997 - 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 1−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective Equipment 1−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signalmen And Bystanders 1−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Inspections And Adjustments 1−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Rope 1−13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane And Area Clearance 1−13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weights, Lengths, And Radii 1−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling 1−18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leaving The Station 1−19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personnel Handling Guidelines 1−19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 1−19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Authorization 1−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment 1−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 1−21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Requirements for Offshore Cranes 1−21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection and Rigging 1−21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Test Procedures 1−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation and Safety 1−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Cab 1−24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher 1−24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windshield Washer Reservoir 1−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dash Panel 1−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Indicator Light Cluster 1−30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Column, Pump Disconnect, And Foot Operated Controls 1−31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission Controls 1−33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shifting The Transmission 1−33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s Manual

ii Section 1 − Operating Instructions

Dual Switch Range Selector Style Shifter 1−33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double−Clutching 1−34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upshifting 1−34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Downshifting 1−34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Skip Shifting 1−35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Brake 1−35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Brake Controls 1−35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Brake Operation 1−35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Descending A Grade 1−35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slippery Pavement 1−36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cruise Controls 1−36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Set The Cruise Control 1−36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting The Cruise Control 1−36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suspending And Resuming A Set Speed 1−37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turning The Cruise Control Off 1−37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Cab Seat 1−37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Disconnect Switches 1−38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Carrier Cab Fuse Box 1−38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Control Module Fuses 1−38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Interface Box 1−38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Operator’s Cab 1−40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Top Hatch Wiper 1−40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher 1−41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Operator’s Cab Fuse Panel 1−41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Operator’s Cab Interior Light 1−41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rated Capacity Limiter Panel 1−41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Upper Operator’s Cab Control Panel 1−42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gauge Panel 1−43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Side Panel 1−45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s Seat 1−46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s Manual

iiiSection 1 − Operating Instructions

Main Outrigger Operation 1−47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Extend Outrigger Beams 1−48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

To Retract Outrigger Jacks − Lower The Crane 1−49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Retract Outrigger Beams 1−50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bumper Outrigger 1−50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bumper Outrigger Control Switch 1−50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Extend Bumper Outrigger 1−50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Retract Bumper Outrigger 1−50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane System Controls 1−51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Throttle Controls 1−51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing System 1−51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Brake Pedal 1−51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Control Lever 1−51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel Swing Lock 1−53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Park Brake 1−53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

360° Swing Lock 1−54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire Rope Winch System 1−54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warm-Up Procedure 1−54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Winch Control Lever 1−55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Winch Control Lever 1−55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Operation 1−55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Control Switch 1−55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Speed Hoist Or Lower 1−55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Disable 1−55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Winch Circuit Switch 1−55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drum Rotation Indicators 1−55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Hoist System 1−56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Telescope System 1−56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Telescope Control Pedal 1−56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Telescope Override Switch 1−57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Oil Cooler Fan Switch 1−58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s Manual

iv Section 1 − Operating Instructions

Crane Monitoring System 1−58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Lockout Pin And Flag 1−59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

System Description 1−61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Unit 1−61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Operation 1−62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Perform System Test 1−62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Bypass 1−62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Inoperative Or Malfunctioning 1−63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuration Selection 1−63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Select Rigging/Travel Mode 1−68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Cancel Audible Alarm And Reset Function Limiters 1−68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Settable Alarms 1−68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Length/Angle/Height/Swing Operator Alarms 1−69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Set Operator Defined Area Alarm 1−71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Entering And Exiting The Upper Operator’s Cab 1−75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Break-In Period 1−75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Starting Operations 1−75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Starting Procedure 1−76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Start The Engine From The Carrier Cab 1−76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Start The Engine From The Upper Operator’s Cab 1−77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Shutdown Procedure From The Carrier Cab 1−77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Shutdown Procedure From The Upper Operator’s Cab 1−77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Jump Starting The Crane 1−78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Aids 1−79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Pump Disconnect 1−79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric Engine Block Preheater 1−79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Start The Electric Engine Block Preheater 1−79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Stop The Electric Engine Block Heater 1−79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ether Start System 1−80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing The Ether Fuel Cylinder 1−81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s Manual

vSection 1 − Operating Instructions

Diesel Cab Heater 1−82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Start The Diesel Cab Heater 1−82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Stop The Diesel Cab Heater 1−82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Drain Water 1−82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Cab Heater 1−83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Start The Hydraulic Cab Heater 1−83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Stop The Hydraulic Cab Heater 1−83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Signals 1−84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Operation 1−84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

During Operation 1−85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pick And Carry Operation 1−86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling The Crane 1−86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Job Site Travel 1−86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Highway Travel 1−87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Counterweight Removal 1−87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Remove The Counterweights 1−87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To Install The Counterweights 1−89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traveling With Boom Dolly/Trailer 1−89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Dolly/Trailer Installation 1−90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boom Dolly/Trailer Removal 1−91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting The Crane 1−92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Towing The Crane 1−92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transporting The Crane 1−94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crane Storage 1−94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Short Term Storage 1−94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Long Term Storage 1−95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator’s Manual

vi Section 1 − Operating Instructions

Operator’s Manual

1−1Section 1 − Operating Instructions

Figure 1−1Crane Nomenclature

1. Four Section Boom2. Upper Operator’s Cab3. Front Winch

4. Rear Winch5. Counterweights6. Rear Outrigger

7. Turntable Bearing8. Fuel Tank9. Front Outrigger

10. Carrier Cab11. Bumper Outrigger

1 2 3 4

567891011

On DeliveryWhen a new crane is delivered, follow the instructionsoutlined in the latest version of Technical Bulletin Gen-eral Series #213. A copy of this bulletin can be ob-tained from your Distributor.

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

Safe operations of a hydraulic crane requires a welltrained, qualified operator. Crane operation is more in-volved than it may appear, and operation by a carelessor 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 equip-ment, but if not used properly, it can be dangerous.

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

Figure 1−2Read and understand all points covered in theOperator’s Manual before operating the crane.

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

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.With the boom removed from upper, do notswing over side on tires or on retractedoutriggers.

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

WrongRight

Figure 1−3Shutdown the engine, ensure that the operator has vacated the upper operator’s cab, andinsert blocking through the diamond shaped hole closest to the base section of the boombefore putting hands or tools inside a boom section.

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

Keep clear ofmoving parts toprevent seriousbodily injury.

General Safety RulesThe following is a list of safety rules which should be fol-lowed during all crane operations.

Operator Awareness1. Read and understand this Operator’s Manual, all safety

manuals, and the Crane Rating Manual and heedthem. These manuals contain important information.

2. An operator must not eat, read, or otherwise diverthis attention while operating a crane. Remem-ber−operating is a full-time job.

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

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

5. Keep your shoes clean. Before entering the operator’scab, clean any mud, gravel, moisture or grease from

your shoes. Slippery shoes could cause momentaryloss of control of crucial foot operated controls.

6. Keep all walking surfaced non-skid materials onthe crane clean. Non-skid materials are placed onthe crane assist operators and service personnelwith safe access/egress to/from the crane and to/from adjustment and inspection areas. Do not al-low non-skid materials to become contaminatedwith mud, 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 be-comes ineffective due to wear, age, or destroyed inany way, it must be replaced.

7. Keep fingers, feet, and clothing away fromsheaves, drums, and ropes unless the crane isshutdown and everyone knows what you are do-ing. Do not place a hand on wire ropes whenclimbing on the crane. A sudden movement couldpull them into the drums or sheaves.

8. Shutdown the engine, ensure that the operator hasvacated the operator’s cab, and insert blockingthrough the diamond shaped hole closest to theboom base section, to prevent movement of the indi-vidual sections, before putting your hands or tools in-side the boom. Unsuspected movement of theboom section could sever fingers, hands, arms, etc.

9. The operator, supervisor, or person in charge of theload must observe the following rules:a. Loads must be well secured before lifting. Be

sure that the rigging cannot slip off or pull awayfrom 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, ingood condition, and not twisted around eachother.

Operator’s Manual


A 3 Degree Side Tilt CanReduce Capacities

By Over 50%.

Grade Ground LevelOr Block Under Crane.The Load Should HangParallel With The Boom.

WrongRight

Figure 1−5Level the crane.

c. The load must not catch on an obstructionwhen lifting or swinging. Be sure the load, falllines, or any other parts of the crane do notsnag or strike any obstruction.

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

e. When hoisting with single part line, especiallyin long falls applications, the design of wirerope and 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 CraneRating Manual for the specific types of rotationresistant wire rope recommended for yourcrane.

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

g. Do not wrap the winch rope around the load.Do not use discarded, worn, or damaged wireropes for slings. They may break and drop theload.

h. The crane must be level before making a lift.Use the bubble level, to level the crane. Checkits accuracy frequently with a carpenter’s level.Remember, a three degree side tilt can reducecapacities by 50% or more.

Operator’s Manual


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

Can Cause This!

Wrong

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

Wrong

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

10. Don’t let the load or bucket hit the boom, fly, or jib.Don’t let the boom or attachment rest, or hit, abuilding or any other object. A dent or other dam-age could result, which will weaken the boom or at-tachment. If the damage is severe, the attachmentcould collapse. If a lattice or diagonal bracingmember on the fly is broken, cracked, or bent, con-tact your local distributor for repair procedures. If

the boom or fly is struck, or damaged by anything,STOP. The loading on a boom or attachments in-creases as they are lowered, therefore their sus-pension systems could collapse during lowering.Use another crane to lower a damaged boom or at-tachment.

11. Don’t pull sideways on the boom, not even a little.Lift straight up on every load. Moving trucks, railcars, barges, or anything else pulling sideways onthe winch rope could buckle the boom. It couldalso damage the swing mechanism. Pulling side-ways on a boom can overturn the crane.

12. Do not �two block" (pulling the hook block into thehead machinery) as this can cause winch rope andsheave breakage resulting in an accident.

13. After slack winch rope operation, make sure thewinch rope is properly seated in sheaves and ondrums before continuing to operate. Use a stick ormallet to set the winch rope, not your hands.

14. Do not lower the load beyond the point where lessthan three full wraps of winch rope are left on thedrum. This condition could occur when lowering aload beyond ground level. If all the winch rope runsoff the drum, the load will jerk which could breakthe winch rope.

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

Operator’s Manual


Right

Figure 1−8Crane level, all beams extended equally (allfully extended, all intermediately extended, orfully retracted), and tires clear of the ground.

16. Don’t alter any part of the crane. Additions to, orchanges in, any part of the equipment can createloadings for which the crane was not designed.Such changes may seriously affect the usable ca-pacities and make the entire Crane Rating Manualinvalid. Such changes can dangerously overloador weaken critical parts and may cause disastrousfailure.

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

18. When operating on outriggers, all beams must beextended equally; all fully extended, all intermedi-ately extended, or all fully retracted. All jacks mustbe extended so all tires are clear of the ground, andthe crane must be level. Be sure that blocking orpontoons are set on a firm surface, adequate tosupport the blocking, pontoon, crane and loadwithout settling, slipping, or collapsing. Blockingor matting under pontoons must form a smooth,level surface under the entire pontoon. Do notblock under outrigger beams inside the pontoonsas this reduces stability. Blocking must be underpontoons only. Remember−there are tremendousloadings on pontoons and blocking − the weight ofthe entire crane plus any load.

Figure 1−9Watch that carrier cab!

Wrong

When blocking or matting under pontoons, besure 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, causingthem to collapse.

Capacities are based on outriggers equally ex-tended; all fully extended, all intermediately ex-tended, or all fully retracted. Working on outriggersthat are not equally extended will reduce capaci-ties and crane stability considerably and couldcause an accident. Do not make any lifts while onoutriggers without the outrigger beams equally ex-tended.

19. Before attempting to move the carrier, make surethere is enough air pressure to operate the brakes.Always check the brake operation before travelingthe crane.

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

21. Do not coast downhill with the transmission in neu-tral. It makes control of the crane more difficult anddangerous.

22. Shift the transmission to neutral before operatingthe crane. Crane operation can cause movementwhich can damage the transmission or drive line.When parking, shift to neutral and engage the parkbrake. Block wheels if on an unlevel surface.

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

Operator’s Manual


Figure 1−10Handling The Fly Section.

RightWrong

1. Use The Connecting Lugs 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

12

2

3

Figure 1−11Fly Section Nomenclature

1. Head Sheave2. Main Chord3. Lattices4. Picture Frame

5. Connecting Lugs6. Head Machinery Cross

Shaft

1

23

4

5

6

24. Use care handling the fly when loading, transport-ing, and unloading. Damage that occurs duringthese operations can go undetected and could re-sult in failure of the attachment, once subjected toloading. Do not attach slings to the lattices, whenlifting the fly, as they will bend. It is recommendedthat the connecting lugs and/or head machinerycross shaft be used as the lifting points. However, itis permissible to attach nylon straps around all fourmain chords.

25. Block under and between the fly when loadingthem on a transport vehicle. When securing the flyto a transport vehicle, it is best to use syntheticwebs or slings. If using wire rope slings, pad the flyto protect it from damage. Do not overtighten thetie downs or the fly may be damaged. Do not usechain ties downs, as they may dent and damagethe sections.

26. Thoroughly inspect all the elements of each fly be-fore installing it on the crane. Check each mainchord, picture frame, diagonal, lattice, and con-necting lug for bends, dents, and cracked or cor-roded welds. Picture frames must be square. Donot use any fly that is even slightly damaged. Con-sult your local distributor for the proper repair pro-cedures.

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

which can cause death.b. Keep all parts of the crane, fall lines, hook

block, and load at least 15 ft (4.57m) from elec-trical lines or as specified in the �High VoltagePower Line Clearance Chart" or other dis-tances specified by applicable codes. Slowdown crane operation.

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 aroundthe power line. This person should have noother duties while the crane is working aroundthe power line.

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


Wrong

Figure 1−13Crane Equipped With Proximity WarningDevice On The Entire Boom

Shaded area shows �sensitivity zone" with full boom lengthsensor used, and adjusted for 15 ft (4.57m) clearance. Contactcan 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 beelectrified and deadly.

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 thecrane. Don’t allow ground workers to holdload lines, or rigging gear unless absolutelynecessary. In these cases use dry plasticropes as tether lines. Make certain everyonestays at least 15 ft (4.57m) away from the load,or a distance specified in the �High VoltagePower Line Clearance Chart", or such distanceas required by applicable codes.

f. The use of boom point guards, proximity de-vices, insulated hooks or swing limit stops donot assure safety. Even if codes or regulationsrequire the use of such devices, you must fol-low rules listed here. If you do not follow them,the result could be serious injury or death.

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

h. When operating near radio or T.V. transmittingstations, 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

Wrong

Figure 1−14Crane Equipped With Proximity WarningDevice On The Boom Tip

Shaded area shows �sensitivity zone" with the probe near theboom peak and adjusted for 15 ft (4.57m) clearance. Contactcan 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 beelectrified and deadly.

transmitter or antenna. Painful, dangerousshocks could occur. Consult trained electronicpersonnel 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 anarc is cutting through the cab.

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 anarc 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 awayuntil you are at least 15 ft (4.57m) away (or adistance specified in the �High Voltage PowerLine Clearance Chart" or as specified by localcodes). Stop the crane. Make a thorough in-spection for crane damage before further use.

Operator’s Manual


This Man Is Not Protected.

Wrong

Figure 1−15Crane Equipped With Insulated Link

1

1. Insulated Link

f. If you can not disengage from the electrical lineand the crane is not on fire or no arc is cuttingthrough the cab, stay in your seat until thepower 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, landingwith feet together, then hop away from thecrane with feet together, or shuffle feet to keepthem close together. This could help preventpersonal injury.

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

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

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

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

wooden stick.e. Open magnet disconnect switch at magnet

control panel before connecting or discon-necting leads.

