

with the boom positioned over anything or the crane

itself that the boom could damage if it should lower.For instance the boom hoist cylinder may drift allow

ing the boom to lower and damage the engine

hood. Position the boom over the front to avoid the

engine hood on the rear of the crane.

Operator's Manual


Personnel Handling Guidelines

Introduction

The following information is intended to provide Link‐Belt's recommended minimum requirements that

must be followed when handling personnel with a

personnel basket or work platform (hereafter referred

to as a work platform) suspended by wire rope from

the boom of Link‐Belt cranes. These requirements

are based upon several sources and are put forth inrecognition of current industry practices. However,

safety, when handling personnel, remains the full re

sponsibility of job site management and is depend

ent upon the responsible action of every person on

the job involved in the related work.

This information is intended to supplement and not

to supersede or replace any more restrictive federal,state, or local regulations, safety codes, or insurance

requirements. It is intended to serve users of per

sonnel work platforms in achieving the following ob

jectives.

1. Reduce risk of personal injuries to users and the

public.2. Inform users of their respective responsibilities.

3. Provide standards of equipment requirements.

4. Provide standards for tests and inspections.

5. Provide standards of operation to promote safety.

Link‐Belt cranes are designed and intended for

handling material. They are not normally equipped

with secondary systems or other devices required bypersonnel lift or elevator standards and are not inten

ded for handling personnel for construction or

amusement purposes. Use of cranes for these pur

poses is hazardous and is not recommended by

Link‐Belt. However, Link‐Belt understands that cir

cumstances may occur (in construction work) whenlifting or lowering personnel on a materials handling

crane load line is the only or the least hazardous

method available to position personnel. In fact, Oc

cupational Safety and Health Administration (OSHA)

Part 29 CFR 1926.550(g) states “The use of a crane

or derrick to hoist employees on a personnel workplatform is prohibited, except when the erection, use,

and dismantling of conventional means of reaching

the work site, such as personnel hoist, ladder, stair

way, aerial lift, elevating work platform, or scaffold

would be more hazardous or is not possible because

of structural design or work site conditions.”

Much corollary and supplementary information iscontained within the following resource documents

pertaining to both cranes and personnel work platforms. Job site management must ensure all re

quirements listed in these resource documents are

followed for all personnel handling operations.

� American National Standards Institute Reference -

ANSI Standards A10.28, A92.2, A92.3, B30.5, and

B30.23.

� Power Crane and Shovel Association (PCSA) Bureauof the Association of Equipment Manufacturers

(AEM) Reference - PCSA Standard No. 4.

� American Petroleum Institute (A.P.I.) Specification

2C.

� OSHA Part 29, CFR 1926.550 Cranes and Derricks.

Authorization

Authorized use of a work platform may be permitted

only after the following on‐site procedures have been

performed:

1. A competent person on the job site (job site man

ager) specifically responsible for the overall work

function to be performed has determined thatthere is no practical alternative means to perform

the needed work and has authorized a personnel

lifting operation.

2. For each instance of such lifting, a competent per

son responsible for the task has attested to the

need for the operation by issuing a written state

ment describing the operation and its time frameand itemizing that each of the on-site authoriza

tion requirements has been met. The written state

ment, after being approved by a qualified person,

shall be retained at the job site. (Refer to Personnel

Handling Pre-Lift Check List For Link‐Belt Cranes

found later in this Section for a sample check list.)3. Review of crane inspection records has been con

ducted to ensure the crane being used meets ap

plicable provisions in ANSI B30.5 and B30.23.

4. Review of the work platform inspection records

and specifications has been conducted to ensure it

meets applicable design standards (refer to ANSI

A10-28).5. Review of the personnel lifting operation practices

specified in these instructions have been conduc

ted with job site managers and crane operator(s),

foreman, designated signal person, personnel to

be lifted, safety supervisor, and any other per

son(s) who has jurisdiction over the operation toensure that they are aware of the hazards of the op

eration and they are aware of provisions of these

instructions that must be adhered to before and

during the personnel lifting operation.

Operator's Manual


Equipment1. The crane system shall be equipped with the fol

lowing:

a. A fully functional working operational aid such

as a Rated Capacity Limiter (RCL) system - A

system consisting of devices that sense crane

loading, boom length (extendable booms

only), boom angle, and also automaticallyprovide an audible/visual signal when the

loading conditions approach, reach, and/or

exceed the rated capacity values. When the

Actual Load exceeds the Rated Capacity, the

system supplies a signal to a function cutout

system. The operational aid shall be equippedwith these additional devices:

1. Anti-two block device to prevent damage

to the hoist rope, other crane components,

or attachments, and subsequent endan

germent of personnel.

� It is required that the anti-two blockdevice warn both audibly and visually as

well as have the capability to cutout the

controls/functions that may cause a two

block condition.

2. Boom angle indicator.

� Cranes with extendable booms must

utilize a boom angle indicator having“high and low” set points and audible/

visual alarm(s) capable of activating

function cutouts.

b. Boom hoist and load line shall have power

lowering and raising and shall have an auto

matic brake which is applied when the applicable control is in neutral, or when the anti-two

block device is actuated.

c. If the crane is equipped with a “free‐fall“ hoist,

steps shall be taken to ensure its use is not

possible during the use of the work platform.

(Note: A.P.I. applications do not permit the

crane to be equipped with free‐fall.)d. Each crane shall have a mechanical swing

park brake or swing lock capable of being set

at any swing position, and shall have a variable

swing brake or swing controls capable of stop

ping the upper swing motion smoothly. The

swing brake must be properly maintained at alltimes to ensure its holding capability.

Note: All operational aids and equipment

must be maintained in operable condition.

2. The work platform shall be designed by a qualified

engineer competent in structural design. Its main

tenance, and its attachment to the crane load line,

is the responsibility of the job site management.

Their arrangement shall comply with the followingas a minimum:

a. The work platform harness must be of suffi

cient length to prevent any portion of the work

platform or the harness from coming in contact

with the boom at any working boom angle.

b. Audible and visual alert systems shall be

provided to the personnel in the work platformto signal for assistance in the event of an emer

gency.

c. Hooks on hook ball assemblies, hook block

assemblies, or other assemblies, shall be of a

type that can be closed and locked, (with a

working safety latch) eliminating the hookthroat opening, and shall be full load-bearing,

and contain a manual trigger release.

3. No unauthorized alterations or modifications shall

be made to the basic crane.

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

standing of the crane's maintenance, lubrication,

and adjustment instructions as outlined in the

Operator's Manual.

2. The crane shall be maintained, lubricated, and ad

justed, by a designated person, as specified in the

Operator's Manual.

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

4. All decal precautions and instructions shall be

strictly observed.

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

immediately prior to commencement of operation.(Refer to the Crane Operator's Manual and ANSI

B30.5, Section 5, Section 5-2.1.2 and 5.2.4, and

ANSI B30.23 for the required inspection proced

ures for the crane. Refer to ANSI A10-28 for in

spection procedures required for the work plat

form.)2. The inspection shall be performed once daily when

the crane is being used in work platform service or

each time the crane is converted from material lift

ing to personnel handling operation. In the event

the operator is replaced, a new inspection is re

quired. Written documentation of all inspections

must be kept on the job site during personnelhandling operations.

3. Inspect the crane and work platform for any loose,

damaged, or missing components.

4. Any structural or functional defect which adversely

affects the safe operation of the lift crane shall be

corrected before any operation utilizing a workplatform begins or continues.

Operator's Manual


5. The hoist drum shall have at least three wraps ofwire rope remaining on the drum at all times when

using a work platform.

6. Minimum load hoist and boom hoist wire rope

safety factors for the combined weight of the lift at

tachments, work platform personnel, and tools

shall be 7:1 for manufacturer's specified construc

tion wire rope and 10:1 for rotation resistant wirerope. (Note: A.P.I. applications require 10:1 for all

rope construction.)

7. Telescopic Boom Cranes - The work platform

shall be suspended from the main boom head

sheaves only. Lattice Boom Cranes - The work

platform shall be suspended from the main boomhead sheaves only, or on a luffing attachment, the

luffing jib head sheaves only. Do not suspend a

work platform from any other lifting sheave(s) on

any attachment.

8. Inspect the wire ropes, hoist drum brakes, boom,

and other mechanical and rigging equipment vital

to the safe operation of the crane. A written recordof this inspection must be maintained on the job

site.

9. In addition to other regular inspections, visual in

spection of the crane and work platform shall be

conducted immediately after testing and prior to

lifting personnel. The following inspections shallbe conducted on extendable booms prior to lifting

personnel:

a. Full power style booms:

1. Inspection of all extension wire ropes at

the access points in the boom where the

end connections are visible - Refer to theOperator's Manual for inspection and ad

justment procedures.

b. Pinning and latching style booms:

1. Inspection of the latching mechanism,

sensors, and hydraulic/electrical circuit at

the access points.

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

fully retracted position.

3. Verification of the accuracy of the boom

length indicator. Refer to the Operator's

Manual for the procedures.

10. The following inspections shall be conducted onfixed length style booms prior to lifting personnel:

a. Inspection of all pendants, pendant links,

pendant spreader bars, and dead end lugs

and links, etc.

b. Inspection of all mechanical linkages, shafts,

drums, etc.

c. Inspection of all chord and lattice members ofall boom sections, luffing jib sections, and live

mast, as equipped.

Crane Test Procedures

The test procedures listed below shall be conducted

at the following intervals:

� Daily

� When an operator is replaced

� When, in the judgement of responsible job site man

agement, there has been a significant change in the

conditions of the personnel lifting operation.

Note: No personnel shall ride the work platform dur

ing any of the tests recommended in this Section.

1. The work platform shall be loaded with ballast at

two times the intended load. This load shall not ex

ceed the rated capacity of the work platform. Do

not exceed the rated lifting capacity of the applicable lift crane capacity chart. (Refer to ANSI

A10.28 for suspended work platform testing and

inspection.)

a. This test load shall be tested for stability.

� The operator and signal person shall con

duct this test.

� This test shall include movement of the work

platform through its entire intended range of

motion, simulating the specific operation to

be undertaken.

� A successful stability test must not produce

instability of the crane or cause permanent

deformation of any component.b. This test load shall be raised and lowered at

maximum power controlled line speed (NOT

FREE‐FALL). The acceleration must be

smooth and the deceleration capability of the

control/braking system shall be confirmed by

bringing the work platform to a smooth stop.(This experience is intended to sharpen the

skill of the operator in handling the work plat

form and to give the operator an opportunity to

evaluate the crane's performance.) The work

platform shall then be inspected for any evid

ent sign of damage or defect.

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

3. With pinning and latching style extendable booms,

a visual inspection shall be conducted to verify that

the boom extend pins are properly set in the exten

ded boom sections.

Operator's Manual


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

and fully understood by operating personnel. It

shall be available to them at all times.

2. Safety when handling personnel remains the full

responsibility of job site management and is de

pendent upon the responsible action of every per

son on the job involved in the related work.3. Mobile lift cranes shall be erected to obtain maxim

um crane stability. The crane must be level and on

firm ground with the outriggers fully extended and

the tires clear of the ground before beginning any

operation.

4. The operator shall not leave the operator's stationwhen the work platform is occupied. The operator

shall remain alert in a position of readiness at the

work station with the engine running and the mas

ter clutch engaged, if crane is so equipped.

5. Unauthorized personnel shall not be in the operat

or's cab on the lift crane, or near the lift crane whilea work platform is suspended from the load line.

6. Any operation in which a work platform is to be sus

pended from the load line shall be carefully

planned by the operator, supervisory personnel,

designated signal person, and personnel to be lif

ted prior to commencement of such operation.

They are to be advised:a. That the crane does not have safety devices

normally used on personnel handling equip

ment.

b. That the safety of the operation depends on

the skill and judgment of the crane operator

and others present.c. Of procedures to enter and leave the work plat

form and other safety procedures.

7. After positioning of the work platform:

a. All brakes and locks on the lift crane shall be

set before personnel perform any work.

b. With pinning and latching style extendable

booms, a visual inspection shall be conductedto verify that the boom extend pins are properly

set in the extended boom sections.

8. Telescope operation is not recommended with any

extendable boom with personnel in the work plat

form.

9. A work platform attached to load line of lift cranesshall not be used for working on any energized

electric power line, or any energized device or facil

ity used for electric power generation or transmis

sion. Minimum working clearance shall be at least

twice that recommended for material handling op

erations in ANSI B30.5b section 503.4.5 and ANSIB30.23.

10. The combined weight of the work platform, any attachment device, personnel, tools, and other

equipment shall not exceed 50% of the lifting capa

city of the applicable lift crane capacity chart.

(Note: A.P.I. applications require 25% of lifting ca

pacity as the limit.)

11. The following actions and operations are strictly

prohibited when working with personnel suspended in a work platform:

a. Cranes shall not travel while personnel are in

the work platform.

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

load lines with personnel suspended in a work

platform.c. No external load shall be lifted by attaching it to

the work platform.

d. Work platform lifts shall be a single crane oper

ation. A work platform shall not be lifted using

two cranes.

e. Hoisting of personnel shall be discontinued

upon indication of any dangerous weatherconditions, wind, or other impending danger.

f. The emergency manual mode operation of

pinning and latching style extendable booms

shall not be utilized.

g. Free-Fall (if equipped) shall not be used.

12. Movement of the work platform with personnelshall be done in a slow, controlled, cautious man

ner with no sudden movements of the crane or

work platform.

13. Clear, unobstructed visibility between personnel

on the work platform and the crane operator shall

be maintained at all times except where a designated signal person has been assigned and posi

tioned such that he is visible to both. Such desig

nated signal person shall have no other duties to

perform when personnel are in the work platform.

14. Voice communication between work platform per

sonnel, the crane operator, and designated signal

person, if assigned, shall be maintained.15. If other cranes or equipment may interfere with the

lifting of personnel, signals or other means of com

munication between all crane or equipment oper

ators shall be maintained to avoid interference with

individual operations.

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

work platform.

17. Personnel in the work platform shall wear personal

fall arrest systems. Anchors used for attachment of

personal fall arrest equipment shall be independ

ent of any anchors being used to support or sus

pend work platforms. Personnel shall keep allparts of body, tools, and equipment inside work

platform during raising, lowering, and positioning.

Operator's Manual


18. Personnel shall always stand firmly on the floor ofthe work platform and shall not sit or climb on the

edge of the work platform or use planks, ladders,

or other devices for attaining a work position. (This

does not apply to offshore personnel transfer bas

kets. Personnel must ride on the exterior of this

type of personnel handling device to assure great

er safety of the operation.)19. When welding is done by personnel in the work

platform, the electrode holders shall be protected

from contact with metal components of the work

platform. If electrically connected electrode hold

ers contact work platform, work platform could be

dropped due to burning/melting of wire ropes suspending the work platform.

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

materials. However, due to the special conditions

commonly existing offshore, the use of cranes to

transfer personnel between vessels or from a ves

sel to a work platform is an established practice.

The safety of the personnel, if a materials handling

crane is used in transferring personnel, dependsupon the skill and judgment of the crane operator

and alertness of the personnel being transferred.

Sea and weather conditions may create additional

hazards beyond the skill of persons involved.

This operation is approved by the American Petro

leum Institute (A.P.I.). By adopting procedures forthis operation, the institute has determined that the

transfer of personnel may be performed safely un

der certain offshore conditions. Therefore,

whenever an offshore crane is used to transfer per

sonnel, all persons involved in the operation must

know and implement the A.P.I. procedures andverify that sea and weather conditions are within

safe limits for the transfer.

In addition to all previous requirements in these In

structions, A.P.I. 2C requires the following:

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

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

Operator's Manual


Personnel Handling

Pre‐Lift Check List for Link‐Belt Cranes

1

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

Name: Title:

Signature: Date: / / Initials

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

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

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

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

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

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

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

are working from the work platform� Hook block or hook ball being used can be closed and locked with a safety latch

7 A working audible and visual alert system is provided to the personnel in the work platform.

8 A mechanical and structural crane inspection has been completed by a designated person.

9Test has been completed with twice the total load in the work platform that is expected for thetotal load during the personnel handling operation.

10 Lifting personnel is allowed from:

� Telescopic Boom Cranes - Main boom head sheaves only� Lattice Boom Cranes - Main boom head sheaves only or on a luffing attachment, the luffing

jib head sheaves only

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

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

13When handling personnel with pinning and latching style booms, it is recommended that theboom be kept in a pinned position. Inspections must be done to ensure that all boom extendpins are set.

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

15 Fall arrest systems are present and in use by personnel in the work platform.

16 Weather and wind conditions are acceptable to safely perform the lift.

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

Operator's Manual


Figure 1-33Operator's Cab

1. Service Brake Pedal

2. Throttle Pedal

3. Crane Rating Manual Holder

4. Gauge And Control Panel

5. Rated Capacity Limiter Display

6. Bubble Level

7. 360° Swing Lock (If Equipped)

8. Seat Console Control Switches

9. Operator's Seat

10. Outrigger Control Box

11. Windshield Washer Reservoir

12. Operator's Manual Holder

13. Fire Extinguisher

14. Swing Brake Pedal

15. Boom Telescope Pedal

16. Fuse Panel

2

5

4

10

1611

13

9

15

14

128

6

3

1

87

ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Operator's Manual


Figure 1-34Top Hatch Wiper

1. Control Switch

2. Wiper Motor

1

2

Operator's CabLocated throughout the operator's cab are severalpanels which contain the controls, switches, andgauges to operate and monitor crane operations. Refer to Figure 1-33. The following is a description ofeach gauge, switch, or control in each panel, alongwith an explanation of their function and/or operation.

Fire ExtinguisherA fire extinguisher is located in the operator's cab below the left console. Refer to Figure 1-33. Raise theleft console to gain access to the extinguisher. It is an AB C type fire extinguisher, meaning it is capable of extinguishing most types of fires. The operator should befamiliar with its location, the clamp mechanism used tosecure it in place, and foremost the operation of the device. Specific instructions, regarding operation, aregiven on the label attached on the fire extinguisher. Acharge indicator on the fire extinguisher monitors thepressure within the tank. Check the indicator daily toensure the fire extinguisher is adequately charged andready for use.

Top Hatch WiperThe top hatch wiper is located in the top left corner ofthe cab roof. Refer to Figure 1-34. The switch for thetop hatch wiper is located on the wiper motor. Move theswitch to the “ON” or “OFF” position as desired.

Windshield Washer ReservoirCheck the windshield washer reservoir daily. The reservoir for washer fluid is located in the lower right rear ofthe cab. Refer to Figure 1-33. Visual inspection candetermine if the washer fluid is adequate. Do not operate the washer when the reservoir is empty. Use specially formulated windshield washer fluid rather thanwater because specialty washer fluids contain additives that dissolve road grime and prevents freezing.

Figure 1-35Typical Fuse Panel Label - Always refer to the

actual label on the crane.

3RD

WRAP

RELAY RUN

RELAY

1

RUN

RELAY

2

NEUTRAL

START

RELAY

TRAVEL

ALARM

RELAYHEATER

FANRELAY

C-

15

B-

15

A-

15

D-

10

E-

10

F-

5

G-

5H

-2

0J-

25

K-

10

L-

10

M-

5

A-RUN RELAYS, GAUGES, START RELAY, PARK BRAKEB-UPPER LIGHTSC-HAZARD, TURN, BRAKE LIGHTSD-DOME LIGHT, HORNE-BOOM LIGHT (OPT)F-RCL DISPLAYG-STROBE LIGHTH-DRIVING LIGHTSJ-HEATER FANK-AXLE OSC. LOCK

L-COMBINATION STEERM-ENGINE COMPUTER, HOUR METERN-WIPER, WASHERP-SWING ALARM, FANR-DRI, WARNING LIGHTSS-HEATER RELAY, HEAT CONTROLT-ENGINE COMPUTER, ENGINE LIGHTSU-OUTRIGGERSV-TOP HATCH WIPERW-FUNCTION LOCKOUTX-TELESCOPE OVERRIDE

Y-BRAKE & STEER WARNING, 3RD WRAPZ-FINE METERING, CTWT REMOVALAA-O/R PINNING, OSCILLATION ADJUSTBB-12 VOLT ACCESSORYCC-EXTERNAL LIGHT BAR (OPT)DD- TRANS CPU, OVERSPEED CONTROLEE-RCLFF-HYDRAULIC KICKOUTGG-GAUGE ALARMHH-WINCH CONTROLJJ-PARK BRAKE, TRANSMISSION

T-

5N

-1

5P

-5

R-

5S

-5

U-

25

V-

10

W-

5X

-1

0Y

-5

Z-

10

AA

-1

0B

B-

10

CC

-1

0D

D-

5

EE

-5

FF

-1

0G

G-

5H

H-

10

JJ-

10

DRIVING

LIGHT

RELAY

BRAKE

RELAY

SWING

Operator's Cab Fuse PanelThe fuse panel is located in the lower left front corner ofthe operator's cab. Refer to Figure 1-33. Located behind the fuse panel cover is a label which designatesthe electrical circuit protected by each fuse. Refer toFigure 1-35. Each fuse has a letter designation whichcorresponds to the upper electrical system as shownon the fuse identification label and the following chart.

Bubble LevelThe bubble level is provided to assist the operator inleveling the crane on outriggers. It is located on theright cab wall. Refer to Figure 1-33.

Gauge And Control Panel

A panel that contains the following controls, gauges,and indicators is located inside the right front corner ofthe operator's cab and is shown in Figure 1-36.

1. Windshield Wiper/Washer Switch

Rotate the wiper/washer knob clockwise

to activate the windshield wiper. Rotate

the knob to the first detent for low speed

wiper and to the second detent for high speed wip

er. Pushing the wiper/washer knob sprays washerfluid on the windshield to clean the window.

2. Stop Engine Indicator Light

This red indicator light will illuminate along

with an alarm buzzer to make the operator

aware of critical engine problems. When

this light illuminates stop operations immediately

and shutdown the engine. Consult the enginemanufacturer's manual and determine the prob

lem before any further operation of the engine.

This light will also flash when using the engine

diagnostic request switch to retrieve active engine

Operator's Manual


fault codes stored in the engine control module(ECM). Refer to engine manufacturer's manual for

the engine fault code descriptions.

Note: The stop engine light will illuminate mo

mentarily when the ignition is turned on as a

means of testing the indicator light. The light

should go out after a short period of time.

3. Check Engine Indicator Light

This amber indicator light will illuminate

along with an alarm buzzer to make the

operator aware of minor engine problems.

When this light illuminates engine operation may

continue. However, consult the engine

manufacturer's manual and determine the problemas soon as possible to avoid prolonged operation of

the malfunctioning engine which could develop into

a major problem. This light will also flash when

using the engine diagnostic request switch to

retrieve inactive engine fault codes stored in the

engine control module (ECM). Refer to enginemanufacturer's manual for the engine fault code

descriptions.

Note: The check engine light will illuminate mo




4. Swing Park Brake Indicator Light

This light will illuminate anytime the swing

park brake is applied and the ignition is on.

5. Upper Lights Switch

This switch operates upper floodlights.

Push the left side of the switch to turn flood

lights on, right side to turn them off.

6. Boom Floodlight Switch

This switch operates the boom floodlight.

Push the left side of the switch to turn flood

light on, right side to turn it off.

7. Rotating Beacon or Strobe Light Switch(If Equipped)

This switch controls the cab rotating bea

con or strobe light. Push the left side of the

switch to turn it on, right side to turn it off.

8. Gauge Lights Dimmer Switch

This switch is used to control the gauge lights. Ro

tate the switch left to dim the gauge lights or rotate

right to brighten gauge lights.

9. Hydraulic Oil Temperature Gauge

This gauge registers the hydraulic oil temperature in the main return line. Normal operating ranges vary with the oils used in dif

ferent climates. Refer to Section 2 of this Operator's Manual for proper oil viscosities and operating temperature ranges. If the hydraulic oil exceeds the maximum operating temperature, an indicator light within the gauge will illuminate and analarm buzzer will sound. Shutdown the crane immediately and correct the problem.