Wrong

Figure 1−16Crane Equipped With Insulated Link AndBoom Point Guard

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

1

Figure 1−17If you must leave the crane, do not step off.Leap as far as you can with feet together andhop or shuffle away from the crane.

Operator’s Manual


Wrong

Figure 1−18No hook riders!

Protective Equipment1. Always replace protective guards and panels be-

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

shoes, hearing protection, and any other safetyequipment required by local job conditions,OSHA, or regulations.

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

4. Keep a dry chemical or carbon dioxide fire extin-guisher of 5BC rating or larger in the cab or in theimmediate area of the crane at all times. Instruct alloperating and maintenance personnel in properuse of the extinguisher. Check periodically tomake sure it is fully charged and in working order.

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

6. When operating a crane equipped with any form ofload indicating mechanism, overload warning sys-tem, or any automatic safety device, rememberthat such devices cannot replace the skill and judg-ment of a good operator. For instance, such de-vices cannot tell when a crane is located on a sup-porting surface that will give away, that too fewparts of line are being used to lift a load, cannot cor-rect for the effects of wind, warn that the devicemay be improperly adjusted, correct for side pullson the boom, or for many conditions which couldoccur and create hazards. It requires all the skill,experience, judgment, and safety consciousnessthat a good operator can develop to attain safe op-eration. Many safety devices can assist the opera-tor in performing his duties, but he should not relyon them to keep him out of trouble.

Figure 1−19Use a signalman, back safely.

Wrong

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 shouldleave the immediate area when crane is operating.

2. Do not allow anyone to ride on the hook ball, hookblock or any part of the load or attachment forconstruction work or recreational activities. (Thisapplies to recreational activities such as �bungeejumping" or �bungee cord jumping"). Cranes areintended to lift objects, not people. They are notelevators.

3. Do not carry passengers! There is only one seatand it is for the operator. A fall from the crane cancause death or serious injury.

4. Always look before you back up, or better yet, posta signalman to guide you. If crane is equipped witha back up alarm, make sure it is working properly.Use the horn as a signal. Use a code such as onebeep − stop, two beeps − forward, and threebeeps − backward. Make sure everyone on thejob 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 cranedamage.

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

poorly maintained crane. Pay particular attentionto the clutches, brakes, attachments, and wireropes. If a component is worn or damaged, re-place it before operating.

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

3. When performing repetitive lift applications, espe-cially at or near maximum strength limited capaci-ties, an inspection of the major structural areas ofthe crane, for cracks or other damage, should beconducted on a regular basis. (A non-destructive

Operator’s Manual


test such as magnetic particle or dye penetrantmay even be considered.) Along with inspectionfor cracks and damage, frequently check the criti-cally loaded fasteners, such as the turntable bear-ing mounting capscrews, to ensure they have notbeen stretched. Not only does frequent inspectionpromote safety, but it is also much easier and lessexpensive to perform a repair when a crack issmall, before it has a chance to traverse through astructural member. Any sign of cracks or damagemust be repaired before continuing operations.Consult your distributor for repairs.

4. When performing maintenance on the crane, dothe following:a. Fully retract the boom. Lower the boom to the

limit of the boom hoist cylinders or on to theboom rest.

b. Shutdown engine, disengage the main pump,and work all control levers back and forth to re-lieve 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 reservoirbefore opening it or disconnecting a line.

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

f. Post warning signs in cab so no one will try tostart the engine. Never adjust, maintain, or re-pair a crane while it is in operation.

5. Always reduce pressure in hydraulic system tozero before working on any part of the system. Pinsized and smaller streams of hydraulic oil underpressure can penetrate the skin and result in seri-ous infection. Do not use your hand to check forleaks. If hydraulic oil does penetrate the skin, seekmedical treatment immediately.

6. Always reduce pressure in air system to zero be-fore working on any part of the system. Pin sizedand smaller streams of air under pressure canpenetrate the skin and result in serious infection.Do not use your hand to check for leaks. If air doespenetrate the skin, seek medical treatment imme-diately.

7. Use extreme care when working with circuits withaccumulators. Check that hydraulic pressure is re-lieved before opening the circuit for repairs.

8. When setting pressures, never exceed the manu-facturer’s ratings. Always follow instructions ex-actly. Over pressurization can cause hydrauliccomponent damage or failure of mechanical partson the crane. Either of the above can lead to an ac-cident.

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

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

CRANE OUT OF SERVICEDo not operate the crane or startthe engine without first notifyingthis mechanic. Personnel within the crane could be hurt or killed.Crane damage may also result frompremature operation of systemswhich are still under repair.

Signed:

DANGER

9. When making repairs, which require welding, useproper welding procedures. Also make note of thefollowing: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 effected byelectric arc welding. Contact the distributor orfactory for proper procedures.

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

d. The welding ground cable should always beconnected as close as possible to the area be-ing welded. This minimizes the distance thatelectricity must travel.

e. Disconnect computers and other electronicequipment (such as rated capacity limiters andengine computers) to prevent damage. Con-tact the distributor or for proper procedures.

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

Operator’s Manual


Figure 1−21Use a guard when inflating tires.

Right

Figure 1−22Allow engine to cool before removing theradiator cap.

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

11. Keep all walking surfaced non-skid materials onthe crane clean. Non-skid materials are placed onthe crane assist operators and service personnelwith safe access/egress to/from the crane and to/from adjustment and inspection areas. Do not al-low non-skid materials to become contaminatedwith mud, 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 be-comes ineffective due to wear, age, or destroyed inany way, it must be replaced.

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

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

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

WARNINGBattery posts, terminals, and relatedaccessories contain lead and leadcompounds. Wash hands after handling.

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

15. When using jumper cables to start an engine, besure to connect negative post to negative post, andpositive post to positive post. Always connect thetwo positive posts first. Any spark could cause thebattery to explode. Refer to �Jump Starting theCrane" found later in this Section of this Operator’sManual for the proper procedure.

16. Test the automatic winch brake by raising the loada few inches and holding. It should hold withoutslipping. It takes more braking power to hold a loadin the air when the drum is full of rope than when itis a few inches above the ground with only a fewwraps on the drum.

Operator’s Manual


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

tional Safety And Health Act) regulations state �athorough inspection of all ropes shall be madeonce a month and a full written, dated, and signedreport of the rope condition be kept on file wherereadily available." Replace any worn or damagedrope. 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 linespecified on the Wire Rope Capacity Chart locateding the Crane Rating Manual to handle the load.Local codes may require more parts of line than isshown. Check code requirements and use themwhere applicable.

3. Non-rotating, rotation-resistant, or spin-resistantwire ropes are recommended for single part of lineapplications. This is of utmost importance for longfall hoist line applications. Only if certain criteria aremet may a swivel hook ball be used with rotationresistant rope. Refer to �Single Part Line Hoisting’and �Hook Ball Usage With Rotation ResistantRope" found in Section 5 of this Operator’s Manu-al.

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

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

6. 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 haz-ards 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 wander-ing onto the job site.

Thursday . . . . .

Wrong

Figure 1−24Do not operate the crane with worn ordamaged wire rope.

�I thought I could savemoney by running thisrope until Friday."

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, or raise orlower jacks, without first making sure no one is inthe way. If your vision is obscured, locate a signal-man 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 found later in this Operator’sManual or the label located on the crane. Use thehorn to signal or warn. Make sure everyone onthe job site understands signals before startingoperations.

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 exca-vation. 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 1−25Safety Instruction Label

Operation under conditions whichexceed listed capacities may result inoverturning.

Swinging, extending or lowering boomto radii where no capacities are listedmay result in overturning even withouta load.

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 de-termine exact weight. Remember the weight youare lifting includes the weight of any lifting slings orgear, the hook block, and any other weight on thehook. If lifting off the boom with the fly installed, theweight of the fly and rigging must also be consid-ered as part of the load. The total load weight mustnever exceed the rated capacity of the crane, aslisted in the Crane Rating Manual, for the position,boom length, load radius, and condition of opera-tion being used. Remember − capacity chart rat-ings in the Crane Rating Manual are based on idealconditions:

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

leaving the factory

When such conditions cannot be attained, loadsbeing handled must be reduced to compensate.The amount loads are reduced depends upon howgood or how poor, the actual operating conditionsare. It is a matter of judgment and experience.Some factors which may require reduction of ca-pacities are:

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

Wrong

Figure 1−26Know your load.

�It looked likeabout 5 ton."

When in doubt, do not take a chance. Reduce rat-ings more than you think you need. Avoid workinga crane in high winds. If you must work in a wind,reduce capacities considerably below thoseshown in the Crane Rating Manual. Wind blowingagainst the load and the boom produces a sideload on the boom and reduces its capacity.

When lifting loads in a wind which have large sur-face areas, such as building panels, the movementof the load may pose a danger to workmen orbuilding structures. Out swing of a load will in-crease the load radius, and may overload thecrane. This could lead to boom failure or the cranetipping.

2. When operating off the main boom with the flyerected, deductions must be made for its weight.The weight of the fly, pendants, etc., must be sub-tracted to obtain a �NET" capacity. Failure to do socould result in an overload condition and causeboom failure. Refer to the Crane Rating Manual foramounts to be deducted.

3. 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 theCrane Rating Manual for amount to be deducted.

Operator’s Manual


Wrong

Figure 1−27Do not lift two loads at the same time.

4. Do not lift two loads at the same time, even if thetotal load weight is within crane capacity. Loads onthe 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.

5. Some capacities on hydraulic cranes are based onstrength of materials. In these cases, overloadsmay cause something on the crane to break, be-fore it will tip. Do not use signs of tipping as a warn-ing of overload.

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

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

Figure 1−28Do not push with the boom.

Wrong

8. When performing repetitive lift applications, espe-cially at or near maximum strength limited capaci-ties, be aware that these applications may reducecomponent life. These applications include re-peated lifting (or lifting and swinging) of near 100%strength limited capacities and repeated liftingmaximum moment loads. These applications mayfatigue the major structural portions of the crane.Although the crane may not break during these ap-plications, they can reduce the fatigue life andshorten the service life of the crane. To improve theservice life, while performing repetitive lift applica-tions, consider reducing the capacities to 70% ofmaximum 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.

9. Always refer to the Crane Rating Manual afterchanging the arrangement of the attachments forthe correct lifting capacities.

10. The boom must be extended in the correct mannerbefore making a lift. The capacities listed in theCrane Rating Manual for this crane are based onthe boom sections being extended in accordancewith boom mode �A" or �B".

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

12. Know the load radius. Don’t guess at it. Determinethe load radius by using the boom angle indicator,the boom length indicator and the Crane RatingManual, or measure it with a steel tape. Remember− Radius is the horizontal distance from the center-line of rotation of the upper to the center of gravityof the load, when the load is hanging free.

Operator’s Manual


Figure 1−29Pinch Point Label

13. Do not operate a hydraulic crane at radii or boomlengths where the Crane Rating Manual shows nocapacity. Do not use a fly not designed for thiscrane. Either of the above can tip the crane over orcause attachment failure. In some cases, thecrane can tip over with no load on the hook, for-ward or backward! Also, if the boom is fully ex-tended at a low angle, the crane may tip until theboom touches the ground. In any of these cases,injury or crane damage could result.

14. When lifting a load with any crane, the load mayswing out, or sideways. The load radius will in-crease. Due to the design of hydraulic cranebooms, (cantilever boom, supported by cylindersand overlapping sections) this increase is muchmore pronounced. The increase or out swing ofthe load can overload the boom, and lead to boomfailure or tipping. Also, movement of the load cancause it to hit something. Make sure the load beinglifted will remain within capacity as it is lifted and theboom deflects.

15. 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 tipover. Sometimes at low angles, a hydraulic craneboom can be extended with a load, but cannot beretracted. This is because more power is availablein the boom telescope cylinders to extend than toretract. If an operator extends the boom underload, he may not be able to retract the boom andmay get into a dangerous situation.

16. Know the boom length. Don’t guess. Use of an in-correct boom length can cause an accident.

17. When lowering or retracting the boom, the load willlower. To compensate for this, the operator musthoist up on the winch rope. Otherwise, movementof the load may cause an accident. When extend-ing the boom, the load will raise. the operator musthoist down the winch rope to keep the load inplace. Extending the boom without winchingdown, can lead to �two blocking". This is when thehook block or the hook ball contacts the head ma-chinery. Two blocking can lead to sheave or ropedamage.

18. The winch rope must be vertical when starting tolift. If not, the load will swing in, out, or sidewayswhen lifted from the ground. The crane will lean to-ward the load when lifting heavy loads. This iscaused by elasticity of the crane and the boom.This lean will increase operating radius so the loadwill swing outward when it clears the ground. Thisout swing is dangerous to anything in the path ofthe load, and because of the increase in load ra-dius may overload the crane. To overcome this outswing, boom up as the load is lifted so winch ropesremain vertical. When setting the load on theground, lower boom after the load touches down toavoid hook block swing when it is unhooked fromload.

19. Pinch points, which result from relative motion be-tween mechanical parts, can cause injury. Keepclear of the rotating upper or moving parts.

Operator’s Manual


Figure 1−30Watch that side tilt!

Just a little side tilt whenworking over the end.

Look what happens over the side. . . .LOAD RADIUS INCREASES!

Wrong

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

21. Watch out for centrifugal force when swinging aload. 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 theload can side load the boom.

22. Keep the winch ropes as short as possible to pre-vent excessive swinging. Always use the shortestboom length which will do the job. Remember −the shorter the boom, the better the capacity.

23. Do not move a crane away from the load while han-dling near capacity loads. Due to load inertia(weight) the load will tend to stay in position whenthe crane starts to move, and then will swing in to-wards the crane. The inertia effect will tend to in-crease load radius and decrease stability. Thiscould lead to boom failure or crane tipping.

Figure 1−31Watch that centrifugal force!

Wrong

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

1

2

24. Don’t increase the maximum allowable counter-weight. Don’t add anything to the crane that willact as additional counterweight. Remember thatanything which has weight, if carried behind thecrane’s center of gravity, acts as counterweight.Adding counterweight affects backward stability ofthe crane, particularly when working over the side.It also encourages overloading of the crane.

25. Working areas for cranes are defined per the Work-ing Areas Chart located in the Crane Rating Manu-al. Permissible loads, per the Crane Rating Manu-al, will vary from lifting quadrant to lifting quadrant.The operator must make sure capacity ratings arenot exceeded regardless of which quadrant he isoperating in, or when swinging from one quadrantto another.

26. When making lifts on tires, the tires must be inflatedto pressures shown on the Tire Inflation label lo-cated on the carrier or in the Crane Rating Manual.

Operator’s Manual


Traveling1. Traveling with a suspended load should be

avoided if possible. It is especially hazardouswhen terrain is rough or irregular, on a side slope,or in a hilly area. When traveling with a load, 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 asmooth, level route is not available, don’t travelwith a suspended load. Grade the route to pro-vide a smooth, level path. If it is not possible tograde the route, move the load by stepping.Level the crane on outriggers, lift the load andset it down ahead of the crane. Travel the un-loaded crane beyond the load, level the craneon outriggers, lift the load, swing and set itdown farther along the route. Continue thisprocedure until the load is at its destination.

c. Carry loads as close to the ground as possible.d. Do not allow side swing of the load.e. Don’t attempt to carry loads which exceed the

crane’s rating. Refer to On Tires and Pick AndCarry capacities shown in the Crane RatingManual.

f. Don’t travel with a load on soft ground. If thecrane 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 anytime.

h. Fully extend outrigger beams. Extend or re-tract jacks until pontoons just clear the ground.

i. Check clearance for the extra width of thecrane with the outriggers extended. Outriggerbeams or pontoons must not hang on any ob-struction.

j. Inflate tires as shown on the Tire Inflation labellocated on the carrier or Tire Inflation chart lo-cated in the Crane Rating Manual when mak-ing lifts on tires.

k. See �Pick And Carry Operation" found later inthis Section of this Operator’s Manual for moredetails.