10. Fuel Level Gauge

This gauge registers the level of fuel in thefuel tank. The fuel tank capacity is 75 gal(284L). Refer to the engine manufacturer's

manual for the correct grade of diesel fuel. Whenthe fuel level reaches an eighth of a tank, an indicator light within the gauge will illuminate.

11. Tachometer

The tachometer registers engine speed in revolutions per minute (rpm). Refer to the engine manufacturer's manual for suggested operating speeds.

12. Coolant Temperature Gauge

This gauge registers the engine coolingsystem temperature. For proper coolingsystem operating temperature range, refer

to the engine manufacturer's manual. If the cooling system overheats, reduce engine speed orshift to a lower gear, or both, until the temperaturereturns to normal operating range. If engine temperature does not return to normal temperature,refer to engine manufacturer's manual. When thecoolant temperature exceeds normal operatingrange an indicator light within the gauge will illuminate, an alarm buzzer will sound, and the stop engine light will illuminate.

Operator's Manual


Figure 1-36Gauge And Control Panel

1. Windshield Wiper/Washer Switch

2. Stop Engine Indicator Light

3. Check Engine Indicator Light

4. Swing Park Brake Indicator Light

5. Upper Lights Switch

6. Boom Floodlight Switch7. Rotating Beacon or Strobe Light Switch

8. Gauge Lights Dimmer Switch

9. Hydraulic Oil Temperature Gauge

10. Fuel Level Gauge

11. Tachometer

12. Coolant Temperature Gauge

13. Fine Metering Switch

14. Rated Capacity Limiter (RCL) Display15. Ignition Switch

16. Horn Button

17. 12V DC Accessory Outlet

18. Heater/Air Conditioner Selector Switch

19. Heater or Fan Speed Switch

20. Temperature Control Knob

21. Check Gauges Audible Alarm

22. Throttle Lock Switch23. Function Lockout Switch

24. Third Wrap Warning Light

25. First Layer Warning Light

4

16

5

6

7

1

23

15

21

18

24

25

22

12

9

10

11

17

8

14

19

20

2

3

13

Operator's Manual


13. Fine Metering Switch

This switch is used to activate the fine me

tering system. Refer to “Fine Metering

System” found later in this Section of the

Operator's Manual.

14. Rated Capacity Limiter Display

This displays the boom length, boom angle, loadweight, etc. See “Crane Monitoring System” found

later in this Section of the Operator's Manual for

complete operating instructions.

15. Ignition Switch

The ignition switch is the conventional, key operated, automotive type. It controls engineoff/on/start, accessories, and energizes the instrument panel in the operator's cab.

16. Horn Button

Press this button to sound the horn. Be

fore starting the engine, it is recom

mended to sound the horn twice in succession, wait 10-15 seconds while making a visu

al check to verify that there are no persons under

or in close proximity to the crane. There also is a

horn button located on the right hydraulic control

lever.

17. 12V DC Accessory Outlet

Use this outlet for electrical accessories.

CAUTIONDo not connect an accessory to any part of thecrane other than the accessory outlets or

cigarette lighter. Damage to the crane's

electrical system may result. If it is necessary

to do so, contact your Link‐Belt distributor.

18. Heater/Air Conditioner Selector Switch(If Equipped)

If cab is equipped with air conditioning and

heater, this switch selects which system to

operate. Press the top part of the switch toturn the heater on, bottom part to turn the air condi

tioning on.

19. Heater or Fan Speed Switch

This switch controls the cab heater if cab is

not equipped with air conditioning. Press

the top part of the switch to turn the unit on,bottom part to turn it off. If cab is equipped with air

conditioning, this switch controls the fan speed.

20. Temperature Control Knob

Turn the climate control knob to adjust the temper

ature in the cab.

21. Check Gauges Audible Alarm

This buzzer alarm will sound to alert the operator

that a gauge is detecting an abnormal operating

range. The check engine or stop engine light willalso illuminate when applicable. The problem

should be repaired before operating the crane.

22. Throttle Lock Switch

This switch is used to hold the engine at aconstant speed. This provides the operatorwith more flexibility for certain job require

ments. Refer to “Throttle Lock System” found later inthis Section of the Operator's Manual.

23. Function Lockout Switch

This switch is used to disable hydraulicfunctions which are operated by the con

trol levers and boom telescope foot pedal.

Press the top part of the switch to disable hydraulic

functions and to prevent inadvertent operation of

these controls. To allow normal operation of the

control levers and boom telescope foot pedal,

press the bottom part of the function lockoutswitch. The bottom part of the switch will illuminate

to indicate switch is in the ON position.

24. Third Wrap Warning Light (If Equipped)

The crane may be equipped with the third

wrap indicator option. When the third

wrap indicator switch is ON, this red warning light will illuminate and a buzzer will sound to

alert the operator when the wire rope is down to the

third wrap on the winch drum(s).

WARNINGThree (3) full wraps of wire rope must bemaintained on the winch drum at all times

during operation. Rope failure may occur.

25. First Layer Warning Light (If Equipped)

The crane may be equipped with a first layer warning light option. When the third

wrap indicator switch is ON, this red warn

ing light will illuminate to alert the operator when

there is only one layer of wire rope remaining on the

winch drum(s).

Operator's Manual


Figure 1-37Seat Console Control Switches

Left Right

1. Boom Telescope Override Switches

2. First Layer/Third Wrap Indicator Switches

3. Drum Rotation Indicator Switch 4. Winch Control Switches

1 432

Seat Console Control SwitchesControl switches are located on the left and rightconsoles of the operator's seat. Refer to Figure 1-33and Figure 1-37.

1. Boom Telescope Override Switches

These switches are provided to manuallyoverride the telescope system when theboom is not extending/retracting proportionally in all boom modes. Use theseswitches for that purpose only. Press the

switch to enter telescope override

mode. Use the switch to select the boom sections to override as follows:

Top position of the switch will override the inner and center sections allowing only the tipand outer sections to extend and retract.

Center position of the switch will override theinner, outer, and tip sections allowing onlythe center section to extend and retract.

The bottom position of the switch will overridethe center, outer, and tip sections allowingonly the inner section to extend and retract.

2. First Layer/Third Wrap Indicator Switch

(If Equipped)

This switch operates the first layer/third

wrap indicator system for the winch

drum(s). Press the switch to monitor

the front drum and press the switch to

monitor the rear drum. Press bothswitches to monitor both drums. When this

switch(es) is in the “ON” position, a red warning

light will illuminate and a buzzer will sound to alert

the operator when the wire rope is down to the first

layer and/or third wrap on the winch drum(s). Re

fer to Figure 1-36 for warning light location.

3. Drum Rotation Indicator Switch

This switch is used to activate the drum ro

tation indicator system. To activate the

system, press the bottom part of the

switch. Press the top part of the switch to deacti

vate the system. The bottom part of the switch willilluminate to indicate switch is in the ON position.

Refer to “Drum Rotation Indicators” found later in

this Section of the Operator's Manual for complete

operating procedures.

4. Winch Control Switches

These switches are used to control engag

ing/disengaging the high speed hoist and

disabling the front and/or rear winch. Re

fer to “Wire Rope Winch System” found later in this

Section of the Operator's Manual for complete operating procedures.

Operator's Manual


Figure 1-38Cab Heater Shutoff

1. Shutoff Valves

1

1

Cab HeaterA cab heater is used to heat the upper cab.. The cab

heater uses engine coolant circulating through the unitto provide heat. Normally the engine coolant circulates

through the heater in the cab regardless of whether the

heater switch is turned on or not. During warm weather

conditions, the operator may wish to shutoff the flow of

hot engine coolant to the heater to reduce the temperature in the cab. Shutoff valves are located on the en

gine to perform this function. Refer to Figure 1-38 for

shutoff valve location. Refer to Figure 1-36 for control

location.

To Start The Cab Heater1. With the engine running, press the heater switch or

if crane is equipped with air conditioning, press the

top part of the heater/air conditioner selector

switch to turn the heater on.

2. Turn the temperature control knob to the desired

setting.3. If cab is equipped with air conditioning, use the fan

speed switch to control the air in the cab. If cab is

not equipped with air conditioning, use the heater/

fan speed switch to control the air in the cab.

To Stop The Cab Heater1. Press the heater switch to the off position.

2. During warm weather conditions or if the heater is

not going to be used for an extended period of

time, rotate the temperature control knob to the

coolest setting.

Cab Heater Shutoff

WARNINGShutdown the engine and allow it to coolbefore operating the heater shutoff valves.

The valves may be hot and could cause

serious burns.

1. Shutdown the engine and rotate the handles on

the shutoff valves clockwise to stop the flow of en

gine coolant to the heater; Counterclockwise to restore it. Refer to Figure 1-38.

Air Conditioning (If Equipped)

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

tioning unit. Use the following instructions to operate

the unit. Refer to Figure 1-36.

1. Start the engine and allow all operating temperatures and pressures to reach their normal range.

2. Press the bottom part of the heater/air conditioner

selector switch to activate the air conditioning unit.

3. Press the fan speed switch to control the amount of

air blown into the cab.

4. Turn the temperature control knob to the desiredsetting.

5. To turn the unit off, press the heater/air conditioner

selector switch to the off position.

Operator's Manual


1. Steering Wheel

2. Transmission Oil Temperature Gauge

3. Indicator Light Bars

4. Voltmeter Gauge

5. Transmission Shift Lever

6. Emergency Hazard Switch

7. Transmission Range Select Switch

8. Engine Diagnostic Connector

9. Combination Steering Switch

10.Ether Start Switch

11.Travel Park Brake Switch

12.Tilt/Telescoping Column Lever

13.Engine Diagnostic Request Switch

14.Turn Signal/Horn/Driving Lights Lever

Figure 1-39Steering Column And Wheel

12

14

1

7

5

4

811

9

2

6

3

13

10

Operator's Manual


Steering Column And Wheel

The following is a description of the controls on the

steering column along with an explanation of their func

tion and/or operation. Refer to Figure 1-39.

1. Steering Wheel

Turn the steering wheel clockwise for right turns

and counterclockwise for left turns.

Note: Relative direction of the steering wheel is

based on the position of the upper over the

carrier.

2. Transmission Oil Temperature Gauge

This gauge registers the hydraulic oil tem

perature in the wheel motor return line.

Normal operating ranges vary with the oils

used in different climates. Refer to Section 2 of this

Operator's Manual for proper oil viscosities and

operating temperature ranges. If the hydraulic oilexceeds normal operating temperature, an indica

tor light within the gauge will illuminate and an

alarm buzzer will sound. Shutdown the crane im

mediately and correct the problem before continu

ing operations. If the crane is using Grade 100 oil,

the indicator light and buzzer will activate at 190° F(88° C). If the crane is using Grade 68 oil, the indi

cator light and buzzer will activate at 170° F (77°C).

If the crane is using Grade 22 oil, the indicator light

and buzzer will activate at 110° F (43° C).

Note: If the grade of hydraulic oil used in thecrane is changed, the transmission oil temperature gauge alarm switch located in the wheelmotor return tube must be changed to correspond with the grade of oil being used. Refer to“Hydraulic Reservoir Oil Change” in Section 2of this Operator's Manual.

3. Indicator Light Bars

Three indicator light bars are located on the steering column and contain the following indicatorlights:

Left Turn Signal - This light will blink to indicate that the left turn signal is on or thehazard lights are flashing.

Engine Oil Pressure - This indicator lightwill illuminate when the engine oil pressureis not within normal operating range. If

there is no engine oil pressure after 10-15 seconds of running time, shutdown the engine immediately and repair the problem to avoid enginedamage.

Rear Wheel Offset - This indicator light willilluminate to alert the operator that the rearwheels are out of line with the carrier. Refer

to “Combination Steering” found later in this Section of the Operator's Manual for complete operating procedures.

Emergency Steer - On cranes equippedwith emergency steer, this light alerts theoperator that power steering pump pres

sure is low. When the emergency steering indicator light illuminates, there is enough oil in storage tonegotiate approximately eight 90� turns. Park thecrane and shutdown the engine if this indicatorlight illuminates. Discontinue further operationsuntil the problem is resolved.

Travel Park Brake Engaged - This light willilluminate anytime the park brake is engaged and the ignition is on.

Service Brake Warning - This light will illuminate to warn the operator of an imminent brake failure. When this light illumi

nates, approximately twelve brake applicationscan be obtained prior to complete brake systemfailure. When this light illuminates discontinue operations immediately, park the crane, and correctthe problem before placing the crane back into service.

Right Turn Signal - This light will blink toindicate that the right turn signal is on orthe hazard lights are flashing.

Case Drain Filter Change - This indicator

light will illuminate to alert the operator thatthe case filter is being by‐passed. If this

light illuminates, change the filter immediately. Re

fer to “Hydraulic Case Drain Filter Change” found

in Section 2 of this Operator's Manual.

Hydraulic Charge Filter -This indicator

light will illuminate to alert the operator thatthe hydraulic charge filter is being by‐

passed. If this light illuminates, change the filter im

mediately. Refer to “Hydraulic Charge Flow Filter

Change” found in Section 2 of this Operator's

Manual.

Operator's Manual


Travel Pump CPU - This light will flash toalert the operator that a fault has been de

tected from the travel pump control unit.

Refer to “Travel Pump Control Unit” found later in

this Section of the Operator's Manual. There is an

indicator light on the PCU that will flash the same

codes. The following describes the flash pattern

fault code.

Flashing Pattern:

1 Flash = Loss of engine speed feedback sig

nal.

3 Flashes = DC voltage supply to module is less

than 8.5 volts.

4 Flashes = Either an electrical short or an opencircuit has occurred.

5 Flashes = Loss idle validation signal.

9 Flashes = Bad learn‐in has occurred.

Note: The pump CPU light will illuminate mo




Engine Speed Warning - This light will illu

minate along with an alarm buzzer to alert

the operator that the engine speed is too

high. When this light illuminates, decrease engine

speed until light extinguishes.

4. Voltmeter Gauge

This gauge registers the charge in the battery and the output of the alternator

through the regulator. It should read 12volts with the key on, and 12.5 to 14 volts with theengine running. When the charge or the voltage in

the battery is not within normal operating range anindicator light within the gauge will illuminate.

5. Transmission Shift Lever

The transmission shift lever is used to select the

forward or reverse gear in the transmission. To put

the transmission in forward or reverse gear, pushthe lever up and then push forward to engage the

forward gear, or backward to engage the reverse

gear.

6. Emergency Hazard Switch

This switch controls the emergency hazard

flashers. Push the switch to turn flashers on, pushthe switch again to turn them off.

7. Transmission Range Select Switch

This switch is used to select either the2‐Wheel High drive mode, 2‐Wheel Low

drive mode, or 6‐Wheel Low drive mode.

Bring the crane to a complete stop and

position the transmission shifter to neutral

before changing the position of the range select

switch.

8. Engine Diagnostic Connector

The diagnostic connector provides access to diag

nostic codes within the engine control module

(ECM). The service technician can plug in a data

reader to retrieve the engine fault codes stored in

the ECM. Refer to the engine manufacturer's man

ual for information on engine diagnostics and engine fault code descriptions.

9. Combination Steering Switch

The crane is equipped with four different modes of

steering in order to provide maximum maneuver

ability on the job site. Refer to “Combination Steer

ing” found later in this Section of the Operator'sManual for complete operating procedures.

Operator's Manual


10. Ether Start Switch (If Equipped)

The ether start system is activated by

pressing this switch while cranking the en

gine. Refer to “Ether Start” in this Sectionof the Operator's Manual for additional details and

operating instructions.

11. Travel Park Brake Switch

This switch controls engaging and releas

ing the park brake.

WARNINGDo not use the park brake to stop the crane inmotion (as a service brake) except in cases of

extreme emergency. Application cannot be

controlled.

To Engage Park Brakea. Bring the crane to a complete stop by applying

the carrier service brake.

b. Shift the transmission to neutral.

c. Move park brake switch to “ON” position.

d. Park brake indicator light should illuminate.

To Release Park Brake

a. Apply the carrier service brake.b. Move park brake switch to the “OFF” position.

c. The park brake indicator light should go out.

12. Tilt/Telescope Column Lever

This lever controls the tilt (angle) and telescoping

function of the steering column.

To change steering column height and angle:a. Bring the crane to a complete stop.

b. Shift the transmission to neutral and engage

the park brake.

c. Rotate the tilt/telescoping column lever.

d. Position the steering wheel at the desired

height and angle and rotate lever to lock it in

place.e. Check all steering wheel functions before con

tinuing operation.

13. Engine Diagnostic Request Switch

This switch is used to activate the stop engine indi

cator light to flash active engine fault codes. When

the engine is not running and with the ignition on,pressing and holding the switch will flash out en

gine fault codes through the stop engine indicator

light.

Refer to the engine manufacturer's manual for information on engine diagnostics and engine fault

code descriptions.

14. Turn Signal/Horn/Driving Lights Lever

Turn Signal - Pull the lever down for left turn signal,

push up on lever for right turn signal.

Horn - Push the end of the lever to sound the horn.

Driving Lights - Rotate the lever to the first detent

to illuminate the parking lights, the second det

ent for headlights. Rotate the lever to the off

position to turn all lights off.

Operator's Manual


Transmission ControlsThe transmission is a continuously variable hydrostatic

drive. The transmission shifter is located on the steer

ing column. Refer to Figure 1-39. The transmission

shifter has three‐positions (with lock in neutral feature)

for forward, neutral, and reverse. When using the

range select switch on the steering column, the cranehas 3 forward and 3 reverse speeds. See “Traveling

The Crane” found later in this Section of the Operator's

Manual for necessary preparations before traveling the

crane.

RangeSelect

Max SpeedCrane

Capability

mph km/hrMax Grade

Allowed

6 WD Low 3 4.8 55%

2 WD Low 9 14.5 15%

2 WD High 18.5 29.8 6%

CAUTIONExtended driving in 6 WD Low may damagethe hydraulic system. Limit travel in this mode

to 1/2 hour maximum time period. Select

appropriate travel range based on the grade

of slope.

WARNINGDo not attempt to travel crane up or down agrade larger than the crane capability in a

particular Range Select. Failure to do this

could result in loss of control and/or crane

damage. Also some crane capabilities such

as 6 WD Low maximum gradeability may not

be usable due to such factors as maximum

engine oil pan angle and crane stability.

Note: Relative direction of the crane is based on thecarrier.

Transmission Travel Limits

Travel Conditions Auxiliary Oil CoolerHydraulic Oil

Grade

Max Travel System Temperature

°F °C

Heavy Required

22 110 43

68 170 77

100 190 88

ModerateNot Required

22 110 43

68 170 77

Required 100 190 88

Light

Not Required 22 110 43



Heavy:Extensive 6‐wheel drive (greater than 30% of the time), or grades greater than 10%, or 2‐wheel travelgreater than 5 miles.

Moderate: 6‐wheel drive (5-30% of the time), or grades 5-10%, or 2‐wheel travel 2-5 miles.

Light: 6‐wheel drive (0-5% of the time), or grades 0-5%, or 2‐wheel travel 0-2 miles.

Operator's Manual


Operating The Transmission Shifter

CAUTIONExtended travel may cause the hydraulic oil inthe travel circuit to overheat. Crane damage

may occur if hydraulic oil temperatures are

exceeded. Monitor the trans. temperature

gauge to ensure hydraulic oil temperature

within the travel circuit is not exceeded. Refer

to the Transmission Travel Limits chart for

maximum travel system temperatures.

1. Engage the park brake and place transmission

shifter in neutral position. Start the engine. (Engine will start only when transmission shifter is in

neutral.) Allow the hydraulic oil to circulate for a

few moments.

2. Engage travel swing lock and release the 360�

swing lock, if equipped.

CAUTIONDo not leave the 360� swing lock engagedduring pick and carry operations or when

traveling or transporting the crane. Use the

travel swing lock. Failure to release the 360�

swing lock during these operations may result

in damage to the swing gear.

3. Forward Travela. With the crane at a complete stop, fully apply

the carrier service brakes, shift the transmis

sion to neutral, and release the park brake.

b. Move transmission shifter to the “F” position.

c. Slowly release the service brake while using

the throttle pedal to increase the engine and

travel speed, allowing the crane to accelerate.4. Reverse Travel

a. With the crane at a complete stop, fully apply

the carrier service brakes, shift the transmis

sion to neutral, and release the park brake.

b. Move transmission shift lever to the “R” posi

tion.

Note: The travel/back‐up alarm will sound

anytime the transmission shifter is in re

verse. It will also sound anytime the trans

mission shifter is moved out of neutral and

the upper is not positioned directly over the

front of the carrier.

c. Slowly release the service brake while using

the throttle pedal to increase the engine and

travel speed, allowing the crane to accelerate.

Operator's Manual


Figure 1-40Foot Operated Controls

1. Boom Telescope Control Pedal



4. Throttle Pedal

1 2 3 4

Foot Operated Controls

The following is a description of the foot controls in theoperator's cab along with an explanation of their func

tion and/or operation. Refer to Figure 1-40.

1. Boom Telescope Control Pedal

Depress the toe of the pedal to extend the boom.

Depress the heel to retract the boom. Refer to

“Boom Telescope System” found later in this Section of the Operator's Manual for complete operat

ing instructions.


The swing brake pedal is used to stop rotation of

the upper over the carrier. Refer to “Swing System”

found later in this Section of the Operator's Manualfor complete operating instructions.


The carrier service brakes are controlled by the

brake pedal. Press the pedal down to apply the

service brakes. Release the pedal to release the

service brakes.

The distance the service brake pedal is moved de

termines the braking force. Depress the pedal fully

only in cases of emergency as this makes control

of the crane difficult.

4. Throttle Pedal

Engine speed is controlled by the throttle pedal.

Press the throttle pedal down to increase engine

speed. Release the throttle pedal to decrease en

gine speed.

Operator's Manual


Conventional 4-Wheel Crab

Figure 1-41Steering Modes

Front Front Front

Rear Wheel

Front

Combination Steering

The crane is equipped with four different modes of

steering in order to provide maximum maneuverability

on the job site: conventional, rear wheel, 4‐wheel, and

crab steer. Each steer mode provides slightly different

maneuverability to meet job site requirements. Refer to

Figure 1-41 for illustration of the different steermodes.

Conventional Steer Mode

This steer mode is similar to that of an automobile. In

this steer mode, the front wheels may be turned in

either direction and the rear wheels remain stationary.

Use this steer mode for all extended or high speed

travel.

WARNINGDo not use rear wheel, 4‐wheel, or crab steermode for extended or high speed travel as

steering behavior may be unfamiliar and a

loss of crane control could occur.

Rear Wheel Steer Mode

This steer mode is similar to that of a fork truck. In this

steer mode, the rear wheels may be turned in either di

rection and the front wheels remain stationary. Use this

steer mode for job site travel only; not for extended or

highway travel.

4‐Wheel Steer Mode

This steer mode allows steering with all four wheels.

The front wheels turn in one direction and the rear

wheels turn in the opposite direction. This results in a

greatly reduced turning radius that allows extra ma

neuverability in certain job site conditions. Use this

steer mode for job site travel only; not for extended or

highway travel.

Crab Steer Mode

This steer mode allows steering with all four wheels.

The front and rear wheels turn simultaneously in the

same direction which moves the crane in the diagonal

path of travel. This gives the operator another method

of maneuvering the crane where job site conditions require it. Use this steer mode for job site travel only; not

for extended or highway travel.

Changing Steering Modes

The rear wheel offset light, located on the steering col

umn in the indicator light bars (Figure 1-39), is de

signed to assist the operator in changing steeringmodes by determining when the rear wheels are

straight. This light will come on anytime the rear wheels

are not in‐line with the carrier. Use the following proce

dure when changing steering modes:

1. Bring the crane to a complete stop.

2. Turn the steering wheel until the rear wheel offsetlight goes off.

3. Move the steer switch to the conventional steering

mode.

4. Check all wheels for proper alignment by traveling

the crane a short distance, straight ahead, to en

sure it tracks straight.

5. Bring the crane to a complete stop and move thesteer mode switch to the desired position.

Operator's Manual


1. Power

2. Status

3. High Side Output Driver Status

4. Pulse Width Modulation (PPM) Out

put Driver Status

5. Digital Input Status

6. Module Status

7. Network Status

Figure 1-42Pump Control Unit

7 1

26

53

4

Travel Pump Control UnitThe travel pump control unit is mounted on the right

side wall of the operator's cab, just behind the opera

tor's seat. It is constantly measuring the throttle posi

tion and engine rpm electronically. The unit receives

input from the throttle (hand or foot pedal), engine

speed sensor, transmission shifter, and steer assistpressure switches. The control unit logic is as listed be

low.

1. Automotive style driving: crane travel speed in

creases as throttle increases, pump rpm increases

as throttle increases, pump displacement in

creases as throttle increases.2. Horsepower dissipation: the control unit will send

a signal to put the pump circuit over relief if the en

gine rpm exceeds throttle position by more than

6% of the mapped throttle position rpm. This fea

ture is important during travel and winch operation

to prevent engine over‐speed.

3. Anti‐stall feature: will reduce pump displacementif engine speed drops below throttle position by

more than 6% of mapped throttle position rpm.

This reduces load on the engine and prevents the

engine from stalling.

The pump control unit uses light emitting diodes (let's)to indicate operating conditions and to perform system

diagnostics. The let's are defined in Table A.

Diagnostic Error CodesThe status LED, on the pump control unit, will blink si

multaneously with the “Travel Pump CPU Indicator

Light”, located on the steering column, to alert the op

erator that an error has occurred in the system. Either

light may be used to define an error message Theselights are normally off but will illuminate and blink to in

form the operator of the error condition. Both lights will

blink on for 1/2 second and then blink off for 1/2 second

to indicate one blink. A sequence of blinks will be inter

rupted by blinking off for 1 1/2 seconds. Count the

number of blinks between interruptions to determine

each of the error messages. The error codes are specifically defined in Table B.

Diagnostic ConnectorA diagnostic connector is located in the wire harness,

below the pump control unit, for initial calibration or ex

tensive troubleshooting. Extensive troubleshooting re

quires a laptop computer, diagnostic software, and a

factory trained technician. Contact your area distribu

tor if extensive troubleshooting is required.

Operator's Manual


No. LED Description Qty Color Signal Description

1 Power 1 Green � On: Power On, Normal� Blinks: Power supply Voltage is > 30Vdc� Off: Power supply Voltage is < 8Vdc

2 Status 1 Red � Off: Normal� Blinking: System error, see Table B

3 High Side Output Driver Status 6 Green � On: Corresponding high side output is activated.

� Blinks once per second: Open circuit� Blinks 4 times per second: Short Circuit

4 PWM Output Driver Status

A: Left Side PumpB: Right Side PumpC: HP Dissipation

3 Red/Yellow/Green This LED displays duty‐cycle status for thecorresponding PWM output. The LED willchange from red, to yellow, to green as theduty‐cycle changes from 0% to 100%; displaying yellow at 50%.

5 Digital Input Status 8 Green � Turns on when the corresponding input isactivated. Inputs can be programmed asactive high or low.

� Off: Not Used See Table C

6 Module Status 1 Green/Red � Off: No power applied to module� On Green: Normal� Blinks Green: Standby� Blinks Red: Recoverable fault� On Red: Module has unrecoverable fault� Blinks Red/Green: Self test Mode

7 Network Status

Not Used

Green/R ed � Off: Device in not on line� Blinks Green: Device is on line but has

not established connection to other nodes

� On Green: Device is on line and hasestablished connection toother nodes

� Blinks Red: One or more connections isin a timed-out state

� On Red: The device has detected an errorthat has rendered it incapable ofcommunicating on the network

Table APump Control Unit Indicator Lights

Operator's Manual


Blink Code Error Recommended Action

0 Blinks Normal, no errors � No action required

1 BlinkSpeed feedback signal from engine has beenlost

� Check that engine is running� Check wiring and connections between

pump control unit and the engine

3 Blinks Power supply voltage is < 8.5Vdc� Check fuses� Check crane battery for low voltage� Check circuit wiring and connections

4 BlinksOpen or shorted connection to proportionalvalve solenoids

� Check fuses� Check circuit wiring and connections to pro

portional solenoids� Confirm working condition of solenoids; re

pair or replace, as required.

5 BlinksThrottle switch is not closed or not makingcontact

� Check fuses� Check circuit wiring and connections to

throttle pedal switch� Confirm working condition of throttle pedal

switch; repair or replace, as required.

9 BlinksBad Learn‐In (calibration) of engine No‐LoadRPM.

� Contact area distributor

Table BPump Control Unit Diagnostic Error Codes

StatusIndicator Function

ConnectorPin No.

DIG 1 Direction Mode - Forward F3

DIG 2 Direction Mode - Reverse G3

DIG 3 Learn‐In H3

DIG 4 Not Used J1

DIG 5 Not Used J2

DIG 6 Idle Validation/Limit Switch J3

DIG 7 Left Steer Assist Pressure Switch K2

DIG 8 Right Steer Assist Pressure Switch K3

HSOUT 1 Left Propel Pump - Forward B1

HSOUT 2 Left Propel Pump - Reverse B2

HSOUT 3 Right Propel Pump - Forward C1

HSOUT 4 Right Propel Pump - Reverse C2

HSOUT 5 Horsepower Dissipation D1

HSOUT 6 Error Status Light D2

Table CDigital Input & High Side Output Status Indicators

Operator's Manual


Operator's SeatThis 6‐way adjustable seat is controlled by manual

controls. Refer to Figure 1-43.

WARNINGDo not make seat or console adjustmentswhile operating the crane or while crane is in

motion. Discontinue operations and properly

park crane before making adjustments.

1. Seat And Console Release Lever

Move the seat and console release lever to the left

and hold. Position the seat as desired and release

the lever to lock the seat in place.

2. Seat Release Lever

Move the seat release lever to the left and hold. Po

sition the seat as desired and release the lever to

lock the seat in place.

3. Seat Height Adjustment Lever

Move the height adjustment lever to the left and

hold. Position the seat as desired and release the

lever to lock the seat in place.

4. Arm Rest Height Adjustment Knob

Loosen the knob on the inside of the arm rest.

Position the arm rest as desired and tighten knobto lock the arm rest in place.

5. Seat Back Adjustment Lever

Raise the lever and adjust the seat back to the de

sired position. Release the lever to lock the seat

back in place.

Figure 1-43Operator's Seat

3

2

1

5

4

6

1. Seat and Console Release

Lever

2. Seat Release Lever

3. Seat Height Adjustment

Lever

4. Arm Rest Height AdjustmentKnob

5. Seat Back Adjustment Lever

6. Seat Belt

7. Tool Box


CONSTRUCTION EQUIPMENT

87

6. Seat Belt

A seat belt is provided and must be worn during alloperations. To fasten the seat belt pull the belt out

of the retractor and insert the tongue into the

buckle until you hear a snap and feel the latch en

gage. Be sure the belt is not twisted and is fitting

snugly around the hips, not around the waist.

WARNINGAlways wear the seat belt while operating thecrane. The seat belt must be snug and low

across the hips.

7. Tool Box

A tool box is provided under the operator's seat to

store tools and other crane accessories.

Operator's Manual


1. 15 Amp Circuit Breaker




5. Hour Meter

6. Battery Disconnect Switches

7. Batteries

Figure 1-44Power Panel, Battery Disconnect Switches, And Hour Meter

5

1

67

23

4

Battery Disconnect SwitchesThe battery disconnect switches are located in the bat

tery box on the right front of the upper. Refer to

Figure 1-44.

CAUTIONMajor damage may occur to the electronicequipment from welding on the crane prior to

turning disconnect switches to the “OFF”

position.

Ignition switch should be shut off at least 30

seconds prior to turning disconnect switches

to the “OFF” position.

Move the disconnect switches to the “Off” position be

fore welding on the crane to protect the crane's elec

tronic components from damage due to an electric arctype welder. Ignition switch should be shut off at least

30 seconds prior to turning disconnect switches to the

“OFF” position.

Power Panel Circuit BreakersThe power panel is located on the right front of the up

per. Refer to Figure 1-44. The power panel contains

reset type circuit breakers which service the crane's

electrical system. Depending upon how the crane is

equipped, the power panel may contain up to four re

set type circuit breakers which service the crane's electrical system as follows:

1. 15 Amp Circuit Breaker - Oscillation Relay.

2. 20 Amp Circuit Breaker - Engine Diagnostic Plug.

3. 30 Amp Circuit Breaker - DDEC Relay.

4. 30 Amp Circuit Breaker - Air Conditioning.

Hour MeterThe hour meter is located on the left side of the power

panel box. The hour meter registers engine operating

hours. It is useful in determining lubrication and main

tenance schedules.

Operator's Manual


Outrigger OperationThe outriggers can be used in any one of three

positions; fully retracted, intermediate extended, or

fully extended. The outriggers are controlled by

switches located on a hand held , tethered control box

(Refer to Figure 1-33 and Figure 1-45) and the

extend position levers located on the outrigger boxes(Refer to Figure 1-46). Each outrigger switch (Left

Front, Left Rear, Right Front, Right Rear) controls all

functions of that outrigger beam and jack cylinder. The

mode switch controls outrigger cylinder direction,

extend/retract. Each extend position lever controls the

extend length of the beam. It allows for beams to befully extended, or limits them to intermediate extended

lengths based on the selected position of the extend

position lever.

The outrigger pontoons must set on a smooth, solid

surface flush with ground with no hills or valleys under

them or they may be damaged or destroyed. If there is

any doubt as to the ground conditions, use mats underthe pontoons. Check pontoons before and during op

erations. If they are allowed to settle, they may lose

their effectiveness, and make continued operations

unsafe.

A bubble level is provided on the shifter console, in op

erator's cab, to assist in determining when crane islevel. Refer to Figure 1-33.

The hand held, tethered control box stores on the right

side wall of the cab beside the operator's seat. Refer to

Figure 1-33 for control box location and Figure 1-45

for switch identification. The control box allows the op

erator to remotely control all outrigger functions.

WARNINGDo not extend or retract an outrigger beam orjack unless it is in full view of the operator or

signalman. Make sure all personnel and

obstructions are clear from the path of the

machinery.

To Extend Outrigger Beams1. Park crane in the desired location. Position the

transmission shifter to neutral, engage the park

brake, and shutdown engine.

WARNINGPontoons must be attached to outrigger jacksbefore crane is set on outriggers. If pontoons

should settle, the jacks could disengage from

the pontoons, causing a loss of stability.

Figure 1-45Outrigger Switches

1. Beam - Left Front

2. Jack - Left Front

3. Extend Mode - Beam/Jack

4. Retract Mode - Beam/Jack

5. Beam - Left Rear

6. Jack - Left Rear

7. Jack - Right Rear

8. Beam - Right Rear

9. Jack - Right Front

10.Beam - Right Front

10

9

5

8

1

3

4

6

7

2

2. Remove the pontoons from storage and attach oneto each outrigger jack.

3. Determine the outrigger position desired. Set the

extend position lever as required (Refer to

Figure 1-46).

WARNINGWhen making lifts on outriggers, all outriggerbeams must be equally extended; all fully

retracted, all intermediate extended, or all

fully extended. Failure to do so will cause a

loss of stability and possible crane damage

and/or personal injury.

4. Start the engine.

5. Push an outrigger switch to the “BEAM” position and hold.

6. Push the mode switch to “EXTEND MODE” posi

tion and hold until the beam reaches the selected posi

tion; intermediate extended or fully extended.

7. When beam reaches selected position, release

both switches.8. Repeat steps 5-7, for each outrigger beam, until

all the beams are set to the selected position.

Note: As conditions warrant, a proficient crane

operator may operate multiple beams such as

one end or side at the same time.

Operator's Manual


Figure 1-46Outrigger Extend Position Lever

Improper extension of outriggers can lead to seriouspersonal injury and/or equipment damage. Use onlyspecified outrigger positions with correspondingrated capacity limiter settings.

FULLY EXTENDED

OUTRIGGER POSITION

INTERMEDIATE EXTENDED

OUTRIGGER POSITION

9. If the intermediate extended beam position is to beused, visually check that all beams are properly

positioned in the intermediate extended position.

All beams must be extended until the stop plate

contacts the extend position lever and the arrow is

aligned with the outrigger box collar. Refer to

Figure 1-46.10. Set the rated capacity limiter to the proper setting

to match the position of the outrigger beams.

WARNINGWhen making lifts with the crane onoutriggers, all outrigger beams must be

equally extended; fully retracted,

intermediate extended, or fully extended.

When making lifts with the outrigger beams in

the intermediate extended position, the

extend position lever must be in the

intermediate extended position. Visuallycheck that all outrigger beams are extended

until the stop plate contacts the extend

position lever and the arrow is aligned with the

outrigger box collar before beginning

operations.

Check that the Rated Capacity Limiter is set tothe correct outrigger position before

beginning operation.

Failure to perform any of the above may cause

crane damage and/or serious personal injury.

To Extend Outrigger Jacks - RaiseThe Crane1. With the beams extended to the selected position

(fully retracted, intermediate extended, or fully ex

tended), push an outrigger switch to the “JACK” position and hold.

CAUTIONWhen the hoist line is tied off to the crane orany solid object, the winch system can be

overloaded causing major winch, wire rope,

or crane damage. Do not extend boom, raise

or lower the boom, or raise the crane on

outriggers unless wire rope is spooled off the

drum to prevent tension on the wire rope.

2. Push the mode switch to “EXTEND MODE”

and hold until the jack cylinder is fully extended.

3. Release both switches.

4. Repeat Steps 1-3 for each outrigger jack.

Note: As conditions warrant, a proficient craneoperator may operate multiple jack cylinders

such as one end or side at the same time.

5. Raise or lower jacks as required to level the crane.

6. Check that all tires are clear of the ground and pon

toons are not settling.

Note: A bubble level is provided on the shifter

console to assist in determining when the craneis level.

WARNINGAll capacities listed in the Crane RatingManual, when on outriggers, are based on all

tires clear of the ground, all outrigger beams

equally extended (fully retracted,

intermediate extended, or fully extended),

using the proper chart for the outrigger

position and the crane setting level on a firm,

solid surface. Serious reductions in the cranelifting capacity and unsafe operating

conditions can result if these conditions are

not met.

To Retract Outrigger Jacks - LowerThe Crane1. Fully retract the boom. Swing the upper over the

front of the carrier and engage the travel swing lock.

2. Fully boom down.

Operator's Manual


3. Push an individual outrigger switch to the “JACK” position and hold.

4. Push the center mode switch to “RETRACT

MODE” position and hold until the jack cylin

der is fully retracted.

5. Release both switches.

6. Repeat Steps 3-5 for each outrigger jack.

Note: As conditions warrant, a proficient craneoperator may operate multiple jack cylinders

such as one end or side at the same time.

To Retract Outrigger Beams1. Push an individual outrigger switch to the “BEAM”

position and hold.

2. Push the center mode switch to the “RETRACT

MODE” position and hold until the beam is fully

retracted.3. Release both switches.

4. Repeat Steps 1-3 for each beam.

Note: As conditions warrant, a proficient crane

operator may operate multiple beams such as

one end or side at the same time.

5. Store all pontoons in the brackets provided.

Outrigger Removal SystemThe front and rear outrigger boxes can be removed

from the carrier to reduce the overall weight of the

crane. Quick disconnect type hydraulic fittings are uti

lized to reduce the effort of removing the outrigger

boxes. The outrigger box assemblies weigh approximately 8,000 lb (3 629kg) each. The crane or an auxilia

ry lifting device can be used to remove and install the

outrigger boxes. When using the crane boom to re

move outrigger boxes, always refer to the Crane Rating

Manual to ensure crane capacities are not exceeded.

The auxiliary lifting device, skids, and any rigging usedmust be capable of handling the entire weight of an out

rigger box assembly.

This crane may be equipped with hydraulic pin cylinder

system to ease removal of the outrigger boxes from the

carrier frame.

Outrigger Box Removal1. With crane parked on a firm, level surface, position

transmission shifter to neutral and apply park

brake.

2. Fully retract all outrigger jacks and beams.

3. Remove the pontoons from each outrigger jack

and properly store them on the outrigger box.

4. Remove the capscrews from the connecting pins.If equipped with hydraulic pin removal, remove the

pin locks from the hydraulic pin cylinder. Store the

hardware in the crane's tool box located under the

operator's seat.

WARNINGAll outrigger jacks and beams must be fullyretracted before connecting pins are removedor the hydraulic pin cylinder is retracted.Failure to do so can result in personal injuryand/or crane damage.

5. Remove the connecting pins or retract hydraulic

pin cylinder.

6. Shutdown engine and relieve hydraulic systempressure.

WARNINGHydraulic oil is under pressure and may behot. A sudden release of hot oil could causeburns or other serious injury. Beforeremoving or installing any outrigger circuithydraulic hose, shutdown the engine andrelieve hydraulic system pressure.

7. Remove hydraulic hoses from their ports on the

carrier. Be sure to match up and mate the dust

caps and plugs from all the quick disconnect fit

tings and keep them clean for future use. Refer to

Figure 1-48.8. Remove the electrical connection from the recep

tacle.

WARNINGWhen using the crane's boom or an auxiliarylifting device to handle the outrigger boxes,always ensure lifting capacities are notexceeded.

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

lifting device, rig a sling to lifting shackles on top of

outrigger box.

10. Lift the outrigger box up and away from the crane.

11. Place and secure outrigger box onto a transportvehicle.

12. Repeat procedure for the other outrigger box.

13. Before transporting the crane be sure all hydraulic

hoses and mounting pins are secure.

Operator's Manual


Figure 1-47Standard Outrigger Box Assembly

1

4

6

7

1. Extend Position Lever

2. Connecting Pins

3. Bolt, Washers, And Locknut

4. Electrical Connection

5. Hydraulic Hoses

6. Lifting Shackles

7. Mounting Pins

5

Do not activate outrigger pin removalsystem when crane is on outriggers.

HYDRAULIC OUTRIGGER PIN REMOVAL

23

STANDARD OUTRIGGER PINS OPTIONAL HYDRAULIC OUTRIGGER PIN REMOVAL

VIEW FROM BACK OF OUTRIGGER VIEW FROM UNDER FENDER

Outrigger pin retention devices must bein place to prevent accidental removal.Retention devices must be removed to pullpins. See Operator's Manual.

PIN

UNPIN

BOLT 2 REQDWASHER 4 REQDNUT 2 REQD

PIN 2 REQDCLIP 2 REQD

PINNINGSWITCH

VIEW FROM UNDER FENDER

OUTRIGGERHYDRAULIC

AND ELECTRICALCONNECTIONS

NOTE: INBOARDHYDRAULIC HOSEIS CABLE TIEDTO THE WIREHARNESS

Operator's Manual


Figure 1-48Outrigger Box Assembly With Hydraulic Pin Cylinder

1. Pin Lock

2. Extend Position Lever

3. Electrical Connection

4. Hydraulic Hoses

5. Lifting Shackles

6. Mounting Pins

7. Hydraulic Pin Cylinder

Do not activate outrigger pin removalsystem when crane is on outriggers.

HYDRAULIC OUTRIGGER PIN REMOVAL

2

34

5

6

6

5

71

VIEW FROM UNDER FENDER

OUTRIGGERHYDRAULIC

AND ELECTRICALCONNECTIONS

NOTE: INBOARDHYDRAULIC HOSEIS CABLE TIEDTO THE WIREHARNESS

STANDARD OUTRIGGER PINS OPTIONAL HYDRAULIC OUTRIGGER PIN REMOVAL

VIEW FROM BACK OF OUTRIGGER VIEW FROM UNDER FENDER

Outrigger pin retention devices must bein place to prevent accidental removal.Retention devices must be removed to pullpins. See Operator's Manual.

PIN

UNPIN

BOLT 2 REQDWASHER 4 REQDNUT 2 REQD

PIN 2 REQDCLIP 2 REQD

PINNINGSWITCH

Operator's Manual


Outrigger Box Installation1. With crane parked on a firm, level surface, position

transmission shifter to neutral and apply park

brake.

2. Rig a sling to the lifting shackles on the top of the

outrigger box. Refer to Figure 1-48.

WARNINGWhen using the crane's boom or an auxiliarylifting device to handle the outrigger boxes,always ensure lifting capacities are notexceeded.

3. Using the crane's boom or an appropriate liftingdevice, lift the outrigger box off the transport ve

hicle and set it down to the front or rear of the car

rier, positioning it for installation.

4. Carefully lift the outrigger box enough to align the

mounting pins of the box with the mounting lugs of

the carrier. Lower the box onto lugs.

5. Shutdown the engine and relieve hydraulic systempressure.

WARNINGHydraulic oil is under pressure and may behot. A sudden release of hot oil could causeburns or other serious injury. Beforeremoving or installing any outrigger circuithydraulic hose, shutdown the engine andrelieve hydraulic system pressure.

6. Connect hydraulic hoses to the ports on the carrier.Install all dust plugs to any open port. Plug the

electrical connector into the receptacle.

7. Install the connecting pins. Install the capscrews,

washers, and locknuts to the connecting pins

8. If crane is equipped with the hydraulic pin cylinder,

properly start engine and allow the system pres

sure to reach normal operating range. Activate thehydraulic pin cylinder control switch to extend the

cylinder pin through the carrier mounting lug eyes.

Install the pin locks on each end of the hydraulic

pin cylinder and secure with cotter pins.

WARNINGOutrigger pin locks must be installed to thehydraulic pin cylinders to prevent accidentalpin removal.

Operator's Manual


Crane System ControlsThe following pages, along with Figure 1-49, give de

tailed instructions of individual controls related to crane

operation. It is essential that the operator knows the

function of each control and its duty in the overall op

eration of the crane.

WARNINGRead and understand all “Operating Safety”procedures as well as all other operating

instructions in this manual before attempting to

operate the crane. Operation of the crane by

unqualified personnel may result in an

accident.

Engine ThrottleThe crane is equipped with a throttle pedal to control

the engine speed. Press pedal down to increase engine speed; release to decrease engine speed.

Throttle Lock System

The throttle lock system gives the operator the ability to

set and hold a specific engine speed. Refer to

Figure 1-36. This provides the operator with more

flexibility for certain job requirements.

To lock the throttle, press the throttle pedal until the desired engine speed is reached and press the top part ofthe throttle lock switch and release. The engineshould continue to run at a constant speed when thethrottle pedal is released.

To increase throttle lock setting, either press and holdthe bottom part of the throttle lock switch until desired engine speed is reached and release switch, orpress the throttle pedal until the desired engine speedis reached and press and release the top part of thethrottle lock switch.

To decrease throttle lock setting, press and release thetop part of the throttle lock switch until desired engine speed is reached.

To disable the throttle lock and return to idle, press andhold the top part of the throttle lock switch .