2. Do not exceed the maximum axle load ratings aslisted on the Gross Axle Weight Rating plate.

3. Road the crane safely. Watch for narrow bridgesand low clearances. Check load limits, heights,width and length restrictions in the area you aretraveling. Make sure your crane complies with allregulations.

4. Do not allow anyone to ride in the upper operator’scab during any highway travel. Highway travel isconsidered to be any travel of the crane over 5.0mph (8.0km/h). Refer to �Highway Travel" foundlater in this Section of this Operator’s Manual formore details.

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

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

b. Engage travel swing lock. Release the 360°swing lock.

c. Lash down or otherwise restrain the hookblock.

d. Check for maximum allowable travel speed,and any other travel limitations. Don’t exceedthese maximums. Crane damage or an acci-dent could result.

e. When traveling, outriggers must be fully re-tracted.

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

g. See �Traveling the Crane" found later in thisSection of this Operator’s Manual for more de-tails.

6. If the crane must be towed, shift the transmissionto neutral and move slowly. Slowly take up slack inthe rope or chain. Don’t jerk, the chain or rope maybreak. Keep the chain or rope tight while towing.See �Towing the Crane" found later in this Sectionof this Operator’s Manual for more details.

Operator’s Manual


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

handles and ladders when climbing on or off thecrane. Remain in three point contact with the craneat all times (two hands and one foot or two feet andone hand).

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

brake. Shutdown engine and remove keys.c. Do not depend on a brake to suspend a load

unless the operator is at the controls, alert andready to handle the load. Brake slippage, van-dalism or mechanical malfunctions couldcause the load to drop.

3. Do not leave crane unattended with the engine run-ning.

4. When changing work shifts be sure to notify thenext operator of any changes or problems with thecrane.

Personnel Handling Guidelines

Introduction

The following information is intended to provideLink-Belt’s recommended minimum requirements thatmust be followed when handling personnel with apersonnel basket or work platform (hereafter referredto as a platform) suspended by wire rope from theboom of Link-Belt cranes. These requirements arebased upon several sources and are put forth inrecognition of current industry practices. However,safety, when handling personnel, remains theresponsibility of job site management and isdependent upon the responsible action of everyperson on the job involved in the related work.

This information is intended to supplement and not tosupercede or replace any more restrictive federal,state, or local regulations, safety codes, or insurancerequirements. It is intended to serve users of personnelplatforms in achieving the following objectives.1. Reduce risk of personal injuries to users and the

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

Figure 1−32Do not leave the crane with a load suspended.

Wrong

Link-Belt cranes are designed and intended for han-dling material. They are not normally equipped withsecondary systems or other devices required by per-sonnel lift or elevator standards and are not intendedfor handling personnel for construction or amusementpurposes. Use of cranes for these purposes is hazard-ous and is not recommended by Link-Belt. However,Link-Belt understands that circumstances may occur(in construction work) when lifting or lowering person-nel on a materials handling crane load line is the only orthe least hazardous method available to position per-sonnel. In fact, OSHA (Occupational Safety and HealthAdministration) Part 29 CFR 1926.550(g) states �Theuse of a crane or derrick to hoist employees on a per-sonnel platform is prohibited, except when the erec-tion, use, and dismantling of conventional means ofreaching the work site, such as personnel hoist, ladder,stairway, aerial lift, elevating work platform, or scaffoldwould be more hazardous or is not possible because ofstructural design or work site conditions."

Much corollary and supplementary information is con-tained within the following resource documents per-taining to both cranes and personnel platforms.� American National Standards Institute Reference −

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

� PCSA (Power Crane and Shovel Association) Bureauof the American Equipment Manufacturers Associa-tion Reference − PCSA Standard No. 4.

� A.P.I. (American Petroleum Institute) Specification2C.

� OSHA Part 29, CFR 1926.550 Cranes and Derricks.

Operator’s Manual


Authorization

Authorized use of a work platform may be permittedonly after the following on-site procedures have beenperformed:1. The person on the job site specifically responsible

for the overall work function to be performed hasdetermined that there is no practical alternate wayto perform the needed work and has authorized apersonnel lifting operation.

2. For each instance of such lifting, the personresponsible for the task has attested to the need forthe operation by issuing a statement describingthe operation and its time frame and itemizing thateach of the on-site authorization requirements hasbeen met. The statement, after being approved bythe authorizer, shall be retained at the job site.

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 recordsand specifications has been conducted to ensure itmeets applicable design standards (refer to ANSIA10−28).

5. Review of the personnel lifting operation practicesspecified in these instructions have beenconducted with crane operator(s), foreman, signalperson, personnel to be lifted, safety supervisor,and any other person who has jurisdiction over theoperation to ensure that they are aware of the haz-ards of the operation and they are aware of provi-sions of these instructions that must be adhered tobefore and during the personnel lifting operation.

Equipment1. The crane/platform system shall be equipped with

the following:

Note: All these operational aids must be main-tained in operable condition.

a. An anti-two block device to prevent damage tothe hoist rope, other crane components, or at-tachments, and subsequent endangerment ofpersonnel.

� It is required that the anti-two block devicewarn both audibly and visually as well ashave the capability to lock out those con-trols/functions that may cause a two-blockcondition.

b. Boom hoist and load line shall have power low-ering and raising and shall have an automatic

brake which is applied when the applicablecontrol is in neutral, or when the anti-two blockdevice is actuated.

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

d. A boom angle indicator.

� Cranes with extendable booms must utilize aboom angle indicator having �high and low"set points and audible/ visual alarm(s) capa-ble of activating function lock-outs.

� Cranes with fixed boom lengths must havean accurate and reliable boom angle indica-tor.

e. Boom length indicator

� Cranes with extendable booms must utilize aboom length indicator.

� Cranes with fixed boom lengths do not re-quire a boom length indicator.

f. Audible and visual alert systems shall be pro-vided to the personnel in the platform to signalfor assistance in the event of an emergency.

g. Each crane shall have a mechanical swinglock capable of being set at any swing posi-tion, and shall have a variable swing brake ca-pable of stopping the swing motion smoothly.The swing brake must be properly maintainedat all times to ensure its holding capability.

2. The platform shall be designed by a qualified engi-neer competent in structural design. Its mainte-nance, and its attachment to the crane load line, isthe responsibility of the job site management.Their arrangement shall comply with the followingas a minimum:a. The work platform harness must be of suffi-

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

b. Hooks on hook ball assemblies, sheave blockassemblies, or other assemblies, shall be of atype that can be closed and locked, eliminat-ing the hook throat opening, and shall be fullload-bearing, and contain a manual trigger re-lease. A secondary shackle must be appliedbetween the platform and the lower liftingblock to provide insurance against platformsuspension/connection malfunction.

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

Operator’s Manual


Maintenance1. The crane operator must have a complete unders-

tanding of the crane’s maintenance instructions asoutlined in this Operator’s Manual.

2. The crane shall be maintained as specified in thisOperator’s Manual.

3. The crane and platform decals must be un-derstood and maintained.

4. All decal precautions and instructions shall bestrictly observed.

Additional Requirements for Offshore Cranes1. Link-Belt offshore cranes are designed to handle

materials.

However, due to the special conditions commonlyexisting offshore, the use of cranes to transfer per-sonnel between vessels or from a vessel to a plat-form is an established practice. The safety of thepersonnel, if a materials handling crane is used intransferring personnel, depends upon the skill andjudgement of the crane operator and alertness ofthe personnel being transferred. Sea and weatherconditions may create additional hazards beyondthe 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 thetransfer of personnel may be performed safely un-der certain offshore conditions.

Therefore, whenever an offshore crane is used totransfer personnel, all persons involved in the op-eration must know and implement, the A.P.I. proce-dures and verify that sea and weather conditionsare within safe limits for the transfer.

2. 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.

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

immediately prior to commencement of operation.Inspection shall include all of the equipment vital tothe safety of the operation. (Refer to ANSI A10−28for inspection procedures for the work platform.)

2. The inspection shall be performed once daily whenthe crane is being used in work platform service oreach time the crane is converted from material lift-ing to personnel handling operation. In the eventthe operator is replaced, a new inspection is re-quired.

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

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

5. Minimum load hoist and boom hoist wire rope safe-ty factors for the combined weight of the lift attach-ments, platform personnel, and tools shall be 7:1for manufacturer’s specified construction wirerope and 10:1 for rotation resistant wire rope.(Note: A.P.I. applications require 10:1 for all ropeconstruction.)

6. Wire rope ends shall be seized and anchored (at-tached) to boom, hook balls, hook blocks, anddrums using practices and methods described inthe Wire Rope Users Manual published by theCommittee of Wire Rope Producers, American Ironand Steel Institute.

7. No platform shall be suspended from boom exten-sions, auxiliary boom noses, jibs, swing away flysections, or luffing jibs on extendible boom cranes.Suspension of a platform from other than the mainboom nose is strictly prohibited on extendibleboom cranes.

8. In addition to other regular inspections, visual in-spection of crane and platform shall be conductedimmediately after testing and prior to lifting person-nel.

9. The crane shall be inspected in accordance withthe requirements of ANSI B30.5, Section 5−2.1.2and 5−2.4 and ANSI B30.23.

Operator’s Manual


Crane Test Procedures

The test procedures listed below shall be conducted atthe following intervals:� Daily,� When an operator is replaced, and� When, in the judgement of responsible job site

management, there has been a significant changein 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 attwo times the intended load. This load shall not ex-ceed the rated capacity of the work platform.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 theplatform through its entire intended rangeof motion, simulating the specific opera-tion to be undertaken.

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

b. This test load shall be raised and lowered atmaximum power controlled line speed (NOTFREE-FALL). The acceleration must besmooth and the deceleration capability of thecontrol/braking system shall be confirmed bybringing the work platform to a smooth stop.(This experience is intended to sharpen theskill of the operator in handling the platformand to give the operator an opportunity to eval-uate the crane’s performance.) The work plat-form shall then be inspected for any evidentsign of damage or defect.

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

Operation and Safety1. This Operator’s Manual for the crane shall be read

and understood by operating personnel. It shall beavailable to them at all times.

2. Safety when handling personnel remains the re-sponsibility of job site management and is depen-dent upon the responsible action of every personon the job involved in the related work.

3. Mobile lift cranes shall be erected to obtain maxi-mum crane stability. The crane must be level andon firm ground with the outriggers fully extendedand the tires clear of the ground before beginningany operation.

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

5. Unauthorized personnel shall not be in the opera-tor’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 carefullyplanned by the operator, supervisory personnel,signal person, and personnel to be lifted prior tocommencement of such operation. They are to beadvised:a. That the crane does not have safety devices

normally used on personnel handling equip-ment.

b. That the safety of the operation depends onthe skill and judgement of the crane operatorand others present.

c. Of procedures to enter and leave the work plat-form and other safety procedures.

7. After positioning of the work platform, all brakesand locks on the lift crane shall be set before per-sonnel perform any work.

Operator’s Manual


8. A work platform attached to load line of lift cranesshall not be used for working on any energizedelectric power line, or any energized device or facil-ity used for electric power generation or transmis-sion. Minimum working clearance shall be at leasttwice that recommended for material handling op-erations in ANSI B30.5b section 503.4.5 and ANSIB30.23.

9. The combined weight of the work platform, any at-tachment device, personnel, tools and otherequipment shall not exceed 50% of the lifting ca-pacity of the applicable lift crane load chart. (Note:A.P.I. applications require 25% of lifting capacity asthe limit.)

10. Cranes shall not travel while personnel are on thework platform.

11. No lifts shall be made on another of crane’s loadlines with personnel suspended in a work platform.

12. No external load shall be lifted by attaching to thework platform.

13. Work platform lifts shall be a single crane oper-ation. A work platform shall not be lifted using twocranes.

14. Hoisting of personnel shall be discontinued uponindication of any dangerous weather conditions orother impending danger.

15. Movement of the work platform with personnelshall be done in a slow, controlled, cautious man-ner with no sudden movements of the crane orwork platform.

16. Clear, unobstructed visibility between personnelon the platform and the crane operator shall bemaintained at all times except where a special sig-nal person shall have been assigned and posi-tioned such that he is visible to both. Such signal

person shall have no other duties to perform whenpersonnel are on the platform.

17. Voice communication between platform person-nel, the crane operator, and signal person, if as-signed, shall be maintained.

18. If other cranes or equipment may interfere with thelifting of personnel, signals or other means of com-munication between all crane or equipment opera-tors shall be maintained to avoid interference withindividual operations.

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

20. Personnel on the platform shall wear personal fallarrest systems. Anchors used for attachment ofpersonal fall arrest equipment shall be indepen-dent of any anchors being used to support or sus-pend platforms. Personnel shall keep all parts ofbody, tools, and equipment inside work platformduring raising, lowering, and positioning.

21. Personnel shall always stand firmly on the floor ofthe platform and shall not sit or climb on the edge ofthe platform or use planks, ladders, or other de-vices for attaining a work position. (This does notapply to offshore personnel transfer baskets. Per-sonnel must ride on the exterior of this type of per-sonnel handling device to assure greater safety ofthe operation.)

22. When welding is done by personnel on the plat-form, the electrode holders shall be protected fromcontact with metal components of the platform. Ifelectrically connected electrode holders contactwork platform, work platform could be droppeddue to burning/melting of wire ropes suspendingthe work platform.

Operator’s Manual


1. Carrier Cab Dash2. Steering Wheel3. Transmission Shifter4. Fire Extinguisher

5. Electrical Control Center6. Carrier Cab Seat7. Throttle Pedal

8. Service Brake Pedal9. Clutch Pedal10. Windshield Washer Reservoir

Figure 1−33Carrier Cab Layout

1

2

3

4

5

6

10

87

9

Carrier CabThe carrier cab contains various controls needed todrive the crane. Figure 1−33 illustrates the generallocation of the these controls.

WARNINGThis manual must be thoroughly read andunderstood by the operator before driving thecrane. Crane damage or personal injurycould result from improper operatingprocedures.

Fire ExtinguisherA fire extinguisher is located directly behind the driver’sseat in the carrier cab. Refer Figure 1−33. It is an A B Ctype fire extinguisher, meaning it is capable of extin-guishing 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 de-vice. 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.

Operator’s Manual


Windshield Washer ReservoirCheck the windshield washer reservoir daily. The res-ervoir for washer fluid is located in the lower left of thecab. Refer to Figure 1−33. Visual inspection can de-termine if the washer fluid is adequate. Do not operatethe washer when the reservoir is empty. Use speciallyformulated windshield washer fluid rather than waterbecause specialty washer fluids contain additives thatdissolve road grime.

Dash PanelLocated directly in front of the operator is the dash pan-el. It contains the following controls and is shown inFigure 1−34.

Note: When the key is turned on, the gauges will gothrough an initialization sequence to allow the oper-ator to verify correct operation of the gauges and in-dicator lights. The gauge needle will move counter-clockwise to just below minimum scale for a 1/2second, then clockwise to minimum scale and theindicator light within each gauge will flash. Wheninitialization sequence is complete, all indicatorlights will distinguish, gauge needles will indicateactual readings, and the odometer will display inthe speedometer gauge.

If a gauge is not monitoring its respective function:(1) the indicator light will flash slowly and the gaugeneedle will stay at minimum scale. This indicatesthe gauge is not receiving data from the data bus.(2) the indicator light will flash rapidly and thegauge needle will go to full or minimum scale. Thisindicates the gauge has received invalid or out-of-range data. (3) the indicator light will flash slowly(about once per second) and the gauge needle willgo to full or minimum scale. This indicates thegauge is not receiving any data from the systemcontrol unit (SCU). Repair the problem before driv-ing crane.

1. Fuel GaugeThis gauge registers the level of fuel in the fuel tank.The fuel tank capacity is 100 gal (378.5L). Refer tothe engine manufacturer’s manual for the correctgrade of diesel fuel. When the fuel level reaches aneighth of a tank, an indicator light within the gaugewill illuminate and the message �LOFUEL" will ap-pear in the LCD area of the speedometer/odome-ter message center.

2. Coolant Temperature GaugeThis gauge registers engine cooling system tem-perature. For proper cooling system operatingtemperature range, refer to the engine manufactur-er’s manual. If cooling system overheats, reduceengine speed, shift to a lower gear, or both, untilthe temperature returns to normal operatingrange. If engine temperature does not return tonormal temperature, refer to engine manufactur-er’s manual. When coolant temperature exceedsnormal operating range, an indicator light withinthe gauge will illuminate, an alarm buzzer willsound, the stop engine light will illuminate, and themessage �H20 TEMP" will appear in the LCD areaof the speedometer/odometer message center.

3. Engine Oil Pressure Gauge

This gauge registers the engine oil pressure. Forproper oil pressure operating range, refer to theengine manufacturer’s manual. If there is no en-gine oil pressure after 10−15 seconds of runningtime, shutdown the engine immediately and repairthe problem to avoid engine damage. When the oilpressure is not within normal operating range, anindicator light within the gauge will illuminate, analarm buzzer will sound, the stop engine light willilluminate, and the message �OILPSI" will appearin the LCD area of the speedometer/odometermessage center.

4. Battery Gauge

This gauge registers the charge in the battery andthe output of the alternator through the regulator. Itshould read 12 volts with the key on, and 12.5 to 14volts with the engine running. When the charge orthe voltage in the battery is not within normal oper-ating range an indicator light within the gauge willilluminate and the message �VOLTS" will appear inthe LCD area of the speedometer/odometer mes-sage center.

5. Tachometer

The tachometer registers engine speed in revolu-tions per minute (rpm). Refer to the engine manu-facturer’s manual for suggested operating speeds.

Operator’s Manual


Figure 1−34Carrier Cab Dash Panel

1. Fuel Gauge2. Coolant Temperature Gauge3. Engine Oil Pressure Gauge4. Battery Gauge5. Tachometer6. Speedometer/Odometer Message Center7. Air System Pressure Gauges8. Heat Control Switch

9. Park Brake Control Knob10. Boom Dolly/Trailer Air Control Valve (If

Equipped)11. Cigarette Lighter12. 12V DC Accessory Outlet13. Differential Lock Switch14. Air Ride Suspension Switch15. Indicator Light Cluster

16. Fan Switch (Defroster)17. Climate Control Switch18. Pump Engagement/Throttle Selector

Switch19. Fan Control Override Switch20. Engine Diagnostic Request Switch21. Dash Lights Dimmer Switch22. Headlight Switch

12

435

6

79

13

8

16

11

2221 20

19 1815

14

12

17

10

6. Speedometer/Odometer Message Center

The speedometer registers crane travel speed inmiles per hour (mph) or kilometers per hour (km/h)The Message Center portion of the gauge is usedmost often to display the odometer. The MessageCenter display disappears when the ignition isturned off. To view the display when the ignition isoff, press the Mode button in the bottom portion ofthe gauge. It remains activated for ten seconds af-ter the button is pushed.

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

� Odometer − reads in miles and tenths (for ex-ample, 123456.7). The odometer is not reset-table.

� Trip 1 Odometer − reads in miles and tenths,preceded by a 1 (for example, ).

� Trip 2 Odometer − reads in miles and tenths,followed by a T2 (for example, ).

� Hour meter − reads in hours, followed by theletters HR (for example, 123456HR).

If a warning alarm is triggered, a warning messagewill override all other Message Center displays untilthe alarm condition is corrected. The warningmessage may be temporarily overridden for twentyseconds as described in �Warning Alarms" foundlater in this Section of this Operators Manual.

1 123456.7TRIP MI

2 123456.7TRIP MI

Operator’s Manual


Setting and Resetting Functions in the MessageCenter

Trip Odometers

To Display The Trip 1 or 2 Odometer

Press and release the Mode button until the de-sired trip odometer is displayed.

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

is reset to zero (about three seconds).

Warning Alarms

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

� A warning message can appear in theSpeedometer Message Center display.

� The red warning light in the associated gaugewill turn on.

� An audible warning tone will sound (for selectfunctions only).

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

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

tion. After twenty seconds, the warning mes-sage will reappear.

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

The following identifies the possible warning mes-sages and the conditions that cause them.

Function Message AlarmLow Fuel Warning LO FUEL NoEngine Oil Temp Warning OIL TEMP YesCoolant Temp Alarm H2O TEMP YesHydraulic Oil Temp Alarm HYD TEMP YesFront Air Pressure Alarm LO AIR1 YesRear Air Pressure Alarm LO AIR2 YesBattery Voltage Warning VOLTS No

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

Note: The System Diagnostics Test mode isonly enabled when the ignition is on.

The System Diagnostic Test has three functionsavailable:

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

� Manual − Manual selection of individual mod-ules and telltales to test.

� Fault Display − Recalls up to 128 device fault.

Auto Test SequencePressing the Set button while �AUTO" is displayedstarts the Auto Test sequence. During the AutoTest, the system control unit (SCU) generates itsown gauge needle positioning data and warningLED data. The sequence begins with all gaugeneedles at zero scale and a blank Message CenterDisplay. The SCU moves the gauge needle in uni-son to mid-scale, full scale, back to mid-scale,back to zero, and then exits to the Normal Opera-tion mode.

Pressing the Mode or Set button during the se-quence halts the sequence and returns the displayto �AUTO".

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

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

to select the module to be tested. The mod-ule’s name will appear in the display, startingwith SCU.

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

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

Operator’s Manual


Fault Codes

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

Note: A device fault code does not contain actu-al failure data, only the identification of the de-vice that detected the fault.

7. Air System Pressure GaugesThese gauges register the air pressure in the frontand rear systems. The front gauge registers thepressure of the front brake system. The rear gaugeregisters the pressure of the rear brake system.Normal operating range on both systems is100−120 psi (690−827 kPa). If they do not registerwithin this range, correct the problem before oper-ating. When the air pressure is not within the nor-mal operating range, an indicator light within thegauge will illuminate, an alarm buzzer will sound,and the message �LO AIR1" or �LO AIR2" will ap-pear in the LCD area of the speedometer/odome-ter message center.

8. Heater Control SwitchThis switch controls the temperature of the carriercab heater. Rotate the switch clockwise to in-crease the temperature; counterclockwise to de-crease the temperature.

9. Park Brake Control KnobThis knob controls engaging and releasing thepark brake.

WARNINGAvoid using the park brake to stop the crane inmotion (as a service brake) except in cases ofextreme emergency. Brake wear will not bedistributed evenly and application cannot becontrolled.

To Engage Park Brake

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

To Release Park Brake

a. Apply the service brakes.b. Push the knob in.

Note: If the park brake knob will not stay in thereleased position, check the air system pres-sure. It must be at least 60 psi (414kPa) beforethe brake will release. The emergency parkbrake will also begin to apply, and will fully en-gage if pressure decreases below 40 psi(276kPa).

10. Boom Dolly/Trailer Air Control Valve(If Equipped)

This valve is used on cranes which are equippedwith a boom dolly/trailer, to pressurize the systemwhich supplies air to the dolly/trailer brake circuit.See the operating instructions for �Traveling WithBoom Dolly/Trailer" found later in this Section ofthis Operator’s Manual for operating procedures.

11. Cigarette Lighter

Push knob in to heat element. The knob will pop-up when the element is hot.

12. 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 orcigarette lighter. Damage to the crane’selectrical system may result. If it is necessaryto do so, contact your Link-Belt distributor.

13. Differential Lock Switch

This switch is used to increase rear wheel tractionon slippery roads or soft ground. Under normaldriving conditions the differential lock switchshould remain in the �UNLOCK" position. This willprovide differential action between the front-rearand rear-rear axles. To provide maximum pullingpower when wheels are likely to slip, use the�LOCK" position to limit slipping.

To Engage The Differential

a. Maintain a constant crane speed.

Operator’s Manual


b. Move the Differential Lock switch to the�LOCK" position.

c. Let up on the throttle pedal momentarily to al-low the differential lock to engage.

d. Proceed with caution.

CAUTIONDo not actuate the differential lock when thewheels are slipping or spinning withouttraction. Do not allow wheels to spin withdifferential lock in the �UNLOCKED" position.Either situation can damage the differentialgears.

Note: A buzzer will sound continuously whilethe main differentials are locked as a reminderto unlock them as soon as slippery surface con-ditions have ceased.

To Disengage The Differential Lock

a. Maintain a constant crane speed.b. Move the Differential Lock switch to the �UN-

LOCK" position.c. Let up on the throttle pedal momentarily to al-

low the differential lock to disengage.d. Proceed with caution.

14. Air Ride Suspension

This crane is equipped with an air ride suspensionwhich utilizes air bags to absorb shock. This con-trol is used to adjust the crane’s suspension de-pending on operating conditions. Under normalconditions, this switch should be in the �UP" (in-flated) position. Use the �DOWN" (deflated) posi-tion before raising the crane on outriggers.

15. Indicator Light Cluster

Nine individual indicator lights are contained in thisone location. Refer to �Indicator Light Cluster"found later in this Operator’s Manual for a descrip-tion of each indicator light.

16. Fan Switch (Defroster)

This switch controls the defroster fan. Press theswitch to operate the defroster fan.

17. Climate Control SwitchThis control is used to operate the cab heater andair conditioner (if equipped). Once the desired sys-tem is selected, use the heat control switch to regu-late the temperature inside the cab.

18. Pump Engagement/Throttle Selector SwitchThis switch is used to select from which cab thethrottle pedal will function. When driving from thecarrier cab, this switch must be in the �Lower" posi-tion. When performing crane operations, thisswitch must be in the �Upper" position.

19. Fan Control Override SwitchThe fan control override switch is used to help con-trol engine temperature. With the switch in the�Off" position (top part of switch), the fan will auto-matically come on when the temperature reaches195°F (90°C) and will shut off at 175°F (80°C).With the switch in the �On" position (bottom part ofswitch), the fan will run continuously. Normally theswitch should remain in the �Off" position exceptfor example when climbing a grade. Before climb-ing the grade, turn the switch to the �On" to preventan unexpected power reduction of the engine.

20. Engine Diagnostic Request Switch

This switch is used to activate the check engine in-dicator light to flash active and inactive engine faultcodes. The switch is used to flash codes in the fol-lowing circumstances:a. When the engine is not running and with the

ignition on, pressing and holding the bottompart of the switch will flash out engine faultcodes.

b. When the engine is idling and not in a pro-tected condition, pressing and holding the bot-tom part of the switch will flash out engine faultcodes.

Refer to engine manufacturer’s manual for the en-gine fault code descriptions.

21. Dash Lights Dimmer Switch

This switch is used to dim the dash lights. Rotatethe switch down to dim the lights and rotate up toilluminate dash lights.

22. Headlight Switch

Press the bottom half of this switch to turn head-lights, park lights, and instrument panel lights on.Press the top half to turn them off.

Operator’s Manual


Figure 1−35Indicator Light Cluster

1. Turn Signal Indicator Light2. Cruise Enabled Indicator

Light3. Engine Torque Limit

Indicator Light4. High Beam Indicator Light

5. Stop Engine IndicatorLight

6. Check Engine IndicatorLight

7. Park Brake Indicator Light

4

1

1

567

2 3

Indicator Light Cluster

1. Turn Signal Indicator Light

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

2. Cruise Enable Indicator Light

This indicator light will illuminate to alert the opera-tor that the cruise control system is enabled.

3. Engine Torque Limit Indicator Light

This indicator light will illuminate to alert the opera-tor that the engine torque limiter is activated.

4. High Beam Indicator Light

This indicator light will illuminate to indicate whenthe headlights are on high beam.

5. Stop Engine Indicator Light

This red indicator light will illuminate along with analarm buzzer to make the operator aware of criticalengine problems. When this light illuminates, stopoperations immediately and shutdown the engine.Consult the engine manufacturer’s manual anddetermine the problem before any further opera-tion of the engine.

Note: The stop engine light will illuminate mo-mentarily when the ignition is turned on as ameans of testing the indicator light. The lightshould go out after a short period of time.

6. Check Engine Indicator Light

This amber indicator light will illuminate along withan alarm buzzer to make the operator aware of mi-nor engine problems. When this light illuminates,engine operation may continue. However, consultthe engine manufacturer’s manual and determinethe problem as soon as possible to avoid pro-longed operation of the malfunctioning enginewhich could develop into a major problem. Thislight will also flash when using the engine diagnos-tic request switch to retrieve engine fault codesstored in the electronic control module (ECM).

Note: The check engine light will illuminate mo-mentarily when the ignition is turned on as ameans of testing the indicator light. The lightshould go out after a short period of time.

7. Park Brake Indicator Light

This light will come on any time the park brake isengaged and the ignition is on.

Note: When the park brake control knob ispushed in (released), the park brake remainsengaged until the indicator light goes off.

Operator’s Manual


Figure 1−36Steering Column, Pump Disconnect, And Foot Operated Controls

89

1. Tilt Lever2. Turn Signal Lever3. Steering Wheel4. Horn

5. Ignition Switch6. Ignition Lock7. Hazard Flasher Switch8. Throttle Pedal

9. Service Brake Pedal10. Clutch Pedal11. Engine Diagnostic Connector12. Pump Disconnect Control Handle

1

2

3

4

5

6

11

7

12

10

Steering Column, Pump Disconnect,And Foot Operated ControlsThe steering column and wheel are the conventionalautomotive type equipped with a tilt function. The fol-lowing is a description of the switches and controls onthe steering column, along with an explanation of theirfunction and/or operation. Refer to Figure 1−36.

1. Tilt LeverThis lever controls the tilt (angle) function of thesteering wheel. To change steering wheel tilt:

a. Bring the crane to a complete stop.b. Engage the park brake and shift the transmis-

sion to neutral.c. Pull the tilt control lever toward the steering

wheel and hold.d. Position the steering wheel at the desired an-

gle and release the lever.

e. Check all steering wheel functions before con-tinuing operation.

2. Turn Signal LeverThe turn signal lever controls the following func-tions:

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

b. Headlight Beam Control: Pull the lever towardthe steering wheel and then release to changebeam.

c. Windshield Wiper: Rotate the turn signal levercounterclockwise to activate the windshieldwiper. Rotate the lever forward to the firstdetent for low speed wiper, to the seconddetent for high speed wiper. Rotate clockwiseto turn wiper off.

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

Operator’s Manual


3. Steering WheelTurn the steering wheel clockwise for right turnsand counterclockwise for left turns.

4. HornThe button in the center of the steering wheel acti-vates the horn. Press the button to sound the horn.

5. Ignition SwitchThe ignition switch is the key operated, conven-tional, automotive type. It controls engineoff/run/start and energizes the instrument panelgauges in the carrier cab.

6. Ignition LockThis button locks the key in the ignition switch.Turn the key to the �LOCK" position and push thelever down to remove key and lock the steeringwheel in position.

7. Hazard Flasher SwitchThis switch controls the hazard warning flashers.Press the switch to turn the flashers on. Pull theswitch to turn the flashers off.

8. Throttle PedalEngine speed is controlled by the throttle pedal.Press down on the throttle pedal to increase en-gine speed. Release the throttle pedal to decreaseengine speed.

9. Service Brake Pedal

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

Air Brake Operation

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

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

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

If the air system pressure drops far below the nor-mal operating range of 100−120 psi(690−827kPa), stop the crane and repair the prob-lem. As the air system pressure decreases below60 psi (414kPa), the park brake will automaticallybegin to apply.