Operator's Manual


Figure 1-49Crane Controls


2. Hydraulic Control Lever

(Swing, Rear Winch)


4. Boom Telescope Pedal

5. Service Brake Pedal6. Throttle Pedal

7. Crane Rating Manual Holder

8. RCL Display

9. Bubble Level

10.Hydraulic Control Lever (Swing)

11.Hydraulic Control Lever (Rear Winch)

12.Hydraulic Control Lever (Front Winch)

13.Hydraulic Control Lever (Boom Hoist)

14.Boom Telescope Override Switches15.Swing Park Brake Switch

16.Third Wrap Indicator Switch

17.360° Swing Lock (If Equipped)

18.Horn Button

19.Drum Rotation Indicator Switch

20.Rear Winch Control Switch

21.Front Winch Control Switch

22.Hydraulic Control Lever

(Boom Hoist, Front Winch)23.Outrigger Remote Control Box

24.Travel Swing Lock Control

16

6

22

24

9 17

2

4

7

20

1

18

19

23

8

3

Seat Console Control Switches

Left Right

14 21

5

11

12

10

13

15

Single Axis Controls(If Equipped)

18

15

Operator's Manual


Swing SystemRotation of the upper over the carrier is controlled by

the swing system. Use the following controls to operatethe swing function of the crane:

Swing Brake Pedal

The swing brake pedal is used to stop rotation of the

upper over the carrier. To apply the swing brake, push

down on the swing brake foot pedal. To release the

swing brake, release the swing brake foot pedal.

Swing Control Lever

The control lever, on the left side of the operator's seat,

is used to operate the swing function of the upper.

Move the control lever to the position to swing left;

move it to the position to swing right.

WARNING

Do not exceed maximum boomangles listed on the backward

stability label located in the

operators cab. Crane can tip over

backwards.

To Swing The Upper

1. Compare the boom configuration and length to thecapacity chart in the Crane Rating Manual. Posi

tion the boom safely within the limits specified on

the capacity chart.

2. Ensure that all personnel are out of the swing path.

Dangerous pinch points are created during swinging.

DANGERSwing slowly and cautiously. Watch forcentrifugal force. Out swing of a load

increases the load radius and thus decreases

capacity. Load out swing may result in tipping

or damaging the crane.

All personnel and equipment must be out of

the path of the rotating upper. Failure to do so

could result in severe personal injury orequipment damage.

3. Fully apply the swing brake pedal and release theswing park brake and/or swing lock(s).

4. Release the swing brake pedal and begin to en

gage the swing control lever.

To Stop Upper Swing

1. Ease swing control lever into the neutral position.

Figure 1-50Keep Clear of Pinch Points

2. Apply the swing brake to bring the upper to a com

plete stop.

3. Engage the swing park brake as required.4. Check engagement of the swing park brake by try

ing to swing right, then left. The upper should not

swing.

Travel Swing Lock

Use the travel swing lock to lock the upper directly over

either the front or rear of the carrier. The travel swinglock will engage in these two positions only. Use of the

travel swing lock is mandatory when traveling or trans

porting the crane and during pick and carry operations.

To Release The Travel Swing Lock

1. Fully apply the swing brake pedal.

2. Pull the travel swing lock lever up.

Note: In order to disengage the travel swing lock,it may be necessary to swing the upper slightly torelieve the pressure on the swing lock pin.

3. Move the lever to the right and release. The lever

should remain in the released position.

To Engage The Travel Swing Lock

1. Position the upper directly over either the front or

rear of the carrier. Fully apply swing brake pedal.2. Pull the travel swing lock lever up and to the left.

Then push the lever down to the locked

position.

Note: In order to engage the travel swing lock, itmay be necessary to swing the upper slightly toalign the swing lock pin and retaining ring on thecarrier deck.

3. Check the engagement of the travel swing lock by

trying to swing the upper right, then left. The upper

should not swing.

Operator's Manual


Swing Park Brake

The swing park brake is a multiple disc type brake andis used for holding the upper, in any position, over thecarrier during normal, stationary crane operations. Engage the travel swing lock and release the swing parkbrake for pick and carry and anytime the crane is traveled or transported. An indicator light on the gaugeand control panel (Figure 1-36) will illuminate whenthe swing park brake is applied.

CAUTIONDo not leave the swing park brake appliedduring pick and carry operations or when


travel swing lock. Failure to release the swing

park brake during these operations may result

in damage to the swing mechanism.

To Release The Swing Park Brake1. Fully apply the swing brake pedal.

2. Push the swing park brake switch on the left con

troller. The indicator light will go out. Refer to

Figure 1-49 for switch location.

To Apply The Swing Park Brake

1. Rotate the upper to the desired position over thecarrier. Apply the swing brake pedal to bring the

upper to a complete stop.

2. Push the swing park brake switch on the left con

troller. Indicator light will illuminate. Refer to

Figure 1-49 for switch location.

CAUTIONDo not attempt to apply swing park brake withthe upper in motion. This practice will result in

damage to the swing mechanism. Use the

swing brake pedal to stop rotation of upper.

3. Check engagement of swing brake by trying to

swing upper right, then left. Upper should not swing.

360° Swing LockThe 360° swing lock, if equipped, is a positive lockagainst rotation of the upper over the carrier. The upper is mechanically locked by a manually operatedpawl that engages the gear teeth in the turntable bearing. Use this swing lock during normal, stationarycrane operations. Engage the travel swing lock and release the 360°�swing lock anytime the crane is used forpick and carry or is traveled or transported.

CAUTIONDo not leave the 360° swing lock engagedduring pick and carry operations or when


travel swing lock. Failure to release the 360°

swing lock during these operations may result


To Release The 360°�Swing Lock:1. Fully apply the swing brake pedal.

2. Move the 360° swing lock lever to the “Disengage”

position.

To Engage The 360° Swing Lock:1. Rotate the upper to the desired position over the

carrier. Apply the swing brake pedal to bring the

upper to a complete stop.

CAUTIONDo not attempt to engage 360°swing lock withthe upper in motion. This practice will result in

damage to the swing mechanism. Use swing

brake pedal to stop rotation of the upper.

2. Move the 360°�swing lock lever to the “Engage”

position.

Note: In order to engage the 360° swing lock, it

may be necessary to swing the upper slightly toallow the swing lock pawl to engage in the turn

table gear teeth

3. Check engagement of 360°swing lock by trying to

swing upper right, then left. The upper should not

swing.

Operator's Manual


Wire Rope Winch SystemThis system controls raising and lowering the winch

lines. The system is equipped with a two speed motor

that, when activated, will approximately double winchline speed. The controls for the system are shown in

Figure 1-49. Review the following for control descrip

tions and brief summary of operation.






drum(s) to prevent tension on the wire rope.

WARNINGCold weather operation of the winch requiresa warm‐up procedure. Failure to properlywarm‐up the winch may result in brakeslippage. Warm‐up the winch beforebeginning crane operations.

Warm‐Up Procedure

A warm‐up procedure is recommended at each start‐up and is essential at ambient temperatures below40°F (4°C ). Allow the engine to run at idle speed, withthe main hydraulic pump engaged and the winch control lever(s) in neutral, for several minutes. Once the hydraulic oil begins to warm, operate the winch at lowspeed, with no load, lifting and lowering only the hookblock or hook ball until warm oil circulates throughoutthe winch.

WARNINGThe weight of the load must be known beforemaking a lift. Compare the load weight to the

appropriate capacity chart in the Crane Rating

Manual to ensure compliance with capacity

ratings. Compare the load weight to the Wire

Rope Capacity chart in the Crane Rating

Manual to determine the number of parts ofline required to lift the load. Rig and set up the

crane to ensure compliance with both the

appropriate crane capacity chart and Wire

Rope Capacity chart in the Crane Rating

Manual. Properly set the Rated CapacityLimiter to the correct crane configuration.

Do not lift a load to the point where the hook

block and/or hook ball contacts the head

machinery. “Two blocking” could damage the

hook block, hook ball, and/or the headmachinery. Always keep load and hook block

and/or hook ball a safe distance from the

boom.

Front Winch Control Lever

This lever controls the front winch drum. Pull this con

trol lever back to the position to lift the load. Push

this control lever forward to the to lower the load.

Refer to “Winch Operation” for more specific instructions.

Rear Winch Control Lever (If Equipped)

This lever controls the rear winch drum. Pull this control lever back to the position to lift the load. Push

this control lever forward to the to lower the load.

Refer to “Winch Operation” for more specific instruc

tions.

Winch Operation

The following is a brief description of the basic proce

dure for operating the wire rope winch. Crane opera

tions are to be performed only by a qualified operator

who has read and fully understands the entire content

of this manual.

To Lift A Load: Attach the hook block or hook ball tothe load. Position head machinery directly above theload, pull the control lever back, toward the operator.

Note: When both winch levers are activated simul

taneously, the winch line requiring the most line pull

may not function.

Operator's Manual


To Hold A Load: Return the control lever to the neutralposition. The automatic brake in the winch system willhold the load in position.

To Lower A Load: Push the control lever forward. Return the control lever to neutral to stop the load.

Winch Control Switch(es)

This switch is used to control engaging/disengaging the

high/low speed hoist and disabling the front or rear

winch.

High Speed Hoist Or Lower

Press the winch control switch to the high speed

(� �) position. Move the control lever to the or

position. The high speed hoist will activate after

engaging the control lever. Refer to Figure 1-49.

Note: Using the high speed hoist reduces the maximum line pull by approximately half. The high

speed hoist button can be activated at anytime dur

ing either winch mode. Switching the high speed

hoist button before engaging the winch control

lever will make the system work smoother.

To Return To Standard Winch Mode: Press winchcontrol switch to the low speed (� �) position.Winch will return to standard speed.

Winch Disable

Press the winch control switch(es) to the disable ( )

position to disable the winch(es) to prevent inadvertent

operation of the winch(es) while using the control le

vers to perform other operations.

Drum Rotation Indicators

This system is used to monitor winch drum speeds

through the use of a mechanical signaling device

mounted inside each of the winch control levers. To acti

vate the system, push the bottom part of the drum rotation indicator switch , on the right seat console

(Figure 1-37), to the “ON” position (indicator within

switch will illuminate). Place your thumb over the end of

the control lever being used. As the winch drum rotates,

a mechanical signal will be felt with your thumb. The fre

quency of the mechanical signal is a direct indication ofthe winch drum speed. Push the top part of the drum

rotation switch to deactivate system.

First Layer/Third Wrap Indicator (If Equipped)

The crane may be equipped with a first layer/third wrap

indicator system. This system allows the operator to

monitor the wire rope windings on the drum(s). Thesystem control switches are located on the left seat

console. Press the switch to monitor the front drum

and press the switch to monitor the rear drum. Press

both switches to monitor both drums. When the system

is enabled, a red warning light will illuminate to alert

the operator when there is only one layer of wire rope

remaining on the winch drum(s). When the wire ropewindings are down to the third wrap, a red warning light

will illuminate and a buzzer will sound.

WARNINGThree (3) full wraps of wire rope must bemaintained on the winch drum at all times

during operation. Rope failure may occur.

Operator's Manual


Figure 1-51Boom Nomenclature

1. Base Section

2. Inner Section

3. Center Section

4. Outer Section

5. Tip Section

6. Boom Head Machinery

65421 3

Boom Hoist SystemRaising and lowering the boom is controlled by theboom hoist control lever located on the right arm rest.Refer to Figure 1-49.

WARNING

Do not exceed maximum boomangles listed on the backward

stability label located in the

operators cab. Crane can tip over

backwards.

To raise the boom (boom up): Move the boom hoist

control lever left to the position.







To Lower The Boom (Boom Down): Move the boomhoist control lever to the position.

CAUTIONWire rope must be spooled off the winch drumas the boom is lowered. Failure to do so may

cause two blocking.

To Stop The Boom: Ease the boom hoist control leverinto the neutral position.

Boom Telescope SystemThe crane is equipped with a five section full power

boom. The five section boom consists of a base, inner,center, outer, and a tip section. Refer to Figure 1-51.

The telescoping feature of the boom sections is oper

ated through the use of three hydraulic cylinders and a

cable/sheave mechanism which are an integral part of

the boom assembly. The boom can be extended or re

tracted to the desired length using the boom telescopepedal in the operator's cab. Refer to Figure 1-49. The

telescope feature has three modes of operation. Refer

to Figure 1-52.

Note: Boom must be fully retracted before chang

ing boom modes.

Boom Mode “Amax1”: When using boom mode

“Amax1” only the inner and center sections telescopesimultaneously. This mode offers increased strength

capacities. Select this mode through the rated capac

ity limiter system.

Boom Mode “Amax2”: When using boom mode

“Amax2” only the center, outer, and tip sections tele

scope simultaneously. This mode offers increased stability capacities. Select this mode through the rated ca

pacity limiter system.

Boom Mode “Standard”: When using boom mode

“Standard” all power boom sections extend/retract si

multaneously. This mode offers full boom extension.

Select this mode through the rated capacity limiter sys

tem.

Boom Telescope Control Pedal

Figure 1-49 shows the location of the telescope con

trol pedal in the operator's cab. Depress the toe of thetelescope control pedal to extend the boom. Depress

the heel of the telescope control pedal to retract the

Operator's Manual


boom. Use the telescope mode in conjunction with thetelescope control pedal to extend the boom sections to

the desired length.

Boom Telescope Override Switches

Boom telescope override switches are provided tomanually override the telescope system if the boom is

not extending/retracting proportionally. These

switches are to be used for that purpose only. Press

the switch to enter telescope override mode. For all

boom modes, move the switch to one of the three

positions to override its corresponding boom section

so the boom can be extended/retracted proportionally.

Refer to Figure 1-49 for switch location. Each position

of the switch is defined as follows:

Top position of the switch will override the innerand center sections allowing only the tip and outer sections to extend and retract.

Center position of the switch will override the inner, outer, and tip sections allowing only the center section to extend and retract.

The bottom position of the switch will override thecenter, outer, and tip sections allowing only the inner section to extend and retract.

To Extend The Boom Sections1. Park the crane on a firm level surface, position the

transmission shifter to neutral, and engage the

park brake.

2. Review the appropriate capacity chart in the Crane

Rating Manual to establish boom length, angle,

and load limitations.

Note: Boom must be fully retracted before

changing boom modes.

3. Set the rated capacity limiter to the desired telescope mode.







4. Depress the toe of the telescope control pedal.

CAUTIONWire rope must be spooled off the winchdrum(s) as the boom is extended. Failure to

do so may cause two blocking.

5. Stop the boom sections by releasing the telescope

control pedal.

Note: The telescope control pedal is spring

loaded and should return to the neutral position

when released.

To Retract The Boom Sections

1. Depress the heel of the telescope control pedal.

2. Stop the boom sections by releasing the telescope

control pedal.

Operator's Manual


Figure 1-52Boom Telescope Mode

Boom Mode “Amax1”

Boom Mode “Amax2”

Inner and center sections telescope simultaneously.

Center, outer, and tip sections telescope simultaneously.

Boom Mode “Standard”Inner, center, outer, and tip sections telescope simultaneously.

Base

400000502.52.52.52.5605.05.05.05.0707.57.57.57.58010.010.010.010.09012.512.512.512.510015.015.015.015.011017.517.517.517.512020.020.020.020.013022.522.522.522.514025.025.025.025.015027.527.527.527.5

InnerCenterOuterTip

40000503.33606.667010.008013.339016.6610020.0011023.33

122.527.50

BaseCenterOuterTip

3.336.6610.0013.3316.6620.0023.3327.50

3.336.6610.0013.3316.6620.0023.3327.50

400505.06010.07015.08020.09025.09527.5

BaseInnerCenter

05.010.015.020.025.027.5

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



Operator's Manual


1. Swing Left

2. Swing Right

3. Boom Down

4. Boom Up

5. Front Winch Down

6. Front Winch Up

7. Rear Winch Down

8. Rear Winch Up

Figure 1-53Fine Metering Valve

1

2

3

4

5

6

7

8

N2 N4 N6 N8

N7N5N3N1

FINE METERINGVALVE GUIDE

Fine Metering SystemThis fine metering system is used to adjust the crane's

hydraulic functions to certain job functions or for set

tings that are comfortable to the operator. The system

is for precise controlled operation and heavy lift capac

ity with slower speed. Use for jobs where accuratepositioning is more important than speed. The system

is activated by the fine metering switch located on the

gauge and control panel. Refer to Figure 1-36 for

switch location.

Operator's Manual


1. Hydraulic Oil Cooler Fan Switch

2. Oil Cooler Housing

1

Figure 1-54Hydraulic Oil Cooler Fan Switch

A

OIL COOLERFANONOFF

A2

Hydraulic Oil Cooler Fan

SwitchThe hydraulic oil cooler fan is used to help keep the oilcool during warm weather operations. The fan shouldremain on except in cold weather. The fan switch is located on the rear of oil cooler housing on the left rear ofthe upper. Refer to Figure 1-54.

Operator's Manual


1. Anemometer

2. Transmitter

3. Bushings

4. Bowtie Hair Pin

Figure 1-55Wind Speed Indicator

1

2

Main Boom Fly Base Fly Tip

3

4

Display

Crane Monitoring SystemA Crane monitoring system is available to assist the operator in safe operation of the crane. The following systems outline some of the aids used for monitoringcrane conditions during operation.

Wind Speed Indicator

The crane may be equipped with a wireless windspeed indicator integrated into the Rated CapacityLimiter system. The indicator is used to monitor windspeeds at the main boom head or the fly head when

erected. Refer to Figure 1-55. An anemometermounted on the boom head or fly transmits wind speeddata to the display unit in the operator's cab. Refer to“Wind Speed Restrictions” found in the Crane RatingManual for more information on wind speedrestrictions.

CAUTIONRemove the anemometer assembly from theboom head or fly during transport or beforestoring the fly to prevent damage to the unit.

Operator's Manual


Boom Angle IndicatorA bubble type boom angle indicator is mounted on the

base section of the boom to the right of the operator'scab. Refer to Figure 1-56. It must be adjusted prop

erly and the crane must be level for the unit to accu

rately indicate boom angles. Even under these condi

tions its readings are only approximate. When making

near capacity lifts, measure the load radius to deter

mine crane capacity. Check the adjustment of theboom angle indicator daily to ensure its accuracy. Re

fer to “Boom Angle Indicator Adjustment” found in Sec

tion 3 of this Operator's Manual.

Anti‐Two Block Warning SystemIntegrated into the Rated Capacity Limiter system is an

anti‐two block warning system. An anti‐two block

warning system is a system designed to alert the op

erator before the hook block or hook ball contacts the

head machinery of the main boom, auxiliary liftingsheave, or fly. When a two block situation is imminent,

an audio/visual alarm is activated to alert the operator

of the pending danger. When the alarm activates it is

essential that the operator discontinue operations im

mediately, and correct the two block situation.

CAUTIONDo not alter any component in the anti‐twoblock system. If any components are altered,

the crane may not be protected against a two

block condition. Crane damage may occur.

Three basic components are used to make up the anti‐two block system. The anti‐two block weight, anti‐two

block switch with lockout pin, and the display unit in the

operator's cab. Refer to Figure 1-57 and Figure 1-59

or Figure 1-81.

CAUTIONDo not allow the load to spin out of controlwhen hoisting. The anti‐two block weight maybecome entangled with the wire rope andcould damage the anti‐two block system, wirerope, or boom. Use rotation resistant ropeduring single part line hoisting applications,especially when long fall lifts are involved.

Figure 1-56Boom Angle Indicator

An anti‐two block weight is suspended from the headmachinery switch where lifts are to be made and is

used to hold the switch in the “working” position.

When the anti‐two block weight is lifted by the hook

block, it allows the switch to activate the audio/visual

alarm on the display unit in the operator's cab. In addi

tion to the audio/visual alarm, function limiters will beactivated.

The added feature of hydraulic function limiters, pre

vents the operator from continuing crane functions

which will cause a two block situation to occur. The

crane functions of winch up, boom down, and boom

extend are disabled when the anti‐two block weight islifted. These functions will remain disabled until the two

block situation is corrected or the “cancel alarm”

switch on the display unit is utilized.

The main boom head must always have an anti‐two

block switch. Each of the added attachments used on

the crane must employ a similar head machinery

switch as well, in order for that particular attachment tobe monitored by the system.

The plug assembly is connected to the jumper assem

bly on the boom head when operating from the main

boom. It is connected to the jumper assembly on the

attachment when operating from that attachment.

Check that all the harness connections between the attachments are properly joined and test the system be

fore beginning operations. Test the system by manual

ly lifting the ATB weight and verifying that the function of

winch up, boom down, and boom extend are disabled.

Operator's Manual


Figure 1-57Anti‐Two Block Warning System

1. Jumper Assembly

2. Plug Assembly

3. Anti‐Two Block Switch

4. Anti‐Two Block Weight

5. Lockout Pin & Flag

5

3

4

21

WARNINGMAIN BOOM ATB IS DISABLED

WHEN LOCK OUT PIN IS IN

HOLE. TO OPERATE MAIN BOOM

ATB, REMOVE PIN AND STORE

IN STORAGE HOLE BEHIND

SWITCH. FAILURE TO HAVE

FULLY OPERATIONAL ATB SYSTEM

COULD RESULT IN SERIOUS

INJURY OR DEATH.

LOCK OUT PIN HOLE

Lockout Pin Installed(Switch Inactive)

Lockout Pin Stored(Switch Active)

5

Lockout Pin And Flag

The lockout pin is used to hold the main boom anti‐two

block switch in the “working” position, the same as

having a two block weight suspended from the switch.

When operating from the main boom the lockout pin

and flag must be in the stored position. When operat

ing from an attachment only, the lockout pin must be

installed in the main boom head anti‐two block switch.

When both main boom and any other attachment arereeved for operation, lockout pin and flag must be re

moved from switch and properly stored.

Note: When using main boom and any other attach

ment, anti‐two block weights must be suspended

from each anti‐two block switch.

Operator's Manual


Figure 1-58Crane Monitoring Systems

MicroGuard 534Refer to Page 1-68

MicroGuard 434Refer to Page 1-84

Rated Capacity Limiter Display

Your crane may be equipped with one of the systems

available for this crane. Use Figure 1-58 to determine

which system you have and where to find the appropriate operating instructions.

Operator's Manual


Figure 1-59MicroGuard 534 Rated Capacity Limiter

1. Bar‐Graph

2. Pre‐Alarm Indicator

3. Overload Indicator

4. Maximum Rated Capacity Display

5. Actual Load Display

6. Parts‐of‐Line Display

7. Configuration Selection Buttons

8. Cancel Alarm Button

9. Operator Alarms Button

10. Crane Setup Button

11. Display/Select Button

12. Warning Message Area

13. Boom Length Display

14. Brightness Buttons

15. Load Radius Display

16. Boom Angle Display

17. Erected Attachment Display

6.5 X 1000 LBS MAX

0.5

71.0

90.0ft

110.0ft

24000

1

1

12

4

5

7

14

32

13

55’45�

16

11 10 9 8

17 6

15

!! TWO BLOCK !!

Operator's Manual


MicroGuard 534 Rated Capacity

Limiter

The following describes the function and operation ofthe MicroGuard 534 Rated Capacity Limiter. The system is intended to aid the operator in the efficient operation of the crane by continually monitoring the loadand warning of an approach to an overload or unsafecondition.

WARNINGAlthough the system will alert the operator ofan approaching overload or unsafe condition,

it remains the responsibility of the operator to

operate the crane safely at all times.

This system must never be substituted for the

good judgment of the crane operator using safe

operating procedures. The operator is solelyresponsible for safe operation of the crane.

!!THIS SYSTEM IS AN OPERATOR'S AID -

NOT A SAFETY DEVICE!!

System Description

The system monitors crane functions by means of highaccuracy sensors and continuously compares the loadwith a copy of the crane capacity chart which is storedin the computer memory. If an overload is approached,the system warns by means of audible and visualalarms and is configured to cause function limitation.

The MicroGuard 534 Rated Capacity Limiter providesthe operator with a continuous display of:� Rated Capacity

� Actual Load

� Percentage of Rated Capacity

� Radius of the Load

� Angle of the Main Boom� Crane Configuration

� Length of the Main Boom

An additional feature of the system is the provision ofoperator settable alarms. These alarms, when properly set, provide a method of obstacle avoidance. This isachieved by means of maximum boom angle, maximum load radius, maximum boom head height, leftand right swing, and defined area alarms. Thesealarms can be programmed for each job site and setrapidly for the prevailing site conditions thereby aidingthe operator in safe operation of the crane.