10. Clutch Pedal

On cranes equipped with a manual transmission,the clutch pedal controls engaging/disengagingthe clutch. Release the clutch pedal to engage theclutch. Depress the clutch pedal to disengage theclutch.

The clutch is equipped with a brake to stop thetransmission gears from rotating. This aids in shift-ing smoothly from neutral to first and reverse. Thebrake also aids in smooth upshift under adverseconditions where vehicle road speed rapidly slowsdown. For instance, when accelerating up a hillfrom a standing start. To engage the clutch brake,shift the transmission to neutral and push theclutch pedal down to the limit of its travel.

CAUTIONDo not apply the clutch brake when downshifting. Do not apply clutch brake beforetransmission is in neutral. Either of theseapplications will cause rapid wear of theclutch brake.

11. Engine Diagnostic Connector

The engine diagnostic connector is located under thecarrier cab dash to the left of the steering column. Re-fer to Figure 1−36. The connector allows the engineservice technician to attach the engine diagnostic datareader (DDR) for diagnosing engine problems. Whenthe check or stop engine light illuminates, contact theengine service technician to retrieve the fault codesand repair the engine.

12. Pump Disconnect Control Handle

The hydraulic pump disconnect is used to engage anddisengage the main hydraulic pump. Disengaging themain pump aids in engine start−up by reducing crank-ing resistance. It also allows for disengaging the pumpfor highway travel. Refer to Figure 1−36.

To Engage The Main Pump:a. Warm up the engine using the normal start−up

and warm−up procedure.b. Park the crane and engage the park brake.

Operator’s Manual


c. Shift the transmission to neutral and shutdown theengine.

d. As the engine stops, apply light pressure and pullthe pump disconnect control handle out, to thelimit of its travel.

CAUTIONDo not attempt to engage or disengage thepump with the engine running. Damage couldoccur to the pump and/or pump drive.

Note: In extremely cold weather, it is recom-mended that the pump be allowed to cycle with-out a load for 3−5 minutes at low engine speed.Throttle engine to half throttle and cycle theboom telescope for another 3−5 minutes. Thiswill help prevent cold oil from damaging themain pump.

To Disengage The Main Pump:a. Park the crane and engage the park brake.b. Shift the transmission to neutral and shutdown the

engine.c. Push the handle all the way in.

Note: Disengage the main pump for all highwaytravel. This will prevent unnecessary wear onthe pump and hydraulic components.

Transmission ControlsThe transmission has a 5 speed front section and ahigh−low range section which allows the operator toselect 8 evenly spaced forward speeds and one �LO"speed using a single control lever and a two positionrange control switch. Refer to Figure 1−38. Additional�LO−LO" deep reduction speeds may be selected byusing a deep reduction button. The �LO" and �LO−LO"speeds are for off highway use. The transmission alsohas 3 reverse speeds.

CAUTIONDo not preselect. When making the shift froma deep reduction ratio to low range, move thedeep reduction valve from �IN" to �OUT"immediately before making the shift. This isnot a preselect valve and only torque will holdthe deep reduction gear after the button ismoved to the �OUT" position. The shiftcylinder will make the shift by air as soon astorque is released.

Figure 1−37Manual Transmission Shift Control

Dual SwitchRange Selector

1. Range Preselection LeverUp Position − Hi RangeDown Position − LO Range

2. Deep Reduction Button�In"/Forward Position − Deep Reduction�Out"/Rearward Position − Deep Reduction

1

2

Shifting The Transmission

In the following instructions, it is assumed that the op-erator is familiar with and can coordinate the necessarymovements of the shift lever and clutch pedal to makeprogressive and selective gear engagements in eitherdirection, up or down.

Dual Switch Range Selector Style Shifter

This style shifter uses two dual position switches to se-lect the shift range of the transmission. Refer toFigure 1−37 . Three ranges are available: Deep Re-duction (LO−LO), Low Range, and High Range. Referto Figure 1−38 and Figure 1−39 for the associatedshift pattern for each range.

Operator’s Manual


Figure 1−38Transmission High And Low Range Shift Pattern

With Deep ReductionLever/Button in the�OUT"/REARWARDposition . . .

Shift LO−1−2−3−4 inLOW RANGE.

Range Shift . .

Shift 5−6−7−8 in HIGHRANGE.

Double−Clutching

Smooth upshifting and downshifting of the main trans-mission requires double−clutching. When the opera-tor is ready to make a shift:1. Depress the clutch pedal, to disengage the clutch.2. Move the gear shift lever to neutral.3. Release the clutch pedal to engage the clutch.

a. Upshifts: Decelerate the engine until the en-gine rpm and road speed match.

b. Downshifts: Accelerate the engine until the en-gine rpm and road speed match.

Note: By engaging the clutch with the gear shiftlever in the neutral position, the operator is ableto control the rpm of the transmission since it isregulated by the engine rpm. This procedureenables the operator to match the speed of thetransmission with the road speed.

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

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

Upshifting1. Move the deep reduction valve to the �OUT" posi-

tion to disengage the deep reduction gears.2. With the transmission in neutral, start the engine

and bring the air system pressure to its normal op-erating range. Apply the service brake. Releasethe park brake.

3. Make sure the range preselection lever is in the�LOW RANGE" position.

CAUTIONDo not apply the clutch brake before thetransmission is in neutral. Excessive wear ofthe clutch brake will occur.

Figure 1−39Transmission Deep Reduction Shift Pattern

WHILE IN LOW RANGEONLY and shift lever inLO . . .

LL1 & LL2 can be ob-tained by moving DeepReduction Lever/Buttonto the �IN"/FORWARDposition.

4. Fully depress the clutch pedal to apply the clutchbrake and disengage the clutch. Shift the trans-mission into the �LO" gear position.

5. Release the clutch pedal to start the crane moving.Upshift, double−clutching, from �LO" through 1st,2nd, and 3rd to 4th while in the low range.

6. While in 4th and ready for the next upshift, pull upthe range preselection lever and move the shiftlever, double−clutching, to the 5th speed gear po-sition. As the shift lever passes through neutral,the transmission will automatically shift from lowrange to high range.

CAUTIONNever move the gear shift lever to the �LO"speed gear position after high rangepreselection, or at anytime transmission is inhigh range.

7. Continue upshifting, double−clutching, from 5ththrough 6th and 7th to 8th while in high range.

Downshifting1. Move the gear shift lever, double−clutching, from

8th through 7th and 6th to 5th, while in high range.

CAUTIONLimit clutch pedal travel when downshifting toprevent application of the clutch brake. Use ofthe clutch brake during downshifting willcause excessive wear to the clutch brakediscs.

2. While in 5th and ready for the next downshift, pushdown the range preselection lever and move theshift lever, double−clutching, to the 4th speedgear position. As the shift lever passes through

Operator’s Manual


neutral, the transmission will automatically shiftfrom high range to low range.

3. Continue downshifting, double−clutching, from4th through 3rd, 2nd, and 1st to �LO" while in lowrange.

Skip Shifting

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

Engine BrakeThe engine brake is a device which uses the engine it-self to aid in slowing and controlling the carrier. Whenactivated, the engine brake alters the operation of theengine’s exhaust valves so the engine works as apower−absorbing air compressor. This provides a re-tarding action to the wheels.

WARNINGThe engine brake is a vehicle slowing device.It is not a substitute for the service brakingsystem. The carrier’s service brakes must beused to bring the crane to a complete stop.

Engine Brake Controls

The engine brake control switch is located on the shiftlever. The switch has three retarding levels to regulatethe amount of braking force made available: 1 (Low), 2(Med), and 3 (High). Refer to Figure 1−40. Anotherswitch used to give the engine brake its fully automaticfeature is the clutch pedal activated by its position.

Engine Brake Operation

Once the engine brake switch is moved to the �1" posi-tion, operation of the engine brake is fully automatic.Since the engine brake depends on the free flow of en-gine oil for operation, be sure to let the engine warm upbefore switching it on. The engine brake can be left onwhenever driving, providing the weather and road con-ditions are favorable.

To activate the engine brake, simply remove your footfrom the throttle pedal. Note that the engine brakeremains activated even after the brake pedal has beendepressed, giving the combined power of both theengine and service brakes. The engine brake alone will

Figure 1−40Engine Brake Switch And Cruise Controls

1. Shift Lever2. Cruise Set/Resume Switch

3. Cruise On/Off/Pause4. Engine Brake Switch

1

4

2

3

slow the carrier. However, it is essential that the servicebrakes be used to bring the carrier to a complete stop.

To deactivate the engine brake, reapply the throttlepedal, depress the clutch pedal, or move the controlswitch to the �OFF" position. Always be sure to turn offengine brake switch when you shutdown the engine.

Descending A Grade

An explanation of �control speed" is helpful in under-standing how to use the engine brake while descend-ing a grade. Control speed is the constant speed atwhich the forces pushing the carrier forward on a gradeare equal to the forces holding it back, without usingthe service brakes. For example, you may be able todescend a grade safely at 10 mph (16km/h), without anengine brake. With the engine brake, you might beable to descend that same grade at 25 mph (40km/h),and still remain under control.

Under some circumstances, you may want to comedown a grade at a faster rate than the control speed.This can be done by selecting a higher gear, or the �1"position on the engine brake switch. However, youmay have to apply your service brakes intermittently toprevent over speeding the engine and to keep the vehi-cle at a safe speed.

WARNINGFrequent use of the service brakes, whiledescending a grade, will cause them to heatup and reduce their stopping ability. Theresult can be dangerous �brake fade".

Operator’s Manual


Since the engine brake is most effective at rated enginespeeds, gear selection is very important. You obtainmaximum retarding power when you use the lowestpossible gear without exceeding the recommendedengine speed. Refer to the engine manufacturer’smanual for rated engine speeds.

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

As a general rule for maintaining control speed, esti-mate the gear that you would use to climb the grade.Usually this is the same gear that can be used for a con-trolled descent with an engine brake.

It’s always a good idea to determine if your enginebrake is operational before beginning a long steep de-scent. This can be done by briefly lifting your foot off thethrottle. You will feel the engine brake going into action.

Slippery Pavement

If the engine brake operation is unfamiliar, it is recom-mended that it not be used on slick roads until you gainsome experience with it on dry pavement.

Since the operation of any vehicle under slippery con-ditions is unpredictable, be sure you have plenty of dis-tance when testing service brakes or your enginebrake.

When driving on wet or icy pavement, start with the en-gine brake switch in the �OFF" position and use thesame gear you would normally use under these condi-tions.

Before activating the engine brake be sure that the ve-hicle is maintaining traction and stability using the natu-ral retarding of the engine alone.

If the vehicle is maintaining traction, you may then acti-vate the engine brake by moving the switch to the �1"position. If the drive wheels begin to lock or there is a�fishtail" motion, immediately turn off the engine brakeswitch. Don’t turn the engine brake on until road condi-tions improve.

If there was no tendency for the drive wheels to losetraction and you desire greater slowing power, movethe control switch to the �2" position. If the drive wheelstend to lock, immediately switch the engine brakeswitch into the number �1" position. Do not attempt touse the �2" or �3" position until road conditions im-prove.

In changing weather conditions, check the proper po-sitioning of the control switch often. Remember: donot skip a step when operating the engine brakeswitch. Always go from the �1" position, then to the �2"position, and then to the �3" position.

Cruise ControlsThe crane is equipped with cruise control that allowsthe crane to automatically maintain a constant speed ator above 30 mph (48km/h). The controls are located onthe transmission shift lever. Refer to Figure 1−40.

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

To Set The Cruise Control1. Press and release the �On" switch.2. Accelerate to the desired speed above 30 mph

(48km/h) using the accelerator pedal.3. Press and release the �Set" switch. This will set the

speed. Holding the �Set" switch will allow thecrane speed to decrease. Release of the switchsets cruise to the lower speed.

4. Remove your foot from the accelerator. The cranewill maintain the set speed.

Note: Pressing the accelerator pedal will allowthe crane speed to increase. Taking your footoff the accelerator pedal allows the crane to re-turn to the set speed.

Resetting The Cruise Control

To reset the cruise control to a lower speed, do any ofthe following:

� Press and hold the �Set" switch. Let the crane slow

down to the desired speed and release the �Set"switch. The speed is now set at the lower speed.

� �Tap down" − this that allows the current speed to

decrease in increments of 1 mph (1.6km/h) by amomentary tap of the �Set" switch. Multiple taps ofthe �Set" switch will decrease the speed 1 mph(1.6km/h) for each tap.

To reset the cruise control to a higher speed, do any ofthe following:

� Accelerate to the desired speed, then press and re-

lease the �Set" switch.

� Press and hold the �Res" switch, allow the crane to

accelerate and release the switch.

� �Tap up" − this allows the current speed to in-

crease in increments of 1 mph (1.6km/h) by a mo-mentary tap of the �Res" switch. Multiple taps ofthe �Res" switch will increase the speed 1 mph(1.6km/h) for each tap.

Operator’s Manual


Suspending And Resuming A Set Speed

To suspend the cruise control, do any of the following:

� Press the �Pause" switch or depress the brake or

clutch pedal. The cruise controls are suspended,but can be reset by pressing the �Set" switch or re-turn to the previous set speed with the �Res"switch.

Note: Double clutching will not suspend thecruise control. After a double clutch shift ismade, the crane will maintain the previously setspeed.

� The engine speed drops below the set point (1,000

rpm) or the crane speed drops below the mph setpoint (30 mph [48km/h]). The cruise controls aresuspended, but can be reset by pressing the �Set"switch or return to the previous set speed with the�Res" switch.

Turning The Cruise Control Off

To deactivate cruise controls, do any of the following:

� Press the �Off" switch. All cruise control switches

are off. To resume cruise control, press the �On"switch and reset the speed control by pressing the�Set" switch.

� The cruise control switches are also turned off

each time the crane’s engine is turned off.

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

Seat back angle and the forward and backward posi-tion of the seat should be adjusted to provide operatorcomfort. The seat is adjusted by manual controls. Re-fer to Figure 1−41.

Note: For optimum comfort and proper seat adjust-ment, the operator should �sit back in the seat" andsit erect while making any adjustment.

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

Figure 1−41Carrier Cab Seat

1

2

3

4

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

4. Seat Back AdjustmentKnob

5. Seat Belt

5

1. Air Control Valve

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

2. Height Adjustment Latch

To Raise The Seat:a. Pull out on the air control valve to exhaust all

the air.b. While holding the height adjustment latch in

the released position, push the air controlvalve in to raise the seat to the desired height.

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

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

To Lower The Seat:a. Firmly pull up on the height adjustment latch

while pulling out on the air control valve, ex-hausting air until the latch releases.

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

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

Operator’s Manual


3. Seat Release Lever

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

4. Seat Back Adjustment Knob

To recline the seat back, turn the seat back adjust-ment knob clockwise. To bring the seat back for-ward, turn the knob counterclockwise.

5. Seat Belt

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

WARNINGAlways wear the seat belt while driving thecrane. The seat belt must be snug and lowacross the hips.

Battery DisconnectSwitchesLocated behind the left engine access door is the bat-tery disconnect switches. Refer to Figure 1−42. Movethe disconnect switches to the �Off" position any timewelding is being done on the crane to protect the craneselectronic components from damage due to an electricarc type welder.

CAUTIONSerious damage may occur to the ECM, DDECcomponents, and electronic equipment fromwelding on the crane prior to turningdisconnect switches to the �OFF" position.

Ignition switch should be shut off at least 30seconds prior to turning disconnect switchesto the �OFF" position.

Carrier Cab Fuse BoxThe carrier cab fuse box is located behind the driver’sseat. Remove the access panel to gain access to thefuse box. Located on the back of the box cover is a labelwhich designates the carrier electrical circuit protectedby each fuse. Refer to Figure 1−42. Use a fuse pullerwhen replacing a fuse.