Figure 1-60Overhead Bar Graph And External Light Bar

(If Equipped)

2

3

1. Green Lights - Percentage of Rated Load

2. Amber Lights - Approaching Overload

3. Red Lights - Overload

1

2 31

Display Unit

The following is a description of the control buttons, indicators, and windows on the display unit. Use themalong with Figure 1-59.

1. Bar‐Graph

The Bar‐Graph is a series of twelve colored lights whichgives a visual indication of how much of the crane's capacity is being used and the rate at which an overloadis being approached. Each green light represents 10%of the crane's rated capacity is being used. Yellow indicates 90-99.9%, and the red lights indicate an overload.

Note: System may be equipped with an overheadbar‐graph or an external light bar which operates

similar to the bar‐graph on the display. Refer to

Figure 1-60.


The Pre‐Alarm (yellow) Indicator illuminates at a pre‐set value of 90% of Maximum Rated Capacity and provides a visual indication of an approach to an overload.

Operator's Manual



The Overload Indicator (red) illuminates at a pre‐setvalue of 100% of Maximum Rated Capacity and provides a visual indication of Maximum Allowed Load. Itwill also illuminate whenever a wire rope limit is exceeded. Function limiters will occur simultaneously for anOverload, Wire Rope Limit or a Two Block condition,but function limiters will not occur when exceeding anoperator settable alarm. An audible alarm will soundand a message will appear in the warning messagearea for all 4 conditions.


The Maximum Rated Capacity Display is a digital display of the maximum permitted capacity. It is derivedfrom a copy of the crane's capacity chart which isstored in the computer memory and is the referencecapacity for any lifting operation. It is dependent on theconfiguration currently selected, which is shown in thecrane setup screen, and which determines the sectionof the capacity chart to be used as the rated capacityreference.


The Actual Load Display is a digital display whichshows total load suspended below the boom or flyhead. It includes the load, any slings, pins, or tackleused to secure the load and the hook block or ball.

6. Parts‐of‐Line Display

Parts‐of‐Line Display shows the parts of line currentlyselected for the winch in use.


These buttons are used during the crane configurationselection routine. Refer to “Configuration Selection”found later in this Section of the Operator's Manual.


This button is used to silence the audible alarm whenthe alarm has occurred as a result of either an Overload, Wire Rope Limit, a Two Block, or an Operator Settable alarm. It is also used to reset the function limitrelay when it is necessary to by‐pass function limitwhich has occurred as a result of either an Overload,Wire Rope Limit, or a Two Block alarm.


This button is used to start the operator settable alarmsroutines. Refer to “Operator Settable Alarms” foundlater in this Section of the Operator's Manual.


This button is used to start the configuration selectionroutine. Refer to “Configuration Selection” found laterin this Section of the Operator's Manual.

11. Display/Select Button

This button is used to access the Calibration And Diagnostic Screen. Refer to “System Fault Codes” and“Calibration” found later in this Section of the Operator's Manual.

12. Warning Message Area

The Warning Message Area displays text messages ofvarious alarms which may occur during normal operation of the system. When an alarm occurs, the rectangular area fills in red.


The Boom Length Display gives a continuous indication of the boom length in feet (m). It is the distancefrom the centerline of the boom foot pin to the centerline of the boom head machinery.

14. Brightness Buttons

These buttons are used to adjust the display brightness.

15. Load Radius Display

The Load Radius Display gives a continuous indicationof the radius of the load in feet (m). It is the horizontaldistance from the centerline of rotation to the centerlineof the hook.


The Boom Angle Display gives a continuous indicationof the angle of the main boom relative to horizontal.

17. Erected Attachment Display

The Erected Attachment Display gives a continuousdisplay of the erected attachment with the top numberindicating the actual fly length and the bottom numberindicating the offset angle if applicable.

Operator's Manual


System Operation

The following is a list of procedures which are used tooperate the multiple features of the Rated CapacityLimiter. Use these procedures in conjunction with theprevious display unit control descriptions.

System Self‐Test

At start‐up the system automatically performs a self testafter which all lamps, audible alarms, and digital displays will be functionally tested and all memory areaschecked for accuracy. If faults in the system are detected during a test, the warning message area willshow the words SYSTEM FAULT. If the words SYSTEMFAULT occur, press the Display/Select button to display the diagnostic screen. The diagnostic screen listsinformation about the fault condition by means of an error code. Contact your local distributor for details of thefault codes.

Note: If the batteries have been disconnected inter

rupting power to the computer, the start‐up time for

on‐board computer systems will be longer thannormal.

System Bypass

In emergency situations, the Rated Capacity Limiter

computer can be bypassed. The computer is locatedon the back of the operator's cab. Refer to

Figure 1-61. There is a RCL Status keyswitch adja

cent to the computer to bypass the system. Move the

keyswitch to the “Bypass” position to bypass the sys

tem. For emergency use while the system is bypassed,refer to “System Inoperative or Malfunctioning” found

in this Operator's Manual.

WARNINGThe MicroGuard 534 is not operational whenthe computer is bypassed. Bypass the

system in emergency situations only.

System Inoperative Or Malfunctioning

When operational aids are inoperative or malfunctioning, the following recommendations for continued useof the crane should be followed or the crane should beshutdown.1. Steps shall be taken to schedule repairs and recal

ibration immediately. The operational aids shall be

put back into service as soon as replacementparts, if required, are available and the repairs and

recalibration can be carried out. Every reasonable

effort must be made to expedite the repairs and re

calibration.

Figure 1-61Rated Capacity Limiter Computer

1. Operator's Cab

2. RCL Status Keyswitch

3. Computer

3

21

2. When the rated capacity limiter is inoperative or

malfunctioning, the designated person responsi

ble for supervising the lifting operations shall establish procedures for determining load weights

and shall ascertain that the weight of the load does

not exceed the crane ratings at the radius where

the load is to be handled.

3. When a boom angle or radius indicator is inopera

tive or malfunctioning, the radius or boom angleshall be determined by measurement.

4. When the anti‐two block warning device is inopera

tive or malfunctioning, the designated person re

sponsible for supervising the lifting operations

shall establish procedures, such as assigning an

additional signal person, to furnish equivalent

protection. This does not apply when lifting personnel in load line supported baskets. Personnel

shall not be lifted in load line supported baskets

when the anti‐two block devices are not function

ing properly.

5. When a boom length indicator is inoperative or

malfunctioning, the designated person responsible for supervising the lifting operations shall es

tablish the boom length at which the lift will be

made by actual measurement or markings on the

boom.

6. When a level indicator is inoperative or malfunc

tioning, other means shall be used to level thecrane.

7. In situations where inconsistency exists, verified

weights, measured radii, boom lengths, and au

thorized crane capacities must always take prece

dence over indicator readings.

Operator's Manual


Configuration Selection

In the normal operational mode the system is programmed to remember the last configuration selected. Each timethe system is powered up it will automatically default to that configuration. Only when the crane is rigged differentlymust a new configuration be selected. Use the following procedure to select the crane configuration.

Note: When selecting configurations allowed on outriggers, all beams must be equally extended; all fully

retracted, intermediate extended, or fully extended.

Depending on how the crane is equipped or which selections have been made, some screens shown may not

appear or may not appear as illustrated. The system cannot be programmed for configurations not allowed

by the capacity charts listed in the Crane Rating Manual.

Figure 1-62Carrier Selection

� �

1. From the normal working screen press the CRANE SETUP button. The normal working screen will change and

graphically display the carrier options. Press the corresponding configuration selection button to select thedesired carrier configuration. Press the “More” button to display additional selections. Press the “More” button

again to return to the first carrier selection screen. If rigging is desired, refer to “To Select Rigging/Travel Mode”

found later in this Section of the Operator's Manual.

WARNINGThe MicroGuard 534 is not operational when in the RIGGING/TRAVEL Mode. Return the MicroGuard540 to normal operation before operating the crane.

Operator's Manual


Figure 1-63Counterweight Selection

0

12000

24000

2. The carrier selection screen will change and

graphically display the counterweight options.Press the corresponding configuration selection

button to select the installed counterweight.

Figure 1-64Boom Extend Mode Selection

3. The counterweight selection screen will change

and graphically display the boom mode options.

Press the corresponding configuration selection

button to select the desired boom mode.

Note: Consult the Crane Rating Manual to determine the best boom mode to maximize lift capacity at working radius. Boom mode optionswill only be displayed when the boom is fully retracted.

Figure 1-65Auxiliary Head Selection

4. The boom mode selection screen will change and

graphically display the auxiliary lifting sheave fittedor not fitted. Press the corresponding configura

tion selection button to select the desired auxiliary

lifting sheave configuration.

Figure 1-66Erected Attachment Selection

31'

55'

70'

85'

5. If the crane is equipped with a fly, the auxiliarysheave selection screen will change and graphically display an erected attachment. Press the corresponding configuration selection button to select the installed, erected attachment if required.

Operator's Manual


Figure 1-67Erected Attachment Offset Selection

25

45

6. If an offset fly was previously selected, the erected

attachment selection screen will change andgraphically display the available offset angles.


button to select the installed offset angle if re

quired.

Figure 1-68Rear Winch Lifting Point Selection

7. The erected attachment or erected attachment off

set selection screen will change and graphically

display the rear winch lifting point. Press the corresponding configuration selection button to select

the actual rear winch lifting point. Or press the cor

responding configuration selection button to se

lect the rear winch not in use.

Figure 1-69Front Winch Lifting Point Selection

8. If the crane is equipped with a front winch, the rear

winch lifting point screen will change and graphically display the front winch lifting point. Press the cor

responding configuration selection button to select

the actual front winch lifting point. Or press the cor

responding configuration selection button to select

the front winch not in use.

Figure 1-70Stowed Attachment Selection

24'

55'

9. If the crane is equipped with a fly and was not se

lected as an erected attachment, the winch liftingpoint screen will change and graphically display

the stowed deduct. Press the corresponding con

figuration selection button to select the actual

stowed attachment.

Operator's Manual


Figure 1-71Rear Winch Parts Of Line Selection

10. The crane setup screen will change to the normal

working screen and graphically display the craneconfiguration as previously selected. Press the

corresponding configuration selection button to

select the actual parts of line for the rear winch.

Figure 1-72Front Winch Parts Of Line Selection

11. If the crane is equipped with a front winch and it

was selected, press the corresponding configuration selection button to select the front winch.


button to select the actual parts of line for the front

winch.

Note: From the normal working screen, after

crane setup has been established, only twoselection buttons are active; the winch select

button and the parts of line button.

To change winches, push the winch select but

ton to toggle between winches. The winch lift

ing points cannot be changed without goingthrough the crane setup routine.

The parts of line can be changed for the se

lected winch by pressing the parts of line button

to scroll through the available options for that

winch.

Refer to Figure 1-73 and Figure 1-74 for ex

amples of some normal working screens.

Operator's Manual


Figure 1-73Normal Working Screen Examples

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

In this example the crane is setup on intermediate extended outriggers (1),boom mode Amax2 (2), 24,000 lb counterweight (3) 55' fly stowed (4), the frontwinch available with the auxiliary head and the rear winch selected (5), withthe winch rope reeved over the main boom head (6) with three parts of line (7).

1

2

3

56

7

1

2

3

4

56

7

8

4

Operator's Manual


5


In this example the crane is setup for stationary on tires (1), boom modeAmax1 (2), 24,000 lb of counterweight (3), front winch not in use andthe rear winch selected (4), winch rope reeved over the main boom (5),with three parts of line (6), and the 55' fly stowed (7).

In this example the crane is setup on fully retracted outriggers (1),boom mode Amax1 (2), 12,000 lb of counterweight (3), winch ropereeved over the main boom (4), 55' fly stowed (5), rear winch notin use and the front winch selected (6), with three parts of line (7).

6

5

2

3

1

4

7

7

4

2

31

6

1

Operator's Manual


Figure 1-75Rigging/Travel Mode Screen

�

�

To Select Rigging/Travel Mode

The CRANE SETUP push button is also used to selectRIGGING/TRAVEL MODE. This mode is used to facilitate rigging and travel of the crane by inhibiting function limiters and the audible alarm while selected. Toresume crane operation, select proper outrigger or tireconfiguration per the proper procedure.

WARNINGThe MicroGuard 534 is not operational whenin the RIGGING/TRAVEL Mode. Return the

MicroGuard 534 to normal operation before

operating the crane.

1. From the normal working screen press the CRANE

SETUP button. The crane setup screen will

change and graphically display the carrier options.

2. Press the More button on the carrier options

screen to display RIGGING and TRAVEL modeselection screen. Refer to Figure 1-75.

3. Select for stationary rigging or when trav

eling the crane.

Note: Boom must be fully retracted to enter rigging/travel mode.

Cancel Audible Alarm And Reset Function Limiters

The CANCEL ALARM button is used to cancel theaudible alarm when the alarm has occurred as a resultof either an Overload, a Two Block alarm, or an Operator settable alarm. The audible alarm may be canceledby pressing and releasing the CANCEL ALARM button.The audible alarm remains canceled until the conditionwhich caused the alarm has been removed. For example, if the audible alarm was canceled because of anoverload condition, it will remain canceled until theoverload condition is removed. However, if a differentalarm, e.g. two block condition, was to occur when theaudible alarm was still canceled for an earlier overloadcondition, the new alarm condition would cause the audible alarm to be re‐started.

WARNINGOnce the function limiters have beenby‐passed, the crane is no longer protected

against the condition that initially caused the

function limiters to occur.

Note: The CANCEL ALARM feature is a temporary

function. The audible alarm or function limit is auto

matically reset when the condition which causedthe alarm is no longer present.

The CANCEL ALARM is also used to reset the functionlimiters when it is necessary to by‐pass the function limiters which has occurred as a result of either an overload, a two block alarm, or a rope limit. Function limiters are reset by first canceling the audible alarm (as described above) and then pressing and holding theCANCEL ALARM button for about 3 seconds, afterwhich the function limiters will be reset to allow normaloperation. However, should another different alarmcondition occur when the function limiters had previously been over‐ridden, then the newly occurringalarm condition would cause the function limiters to activate again.

Operator Settable Alarms

Some alarms occur automatically as a result of limitations imposed by the capacity chart. The operator hascontrol over additional alarms which can be set to operate within the normal chart limitations which are in addition to, those already set by the chart.

Operator settable alarms will be stored in the computermemory, even if the crane is shutdown, until they arecleared. Refer to Figure 1-76.

Alarms available for operator use are:

Minimum Boom Angle Maximum Boom Length

Maximum Boom Angle Left and Right Swing

Maximum Tip Height Operator Defined Area

Operator's Manual


Figure 1-76Boom Limit Alarms

SETTABLE ALARMS

BOOM LIMITS

SWING LIMITS

AREA LIMITS

HEIGHTLENGTH ANGLE

75.0 75.0 60.0

30.0

60.0

75.0

75.0

EXIT

�

EXIT

WARNINGThe operator settable alarms are a warningdevice. All functions remain operational when

entering the operator defined bad area. For

safe operation, adequate distance must be

maintained to allow for operator reaction time

to avoid entering the bad area. It is the

responsibility of the operator to set pointswhich ensure that the crane's boom,

attachment, load, rigging, etc. maintains a

safe working distance and complies with local

safety regulations.

Angle, Length, And Height Operator Settable Alarms1. From the normal working screen press OPERA

TOR ALARM button to access the Settable

Alarms screen.

2. Press the corresponding button for Boom Limits

.

WARNINGAvoid positioning the boom, attachment, load,rigging, etc. into the bad area when setting thealarm values.

When selecting the alarm values, ensure thatthe load will maintain a safe distance from theobstacle.

3. Position the boom in the desired position depend

ing upon the alarm to be set. The numerical value

displayed will be the current position of the boom.

4. Press the corresponding selection button to set thedesired alarm value as defined below. Press the

button again to turn alarm off.

Maximum Boom Length

Maximum Tip Height

Maximum Boom Angle

Minimum Boom Angle

5. When all alarm values are set, press the EXIT but

ton to return to the alarm screen. At the Settable

Alarm screen, press the EXIT button again to return

to the normal working screen.6. Test the alarm, with no load, to ensure the alarm

points have been properly set. When approachingthe alarm set point, the audible will sound intermittently and a warning message will appear in thewarning message area. When exceeding thealarm set point, the audible alarm will sound continuously and a warning message will appear inwarning message area.

Note: An alarm icon will appear on the normal working screen to alert the operator that anoperator alarm has been set.

WARNINGIf crane or obstacle is moved or if a differentsize load is lifted, the alarm(s) must be reset.

Operator's Manual


Figure 1-77Swing Alarm

SETTABLE ALARMS

BOOM LIMITS

SWING LIMITS

AREA LIMITS

SWING ANGLE

95.0

95.0SET

265.0SET

EXIT

�

EXIT

Swing Operator Settable Alarm

To have an alarm whenever the left swing and rightswing exceed pre‐determined alarm points, use the following procedure:1. From the normal working screen press OPERA


Alarms screen.

2. Press the corresponding button for Swing Limits.

3. Swing the boom to the left alarm point .

4. Press the corresponding button for Left Swing

to enter the left alarm point. The displayed value

will be the left alarm setting.5. Swing the boom to the right alarm point.

6. Press the corresponding button for Right Swing

to enter the right alarm point. The displayed

value will be the right alarm setting.

7. Press the EXIT button to return to the settable

alarm screen. Press the EXIT button on the settable alarms screen to return to the normal working

screen.

8. Test the alarm, with no load, to ensure the alarm

points have been properly set. When approaching

the set alarm point, the audible alarm will sound intermittently and “Swing Alarm” will appear in the

warning message area. The audible alarm will acti

vate whenever the swing exceeds the alarm points

and “Swing Alarm” will appear in warning message

area.

Note: Both the left and right swing alarms mustbe set for the system to determine the operatorset working area.


Operator Defined Area Alarm

The operator defined area alarm, when set, will definean imaginary vertical plane between two set points tooptimize the working area. When approaching theplane, the audible alarm will sound intermittently, andthe message “Bad Working Area” will appear in thewarning message area. When passing the plane, theaudible alarm will sound continuously and the message “Bad Working Area” will appear on the warningmessage area. Use the following procedure,Figure 1-78, and Figure 1-79 to set the operator defined area alarm.

WARNINGThe operator defined area alarm is a warningdevice. All functions remain operational when








safety regulations.

Operator's Manual


Figure 1-78Operator Defined Area Alarm

SETTABLE ALARMS

BOOM LIMITS

SWING LIMITS

AREA LIMITS

SWING ANGLE

97.2

EXIT

�

EXIT

Setting Operator Defined Area Alarm1. From the normal working screen press OPERA


Alarms screen.

2. Disable any previously set left and right swingalarms if required.

Note: The left and right swing alarms must becleared prior to setting the defined area alarm.

3. Press the corresponding button for Area Limit .

WARNINGAvoid positioning the boom, attachment, load,rigging, etc. into the bad area when setting theleft or right alarm points.

When selecting the left and right alarm points,ensure that the load will maintain a safedistance from the obstacle. Also ensure thatthe two points are set so that the tailswing ofthe crane will not enter the bad area.

4. Position the boom, attachment, load, rigging, etc.to the right alarm point and press the corresponding button to enter the right alarm point. Thedisplayed value will be the right alarm setting.

5. Position the boom, attachment, load, rigging, etc.to the left alarm point and press the corresponding

button to enter the left alarm point. The displayed value will be the left alarm setting.

Note: For best results, the two points should beseparated by a minimum of 10 ft (3m) or 30 degrees.

6. When both alarm points are set, press the EXITbutton to return to the settable alarms screen.Press the EXIT button on the settable alarms to return to the normal working screen.

7. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approachingthe plane, the audible alarm will sound intermittently and the message “Bad Working Area” will appear on the warning message area. When passingthe plane, the audible alarm will sound continuously and the message “Bad Working Area” will appear on the warning message area.

WARNINGIf crane or obstacle is moved or if a differentsize load is lifted, the area alarm must bereset.


Operator's Manual



Operator's Manual


Figure 1-80Calibration And Diagnostic Screen

CALIBRATION AND DIAGNOSTICS

ERROR CODES

ENTER CALIBRATION

Message Data Count

A00 B0 C00 D00

System Fault Codes

If faults in the system are detected during a test, thewarning message area will show the words SYSTEMFAULT. If the words SYSTEM FAULT occur, press theDisplay/Select button to display the Calibration AndDiagnostic screen. On the Calibration And Diagnosticscreen, press the Error Code button to display errorcodes in the box at the top of the screen. This information can then be used to assist the service technician indetermining the fault. Contact your distributor for assistance with the fault codes.

Calibration

If the system requires calibration, contact you distributor for assistance. Calibration must be done by a qualified technician. Press the Display/Select button to display the Calibration And Diagnostic screen. On theCalibration And Diagnostic screen, press the EnterCalibration button. The calibration screen will be displayed and prompt a calibration key sequence to beginthe calibration routine.

Operator's Manual


Figure 1-81MicroGuard 434 Rated Capacity Limiter

1. Bar‐Graph

2. Two Block Alarm Indicator




6. Contrast Button




10.Test Button

11.Crane Setup Screen

12.Load Radius Display

13.Boom Angle Display

14.Boom Length Display

15.Pre‐Alarm Indicator

16.Overload Indicator

1

2

3

4

5

6

16

15

14

12

13

11

5

10 9 8 7

MicroGuard 434 Rated CapacityLimiterThe following describes the function and operation of

the MicroGuard 434 Rated Capacity Limiter. The system is intended to aid the operator in the efficient op

eration of the crane by continually monitoring the load

and warning of an approach to an overload or unsafe

condition. The display is located in the front right cor

ner of the operator's cab.

WARNINGAlthough the system will alert the operator ofan approaching overload or unsafe condition,

it remains the responsibility of the operator to

operate the crane safely at all times.

This system must never be substituted for the

good judgment of the crane operator using

safe operating procedures. The operator issolely responsible for safe operation of the

crane.

!!THIS SYSTEM IS AN OPERATOR'S AID -

NOT A SAFETY DEVICE!!

Operator's Manual


System Description

The system monitors crane functions by means of high

accuracy sensors and continuously compares the load

with a copy of the crane capacity chart which is storedin the computer memory. If an overload is approached,

the system warns by means of audible and visual

alarms and is configured to cause function limitation.

The MicroGuard 434 Rated Capacity Limiter provides

the operator with a continuous display of:� Rated Capacity

� Actual Load

� Percentage of Rated Capacity

� Radius of the Load

� Angle of the Main Boom

� Crane Configuration� Length of the Main Boom

Note: The head height may be displayed by access

ing the angle/length/height operator settable alarm

screen.

An additional feature of the system is the provision ofoperator settable alarms. These alarms, when proper

ly set, provide a method of obstacle avoidance. This is

achieved by means of minimum and maximum boom

angle, maximum boom length, maximum height, left

and right swing, and defined area alarms. Thesealarms can be programmed for each job site and set

rapidly for the prevailing site conditions thereby aiding

the operator in safe operation of the crane.

Display Unit

The following is a description of the control buttons, in

dicators, and windows on the display unit. Use them

along with Figure 1-81.

1. Bar‐Graph

The Bar‐Graph is an analog bar graph which givesa visual indication of how much of the crane's ca

pacity is being used and the rate at which an over

load is being approached. The 100% RATED CA

PACITY indicator above the bar graph marks the

point at which 100% of the rated capacity of the

crane has been reached. The leading edge of thebar graph aligns with three colored bands around

the bar graph window. Red indicates an overload.

Between the red and yellow is a black notch which

indicates 100% of rated capacity. Yellow indicates

90-99.9%, and green indicates below 90% rated

capacity.

Note: System may be equipped with an optional

overhead bar‐graph or an external light bar

which operates similar to the bar‐graph on the

display. Refer to Figure 1-82.

Figure 1-82Overhead Bar‐Graph And External Light Bar

Option

2 3 4

1. Green Light - Percentageof Rated Load

2. Yellow Light - Approaching Overload

3. Red Light - Overload4. Brightness Control

1

2 31

2. Two Block Alarm Indicator

The Two Block Alarm Indicator illuminates anytime

a two block situation is imminent. An audible alarm

and function limiters will also activate when a two

block situation is imminent. Once the two block sit

uation is corrected the system will return to normal

working mode.


The Maximum Rated Capacity Display is a digital

display of the maximum permitted capacity. It is

derived from a copy of the crane's capacity chart

which is stored in the computer memory and is the

reference capacity for any lifting operation. It is dependent on the configuration currently selected,

which is shown in the crane setup screen, and

which determines the section of the capacity chart

to be used as the rated capacity reference.

Note: All maximum rated load data shown is X

1,000 lb (kg), e.g. 12.6=12,600 lb (kg).


The Actual Load Display is a digital display which

shows total load suspended below the boom or fly

head. It includes the load, any slings, pins or tackle

used to secure the load and the hook block.

Note: All actual load data shown is X 1,000 lb(kg), e.g. 12.6=12,600 lb (kg).

Operator's Manual



These buttons are used during the crane configu

ration selection routine. Refer to “Configuration

Selection” found later in this section of the Operator's Manual.

6. Contrast Button

This button is used to adjust the display contrast.


This button is used to silence the audible alarm

when the alarm has occurred as a result of eitheran Overload, a Two Block or an Operator Settable

alarm. It is also used to reset the function limit relay

when it is necessary to by‐pass function limit which

has occurred as a result of either an Overload or a

Two Block alarm.


This button is used to start the operator settable

alarms routines. Refer to “Operator Settable

Alarms” found later in this Operator's Manual.


This button is used to start the configuration selec

tion routine. Refer to “Configuration Selection”found later in this section of the Operator's Manual.

10. Test Button

This button is used to initiate a system self test andalso used to display fault codes. Refer to “To Per

form System Test” found later in this section of the

Operator's Manual.

11. Crane Setup Screen

The Crane Setup Screen provides the operator

with a graphical representation of the crane's cur

rent configuration during the normal working

mode. It also provides graphical icons used during

the crane configuration selection routine.

12 Load Radius Display

The Radius Display gives a continuous indication

of the radius of the load in feet (m). It is the horizontal distance from the centerline of rotation to the

centerline of the hook.


The Boom Angle Display gives a continuous indi

cation of the angle of the main boom relative to hor

izontal.


The Boom Length Display gives a continuous indi

cation of the boom length in feet (m). It is the dis

tance from the centerline of the boom foot pin tothe center line of the boom head machinery.


The Pre‐Alarm (amber) Indicator illuminates at apre‐set value of 90% of Maximum Rated Capacity

and provides a visual indication of an approach to

an overload. The pre‐alarm indicator will also illu

minate when an operator settable alarm value is

approached.


The Overload Indicator (red) illuminates at a pre‐

set value of 100% of Maximum Rated Capacity and

provides a visual indication of Maximum Allowed

Load. It will also illuminate whenever a wire ropelimit is exceeded or an operator settable alarm has

been reached or exceeded. Function limiters will

occur simultaneously for an Overload, Wire Rope

Limit or a Two Block condition, but function limiters

will not occur when exceeding an operator settable

alarm. An audible alarm will sound for all 4 conditions.

System Operation

The following is a list of procedures which are used tooperate the multiple features of the Rated Capacity

Limiter. Use these procedures in conjunction with the

previous display unit control descriptions.

To Perform System Test

At start‐up the system automatically performs a self test

after which it goes directly to the normal working

screen. The self‐test can be initiated anytime during

normal operation of the system by using the TEST but

ton.

One press (press and release) will cause the system to

execute a self test routine during which all lamps,

audible alarms, and digital displays will be functionally

tested and all memory areas checked for accuracy. If

faults in the system are detected during a test, thecrane setup screen will show the words FAULT

DETECTED. If the words FAULT DETECTED occur,

press and hold the TEST button. This will cause the

display to change to the FAULT mode. In this mode,

information about the fault condition will be displayed

in the crane setup screen by means of an error code.Contact your local distributor for details of the fault

codes.

Operator's Manual


System Bypass

In emergency situations, the Rated Capacity Limiter

computer can be bypassed. The computer is located

on the back of the operator's cab. There is a RCL Sta

tus keyswitch adjacent to the computer to bypass thesystem. Move the keyswitch to the “Bypass” position

to bypass the system. For emergency use while the

system is bypassed, refer to “System Inoperative or

Malfunctioning” found in this Operator's Manual.

WARNINGThe MicroGuard 434 is not operational whenthe computer is bypassed. Bypass the

system in emergency situations only.

System Inoperative Or MalfunctioningWhen operational aids are inoperative ormalfunctioning, the following recommendations forcontinued use of the crane should be followed or thecrane should be shutdown.

1. Steps shall be taken to schedule repairs and recal

ibration immediately. The operational aids shall be

put back into service as soon as replacement

parts, if required, are available and the repairs and

recalibration can be carried out. Every reasonable

effort must be made to expedite the repairs and recalibration.

2. When the rated capacity limiter is inoperative or

malfunctioning, the designated person responsi

ble for supervising the lifting operations shall es

tablish procedures for determining load weights

and shall ascertain that the weight of the load doesnot exceed the crane ratings at the radius where

the load is to be handled.

3. When a boom angle or radius indicator is inopera

tive or malfunctioning, the radius or boom angle

shall be determined by measurement.

4. When the anti‐two block warning device is inopera

tive or malfunctioning, the designated person responsible for supervising the lifting operations

shall establish procedures, such as assigning an

additional signal person, to furnish equivalent

protection. This does not apply when lifting per

sonnel in load line supported baskets. Personnel

shall not be lifted in load line supported basketswhen the anti‐two block devices are not function

ing properly.

Figure 1-83Rated Capacity Limiter Bypass

1. RCL Status Keyswitch

2. Operator's Cab

3. Computer

1

3

2

5. When a boom length indicator is inoperative ormalfunctioning, the designated person responsi

ble for supervising the lifting operations shall es

tablish the boom length at which the lift will be

made by actual measurement or marking on the

boom.

6. When a level indicator is inoperative or malfunctioning, other means shall be used to level the

crane.

7. In situations where inconsistency exists, verified

weights, measured radii, boom lengths, and au

thorized crane capacities must always take prece

dence over indicator readings.

Operator's Manual


Configuration Selection

In the normal operational mode the system is programmed to remember the last configuration selected.Each time the system is powered up it will automaticallychoose that configuration. Only when the crane isrigged differently must a new configuration be selected. Use the following procedure along withFigure 1-84 to select the crane configuration (the following step numbers correspond with the numberedscreens in Figure 1-84).

Note: When selecting configurations allowed onoutriggers all beams must be equally extended; allfully retracted, intermediate extended or fully extended.

Depending on how the crane is equipped or whichselections have been made, some screens shownin Figure 1-84 may not appear or may not appearas illustrated. The system can only be programmedfor configurations allowed as listed on the “Allowable Crane Configuration” chart in the Crane RatingManual.

1. From the normal working screen press the CRANESETUP button. The crane setup screen willchange and graphically display the carrier options.Press the corresponding configuration selectionbutton to select the desired carrier configuration.




2. The crane set‐up screen will change and graphically display the counterweight options. Press thecorresponding configuration selection button toselect the desired counterweight.

3. The crane setup screen will change and graphically display the boom mode options. Press the corresponding configuration selection button to selectthe desired boom mode.

Note: The boom must be fully retracted tochange boom modes.

4. The crane setup screen will change and graphically display the auxiliary lifting sheave fitted or notfitted. Press the corresponding configurationselection button to select the desired auxiliary lifting sheave.

5. If the crane is equipped with a fly, the crane setupscreen will change and graphically display anerected attachment. Press the corresponding

configuration selection button to select the desirederected attachment if required.

6. If an offset fly was previously selected, the cranesetup screen will change and graphically display

the available offset angles. Press the correspond

ing configuration selection button to select the de

sired offset angle if required.

7. The crane setup screen will change and graphically display the front winch lifting point. Press the


select the desired front winch lifting point as indi

cated by the flashing arrows. Or press the corre

sponding configuration selection button to select

the front winch not in use.8. If the crane is equipped with a rear winch, the crane

setup screen will change and graphically display

the rear winch lifting point. Press the correspond

ing configuration selection button to select the de

sired rear winch lifting point as indicated by theflashing arrows. Or press the corresponding con

figuration selection button to select the rear winch

not in use.

9. If the crane is equipped with a fly and was not se

lected as an erected attachment, the crane set‐upscreen will change and graphically display the

stowed deduct. Press the corresponding configu

ration selection button to select the desired stowed

deduct if required.

10. The crane setup screen will change to the normal

working screen and graphically display the craneconfiguration as previously selected. Press the


select the desired parts‐of‐line for the rear winch.

11. If the crane is equipped with a front winch and it

was selected, press the corresponding configuration selection button to select the front winch.


button to select the desired parts‐of‐line for the

front winch.

Note: From the normal working screen, aftercrane setup has been established, only two

selection buttons are active; the winch select

button and the parts of line button.

To change winches, push the winch select but

ton to toggle between winches. The winch lift

ing points cannot be changed without goingthrough the crane setup routine.

The parts‐of‐line can be changed for the se

lected winch by pressing the parts‐of‐line but

ton to scroll through the available options for

that winch.

Refer to Figure 1-85 and Figure 1-86 for ex

amples of some normal working screens.

Operator's Manual


NO OBX

3

No Fly

CRANE SETUP

31’ Fly

55’ Fly

70’ Fly

85’ Fly

2

25

45

Std

555’ Fly25 �

Std

155’ Fly25 ��

Figure 1-84Configuration Selection Flow Chart

1

56

7

2

4

8

11 10��

A1

A2

2424

CRANE SETUP

CRANE SETUP

CRANE SETUP

CRANE SETUP

CRANE SETUP

CRANE SETUP

Standard

0

12000

CRANE SETUP

24000

CRANE SETUP

More...

NO OBX

2.5 MPH

None

55’

24’

Crane Set Up

9

Operator's Manual



A1

5

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

boom mode Amax1 (2), auxiliary head fitted (3), fly base & tip stowed (4),

the rear winch available with the aux head and the front winch selected (5)

with the winch rope reeved over the main boom (6), with five parts of line

(7), two operator alarms have been set (8), 24,000 lb counterweight (9).

1 2

3

4

5

7

Std

1 55’ Ofst45�

In this example the crane is setup on fully extended outriggers

(1), boom mode Standard (2), 55' offset fly erected with 45° off

set (3), the front winch available with the main boom and the rear

winch selected (4), with the winch rope reeved over the 55' off

set fly (5), with one part of line (6), 24,000 lb counterweight (7).

12

3

4

6 5

6

8

24

924

7

Operator's Manual



A1

3

In this example the crane is setup for stationary on tires (1),

boom mode Amax1 (2), rear winch not in use and the front

winch selected (3), winch rope reeved over the main boom

(4), with three parts of line (5), 24,000 lb counterweight (6).

6

2

3

5

A2

1

In this example the crane is setup on fully retracted outrig

gers (1), boom mode Amax2 (2), fly base & tip stowed (3),

rear winch not in use and the front winch selected (4),

with one part of line (5), no counterweight (6).

1

2

34

5

4

24

1

60

Operator's Manual



A2

3

In this example the crane is setup for pick and carry creep speed (1),

no outrigger box installed (2), boom mode Amax2 (3), rear winch not

in use and the front winch selected (4), winch rope reeved over the

main boom (5), with three parts of line (6), and no counterweight (7).

7

3

4

65

0

1

NO OBX

2

A2

3

In this example the crane is setup for pick and carry (1), 2.5 mph speed

with outrigger boxes installed (2), boom mode Amax2 (3), rear winch not

in use and the front winch selected (4), winch rope reeved over the main

boom (5), with three parts of line (6), and 12,000 lb counterweight (7).

7

3

4

65

12

12

2.5 MPH

Operator's Manual


To Select Rigging/Travel Mode

The CRANE SETUP push‐button is also used to select

RIGGING/TRAVEL MODE. This mode is used to facili

tate rigging and travel of the crane by inhibiting func

tion limiters and the audible alarm while selected. Toresume crane operation, select proper outrigger or tire

configuration per the proper procedure.




1. From the normal working screen press the CRANE

SETUP button. The crane setup screen will

change and graphically display the carrier options.

2. Press the corresponding configuration selectionbutton to select RIGGING/TRAVEL MODE. Refer

to Figure 1-88.

3. The crane setup screen will change and graphical

ly display the RIGGING/TRAVEL MODE icon.

To Cancel Audible Alarm And Reset FunctionLimiters

The CANCEL ALARM button is used to cancel the audible alarm when the alarm has occurred as a result of

either an overload, a two block alarm, or an operator

settable alarm. The audible alarm may be canceled by

pressing and releasing the CANCEL ALARM button.

The audible alarm remains canceled until the condition

which caused the alarm has been removed. For example, if the audible alarm was canceled because of an

overload condition, it will remain canceled until the

overload condition is removed. However, if a different

alarm, e.g. two block condition, was to occur when the

audible alarm was still canceled for an earlier overloadcondition, the new alarm condition would cause the au

dible alarm to be re‐started.

WARNINGOnce the function limiters have beenby‐passed, the crane is no longer protected

against the condition that initially caused the

function limiters to occur.

Note: The CANCEL ALARM feature is a temporary

function. The audible alarm or function limit is auto

matically reset when the condition which causedthe alarm is no longer present.

Figure 1-88Rigging/Travel Mode Screen

�

NO OBXCRANE SETUP

NO OBX

2.5 MPH

The CANCEL ALARM is also used to reset the functionlimiters when it is necessary to by‐pass the function lim

iters which has occurred as a result of either an over

load, a two block alarm, or a rope limit. Function limit

ers are reset by first canceling the audible alarm (as de

scribed above) and then pressing and holding theCANCEL ALARM button for about 5 seconds, after

which the function limiters will be reset to allow normal

operation. However, should another different alarm

condition occur when the function limiters had pre

viously been over‐ridden, then the newly occurringalarm condition would cause the function limiters to oc

cur again.

Operator Settable Alarms

Some alarms occur automatically as a result of limitations imposed by the capacity chart. The operator has

control over additional alarms which can be set to oper

ate within the normal chart limitations and which are in

addition to those already set by the chart.

Operator settable alarms will be stored in the computermemory, even if the crane is shutdown, until they are

cleared. Refer to Figure 1-89.

Six alarms are available for operator use.

Minimum Angle Maximum Length

Maximum Angle Left and Right SwingMaximum Height Operator Defined Area

Operator's Manual


MAX

MIN

0

MAX

Figure 1-89Operator Settable Alarms

�

OFF

MAX

MIN0Settable

OFF

OFF

MAX

MIN0

�Exit

Alarms

Exit OFFMAX

MenuExit

OFF

Settable

Exit

Alarms

OFF

00.0

00.0

WARNINGThe operator settable alarms are a warningdevice. All functions remain operational when








safety regulations.

Setting Length/Angle/Height/Swing Operator Alarms

1. From the normal working screen press OPERA

TOR ALARM button to access the Operator Set

table Alarm screen.

2. Press the corresponding selection button to select

the desired alarm to be set.

Note: The bottom value displayed in the max

height alarm box is the current head height.

WARNINGAvoid positioning the boom, attachment, load,rigging, etc. into the bad area when setting thealarm values.

When selecting the alarm values, ensure thatthe load will maintain a safe distance from theobstacle.

3. Place the crane in the desired position dependingupon the alarm to be set. The numerical value dis

played will be the current position of the crane.

Note: If an alarm had been previously set, the

numerical value displayed will be the previous

ly set alarm value. The previous alarm must first

be cleared, then set the new alarm. Alarmswhich are not set are indicated by the word OFF.

4. Press the corresponding selection button to set the

alarm value.

5. When all alarms are set press the EXIT button to re

turn to the normal working screen or press theMENU (Operator Alarm) button to return to the pre

vious menu screen.

6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approachingthe alarm set point the pre‐alarm (amber) indicatorlamp will illuminate, the audible will sound intermittently, and a warning message will appear in theCrane Setup Screen. When exceeding the alarmset point the red lamp will illuminate, the audiblealarm will sound continuously, and a warning message will appear in Crane Setup Screen.

Note: An alarm icon will appear on the normal

working screen to alert the operator that an operator alarm has been set. The number of icons

shown indicate how many operator alarms have

been set.

7. Use the following examples to understand the use

of the procedure.

Operator's Manual


WARNINGIf crane or obstacle is moved or if a differentsize load is lifted, the alarm(s) must be reset.

WARNINGCheck the crane's current configuration,capacity chart, and working area chart in the

Crane Rating Manual to ensure safe, stable

operation under conditions described in the

following examples.

To Set Minimum Angle Alarm

Example: To have an alarm whenever the boom is

below a 30 degree angle, use the following

procedure:

1. From the normal working screen Press the OPER

ATOR ALARM button to access the alarm screen.2. Press the corresponding button for minimum

angle (top right).

3. Move the boom to a 30 degree angle.

4. Press the corresponding button (bottom right) to

enter the alarm. The displayed value will be thealarm setting.

5. Press the EXIT button to return to the normal work

ing screen or the MENU (Operator Alarm) button to

return to the previous menu screen.


points have been properly set. When approaching30 degree boom angle the pre‐alarm (amber) indi

cator lamp will illuminate, the audible will sound in

termittently, and “!Minimum Angle” will appear in

the Crane Setup Screen. The red lamp will illumi

nate, the audible alarm will sound continuously,and “!Minimum Angle” will appear in Crane Setup

Screen whenever the boom is lowered below 30

degrees.

To Set Maximum Angle Alarm

Example: To have an alarm whenever the boom isabove a 60 degree angle use the following

procedure:

1. From the normal working screen press the OPER

ATOR ALARM button to access the alarm screen.

2. Press the corresponding button for maximum

angle (top right).3. Move the boom to a 60 degree angle.

4. Press the corresponding button (middle right) to

enter the alarm. The displayed value will be the

alarm setting.

5. Press the EXIT button to return to the normal working screen or press the MENU (Operator Alarm)

button to return to the previous menu screen.



60 degree boom angle the pre‐alarm (amber) indi

cator lamp will illuminate, the audible will sound intermittently, and “!Maximum Angle” will appear in

the Crane Setup Screen. The red lamp will illumi

nate and the audible alarm will sound continuously

whenever the boom is raised above 60 degrees

and “!Maximum Angle” will appear in Crane SetupScreen.

To Set Maximum Length Alarm

Example: To have an alarm whenever the boom length

exceeds 50 feet, use the following

procedure:1. From the normal working screen press the OPER

ATOR ALARM button to access the alarm screen.

2. Press the corresponding button for maximum

length (top right).

3. Extend the boom to 50 feet.

4. Press the corresponding button (middle left) to enter the alarm. The displayed value will be the alarm

setting.


ing screen or press the MENU (Operator Alarm)

button to return to the previous menu screen.6. Test the alarm, with no load, to ensure the alarm


50 foot boom length the pre‐alarm (amber) indica

tor lamp will illuminate, the audible will sound inter

mittently, and “!Maximum Length” will appear inthe Crane Setup Screen. The red lamp will illumi

nate and the audible alarm will sound continuously

whenever the boom is extended beyond 50 feet

and “!Maximum Length” will appear in Crane Set

up Screen.

To Set Maximum Height Alarm

Example: To have an alarm whenever the boom tip

height exceeds 75 feet, use the following

procedure:

1. Press the OPERATOR ALARM button to access the

alarm screen.2. Press the corresponding button for maximum

height (top right).

Note: The bottom value displayed in the max

height alarm box is the current head height.

3. Extend the boom and/or adjust the boom angle sothat the tip height is 75 feet.

Operator's Manual


4. Press the corresponding button (top right) to enterthe alarm. The displayed value will be the alarm

setting.


ing screen or press the MENU (Operator Alarm)


6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching

75 foot boom tip height the pre‐alarm (amber) indi

cator lamp will illuminate, the audible will sound in

termittently, and “!Maximum Length” will appear in

the Crane Setup Screen. The red lamp will illuminate and the audible alarm will sound continuously

whenever the boom tip height exceeds 75 feet and

“!Maximum Height” will appear in Crane Setup

Screen.

To Set Left & Right Swing Alarms

Example: To have an alarm whenever the LEFT

SWING AND RIGHT SWING exceed

pre‐determined alarm points, use the

following procedure:

1. Press the OPERATOR ALARM button to access the

alarm screen.2. Press the corresponding button for the swing

alarm (middle right).

3. Swing the boom to the left alarm point.

4. Press the corresponding button (top left) to enter

the left alarm point. The displayed value will be theleft alarm setting.

5. Swing the boom to the right alarm point.

6. Press the corresponding button (top right) to enter

the right alarm point. The displayed value will be

the right alarm setting.7. Press the EXIT button to return to the normal work

ing screen or the MENU (Operator Alarm) button to

return to the previous menu screen.



the set alarm point the pre‐alarm (amber) indicatorlamp will illuminate, the audible will sound intermit

tently, and “!Swing Alarm” will appear in the Crane

Setup Screen. The red lamp and the audible alarm

will be activated whenever the swing exceeds the

alarm points and “!Swing Alarm” will appear inCrane Setup Screen.

Note: Both the left and right swing alarms must

be set for the system to determine the operator

set working area.

To Set Operator Defined Area Alarm

The operator defined area alarm, when set, will define

an imaginary vertical plane between two set points to

optimize the working area. When approaching the

plane the pre‐alarm (amber) indicator lamp will illuminate, the audible will sound intermittently, and the mes

sage “Bad Area” will appear on the Crane Setup

Screen. When passing the plane the overload (red)

warning lamp will illuminate, the audible alarm will

sound continuously, and the message “Bad Area” will

appear on the Crane Setup Screen. Use the followingprocedure, Figure 1-90, and Figure 1-91 to set the

operator defined area alarm:

WARNINGThe operator defined area alarm is a warningdevice. All functions remain operational when








safety regulations.

Setting Operator Defined Area Alarm1. From the normal working screen press the OPER

ATOR ALARM button to access the Operator Alarm

screen.2. Clear any previously set left and right swing alarms

if required. Refer to “To Clear Operator SettableAlarms” found later in this section of the Operator'sManual.

Note: The left and right swing alarms must becleared prior to setting the defined area alarm.

3. Press the corresponding button for Area Alarm(bottom right). Refer to Figure 1-90.

WARNINGAvoid positioning the boom, attachment, load,rigging, etc. into the bad area when setting theleft or right alarm points.

When selecting the left and right alarm points,ensure that the load will maintain a safedistance from the obstacle. Also ensure thatthe two points are set so that the tailswing ofthe crane will not enter the bad area.

4. Position the boom, attachment, load, rigging, etc.to the left alarm point and press the correspondingbutton (bottom left) to enter the left alarm point.The displayed value will be the left alarm setting.

Operator's Manual


5. Position the boom, attachment, load, rigging, etc.to the right alarm point and press the corresponding button (top right) to enter the right alarm point.The displayed value will be the right alarm setting.

Note: For best results, the two points should beseparated by a minimum of 10 ft (3m) or 30 degrees.

6. When both alarm points are set, press the EXITbutton to return to the normal working screen orthe MENU button to return to the previous menuscreen.

7. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approachingthe plane the pre‐alarm (amber) indicator lamp willilluminate, the audible will sound intermittently, andthe message “Bad Area” will appear on the CraneSetup Screen. When passing the plane the overload (red) warning lamp will illuminate, the audiblealarm will sound continuously, and the message“Bad Area” will appear on the Crane Setup Screen.