Engine Control ModuleFusesLocated below the battery disconnect switches are two15 amp fuses which protect the ECM’s main power. Ifthe ECM is not functioning, check these fuses and re-place if required. Refer to Figure 1−42.

Engine Interface BoxWhen the transmission is in the lower gears, a torquelimiter is used to protect the power train componentsby reducing maximum engine output torque. This al-lows the use of low ratio transmissions for slow job sitecreep speeds without over torquing components. Thetorque limiter is controlled by the engine interface boxlocated in the electrical control center. Refer toFigure 1−42.

Operator’s Manual


Figure 1−42Electrical Center And Battery Disconnect Switches

1. Engine Interface Box2. Coolant Level Module

3. Flasher4. Carrier Cab Fuse Box

5. Battery Disconnect Switches6. Engine Control Module Fuses

1 2

34

5

6

A B

BA

Operator’s Manual


1. Throttle Pedal2. Rated Capacity Limiter Panel3. Gauge Panel4. Side Panel5. Control Panel

6. Outrigger Control Box7. Interior Light8. Fuse Panel9. Windshield Washer Reservoir10. Fire Extinguisher

11. Tool Box12. Seat And Console Assembly13. Boom Telescope Pedal14. Swing Brake Pedal

Figure 1−43Upper Operator’s Cab

1

2

3

4

5 6

9

10121314 11

7

8

Upper Operator’s CabLocated throughout the upper operator’s cab are sev-eral panels which contain the controls, switches, andgauges to operate and monitor crane operations. Re-fer to Figure 1−43. The following is a description ofeach gauge, switch, or control in each panel, alongwith an explanation of their function and/or operation.

Top Hatch WiperThe top hatch wiper is located in the top right corner ofthe cab roof. The switch for the top hatch wiper is lo-cated on the wiper motor. Move the switch to the �ON"or �OFF" position as desired. Refer to Figure 1−44.

Operator’s Manual


Figure 1−44Top Hatch Wiper

1. Control Switch2. Wiper Motor 1 2

Figure 1−45Fuse Panel Label

Fire ExtinguisherA fire extinguisher is located in the operator’s cab be-low the left console. Raise the left console to gain ac-cess to the extinguisher. It is an A B C type fire extin-guisher, meaning it is capable of extinguishing mosttypes of fires. The operator should be familiar with itslocation, the clamp mechanism used to secure it inplace, and foremost the operation of the device. Spe-cific instructions, regarding operation, are given on thelabel attached on the fire extinguisher. A charge indica-tor on the fire extinguisher monitors the pressure withinthe tank. Check the indicator daily to ensure the fire ex-tinguisher is adequately charged and ready for use.

Upper Operator’s Cab Fuse PanelThe fuse panel is located in the upper right rear cornerof the upper operator’s cab. Refer to Figure 1−43. Lo-cated behind the fuse panel cover is a label which des-ignates the electrical circuit protected by each fuse.Refer to Figure 1−45. Each fuse has a letter designa-tion which corresponds to the upper electrical systemas shown on the fuse identification label.

Upper Operator’s Cab Interior LightThe interior light is located above the fuse panel cover.Use the switch below the light to turn the light on or off.Refer to Figure 1−43.

Figure 1−46Rated Capacity Limiter Panel

1. Throttle Indicator Light2. Hand Throttle Control

Knob

3. Throttle Select Switch4. RCL Display

4

31

2

Rated Capacity Limiter PanelLocated to the lower right of the operator is the RatedCapacity Limiter panel. It contains the following and isshown in Figure 1−46.

1. Throttle Indicator Light

This light will illuminate when the throttle selectswitch is in the �Hand" position.

2. Hand Throttle Control Knob

The hand throttle gives the operator the ability toset as hold a specific engine speed. Turning thethrottle control knob clockwise increases enginespeed; turning it counterclockwise reduces enginespeed. The throttle select switch must be in the�Hand" position to use the hand throttle controlknob. Refer to �Engine Throttle Controls" foundlater in this Section of this Operator’s Manual.

3. Throttle Select Switch

The throttle select switch allows the operator theflexibility to choose between �Hand" operated, or�Foot" operated throttle control.

4. Rated Capacity Limiter Display

This displays the boom length, boom angle, loadweight etc. See �Crane Monitoring System" foundlater in this Section of this Operator’s Manual forcomplete operating instructions.

Operator’s Manual


Figure 1−47Upper Operator’s Cab Control Panel

1. Defroster Fan Switch2. Ignition Switch Indicator Light3. Horn Button4. Swing Park Brake Indicator Light5. Swing Park Brake Switch

6. Drum Rotation Indicator Switch7. Third Wrap Indicator Switch8. Upper Light Switch9. Boom Floodlights Switch10. Air Conditioning Controls

11. Rotating Beacon Switch12. Windshield Wiper Switch13. Function Lockout Switch14. Ignition Switch15. Warning Buzzer

Off

On OnA/C Controls

Off

High

Med

Low

On

Off

OnBoom Floodlight

Rotating Beacon

Off

Upper LightsOn

Off

Wiper/Washer

Rear

On

Off

Off

Front

On

3rd Wrap Ind.

Operate

Disable

Function Lockout

Drum RotationSwing Park Brake

Release

Apply

Engaged

Low Air

HornIgnition

AccOff

On

Start

Defrost Fan

1 2 3 4 5 6 8 9

1112131415 10

7

Upper Operator’s Cab Control PanelLocated overhead and to the right of the operator is theupper operator’s cab control panel which contains thefollowing controls. Refer to Figure 1−47.

1. Defroster Fan Switch

This switch controls the defroster fan. Rotate theswitch to operate the defroster fan.

2. Ignition Switch Indicator Light

This light will illuminate to alert the operator whenthe ignition switch is in the �ON" position.

3. Horn Button

Press this button to sound the horn.

4. Swing Park Brake Indicator Light

This light will illuminate any time the swing parkbrake is applied.

5. Swing Park Brake Switch

This switch is used to hold the upper in any direc-tion over the carrier. Refer to �Swing System"found later in this Section of this Operator’s Manualfor complete operating procedures.

6. Drum Rotation Indicator Switch

This switch is used to activate the drum rotation in-dicator system. To activate the system, flip theswitch up to the �ON" position. Flip the switchdown to the �OFF" position to deactivate the sys-tem. Refer to �Drum Rotation Indicators" foundlater in this Section of this Operator’s Manual forcomplete operating procedures.

7. Third Wrap Indicator Switch

This switch operates the third drum wrap indicatorsystem for the winch drum(s). When this switch isin the �ON" position, a red warning light will illumi-nate and a buzzer will sound to alert the operatorthat the wire rope is down to the third wrap on thewinch drum.

8. Upper Lights Switch

This switch operates upper floodlights. Flip switchup to turn floodlights on, down to turn them off.

9. Boom Floodlight Switch

This switch operates the boom floodlight. Flip theswitch up to turn floodlight on, down to turn it off.

10. Air Conditioning Controls (If Equipped)

These switches control the air conditioner. Use thetop toggle switch to turn the unit on and off and thelower toggle switch to select the desired mode.

11. Rotating Beacon Switch

This switch controls the cab rotating beacon. Flipthe switch up to turn beacon on, down to turn it off.

12. Wiper/Washer Switch

Rotate the wiper/washer knob clockwise to acti-vate the windshield wiper. Rotate the knob to thefirst detent for low speed wiper, to the seconddetent for high speed wiper. Pushing the wiper/washer knob sprays washer fluid on the windshieldto clean the window.

Operator’s Manual


13. Function Lockout Switch

This switch is used to disable hydraulic functionswhich are operated by the control levers and boomtelescope foot pedal. Move switch to the �DIS-ABLE" position to prevent inadvertent operation ofthese controls. To allow normal operation of thecontrol levers and boom telescope foot pedal,move function lockout switch to the �OPERATE"position.

14. Ignition Switch

The ignition switch is the conventional, key oper-ated, automotive type. It controls engineoff/on/start, accessories, and energizes the instru-ment panel in the upper operator’s cab.

15. Warning Buzzer

This buzzer is a multiple purpose alarm. It willsound in the following conditions: Low engine oilpressure, high engine coolant temperature, andhigh hydraulic oil temperature. The buzzer will alsosound when the check or stop engine lights are illu-minated. If this buzzer sounds, stop the crane andcorrect the problem before continuing operations.

Gauge PanelLocated in the front right corner of the upper operator’scab is the gauge panel which contains the followinggauges. Refer to Figure 1−48.

Note: When the key is turned on, the gauge needleon the coolant temperature, engine oil pressure, hy-draulic oil temperature, tachometer, battery, andfuel gauges will go to the 12 o’clock position and anindicator light within each gauge will flash as ameans of testing the gauge. The needle will returnto the normal operating position and the lightshould go out after a short period. If the gauge isnot monitoring its respective function, the indicatorlight will illuminate and the needle will sweep backand forth then move and remain at the 10 o’clockposition. Repair the problem before driving or op-erating the crane.

Figure 1−48Gauge Panel

1. Tachometer2. Engine Oil Pressure

Gauge3. Coolant Temperature

Gauge4. Fuel Level Gauge5. Battery Gauge

6. Hydraulic Oil Tempera-ture Gauge

7. Stop Engine IndicatorLight

8. Check Engine IndicatorLight

2

3

6

4

5

7

1

8

1. Tachometer

The tachometer registers engine speed in revolu-tions per minute (rpm). Refer to the engine manu-facturer’s manual for suggested operating speeds.

2. Engine Oil Pressure Gauge

This gauge registers the engine oil pressure. Forproper oil pressure operating range, refer to theengine manufacturer’s manual. If there is no en-gine oil pressure after 10−15 seconds of runningtime, shutdown the engine immediately and repairthe problem to avoid engine damage. When the oilpressure exceeds normal operating range, an indi-cator light within the gauge will illuminate, an alarmbuzzer will sound, and the stop engine light will illu-minate.

Operator’s Manual


3. Coolant Temperature Gauge

This gauge registers the engine cooling systemtemperature. For proper cooling system operatingtemperature range, refer to the engine manufactur-er’s manual. If the cooling system overheats, re-duce engine speed, shift to a lower gear, or both,until the temperature returns to normal operatingrange. If engine temperature does not return tonormal temperature, refer to engine manufactur-er’s manual. When the coolant temperature ex-ceeds normal operating range, an indicator lightwithin the gauge will illuminate, an alarm buzzerwill sound, and the stop engine light will illuminate.

4. Fuel Level Gauge

This gauge registers the level of fuel in the fuel tank.The fuel tank capacity is 100 gal (378.5L). Refer tothe engine manufacturer’s manual for the correctgrade of diesel fuel. When the fuel level reaches aneighth of a tank, an indicator light within the gaugewill illuminate.

5. Battery Gauge

This gauge registers the charge in the battery andthe output of the alternator through the regulator. Itshould read 12 volts with the key on and 12.5 to 14volts with the engine running.

6. Hydraulic Oil Temperature Gauge

This gauge registers the hydraulic oil temperaturein the main return line. Normal operating rangesvary with the oils used in different climates. Refer toSection 2 of this Operator’s Manual for proper oilviscosities and operating temperature ranges. Ifthe hydraulic oil exceeds the maximum operatingtemperature, an indicator light within the gauge willilluminate and an alarm buzzer will sound. Shut-down the crane immediately and correct the prob-lem.

7. Stop Engine Indicator Light

This red indicator light will illuminate along with analarm buzzer to make the operator aware of criticalengine problems. When this light illuminates, stopoperations immediately and shutdown the engine.Consult the engine manufacturer’s manual anddetermine the problem before any further opera-tion of the engine. Use the engine diagnostic re-quest switch located in the carrier cab to retrieveactive engine fault codes stored in the engine con-trol module (ECM). The message �STOP ENG" willalso appear in the LCD area of the speedometer/odometer when this light illuminates

Note: The stop engine light will illuminate mo-mentarily when the ignition is turned on as ameans of testing the indicator light. The lightshould go out after a short period of time.

8. Check Engine Indicator Light

This amber indicator light will illuminate along withan alarm buzzer to make the operator aware of mi-nor engine problems. When this light illuminatesengine operation may continue. However, consultthe engine manufacturer’s manual and determinethe problem, as soon as possible, to avoid pro-longed operation of the malfunctioning enginewhich could develop into a major problem. Use theengine diagnostic request switch located on thecarrier cab dash to retrieve inactive engine faultcodes stored in the engine control module (ECM)

Note: The check engine light will illuminate mo-mentarily when the ignition is turned on as ameans of testing the indicator light. The lightshould go out after a short period of time.

Operator’s Manual


Figure 1−49Side Panel

1. 360 Degree Swing Lock2. Travel Swing Lock

3. 12V DC Accessory Outlet4. Bubble Level

2 431

Side PanelLocated to the right of the operator is the side panel. Itcontains the following controls and is shown inFigure 1−49.

1. 360° Swing Lock (If Equipped)

This lever is used to lock the upper in any positionover the carrier. Refer to �Swing System" found lat-er in this Section of this Operator’s Manual for com-plete operating procedures.

2. Travel Swing Lock

This lever is used to lock the upper directly over ei-ther the front or rear of the carrier. Refer to �SwingSystem" found later in this Section of this Opera-tor’s Manual for complete operating procedures.

3. 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 orcigarette lighter. Damage to the crane’selectrical system may result. If it is necessaryto do so, contact your Link-Belt distributor.

4. Bubble Level

The bubble level is provided to assist the operatorin leveling the crane on outriggers.

Operator’s Manual


Figure 1−50Upper Operator’s Seat

32

1

5

4

6

1. Seat & ConsoleRelease Lever

2. Seat Release Lever3. Seat Height

Adjustment Lever4. Arm Rest Height

Adjustment Knob

5. Seat BackAdjustment Lever

6. Seat Belt7. Tool Box

7

CONSTRUCTION EQUIPMENT

Operator’s SeatThis 6-way adjustable seat is controlled by manualcontrols. Refer to Figure 1−50.

WARNINGDo not make seat or console adjustmentswhile operating the crane or while crane is inmotion. Discontinue operations and properlypark crane before making adjustments.

1. Seat & Console Release Lever

Move the seat & console release lever to the leftand hold. Position the seat as desired and releasethe 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 tolock the seat in place.

3. Seat Height Adjustment Lever

Move the height adjustment lever to the left andhold. Position the seat as desired and release thelever to lock the seat in place.

4. Arm Rest Adjustment Knob

Loosen the knob on the inside of the arm rest.Position the arm rest as desired and tighten knobscrew.

5. Seat Back Adjustment Lever

Raise the lever and lean back in the seat to adjustthe seat back to the desired position.

6. Seat Belt

A seat belt is provided and must be worn during alloperations. To fasten the seat belt pull the belt outof the retractor and insert the tongue into thebuckle until you hear a snap and feel the latch en-gage. Be sure the belt is not twisted and is fittingsnugly around the hips, not around the waist.

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

7. Tool Box

A tool box is provided under the operator’s seat tostore tools and other crane accessories.

Operator’s Manual


Figure 1−51Outrigger Switches − Hand Held Control Box

1. Bumper Jack Extend2. Beam − Right Front3. Jack − Right Front4. Beam − Right Rear5. Jack − Right Rear6. Jack − Left Rear

7. Beam − Left Rear8. Retract Mode − Beam/Jack9. Extend Mode − Beam/Jack10.Jack − Left Front11.Beam − Left Front12.Bumper Jack Retract

2

3

7

4

11

9

8

6

5

10

12

1

Main Outrigger OperationThe outriggers can be used in any one of three posi-tions; fully retracted, intermediate, or fully extended.The outriggers are controlled from the hand held con-trol box, located in the upper operator’s cab, or one oftwo ground control stations located at the rear outrig-gers, and the extend position pin located at each out-rigger station.