WARNINGIf crane or obstacle is moved or if a differentsize load is lifted, the area alarm must bereset.

Figure 1-90Operator Defined Area Alarm Screens

Exit OFF

00.0

MAX

MIN0

�

Exit

SettableAlarms

OFFMenu

To Clear Operator Settable Alarms1. From the normal working screen press the OPER

ATOR ALARM button to access the Operator Alarm

screen.

2. Press the corresponding selection button to select

the desired alarm to be cleared.3. Press the corresponding button for each alarm un

til the value is replaced with the word OFF.

4. When all alarms are cleared press the EXIT button

to return to the alarm screen or press the MENU


Operator's Manual



Operator's Manual


Figure 1-92Typical Crane Attachment Setup (Provided For Correct Identification Of Attachments)

2

3

4

1. Offset Lattice Fly Tip Section

2. Fly Extensions

3. Offset Lattice Fly Base Section

4. Auxiliary Lifting Sheave

5. Five Section Boom

6. Front Winch7. Rear Winch

1

6 7

5

Operator's Manual


1. Cab Walk

2. Release Handle

Figure 1-93Cab Walk

1

2

Figure 1-94Left Console Warning Label

To prevent personal injury do not attemptto enter the operator's cab prior to raising

the left console stand.

WARNING

Entering And Exiting TheOperator's CabEntering or leaving the operator's cab could be hazardous if certain aspects are not taken into consideration.The elevation of the carrier deck and operator's cabalone could cause serious injury if someone was to fall.For this reason ladders are mounted on each side ofthe carrier to provide easy access to the carrier deckand operator's cab. A cab walk assembly is mountedunder the operator's cab and should be extendedwhen entering/exiting the cab. Refer to Figure 1-93.Turn the release handle to extend/retract the cab walkassembly. Numerous hand grips are also attached tothe cab as well as non‐skid safety strips on the surfaceof the carrier deck, to provide safe entry to the cab. Usethese features to make climbing on the crane as safe aspossible. Remain in three point contact with the craneat all times (two hands and one foot or two feet and onehand).

One more feature which is available to ease entry andexit of the operator's cab, is the adjustable operator'sseat. Move the seat back as required to allow safe entry. The release lever on the forward left hand side ofthe seat allows movement of the seat forward andbackward. This feature also provides operator comfort

during crane operation. Refer to “Operator's Seat”found earlier in this Section of the Operator's Manualfor complete seat operating instructions.

Inside the cab two separate features are provided toprevent accidental operation of the hydraulic controlswhile entering or exiting the operator's seat.

1. Function Lockout SwitchThis switch is used to disable the hydraulic functions which are operated by the control levers andboom telescope foot pedal. The switch is locatedon the gauge and control panel. Refer toFigure 1-36. Press the top part of the switch todisable hydraulic function and to prevent inadvertent operation of these controls. To allow normaloperation of the control levers and boom telescopefoot pedal, press the bottom part of the functionlockout switch. The bottom part of the switch willilluminate to indicate switch is in the “OPERATION”position. This switch must always be in the “DISABLE” position before entering or exiting the operator's seat.

2. Movable Left Side ConsoleThe left side console is hinged at the rear to allowthe operator to lift the console up, out of the waywhile entering or exiting the upper cab. A springassists movement of the console.

Lifting the left side console also performs the sameduty as the function lockout switch, describedabove, disabling all hydraulic functions related tothe control levers and boom telescope foot pedal.Lifting the left side console also automatically applies the swing park brake. Make sure the sideconsole is lifted up, out of the way before attempting to enter or leave the upper cab.

Operator's Manual


Break‐In PeriodOperate a new crane at half throttle for the first twenty(20) hours of operation. A break‐in period under moderate loads will assist in providing long, trouble‐freeperformance.

Before Starting OperationsBefore starting daily operations, make the followingchecks and inspections:

EngineCheck fuel, oil, and cooling systems for proper fluid levels. Check for leaks. Repair or fill as required. Refer toengine manufacturer's manual for additional details.

Gear CasesVisually inspect all gear cases for leaks or damage. Ifleaks or damage exists, repair and fill case to proper lubrication level. Refer to Section 2 of this manual for additional information.

Hydraulic SystemCheck all hoses for chafing, bulging, or other damage.Replace as necessary. Inspect hydraulic system for external leaks. Repair as needed. Check hydraulic reservoir oil level. Add oil if necessary.

LubricationLubricate crane as outlined in Section 2 of this manual.

Note: Operators may have nothing to do with lubrication or maintenance of the crane, but it could beadvantageous for them to be familiar with it. Knowledge of preventive maintenance makes the operator more aware of malfunctions in the crane so repairs can be made with a minimum of downtime.

Tires And WheelsCheck tire inflation. Inflate to pressures per the “Tire Inflation Label” on the left rear fender of the crane or on the “TireInflation Chart” in Crane Rating Manual. Check wheel lugnut torque, each day, for the first five (5) days of operationand every 100 hours of operation thereafter. Refer to Section 3 of this manual for additional information.

Wire Rope And SheavesInspect all wire rope and sheaves for damage or dete

rioration. Replace as necessary. Refer to Section 5 of

this manual for additional information.

General InspectionVisually inspect the entire crane for loose or missing

cotter pins or bolts, or damaged fly chords or lattices.Check for oil or fluid leaks. Make repairs as needed.

Electrical SystemCheck the operation of all lights, windshield wipers,

horns, turn signals, etc. Repair as needed.

BrakesStart the engine and allow the hydraulic system pres

sure to reach its normal operating range. Check that

the service brake indicator light is not lit. Check the

park brake and service brake operations. Adjust or re

pair as needed.

ControlsCheck all controls for proper operation and adjustment. Repair as needed.

Carrier SuspensionCheck that the oscillation suspension is properly adjus

ted and functioning normally. Refer to “Suspension

Height Adjustment” found later in this Section of the

Operator's Manual. During pick and carry operations

and/or when traveling the crane, damage to the axles,

cylinders, and other suspension components can occurif the oscillation suspension is not properly adjusted. Os

cillation cylinders which are not properly adjusted can

leave suspension components unprotected from shock

loads which can lead to major crane damage.

Boom Distortion Due To ThermalEffects Of The SunThe heat from the sun may have a thermal effect on the

sides of telescopic booms causing the sides of the

boom to expand (lengthen). The sides of the boom

may not expand equally if the boom is extended forlong periods of time with only one side of the boom ex

posed to the sun. The unequal expansion may cause

boom distortion (the boom may “deflect” to one side).

This is more noticeable with long boom lengths and/or

long booms with long lattice flys attached to the boom.

For example, a 100 ft (30.5m) main boom, with a 50°F

(10°C ) temperature differential between the two sidesof the boom, may cause the centerline of the main

boom head to “deflect” as much as 3 ft (0.9m) off the

centerline of the crane. Attaching a 50 ft (15.2m) lattice

fly to the same boom may cause the centerline of the fly

head to “deflect” as much as 10 ft (3.0m) off the center

line of the crane. This “deflection” to one side creates a“side load” on the boom and/or fly. Side load on a

boom or fly, whether induced by the load or thermal ef

fects, is dangerous and shall be avoided.

Prior to lifting any loads, inspect the boom or boom and

fly combination to ensure they are straight. If the boom

Operator's Manual


or boom and fly combination is not straight, ensure thatall the boom wear pads are properly adjusted.

If the boom is distorted due to temperature differential

on the sides of the boom, reposition the boom to allow

the thermal effects from the sun to equalize the temper

atures of the side walls of the boom to eliminate the dis

tortion before lifting a load.

Fire ExtinguisherA fire extinguisher is located in the operator's cabunder the left console. Refer to Figure 1-49. Raise the

left console to gain access to the extinguisher. It is an

ABC type fire extinguisher, meaning it is capable of

extinguishing most types of fires. The operator should

be familiar with its location, the clamp mechanism used

to secure it in place, and foremost the operation of the

device. Specific instructions, regarding operation, aregiven on the label attached on the fire extinguisher. A

charge indicator on the fire extinguisher monitors the

pressure within the tank. Check the indicator daily to

ensure the fire extinguisher is adequately charged and

ready for use.

Engine Starting Procedure

WARNINGThis manual must be thoroughly read andunderstood by the operator before starting

the engine. Crane damage or personal injury

could result from improper operating

procedures.

WARNINGDiesel exhaust fumes can beharmful. Start and operate

engine in a well ventilated area.

If it is necessary to operate in an

enclosed area, vent the exhaust

to the outside. Properly

maintain the exhaust system toits original design.

Before attempting to start the engine, the operator

should carefully read and understand the engine start

ing instructions in the engine manufacturer's manual

and this Operator's Manual. Attempting to start or run

the engine before studying these instructions may result in engine damage. The operator should learn and

obey all applicable “Rules of the Road” and if not al

ready a competent driver, obtain instructions to attain

these necessary skills. With the crane fully serviced

and the operator familiar with all gauges, switches,controls and having read and fully understood this en

tire manual, start the engine using the following proce

dures:

1. Walk around the crane to verify that there are no

persons under, or in close proximity to the crane.

2. Engage the park brake.3. Position the transmission shifter to neutral. (En

gine will not start unless the transmission is in neu

tral.)

4. Sound the horn twice in succession, wait 10-15

seconds while making a visual check to verify thatthere are no persons under or in close proximity to

the crane.

5. Turn the ignition switch to the on position to ener

gize the engine electrical system.

6. Turn the ignition switch to the start position. Release the ignition switch immediately after the en

gine starts. If the engine fails to start in 30 seconds,

release the ignition switch and allow the starter mo

tor to cool a few minutes before trying to start

again. If the engine fails to start after four attempts,

refer to the engine manufacturer's manual for instructions.

7. Warm Up - Run the engine at low throttle with no

load while engine is warming up. Observe the fol

lowing instruments for proper indications.

a. Engine Oil Pressure - If there is no oil pressureafter the engine runs 10-15 seconds, shut

down the engine immediately and repair the

problem to avoid major engine damage. Refer

to engine manufacturer's manual for proper oil

pressure operating range.b. Battery Gauge - Observe indicator to ensure

battery and electrical system is working prop

erly. The gauge should indicate 12.5 to 14.0

volts while engine is running. (It should read

12.0 volts when the key is on, without the en

gine running.)8. When the engine has thoroughly warmed up, after

all pressures and temperatures are within operat

ing ranges, and all daily checks have been made,

the crane is ready for operation.

Engine Shutdown Procedure1. Lower any load to the ground and secure it prop

erly.

2. Engage the travel swing lock.

3. Throttle the engine back to idle.

4. Position the transmission shifter to neutral.5. Turn the ignition switch to the “OFF” position.

6. Remove the ignition keys from the cab and lock the

doors if the crane is to be left unattended.

Operator's Manual


Figure 1-95Do not use an open flame near the battery.

Wrong

Jump Starting The CraneThe crane has three (3) 12V batteries. To jump start thecrane a 12V power source and two (2) jumper cables

are required. Refer to Figure 1-96.

WARNINGTo avoid serious personal injury and/orequipment damage, follow these procedures

in the order they are given.

Wear protective clothing and shield your face

and eyes when working around batteries.

Batteries contain sulfuric acid which burns

skin, eyes, and clothing.

Do not jump start a damaged battery. Be surevent caps are tight and level. If another

vehicle is used, be sure booster vehicle and

crane are not touching.

The gases around the battery can explode if

exposed to open flames or sparks. An

explosion could result in serious personalinjury and/or equipment damage.

Battery posts, terminals, and related accesso

ries contain lead and lead compounds. Wash

hands after handling.

Figure 1-96Battery Cable Connections

1. Negative Cable 2. Positive Cable

1

2

+ + +

- --

+ + +

1. Check all battery terminals and remove any corro

sion before attaching jumper cables.2. Connect one end of the first jumper cable to the

12V positive (+) terminal of the discharged battery.

3. Connect the other end of the first cable to the 12V

positive (+) terminal of the 12V power source or

booster battery.

4. Connect one end of the second jumper cable to thenegative (-) terminal of the 12V power source or

booster battery.

5. Connect the other end of the second cable to the

ground stud on the upper frame.

6. If another vehicle is used to jump start the crane,start the booster vehicle. Run the booster vehicle's

engine at a moderate speed and allow discharged

batteries to charge for a few minutes prior to at

tempting to start the disabled crane.

7. Start the disabled crane. After the crane is started,remove jumper cables in reverse order.

8. Let the crane's engine run for a few minutes to

charge the discharged batteries.

9. Check the battery gauge in the operator's cab.

The gauge reading should be increasing toward

14 volts.

Note: If the batteries are severely discharged,

voltage may increase slowly. If voltage does

not increase, replace the batteries and/or check

the electrical system.

Operator's Manual


Figure 1-97Electric Engine Block Preheater

1. Preheater Receptacle 2. Counterweight Removal Receptacle

1 2

Electric Engine BlockPreheaterThe electric engine block preheater uses electricalpower to heat the coolant and circulate it through the

engine. The electric engine block preheater receptacle

is located on the left side of the upper. Refer to

Figure 1-97.

To Start The Electric Engine Block Preheater1. Park crane in suitable area for storage, engage the

park brake, position the transmission shifter to

neutral, and shutdown the engine.

2. Plug an approved extension chord into the recep

tacle located on the left side of the upper. Plug thechord into the receptacle as indicated by the identi

fication label. Plug the other end into a 110V to120V electrical source.

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

hazard.

Note: Unplug the engine block preheater before

starting the engine.

To Stop Electric Engine Block Heater1. Unplug preheater cord from electrical source.

2. Store the cord

Operator's Manual


Figure 1-98Ether Start System Fuel Canister

1. Fuel Canister

1

Ether Start (If Equipped)This system aids engine start‐up by injecting ether intothe air intake while cranking the engine. The system is

equipped with an electronic solenoid that prevents in

jecting ether except when engine is cranking. A ther

mostatic switch on the engine prevents ether from be

ing injected into a hot engine. The ether fuel canister is

located just inside the engine housing door. Refer toFigure 1-98.

WARNINGUse ether start system for starting cold engineonly. Push injector button only while cranking

engine. Use only ether in cold start system.

Do not attempt to use any other type of fuel.

When maintaining or troubleshooting ether

start system, always make sure the area is

well ventilated and away from heat, openflames or sparks. Wear goggles to avoid eye

injury. When opening ether fuel line or

disconnecting atomizer, make sure it is

pointed away from you. The ethyl ether fuel

used in this system is extremely flammable,toxic, harmful and can be fatal.

To Start The Engine Using Ether Start1. With the transmission shifter in neutral and the

park brake engaged, start cranking the engine.

2. While the engine is cranking, press the ether startswitch, located on the left side of the steering col

umn. (Refer to Figure 1-39 for ether start switch

location.) Hold the button for 2 seconds. (Do not

hold the button in over 2 seconds.)

3. Release the ether start button to inject ether into

the air intake. Allow 3 seconds for the ether to discharge. If the engine fails to start, repeat Steps

2-3.

Operator's Manual


Crane OperationCranes are used primarily for making heavy lifts. In order to do this properly, certain procedures must be fol

lowed. The following is a suggested procedure for

making typical lifts:

Note: Before operating the crane near airports, radio

and microwave towers, power lines, etc., always con

sult and comply with all local, state, and federal laws.

1. Determine the weight to be lifted. Be sure to add

the weight of the hook block, slings, rigging, fly,

etc. Determine height to which the load must be

lifted.

2. Consult the capacity chart, Working Areas and

Working Range charts in the Crane Rating Manuallocated in the operator's cab. Find the shortest

boom length and load radius that will accomplish

the job.

3. Position the crane so a minimum swing is neces

sary. Do not swing the upper over areas not covered on the capacity chart in the Crane Rating

Manual, as the crane could tip, even without a load

on the hook in these areas.

4. The crane must be supported by a firm, solid level

surface before starting to lift. All capacities in theCrane Rating Manual are based on the crane being

level in all directions. If the crane is not level, out

swing or side swing of the load will greatly reduce

lifting capacities and could cause crane damage or

an accident. If the ground is soft, use mats.

5. If outriggers are used, the following points must beobserved:

a. The outrigger beams must all be equally ex

tended (all fully retracted, intermediate ex

tended, or fully extended) to lift the loads

shown in the Crane Rating Manual. Serious reductions in lifting capacity will result if beams

are not in the same position and this could lead

to serious crane damage or an accident.

b. Outrigger pontoons must be on solid, smooth

footing, flush with the ground (no hills, or valleys under pontoons), otherwise pontoons

may be damaged or destroyed. If there is any

doubt, use mats.

c. All capacities listed for the crane on outriggers

are based on the outrigger jacks being used to

raise the crane so that all tires are clear of theground and the crane is level. A bubble level is

provided in the operator's cab to assist the op

erator in leveling the crane.

6. When making lifts on tires, the following points

must be observed:

a. All tires must be inflated to pressures as listedon the Tire Inflation label located on the left rear

fender of the crane.

b. On tire lifts are to be made from the main boom

only. Do not use the auxiliary lifting sheave, or

fly.

c. Lifts while on tires must be from firm level surface. Use mats and/or grade the supporting

surface as required to ensure safe lift.

7. Make sure the Rated Capacity Limiter is properly

set to match the crane configuration.

8. Raise the boom and swing over the load. Extendthe boom to the desired length. Make sure power

boom sections extend per the selected boom

mode.

9. Lower the hook block and fasten it onto the load.

The following points must be observed:a. The boom peak must be directly above the

load. Booms are made to lift, and should never

be used to drag a load sideways.

b. Always use chains, wire ropes, or slings of am

ple size and make periodic checks of their con

dition.c. Always use sufficient parts of line. Consult

Wire Rope Capacity chart in the Crane Rating

Manual located in the operator's cab for the

number of parts of line needed for a given lift.

d. When lifting loads, care should be taken to prevent sudden loading or unloading of the winch

rope. Ease into the load. Lift the load a few

inches off ground and hold to check brakes.

10. Lift the load to the desired height. Boom to the de

sired angle. Be careful when booming down orswinging the load, as these increase the load ra

dius and result in a decrease in capacity. Make

sure the load being lifted remains within the lifting

capacity of the crane at the boom length and ra

dius being used.

11. Control the load at all times. Use hand lines toguide the load. Do not guide loads into place with

your hands. Swing slowly and smoothly. Avoid

jerks when starting or stopping swings.

12. If the crane is to travel with a suspended load, refer

to “Pick And Carry Operation” found later in thisSection of the Operator's Manual for further in

structions.

Operator's Manual


During OperationThe operator must remain alert to possible malfunctioning of the crane while operating. If the crane does

malfunction, lower the load and shutdown the crane

until the problem is found and corrected. During op

eration, the operator must:

1. Remain alert to any noise or loss of power, or bad

response to control of the crane. Watch the engineoil pressure and water temperature gauges for

proper operating ranges.

2. Watch the hydraulic system oil temperature

gauge. If the temperature exceeds maximum tem

perature, shutdown the crane until the problem iscorrected. (Refer to Section 2 of this manual for the

maximum temperature for each viscosity of hy

draulic oil.)

3. Listen for any unusual noises in the hydraulic system, power train, or the speed reducers. If any,

correct problem.

4. Make sure all controls work freely and easily, with

no sticking or binding. Lubricate or adjust as nec

essary.

5. Watch for oil leaks or any loss of control. If any develop, correct before continuing operation.

6. If working on outriggers, periodically check the

outriggers to make sure the crane is level and sta

ble. If working on tires, make sure the tires are in

flated to the proper pressure. (Refer to the TireInflation label located on the left rear fender of the

crane for proper tire pressure.)

7. Heed all warning and caution labels. Observe

good safety practices at all times.

Operator's Manual


Figure 1-99Hand Signals

permission of the Publisher the American Society of Mechanical Engineers, 345 E. 47th Street, New York, New York 10017.

USE WHIP LINE

MOVE SLOWLY

TRAVEL

RAISE BOOM

LOWER THE LOAD

DOG EVERYTHING

LOWER

LOWER BOOM

RAISE THE LOAD

EMERGENCY STOP

USE MAIN HOIST

SWING

(Telescoping booms)

(One track)

STOP

(Both tracks)TRAVEL TRAVEL

EXTEND BOOM

(Telescoping booms)EXTEND BOOM

(Telescoping booms)RETRACT BOOM

(Telescoping booms)RETRACT BOOMRAISE THE BOOM AND LOWER THE BOOM AND

HOIST

Extracted from the American National Standard, Crawler, Locomotive and Truck Cranes, ANSI B30.5b-1985, with the

Hand SignalsHand Signals are important for communications between the designated signalman and the operator. A

hand signal chart, Figure 1-99, is included in this Sec

tion of the Operator's Manual. A copy is also located on

the front outrigger box and on the right side window of

the operator's cab.

These signals should be used at all times unless voiceinstructions with a radio or telephone are being used.

One person should be designated as a signalman and

their signals obeyed by the operator. Obey a stop sig

nal from anyone.

Operator's Manual


Counterweight Removal

SystemAccess to certain job sites may require the crane to

be transported on roads with strict vehicle load limita

tions. In order to meet such limitations the crane may

be equipped with a counterweight removal systemso the counterweight can be removed and trans

ported separately. Removing the counterweight can

reduce the weight of the crane by as much as 24,000

lb (10 886kg).

Counterweight Removal1. Park the crane on a firm level surface, position the


park brake.

2. Properly level the crane on fully extended outrig

gers with all tires clear of the ground.3. Fully retract all boom sections. If equipped, prop

erly store the fly on the boom.

4. Install the counterweight removal brackets to the

rear outrigger box if required. Refer to

Figure 1-100. Removal brackets weigh approxi

mately 44 lb (20kg) each.5. Swing the upper over the front of the carrier. En

gage the travel swing lock.

6. Install the hand held remote control box to the left

rear of the upper. Plug the box into the receptacle

as indicated by the identification label.

7. Remove the lock pins and pins which secure thecounterweight to the upper frame.

Note: Counterweight cylinders may have to be

raised (retracted) to relieve pressure on the

pins to ease removal.

8. Push the “Down” button on the remote control box

to lower the counterweight to the counterweight re

moval brackets.

WARNINGTo avoid personal injury, do not stand undercounterweight during lowering or raising of

the counterweights.

9. Remove the lock pins and pins which secure thecounterweight to the counterweight removal cylin

ders.

10. Push the “Up” button to retract the cylinders away

from the counterweight.

11. Swing the upper over the rear of the carrier. Attach

a sling to the counterweight using the lifting bars

cast into the counterweight.12. Attach other end of sling to the crane's hook block.

WARNINGWhen operating the crane with nocounterweight, always refer to the Crane

Rating Manual to ensure lifting capacities are

not exceeded.

Do not travel or transport the crane with the

counterweight positioned on the removal

brackets. Counterweight may fall causingsevere personal injury and/or crane damage.

13. Lift counterweight off removal brackets and onto

transport vehicle.

CAUTIONWhen swinging over the rear, boom hoistcylinder may contact counterweight removal

brackets at low boom angles. When operating

at low boom angles, be aware that

counterweight removal brackets may be

installed to outrigger box.

14. Remove the hand held remote control box from the

left rear of the upper. Store in crane's tool box lo

cated under the operator's seat.

Operator's Manual


KEEP CLEAR

OF MOVING

Figure 1-100Counterweight Removal System

COUNTERWEIGHT

TO PREVENT

SERIOUS BODILY

INJURY.

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

2. Pin & Lock Pin - Counterweight To Upper Frame

3. Pin & Lock Pin - Counterweight To Counterweight

4. Counterweight Removal Brackets

5. Hand Held Remote Control Box

6. Lifting Bar

2

5

1

4

WARNINGDo not travel or transport

crane with the

counterweight positioned

on the removal brackets.Counterweight may fall

causing severe personal

injury and/or crane damage.