The outrigger switches, at each station, control bothoutrigger functions. Each individual outrigger switchcontrols all functions of that outrigger beam and jackcylinder. The mode switch controls outrigger direction,extend/retract. Refer to Figure 1−51, Figure 1−52,and Figure 1−53. Each extend position pin controlsthe extend length of the beam. When the pin isinstalled, it allows the beam to be extended to its inter-mediate position or the fully retracted position.

Left Side

Figure 1−52Outrigger Switches − Ground Controlled

Right Side

All of the outrigger pontoons must set on a smooth,solid surface flush with the ground with no hills or val-leys under them or they may be damaged or de-stroyed. If there is any doubt as to the ground condi-tions, use mats under the pontoons. Check pontoonsbefore and during operations. If they are allowed tosettle, they may lose their effectiveness, and make con-tinued operations unsafe.

A bubble level is provided on the side panel in the up-per operator’s cab and at each ground control stationto assist in determining when crane is level.

Included in the ground control outrigger stations is athrottle switch which will increase engine speed duringoutrigger operation and an axle lift switch that can beused to raise the rear axles while on outriggers.

Operator’s Manual


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

park brake, shift transmission to neutral, and shut-down engine. Engage the main hydraulic pump.

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

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

3. Determine the outrigger position desired. Installthe extend position pins, as required. Refer toFigure 1−53.

WARNINGWhen making lifts on outriggers, all outriggerbeams must be equally extended; all fullyretracted, all intermediate extended, or allfully extended. Failure to do so will cause aloss of stability and possible crane damageand/or personal injury.

4. Start the engine.

Note: To operate the outriggers from the handheld control box in the upper operator’s cab, theupper operator’s cab ignition switch must be inthe �ON" position.

WARNINGDo not extend or retract an outrigger beam orjack unless it is in full view of the operator orsignalman. Make sure all personnel andobstructions are clear from the path of themachinery. Unsuspected movement mayoccur.

5. Push an individual outrigger switch to the �BEAM"position and hold. Push the center mode switch to�EXTEND MODE ON" position and hold.

6. When the beam reaches the selected position, re-lease both switches.

7. Repeat Steps 5−6, for each outrigger beam, untilall the beams are in the selected position.

8. If the intermediate beam position is to be used,visually check that all beams are properly posi-tioned in the intermediate position by observingthe decals on the side of the beams. All beamsmust be extended until the hydraulic system goesover relief.

9. Set the Rated Capacity Limiter to the proper settingto match the position of the outrigger beams.

WARNINGWhen making lifts on outriggers, all outriggerbeams must be equally extended; all fullyretracted, all intermediate extended, or allfully extended. Failure to do so will cause aloss of stability and possible crane damageand/or personal injury.

When making lifts with the outrigger beams inthe intermediate position, the extend positionpins must be installed in the beams. Visuallycheck that all beams are properly positionedin the intermediate position by observing thedecals on the side of the beams. All beamsmust be extended until the hydraulic systemgoes over relief before beginning operations.

Check that the Rated Capacity Limiter is set tothe correct outrigger position beforebeginning operation.

Failure to perform any of the above may causecrane damage and/or serious personal injury.

To Extend Outrigger Jacks − RaiseThe Crane1. Ensure the air ride suspension switch in the carrier

cab is in the �DOWN" position.2. With the beams extended to the selected position

(fully extended, intermediately extended, or fullyretracted), push an individual outrigger switch tothe �JACK" position and hold.


Operator’s Manual


Figure 1−53Outrigger Extend Positions

1. Extend Position Pin In The Retracted Position2. Extend Position Pin In The Intermediate Position3. Extend Position Pin In The Fully Extended Or Stored Position

321

3. Push center mode switch to �EXTEND MODE ON"and hold until the pontoon just contacts theground.

4. Release both switches.5. Repeat Steps 2−4 for each outrigger jack.

Note: As conditions warrant, a proficient craneoperator may operate multiple jack cylinderssuch as one end or side at the same time.

6. Extend the jack cylinders until all tires are clear ofthe ground.

Note: A bubble level is provided on the sidepanel, in the upper operator’s cab, and at eachground control station to assist in determiningwhen the crane is level.

7. Raise or lower jacks as required to level the crane.8. Check that all tires are clear of the ground and pon-

toons are not settling.

WARNINGAll capacities listed on the capacity charts inthe Crane Rating Manual, when on outriggers,are based on all tires clear of the ground, alloutrigger beams equally extended (fullyretracted, intermediately extended, or fullyextended), using the proper chart for theoutrigger beam position and the crane settingon all pontoons on a firm, level solid surface,and the front bumper outrigger properlyextended. Major reductions in the crane liftingcapacity and unsafe operating conditions canresult if these conditions are not met.

9. Properly extend the front bumper outrigger. Referto �Bumper Outrigger" found later in this Section ofthis Operator’s Manual.

To Retract Outrigger Jacks − LowerThe CraneIt is recommended that lowering the crane be donefrom the ground control stations.1. Retract boom fully. Swing the upper over the front

of the carrier and engage the travel swing lock.2. Boom down and set boom on boom rest.3. Engage the park brake.

WARNINGIf the rear air suspension is allowed to hang inits fully extended (lowered) position, theaction of the suspension compressing willcause the crane to move slightly forward asthe weight transfers from the outriggers to thetires. The suspension lift system will minimizethis if the axles are lifted to the highestpossible position before lowering the craneonto the tires.

4. Ensure that the air ride suspension switch in thecarrier cab is in the �Down" position and that therear axles are lifted to their highest position with theaxle lift switch.

Operator’s Manual



5. Properly retract the front bumper outrigger. Referto �Bumper Outrigger" found later in this Section ofthis Operator’s Manual.

6. Push an individual outrigger switch to the �JACK"position and hold.

7. Push the center mode switch to �RETRACT MODEON" position and hold. Carefully retract jack untilthe pontoon just clears the ground.

8. Release both switches.9. Repeat Steps 6−8 for each outrigger jack.

Note: As conditions warrant, a proficient craneoperator may operate multiple jack cylinderssuch as one end or side at the same time.

10. Fully retract all jacks.

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 ON" position and hold until the beam is fullyretracted.

3. Release both switches.4. Repeat Steps 1−3 for each beam.5. Store all pontoons in the brackets provided.6. Store the extend position pins, as required.

Bumper OutriggerThe bumper outrigger is provided to permit the samelifting capacities over the front as over the side when itis used with the main outriggers. Refer to the CraneRating Manual for specific capacities.

Bumper Outrigger Control SwitchThe bumper outrigger can be controlled from the con-trol panel in the upper operator’s cab or from theground control switch (toggle type) located on the frontbumper, just above the left headlight.

To Extend Bumper Outrigger1. Level the crane on the main outriggers.

CAUTIONAlways level the crane on the main outriggersbefore extending the bumper outrigger.Failure to do so could result in structuraldamage to the crane as the bumper outriggeralone will not properly support the weight ofthe crane.

2. The bumper outrigger pontoon must set on asmooth, solid surface flush with the ground with nohills or valleys under them or they may be dam-aged or destroyed. If there is any doubt as to theground conditions, use a mat under the pontoon.Check pontoon before and during operations. If itis allowed to settle, it may lose its effectiveness,and make continued operations unsafe.

3. Push the bumper outrigger switch down to extendthe cylinder. Hold the switch until the pontoonrests firmly on a solid surface and the hydraulicsystem goes over relief.

WARNINGAlways stand in clear view of the outriggerjack when operating it. Be sure nothing is inthe path of it to avoid personal injury ordamage to the crane. Unsuspectedmovement may occur.

4. Release the switch.

To Retract Bumper Outrigger1. Push the bumper outrigger switch up and hold until

cylinder is fully retracted.

CAUTIONThe bumper outrigger must be retractedbefore the main outriggers. It alone will notproperly support the weight of the crane.

Operator’s Manual


Figure 1−54Keep Clear of Pinch Points

Crane System ControlsThe following pages, along with Figure 1−56, give de-tailed instructions of individual controls related to craneoperation. It is essential that the operator knows thefunction 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 operatinginstructions in this Operator’s Manual beforeattempting to operate the crane. Operation ofthe crane by unqualified personnel may resultin an accident.

Engine Throttle ControlsTwo throttle controls are located in the upper opera-tor’s cab to provide the operator with flexibility of en-gine throttle operation. A foot throttle is located on thecab floor and a hand throttle is mounted above theRated Capacity Limiter display. Refer to Figure 1−46and Figure 1−56.

Using the hand throttle gives the operator the ability toset and hold a specific engine speed. Turning thethrottle control knob clockwise increases enginespeed; counterclockwise reduces it. The throttle selectswitch must be in the �Hand" position to use the handthrottle control knob. The throttle indicator light will illu-minate when the throttle select switch is in the �Hand"position. Once the hand throttle is set to a desired en-gine speed it will remain in that position until manuallymoved to a new setting. To operate the foot throttle,move the throttle select switch to the �Foot" positionand press down to increase engine speed; release todecrease engine speed.

Figure 1−55Back Stability Label

Swing SystemRotation of the upper, over the carrier, is controlled bythe swing system. Use the following controls to operatethe swing function of the crane.

Swing Brake PedalThe swing brake pedal is used to stop rotation of theupper over the carrier. To apply the swing brake, pushdown on the swing brake foot pedal. To release theswing brake, release the swing brake foot pedal.

Swing Control LeverThe 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 appropriate position toswing the upper.

WARNINGDo not exceed maximum boom angles listedon the back stability label located in the upperoperator’s cab. This crane can tip overbackwards when on tires or retractedoutriggers.

Operator’s Manual


Figure 1−56Crane Controls

1. Crane Rating Manual Holder2. RCL Display3. Throttle Pedal4. 360° Swing Lock (Option)5. Travel Swing Lock6. Drum Rotation Indicator7. Hydraulic Control Lever

(Boom Hoist, Rear Winch)8. Winch Control Switch (Front & Rear Drum)

9. Horn Button10.Bubble Level11.Outrigger Remote Control Box12.Boom Telescope Override Switch13.Winch Circuit Switch14.Fire Extinguisher15.Hydraulic Control Lever

(Swing, Front Winch)

16.Boom Telescope Pedal17.Tool Box18.Swing Brake Pedal19.Hydraulic Control Lever (Boom Hoist)20.Hydraulic Control Lever (Front Winch)21.Hydraulic Control Lever (Rear Winch)22.Hydraulic Control Lever (Swing)

12

3 75 104

1516

1

86

14

Single Axis Controls

9

6

19

20

21

22

11

2

1718 13

Operator’s Manual


To Swing The Upper:1. Compare the boom configuration and length to the

capacity chart in the Crane Rating Manual. Posi-tion the boom safely within the limits specified onthe capacity chart.

DANGERSwing slowly and cautiously. Watch forcentrifugal force. Out swing of a loadincreases the load radius and thus decreasescapacity. Load out swing may result in tippingor damaging the crane.

All personnel and equipment must be out ofthe path of the rotating upper. Failure to do socould result in severe personnel injury orequipment damage.

2. Fully apply the swing brake pedal and release theswing park brake and/or swing lock(s).

3. Release the swing brake pedal as you begin to en-gage the swing control lever.

To Stop Upper Swing:1. Ease swing control lever into the neutral position.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 notswing.

Travel Swing Lock

Use the travel swing lock to lock the upper directly overeither the front or rear of the carrier. The travel swinglock will engage in these two positions only. Use of thetravel 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. Press the button in the center of the travel swing

lock knob and pull the knob up.3. Release the button and knob. The knob should re-

main in the released position.

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. Press the button in the center of the travel swing

lock knob and push the knob down.

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 bytrying to swing the upper right, then left. The uppershould not swing.

Swing Park Brake

The swing park brake is a self contained dry multipledisc type and is used for holding the upper, in any posi-tion, over the carrier during normal, stationary craneoperations. Engage the travel swing lock and releasethe swing park brake anytime the crane is traveled ortransported. An indicator light on the control panel willilluminate when the swing park brake is applied.

CAUTIONDo not leave the swing park brake appliedduring pick and carry operations or whentraveling or transporting the crane. Use thetravel swing lock. Failure to release the swingpark brake during these operations may resultin damage to the swing mechanism.

To Release The Swing Park Brake:1. Fully apply the swing brake pedal.2. Flip the swing park brake toggle switch on the con-

trol panel to the �RELEASE" position. The indicatorlight will go out. Refer to Figure 1−47 for toggleswitch and indicator light location.

To Apply The Swing Park Brake:1. Rotate the upper to the desired position over the

carrier. Apply the swing brake pedal to bring theupper to a complete stop.

2. Flip the swing park brake toggle switch on the con-trol panel to the �APPLY" position. Indicator lightwill illuminate. Refer to Figure 1−47 for toggleswitch and indicator light location.

CAUTIONDo not attempt to apply swing park brake withthe upper in motion. This practice will result indamage to the swing mechanism. Use theswing brake pedal to stop rotation of upper.

3. Check engagement of swing park brake by trying toswing upper right, then left. Upper should not swing.

Operator’s Manual


360° Swing LockThe 360° swing lock, if equipped, is a positive lockagainst rotation of the upper over the carrier. The up-per is mechanically locked by a manually operatedpawl that engages the gear teeth in the turntable bear-ing. Use this swing lock during normal, stationarycrane operations. Engage the travel swing lock and re-lease the 360°�swing lock anytime the crane is traveledor transported.

CAUTIONDo not leave the 360° swing lock engagedduring pick and carry operations or whentraveling or transporting the crane. Use thetravel swing lock. Failure to release the 360°swing lock during these operations may resultin damage to the swing mechanism.

To Release The 360°�Swing Lock:1. Fully apply the swing brake pedal.2. Move the 360° swing lock lever to the �Disengage"

position. Refer to Figure 1−56 for location.

To Engage The 360° Swing Lock:1. Rotate the upper to the desired position over the

carrier. Apply the swing brake pedal to bring theupper to a complete stop.

CAUTIONDo not attempt to engage 360°swing lock withthe upper in motion. This practice will result indamage to the swing mechanism. Use swingbrake 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, itmay be necessary to swing the upper slightly toalign the swing lock pin with the swing speedreducer brake disc.

3. Check engagement of 360°swing lock by trying toswing upper right, then left. The upper should notswing.

Wire Rope Winch SystemThis system controls raising and lowering the winchlines. The system is equipped with a two speed motorthat, when activated, will approximately double winchline speed. The controls for the system are shown inFigure 1−56. Review the following for control descrip-tions and brief summary of operation.

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 con-trol lever(s) in neutral, for several minutes. Once the hy-draulic oil begins to warm, operate the winch at lowspeed, with no load, lifting and lowering only the hook-block until warm oil circulates throughout the winch.

WARNINGThe weight of the load must be known beforemaking a lift. Compare the load weight to theappropriate capacity chart in the Crane RatingManual to ensure compliance with capacityratings. Compare the load weight to the wirerope strength chart in the Crane RatingManual to determine the number of parts ofline required to lift the load. Rig and set up thecrane to ensure compliance with both theappropriate crane capacity chart and wirerope capacity chart in the Crane RatingManual. Properly set the Rated CapacityLimiter to the correct crane configuration.

Do not lift a load to the point where the hookblock contacts the head machinery. �Twoblocking" could damage the hook blockand/or the head machinery. Always keep loadand hook block a safe distance from theboom.

Operator’s Manual


Front Winch Control LeverIf equipped, this lever controls the front winch drum.Pull this control lever back, toward the operator, to liftthe load. Push this control lever forward, away from theoperator, to lower the load. Refer to �Winch Operation"for more specific instructions.

Rear Winch Control LeverThis lever controls the rear winch drum. Pull this con-trol lever back, toward the operator to lift the load. Pushthis control lever forward, away from the operator tolower the load. Refer to �Winch Operation" in this Oper-ator’s Manual for more specific instructions.

Winch OperationThe 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 operatorwho has read and fully understands the entire contentof this manual.