DANGER

Do not deface or remove this label.

4

6

3

DO NOT ALLOWBOOM TO CONTACT

CTWT BRACKET

Operator's Manual


Counterweight Installation1. Park the crane on a firm level surface, position the


park brake.2. Properly level the crane on fully extended outrig

gers with all tires clear of the ground.

3. Install the counterweight removal brackets to the

rear outrigger box if required. Refer to

Figure 1-100. Removal brackets weigh approxi

mately 44 lb (20kg) each.





installed on outrigger box.

4. Attach a sling to the counterweight using the liftingbars cast into the counterweight.

5. Using the crane, pick the counterweight off the

transport vehicle.

WARNINGWhen operating the crane with nocounterweight, always refer to the Crane

Rating Manual to ensure lifting capacities are

not exceeded.

6. Swing the upper over the rear of the carrier. En

gage the travel swing lock. Set the counterweight

on the removal brackets. Make sure counterweight is balanced on the removal brackets.

WARNINGCounterweight must be balanced on theremoval brackets. Counterweight may fall

causing personal injury and/or crane

damage.

7. Swing the upper over the front of the carrier and engage the travel swing lock.

8. Install the hand held remote control box to the left

rear of the upper. Plug the box into the receptacle

as indicated by the identification label.

9. Push the “Down” button on the remote control box

to extend the counterweight removal cylinders to

align connecting lugs on the counterweight.10. Install the pins and lock pins to secure the counter

weight to the counterweight removal cylinders.

11. Push the “Up” button on the remote control box to

retract the cylinders and lift the counterweight.

WARNINGTo avoid personal injury, do not stand undercounterweight during lowering or raising of

the counterweights.

12. Continue to lift counterweight until the lugs on the

counterweight align with the lugs on the upperframe.

13. Install the pins and lock pins that secure the coun

terweight to the upper frame.

14. Lower (extend) cylinders slightly to transfer the

weight of the counterweight from the cylinders to

the upper frame.

15. Remove the hand held remote control box andstore in the crane's tool box located under the op

erator's cab seat.

Operator's Manual


Pick And Carry OperationTravel during pick and carry operations is restricted to

speeds of 2.5 mph (4km/h) or less, and creep, on afirm, level surface. Creep is defined as crane move

ment limited to 200 ft (61m) in a 30 minute period and

not to exceed 1mph (1.6km/h) maximum speed. Lifts

are to be made off the main boom only, with the crane

prepared as follows:

1. If equipped, the fly must be secured in the storedposition on boom.

2. Ensure that the suspension has been adjusted to

the proper travel height. Refer to “Suspension

Height Adjustment” found later in this Section of

the Operator's Manual.3. Inflate the tires to the required pressure listed on

the Tire Inflation label located on the left rear fend

er.

4. Make sure the Rated Capacity Limiter is properly

set to the correct pick and carry configuration. Donot exceed Pick And Carry capacities. Refer to

Creep or 2.5 mph (4km/h) capacity charts in the

Crane Rating Manual.

5. Level the crane on fully extended outriggers (if

installed) with the tires clear of the ground.

Note: The crane can perform pick and carry operations with the outrigger boxes removed. Re

fer to the appropriate capacity chart in the

Crane Rating Manual before performing pick

and carry operations without the outrigger

boxes installed.

6. Position the upper over the rear of the carrier andengage the travel swing lock. Release the swing

park brake and the 360° swing lock if equipped.

CAUTIONDo not leave swing park brake applied or 360°swing lock lever in the engaged position

during pick and carry operations. Failure to

release these devices during this operation

may result in damage to the swing speed

reducer.

7. Boom must be extended in accordance with boommode “Amax1”, “Amax2”, or “Standard” as appli

cable.

8. Retract all outrigger jacks (if installed) just clear of

the ground but leave the outrigger beams fully ex

tended.

9. Attach as many hand lines as necessary to preventthe load from swinging during travel.

10. Carefully attach the load to the winch rope and lift it

only as high as necessary.

11. Move the range select switch located on the over

head control panel to the 6‐wheel drive mode.



exceeded. Monitor the trans temperature



to “Transmission Controls” found earlier in

this Section for maximum travel systemtemperatures.

12. Carefully travel at no more than creep speed or 2.5

mph (4km/h) depending on which chart was se

lected with the Rated Capacity Limiter.

13. If outrigger boxes are installed on the crane, take

extra care due to the increased overall widthcaused by the extended outrigger beams. The

outriggers or pontoons must not be allowed to hit

any obstructions. Maintain a safe distance from all

personnel and obstructions. Travel only on a firm,

level surface.

14. Once the desired destination is reached, positionthe transmission shifter to neutral and apply the

park brake.

Operator's Manual


Traveling The CraneCertain conditions must be met for safe travel. Refer to

the following outlined procedures before travelingcrane.

WARNINGDo not use rear wheel, 6‐wheel, or crab steermode for extended or high speed travel as

steering behavior may be unfamiliar and a

loss of crane control could occur.

Do not travel with upper over the side. Crane

may tip over causing personal injury and/or

crane damage. Engage the travel swing lock.

Highway Travel

Highway travel is considered to be any travel of thecrane over 2.5 mph (4km/h). The following conditions

and precautions must be met for any highway travel.

1. If equipped, the fly must be secured in the stored

position on boom.

CAUTIONDo not leave the swing park brake applied orthe 360° swing lock lever in the engaged

position when traveling the crane. Failure to

release these devices during this operation

may result in damage to the swing speed

reducer.

2. The boom must be over the front of the crane with

the travel swing lock engaged. Release the swingpark brake and the 360° swing lock if equipped.

3. All boom sections must be fully retracted with the

boom at 0° angle. Secure the hook block to pre

vent excessive swinging.

DANGERIt is recommended that the boom bepositioned at 0 degrees when traveling the

crane on the highway. However, it may be

necessary to raise the boom slightly to

increase right side visibility. If the boom must

be raised, extreme care must be taken to avoid

boom contacting any overhead obstacles,especially power lines.

4. All outriggers must be fully retracted (jacks andbeams) with all pontoons removed from jacks and

stored properly.

Note: The crane can travel with the outrigger

boxes removed.

5. The drive train must be set to 2‐Wheel drive and the

steering selection switch in the conventionalmode.

6. Ensure that the suspension has been adjusted to



the Operator's Manual.7. Check all tires for correct pressure, adjust if re

quired. Refer to the Tire Inflation label located on

the left rear fender of the carrier.



exceeded. Monitor the trans temperature



to “Transmission Controls” found earlier in

this Section for maximum travel systemtemperatures.

8. During highway travel there must be at least a 30

minute rest period every 50 miles of driving or 2

hours of sustained operation whichever occursfirst and a 60 minute rest period after 4 hours of op

eration.

9. Obey all “Rules of the Road” and travel carefully.

Operator's Manual


Job Site Travel

Job site travel is limited to speeds of 2.5 mph (4km/h) or

less. The crane may be traveled on the job site with no

load per the following procedure:1. Ensure that the suspension has been adjusted to



the Operator's Manual.

2. Inflate the tires to pressure listed on the Tire Infla

tion label located on the left rear fender or the TireInflation chart located in the Crane Rating Manual for

2.5 mph (4km/h) maximum speed.

3. Level the crane on fully extended outriggers (if

installed).





installed on outrigger box.

Note: The crane can travel with the outriggerboxes removed only with the main boom fully

retracted and all fly attachments removed or

properly stored.

4. If traveling on a firm, smooth, and level surface, refer

to the job site travel chart for the proper crane config

uration. Do not move the boom during travel.5. If traveling on a slope, travel directly up or down the

slope. Position the upper and attachments in the

following arrangement:

a. The upper over the front of the carrier. Theboom fully retracted at 0°. The fly base and tip

stored.

CAUTIONDo not leave the swing park brake applied orthe 360° swing lock lever in the engaged

position when traveling the crane. Failure to

release these devices while traveling may

result in damage to swing speed reducer.

6. Engage the travel swing lock. Release the swing


7. Fully retract all outrigger jacks and beams (if instal

led) and properly store the pontoons.8. Secure hook ball/block to prevent excessive

swinging.



exceeded. Monitor the trans. temperature



to the Transmission Travel Limits chart for

maximum travel system temperatures.

9. Carefully travel at no more than 2.5 mph (4km/h).

Maintain a safe distance from all personnel, ob

structions, and power lines.10. Once the desired destination is reached, position

the transmission shifter to neutral and apply the

park brake.

Operator's Manual


Job Site Travel, No Load

Upper Over The FrontBoom Fully Retracted

2.5 MPH (4km/h) Maximum

Counterweight Maximum Boom Angle (°)

lbs kg 31'-55' Fly Stored31'

Fly Base Erected2° Offset

55' Fly Erected2° Offset

70'-85'Fly Erected

2° Offset

0 0 45 45 45 PROHIBITED

12,000 5 445 45 45 45 PROHIBITED

24,000 10 885 45 45 45 25

Job Site Travel, No Load

Upper Over The RearBoom Fully Retracted

2.5 MPH (4km/h) Maximum

Counterweight Maximum Boom Angle (°)

lbs kg 31'-55' Fly Stored31'

Fly Base Erected2° Offset

55' Fly Erected2° Offset

70'-85'Fly Erected

2° Offset

0 45 PROHIBITED PROHIBITED PROHIBITED

12,000 5 445 45 45 45 PROHIBITED

24,000 10 885 45 45 45 25

Operator's Manual


Towing The CraneAlways use good judgment and reliable equipmentwhen towing the crane. Towing the crane should be

done in emergency situations and for short distances

only. Use extra caution when towing the crane on the

highway and in traffic.

CAUTIONDo not tow the crane long distances and over1 mph (1.6km/h). Damage to the hydraulic

travel motors will occur. Tow the crane only

for short distances and at low speeds.

When making connections between the crane and

towing vehicle, be sure none of the connections willcause damage to either vehicle. The recommended

connecting points on the crane are the outrigger box

mounting lugs. Refer to Figure 1-101. Be sure to use

towing equipment of ample size and strength.

Always exercise safety and follow all local codes whentowing the crane. Prepare the crane as follows before

towing it.

1. If equipped, store the fly on the boom.

CAUTIONDo not leave the swing park brake applied orthe 360° swing lock engaged when towing the

crane. Failure to release these devices during

this operation may result in damage to the

swing speed reducer.


the travel swing lock engaged. Release swing parkbrake and the 360° swing lock if equipped.

3. All boom sections must be fully retracted with the

boom at a 0° angle. Secure the hook block to pre


4. All outriggers must be fully retracted (jacks and

beams) with all pontoons removed from jacks andstored properly.

5. The transmission shifter and all control levers in the

operator's cab must be in the neutral position.

6. Unlock the steering column by turning the ignition

switch to the “ON” position. Turn on the hazardflashers.

7. Release the park brake when the crane is attached

to the towing vehicle and ready to be towed. Re

leasing the park brake may require the brake to be

manually “caged” to allow the front wheels to rotate. Refer to “Caging The Park Brake” found in

this Section of the Operator's Manual.

Lifting The CraneThe entire crane (except the fly) can be lifted or the

components may be removed from the crane and lifted

individually. Refer to Figure 1-101 for the center of

gravities (CG's) and weights for the entire crane and

the individual components. The following conditions

and precautions must be met before lifting the crane orremoving any component.

1. The crane must be parked on a firm level surface

with the travel swing lock engaged, the swing park

brake released, and if equipped the 360° swing

lock disengaged.

2. Use lifting equipment, shackles, slings, etc., ofsuitable size and strength. All lifting equipment

must be inspected before lifting the crane. The in

spection must be recorded and dated in accor

dance with current OSHA regulations.

3. When lifting the entire crane (without fly), extend

the outrigger beams to the intermediate position

and install slings around the beams. Protect slingsfrom any sharp edges.

4. The weights and locations of all CG's include all

possible options (heaviest crane) except the fly.

Use the CG's as a starting point. Center hoist line

on the CG, lift a few inches and adjust the hoist line

to keep the crane/components level at all times.5. Removal of any components from the crane will

shift the CG of the entire crane. Adjust hoist line to

account for the removal of any component.

6. The hook block and ball are assumed to be stored

in the front carrier storage compartment.

7. Do not lift crane with fly attached to boom. Dam

age to the fly may result. Remove the fly from thecrane before lifting. Refer to Section 4 of this Oper

ator's Manual for the correct procedures for remov

ing the fly.

8. Use only properly attached nylon straps to lift fly

base or fly tip to prevent damage to the compo

nent. Protect the straps from sharp edges.9. Do not allow the hoist lines to contact boom while

lifting crane. Damage to the boom may result.

Operator's Manual


Figure 1-101Towing And Lifting The Crane

Description Weight

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

(1.5 m)

(.1 m)

ROTATION

(4.1m)

(3.1m)

(5.9m)

(2.0 m)

TOW AND TIEDOWN POINTSCARRIER

TOW AND TIEDOWN POINTS

5'-1”

0'-5”

31' FLY BASE

OUTRIGGERS

OUTRIGGERS

UPPER SUPERSTRUCTURE

COUNTERWEIGHTS

AUXILIARYWINCH

13'-4”

FLYLUG

24' FLY TIP

10'-4”

19'-4” BOOMFOOT PIN

AUXILIARYARM

BOOM HOISTCYLINDER BOOM

HOIST PIN

6'-7”

TIPLUG

ROTATION

TOTAL CRANE

LIFT POINT67,060 LBS(30,415kg)

LIFT POINT63,070 LBS(28 610kg)

BOOM (FULLYRETRACTED, 0°BOOM ANGLE)

OF

OF

Operator's Manual


Figure 1-102Caging The Park Brake

1. Cover Plate

2. Caging Bolt

3. Jam Nut

4. Washer

5. Hub Cover

1

2

3

4

5

Caging The Park BrakeIf the park brake can not be released to tow the crane, it

may have to be manually “caged” to allow the frontwheels to rotate. Use the following procedure to cage

and uncage the park brake. Refer to Figure 1-102.

1. Clean the surface of the cover plate.

2. Remove the center plug (not shown) from the cov

er plate.

3. Install the jam nut on the caging bolt as far as possible.

Note: The caging bolt with jam nut is supplied

with the crane and should be found in the

crane's tool box located under the operator's

seat. If the bolt can not be found, refer to the

crane's Parts Manual for replacement.

CAUTIONDo not use a pneumatic impact wrench toinstall caging bolt. Caging bolt and/or piston

may be damaged. Use only hand tools to

install caging bolt.

4. Place the washer on the caging bolt and manuallyinstall the caging bolt through the cover plate and

into the piston within the brake.

5. Hand tighten the caging bolt until it bottoms out in

the piston. Do not use a hand or power tool for this

step.

6. Loosen the caging bolt 1/4 turn.

7. While holding the caging bolt with a wrench, manually turn only the jam nut until it contacts the wash

er (4) against the cover plate.

8. Continue to hold the caging bolt stationary with

one wrench while tightening the jam nut with a sec

ond wrench. Rotate the jam nut approximately 3/4

turn to cage the spring washers and release thepark brake.

9. Confirm that the park brake is released by manual

ly rotating the hub cover.

Uncaging The Park Brake1. While holding the caging bolt stationary with one

wrench, loosen the jam nut with a second wrench

by turning it counter‐clockwise. Rotate the jam nut

until the washer is loose; approximately two full

turns.

2. Remove the caging bolt from the cover plate byturning it counter‐clockwise.

3. Apply pipe sealant to the threads of the center plug

(not shown) and install it in the cover plate.

4. Properly store the caging bolt, jam nut, and washer

in the crane's tool box located under the operator's

seat.

Operator's Manual


Figure 1-103Transporting The Crane

A

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

Transporting The CraneWhen transporting the crane, precautions should betaken in securing the crane to the trailer, barge, or other

means of conveyance. The outrigger box mounting

lugs are the recommended tie down points.

If chains are wrapped around the outrigger box collar,

be certain the chains will not damage the hydraulic

lines and fittings. The chains should be wrappedaround the outrigger box, not the outrigger beam.

Always exercise safety and follow all local codes when

loading, unloading, or transporting the crane.

WARNINGDo not use towing shackles as a means oflifting crane. These shackles are not intended

to be used to lift the crane and may break if

subjected to the entire weight of the crane.

Severe personal injury or extensive

equipment damage may result from this

practice.

Prepare crane as follows before transporting it:1. If equipped, store the fly on boom.


the travel swing lock engaged. Release the swing


CAUTIONDo not leave the swing park brake applied orthe 360° swing lock engaged when

transporting the crane. Failure to release

these devices during this operation may result


3. All boom sections must be fully retracted with theboom at a 0° or less. Secure the hook block to pre


4. If outrigger boxes are installed on the crane, all out

riggers must be fully retracted (jacks and beams)

with all pontoons removed from jacks and stored

properly.5. Position the transmission shifter to neutral and en

gage the park brake.

6. If transport height adjustment is required, refer to

“Suspension Height Adjustment” found later in this

Section of the Operator's Manual.7. All control levers in the operator's cab must be in

the neutral position.

8. Lock all windows and doors. Remove the keys

from the crane.

9. Depending on the specific situations, furtherpreparations may be needed to protect the crane

from the environment or vandalism. See “Crane

Storage” for further suggestions.

Operator's Manual


1. Front Wheels Suspension Adjustment Location

2. Left Center And Left Rear Wheel Suspension Adjustment Location

3. Right Center And Right Rear Wheel Suspension Adjustment Location

Figure 1-104Suspension Height

1 2

3SUSPENSION HEIGHT ADJUSTMENT

UP

DOWN

Suspension Height Adjustment

The oscillation suspension cylinders can be retracted

to reduce the overall height of the crane during trans

port. A hand held remote control box with 20 ft (6.1m)

of cable is used to adjust the height of the crane. (Thisis the same remote control box as used on the counter

weight removal system.) Refer to Figure 1-104. A

quick connect electrical connection is provided under

the left front fender for the front wheels. A second quick

connect electrical connection is provided under the left

rear fender for the left side center and rear wheels. Athird quick connect electrical connection is provided

under the right rear fender for the right center and rear

wheels.

Once the crane reaches the job site and is unloaded

from the transport vehicle, the suspension must be

properly adjusted to the correct travel height before operating the crane.

CAUTIONDo not travel the crane with the axle oscillationcylinders fully extended or fully retracted.

Major damage to suspension components

can occur if the crane's oscillation

suspension is not properly adjusted.

Oscillation cylinders which are not properly

adjusted can leave suspension components

unprotected from shock loads which can leadto major crane damage. Inspect the axle

oscillation cylinders daily for the proper

adjustment as required.

Operator's Manual


Use the following procedures to adjust the travelheight.

Note: This procedure is potentially very dangerous.

It requires no fewer than three people to perform.

One person in the operator's cab, one person to

make adjustments, and one person to carefully

watch so no one gets hurt.

1. Park the crane on a firm level surface.2. Position the upper directly over the front of the car

rier, boom fully retracted at 0 degree angle, and the

travel swing lock engaged.

3. Select 2‐wheel high drive mode.

DANGERWorking in close proximity with the tires with thetransmission in gear can be extremely

dangerous. Ensure the park brake is applied

and fully functional. Post a signal person to

watch carefully to ensure the safety of the

person servicing the crane. Failure to comply

with the above could result in a fatal accident.

4. Apply the park brake, block the wheels if necessary, and move the transmission shifter to forward.

5. Measure the non‐painted rod length for each

oscillation cylinder pair (front, right, and left side).

The sum of the exposed rods should equal 4.25in ± 0.125 in (10.8cm ± 0.3cm). If suspension

cylinders are not within specification proceed

to the next step.

6. With the crane on a firm, level surface and on tires,

push the UP button to extend the oscillation cylin

ders until the measured sum of the exposed rodsequals 4.25 in (10.8cm) for each cylinder pair

(front, right, and left side).

Note: Do not retract suspension cylinders to

obtain the measured sum of the exposed rods.

7. Measure the non‐painted rod length on the frontoscillation cylinder pair. Measured sum should

equal 4.25 in ± 0.125 in (10.8cm ± 0.3cm).

8. Measure the non‐painted rod length on the left rear

oscillation cylinder pair. Measured sum should

equal 4.25 in ± 0.125 in (10.8cm ± 0.3cm).

9. Measure the non‐painted rod length on the right rearoscillation cylinder pair. Measured sum should equal

4.25 in ± 0.125 in (10.8cm ± 0.3cm).

10. For transporting the crane, the suspension may be fully

lowered exposing 0 inches of rod length. Press the

DOWN button and hold until cylinders are fully retracted.

11. Move the transmission shifter to neutral.

12. Disconnect the control box and store in the storage

box located behind the fuel tank.

Operator's Manual


Crane StorageAnytime the crane is going to be left unattended itshould be prepared so that it will not be damaged by

the elements, be an attraction to vandals, or a plaything

for children.

Short Term Storage1. Do not leave crane where it will be a traffic hazard.

2. Lower all loads to the ground.

3. The travel swing lock must be engaged.

4. Fully retract the boom. Boom down to 0°. The fly

may be erected if the crane is on outriggers.5. Tie off the hook block to the towing shackles.

Winch lines should be snug.

6. All control levers must be in the neutral position.

7. Position the transmission shifter to neutral, engage

the park brake, and shutdown the engine. Blockthe wheels to prevent the crane from rolling if on

tires.

8. If the crane is on outriggers, the outriggers must be

properly set and supported so the crane will re

main level.9. In cold weather, locate the crane where it will not

freeze to the ground.

10. To preserve battery life, move the battery discon

nect switches to the off position.

11. Lock all windows and doors. Remove the keys

from the crane.

Long Term Storage1. Store the crane inside a building if possible.

2. Thoroughly clean the crane.3. Touch up any spots where paint has chipped. This

will prevent rusting.

4. Lubricate the entire crane as per the lubrication

chart. Make sure all gear cases are filled to their

proper oil level.5. Inflate tires to proper pressure as shown on the Tire

Inflation label located on the left rear fender of the

crane or the Tire Inflation chart located in the Crane

Rating Manual. Check tire pressures periodically

during storage to make sure they do not go flat. If

possible block the crane up so the tires are clear ofthe ground. Make sure the blocking is placed so

the crane cannot fall off it. If this is not possible, set

the crane on planks so the tires will not sink in the

ground. Block tires to prevent crane from rolling.

6. Fully retract all hydraulic cylinders if possible. Fully

retract the boom and store the fly, if equipped.Cover all cylinder rods and machined and un

painted surfaces with a coat of grease.

7. Leave all control levers in neutral.

8. Position the transmission shifter to neutral, engage

the park brake, and shutdown the engine.9. Prepare the engine as per the engine manufactur

ers manual. Make sure antifreeze protection is suf

ficient to prevent the engine from freezing. If anti

freeze protection is not adequate, completely drain

the engine block.10. After the engine has cooled, cover all open areas

around the engine, cab, etc. to prevent entry of

water. Cover the entire engine area with a tarp if

possible.

11. To preserve battery life, move the battery discon

nect switches to the off position.12. Remove the keys and lock the cab doors if in a lo

cation where vandalism may occur. Cover all cab

glass with plywood or boards to prevent glass

breakage. Provide a means of locking the engine

access doors, fuel tank, and hydraulic reservoir.13. Drain all moisture from the air reservoirs to prevent

rust and deterioration.

14. Store the crane so it does not provide a plaything

for children. Such a unit can be an “attractive nui

sance” for children to play on. If they fall off it or get

entangled, serious injury may result.15. While in storage, the crane should be “exercised”

every 60 days to ensure the working condition of

the crane. Remove necessary tarps and covers,

start the engine, and operate all switches, control

cables, and hydraulic functions several times to circulate lubricants and to keep all mechanisms and

linkages operative.

1068 - Section 01.pdf

Documents

Transcript of 1068 - Section 01.pdf