To Lift A Load: Attach the hook block or ball to theload. Position head machinery directly above the load,pull the control lever back, toward the operator.

Note: When both winch levers are activated simul-taneously, the winch line requiring the most line pullmay not function.

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. Re-turn the control lever to neutral to stop the load.

Winch Control SwitchThis switch is used to control engaging/disengaging thehigh/low speed hoist and disabling the front or rearwinch.

High Speed Hoist Or LowerMove the winch control switch to the �HIGH SPEED"position. Move the control lever to the �UP" or �DOWN"position. The high speed hoist will activate after engag-ing the control lever. Refer to Figure 1−56.

Note: Using the high speed hoist reduces the maxi-mum line pull by approximately half. The highspeed hoist button can be activated at anytime dur-ing either winch mode. Switching the high speedhoist button before engaging the winch controllever will make the system work smoother.

To Return To Standard Winch Mode: Move winchcontrol switch to the �LOW SPEED" position. Winchwill immediately return to standard speed.

Winch DisableMove the winch control switch(es) to the �DISABLE"position to disable the winch(es) to prevent inadvertentoperation of the winch(es) while using the control le-vers to perform other operations.

Winch Circuit SwitchOn cranes equipped with both a front (auxiliary) andrear (main) winch, a winch circuit switch is provided toallow an equal amount of oil to flow to both winches forsimultaneous operation or a combined flow for singlewinch operation. Move the switch to the �SEPARATE"position for single winch operation or to the�COMBINED" position for simultaneous winchoperation.

Drum Rotation IndicatorsThis system is used to monitor winch drum speedsthrough the use of a mechanical signaling devicemounted inside each of the winch control levers. To acti-vate the system, move the drum rotation indicatorswitch, on the control console (Figure 1−47), to the�ON" position. Place your thumb over the end of thecontrol lever being used. As the winch drum rotates, amechanical signal will be felt with your thumb. The fre-quency of the mechanical signal is a direct indication ofthe winch drum speed. Move drum rotation switch tothe �OFF" position to deactivate system.

Operator’s Manual


Figure 1−57Boom Nomenclature

1. Boom Head Machinery2. Tip Section3. Outer Mid Section

4. Inner Mid Section5. Base Section

1 2 3 4 5

Boom Hoist SystemRaising and lowering the boom is controlled by theboom hoist control lever located on the right arm rest.Refer to Figure 1−56.

WARNINGDo not exceed maximum boom angles listedon the back stability label located in the upperoperator’s cab. This crane can tip overbackwards when on tires or retractedoutriggers.

To Raise The Boom (Boom Up): Move the right con-trol lever to the �Boom Up" position.

To Lower The Boom (Boom Down): Move the rightcontrol lever to the �Boom Down" position.

CAUTIONWire rope must be spooled off the winch drumas the boom is lowered. Failure to do so maycause two blocking.

To Stop The Boom: Ease the right control lever intothe neutral position.

Boom Telescope System

The crane is equipped with a four section full powerboom. The four section boom consists of a base sec-

tion, inner mid section, outer mid section, and a tip sec-tion. Refer to Figure 1−57.

The telescoping feature, of the boom sections, is oper-ated through the use of two hydraulic cylinders and acable/sheave mechanism which are an integral part ofthe boom assembly. The boom can be extended or re-tracted to any desired length using the control pedal inthe upper operator’s cab. The telescope feature hastwo modes of operation. Refer to Figure 1−58.

Boom Mode �A": When using boom mode �A" only theinner mid boom section extends/retracts. This modeoffers increased strength capacities. Select this modethrough the Rated Capacity Limiter system.

Boom Mode �B": When using boom mode �B" allboom sections extend/retract simultaneously. Thismode offers increased stability capacities. Select thismode through the Rated Capacity Limiter system.

Note: Boom must be fully retracted before chang-ing boom modes.

Boom Telescope Control Pedal

Figure 1−56 shows the location of the telescope con-trol pedal in the upper operator’s cab. Depress the toeof the telescope control pedal to extend the boom. De-press the heel of the telescope control pedal to retractthe boom. Use the telescope mode in conjunction withthe telescope control pedal to extend the boom sec-tions to the desired length.

Operator’s Manual


Figure 1−58Boom Telescope Mode

Boom Mode �A" Boom Mode �B"Boom Length

ft (m)

41(12.5)

50(15.2)

60(18.3)

69.6(21.2)

70(21.3)

80(24.4)

90(27.4)

100(30.5)

110(33.5)

120(36.6)

127(38.7)

Boom Telescope Override Switch

This switch is provided to manually override the tele-scope system when the boom is not extending/retract-ing proportionally. Use this switch for that purposeonly. While in boom mode �B", the switch will stop oneof the boom sections so the boom can be extended/re-tracted proportionally. Refer to Figure 1−56 for switchlocation in the upper operator’s cab.

To Extend The Boom Sections1. Park the crane on a firm, level surface, engage the

park brake, and shift the transmission to neutral.2. Compare the crane setup to the appropriate ca-

pacity chart in the Crane Rating Manual. Positionthe boom safely within the limits specified on thecapacity chart.

3. Review the appropriate capacity chart in the CraneRating Manual to establish boom length, angle,and load limitations.

4. Set the Rated Capacity Limiter to the desired tele-scope mode.

5. Depress the toe of the telescope control pedal.

CAUTIONWire rope must be spooled off the winchdrum(s) as the boom is extended. Failure todo so may cause two blocking.

6. Stop the boom sections by releasing the telescopecontrol pedal.

Note: The telescope control pedal is springloaded and will return to the neutral positionwhen released.

To Retract The Boom Sections1. Depress the heel of the telescope control pedal.2. Stop the boom sections by releasing the telescope

control pedal.

Operator’s Manual


Figure 1−59Hydraulic Oil Cooler Fan Switch

1. Access Door2. Hydraulic Oil Cooler Fan Switch

1 2

Hydraulic Oil Cooler FanSwitchThe 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 lo-

cated by the oil cooler fan and can be accessed fromthe door on top of the oil cooler housing behind the up-per operator’s cab. Refer to Figure 1−59.

Crane Monitoring SystemCrane monitoring systems are available for monitoringboom length, boom angle, load weight, and two blockcondition. Some systems monitor only one of theseconditions and others a combination of them.

Anti-Two Block Warning SystemIntegrated into the Rated Capacity Limiter System is ananti-two block warning system. An anti-two blockwarning system is an electromechanical system de-signed to alert the operator before the hook block orhook ball contacts the head machinery of the mainboom, auxiliary lifting sheave, or fly. When a two blocksituation is imminent, an audio/visual alarm is activatedto alert the operator of the pending danger. When thealarm activates, it is essential that the operator discon-tinue operations immediately and correct the two-block situation.

Three basic components are used to make up the anti-two block system. The anti-two block weight, anti-twoblock switch with lockout pin, and the display unit in theoperator’s cab. Refer to Figure 1−60 and Figure 1−61.

Operator’s Manual


Figure 1−60Anti-Two Block Warning System

1. Jumper Assembly2. Plug Assembly3. Anti-Two Block Switch

4. Anti-Two Block Weight5. Lockout Pin & Flag6. Lockout Pin Storage Hole

Lockout Pin Installed

5

3

4

216

WARNINGMAIN BOOM ATB IS DISABLEDWHEN LOCK OUT PIN IS IN HOLE. TO OPERATE MAIN BOOMATB, REMOVE PIN AND STOREIN STORAGE HOLE BEHIND SWITCH. FAILURE TO HAVEFULLY OPERATIONAL ATB SYSTEMCOULD RESULT IN SERIOUSINJURY OR DEATH.

LOCK OUT PIN HOLE

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.

The added feature of hydraulic function limiters, pre-vents the operator from continuing crane functionswhich will cause a two block situation to occur. Thecrane functions of winch up, boom down, and boomextend are disabled when the anti-two block weight islifted. These functions will remain disabled until the twoblock situation is corrected or the �cancel alarm"switch on the display unit is utilized.

The main boom head must always have an anti-twoblock switch. Each of the added attachments used onthe crane must employ a similar head machineryswitch 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 mainboom. It is connected to the jumper assembly on theattachment when operating from that attachment.

Check that all the harness connections between the at-tachments are properly joined and test the system be-fore beginning operations.

Lockout Pin And Flag

The lockout pin is used to hold the main boom anti-twoblock switch in the �working" position, the same ashaving a two block weight suspended from the switch.

When operating from the main boom the lockout pinand flag must be in the stored position. When operat-ing from an attachment only, the lockout pin must beinstalled in the main boom head anti-two block switch.

When both main boom and attachment are reeved foroperation, lockout pin and flag must be removed fromswitch and properly stored.

Note: When using main boom and attachment, anti-two block weights must be suspended from eachanti-two block switch.

Operator’s Manual


Figure 1−61Microguard 434 Rated Capacity Limiter

1. Bar-Graph2. Two Block Alarm Indicator3. Maximum Rated Capacity Display4. Actual Load Display5. Configuration Selection Buttons6. Contrast Button

7. Cancel Alarm8. Operator Alarms Button9. Crane Setup Button10. Test Button11. Crane Set-up Screen

12. Load Radius Display13. Boom Angle Display14. Boom Length Display15. Pre-Alarm Indicator16. Overload Indicator

1

2

3

4

5

6

16

15

14

12

13

10 9 8 7

11

5

MicroGuard 434 Rated CapacityLimiter

The following describes the function and operation ofthe Microguard 434 Rated Capacity Limiter. The sys-tem is intended to aid the operator in the efficient op-eration 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 tooperate the crane safely at all times.

This system must never be substituted for thegood judgment of the crane operator using safeoperating procedures. The operator is solelyresponsible 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 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 434 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

Note: The head height may be displayed by access-ing the angle/length/height operator settable alarmscreen.

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 isachieved by means of minimum and maximum boomangle, maximum boom length, maximum 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.

Display Unit

The following is a description of the control buttons, in-dicators, and windows on the display unit. Use themalong with Figure 1−61.

1. Bar-Graph

The Bar-Graph is an analog bar-graph which gives avisual indication of how much of the crane’s capacity isbeing used and the rate at which an overload is beingapproached. The 100% RATED CAPACITY indicatorabove the bar-graph marks the point at which 100% ofthe rated capacity of the crane has been reached. Theleading edge of the bar-graph aligns with three coloredbands around the bar-graph window. Red indicates anoverload. Between the red and yellow is a black notchwhich indicates 100% of rated capacity. Yellow indi-cates 90−99.9%, and green indicates below 90% ratedcapacity.

Note: System may be equipped with an overheadbar graph or and external light bar which operatessimilar to the bar graph on the display. Refer toFigure 1−62.

2. Two Block Alarm Indicator

The Two Block Alarm Indicator illuminates anytime atwo block situation is imminent. An audible alarm andfunction limiters will also activate when a two block situ-ation is imminent. Once the two block situation is cor-rected the system will return to normal working mode.

3. Maximum Rated Capacity Display

The Maximum Rated Capacity is a digital display of themaximum permitted capacity. It is derived from a copyof the crane’s capacity chart which is stored in the com-puter memory and is the reference capacity for any lift-ing operation. It is dependent on the configuration cur-rently selected, which is shown in the crane set-upscreen, and which determines the section of the ca-pacity chart to be used as the rated capacity reference.

Note: All maximum rated load data shown is X 1,000lb (kg), e.g. 12.6=12,600 lb (kg).

4. Actual Load Display

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.

Note: All actual load data shown is X 1,000 lb (kg),e.g. 12.6=12,600 lb (kg).

5. Configuration Selection Buttons

These buttons are used during the crane configurationselection routine. Refer to �Configuration Selection"found later in this Section of this Operator’s Manual.

6. Contrast Button

This button is used to adjust the display contrast.

7. Cancel Alarm Button

This button is used to silence the audible alarm whenthe alarm has occurred as a result of either an Over-load, a Two Block or an Operator Settable alarm. It isalso used to reset the function limit relay when it is nec-essary to by-pass function limit which has occurred asa result of either an Overload or a Two Block alarm.

8. Operator Alarms Button

This button is used to start the operator settable alarmsroutines. Refer to �Operator Settable Alarms" foundlater in this Operator’s Manual.

9. Crane Set Up Button

This button is used to start the configuration selectionroutine. Refer to �Configuration Selection" found laterin this Section of this Operator’s Manual.

Operator’s Manual


Figure 1−62Overhead Bar Graph And External Light Bar(If Equipped)

2 3 4

1. Green Lights − Percent-age of Rated Load

2. Yellow Lights − Approach-ing Overload

3. Red Lights − Overload4. Brightness Control

1

2 31

10. Test Button

This button is used to initiate a system self test and alsoused to display fault codes. Refer to �To Perform Sys-tem Test" found later in this Section of the Operator’sManual.

11. Crane Set-Up Screen

The Crane Set-Up Screen provides the operator with agraphical representation of the crane’s current config-uration during the normal working mode. It also pro-vides graphical icons used during the crane configura-tion selection routine.

12. Load Radius Display

The Radius Display gives a continuous indication of theradius of the load in feet (m). It is the horizontal dis-tance from the centerline of rotation to the centerline ofthe hook.

13. Boom Angle Display

The Boom Angle Display gives a continuous indicationof the angle of the main boom relative to horizontal.

14. Boom Length Display

The Boom Length Display gives a continuous indica-tion 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.

15. The Pre-Alarm indicator

The Pre-Alarm (amber) Indicator illuminates at a pre-set value of 90% of Maximum Rated Capacity and pro-vides a visual indication of an approach to an overload.

The pre-alarm indicator will also illuminate when an op-erator settable alarm value is approached.

16. Overload Indicator

The Overload Indicator (red) illuminates at a pre-setvalue of 100% of Maximum Rated Capacity and pro-vides a visual indication of Maximum Allowed Load. Itwill also illuminate whenever a wire rope limit is exceed-ed or an operator settable alarm has been reached orexceeded. Function limiters will occur simultaneouslyfor an Overload, Wire Rope Limit or a Two-Block condi-tion, but function limiters will not occur when exceedingan operator settable alarm. An audible alarm willsound for all 4 conditions.

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.

To Perform System Test

At start-up the system automatically performs a self testafter which it goes directly to the normal workingscreen. The self-test can be initiated any time duringnormal operation of the system by using the TEST but-ton.

One press (press and release) will cause the system toexecute a self test routine during which all lamps, audi-ble alarms, and digital displays will be functionallytested and all memory areas checked for accuracy. Iffaults in the system are detected during a test, thecrane set-up screen will show the words FAULT DE-TECTED. If the words FAULT DETECTED occur, pressand hold the TEST button. This will cause the display tochange to the FAULT mode. In this mode, informationabout the fault condition will be displayed in the craneset-up screen by means of an error code. Contact yourlocal distributor for details of the fault codes.

System Bypass

WARNINGThe Microguard 434 is not operational whenthe computer is bypassed. Bypass thesystem in emergency situations only.

In emergency situations, the Rated Capacity Limitercomputer can be bypassed. The computer is locatedon the back of the upper operator’s cab. There is a by-pass wire harness attached to the upper operator’scab wire harness. A bypass instruction label is locatedon the computer or the wire harness. Follow the in-

Operator’s Manual


structions on the label to install the bypass wire har-ness when required. For emergency use while the sys-tem is bypassed, refer to �System Inoperative or Mal-functioning" found in this Operator’s Manual.

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 beput back into service as soon as replacementparts, if required, are available and the repairs andrecalibration can be carried out. Every reasonableeffort must be made to expedite the repairs and re-calibration.

2. When the rated capacity limiter is inoperative ormalfunctioning, the designated person responsi-ble for supervising the lifting operations shall es-tablish procedures for determining load weightsand shall ascertain that the weight of the load doesnot exceed the crane ratings at the radius wherethe load is to be handled.

3. When a boom angle or radius indicator is 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 operationsshall establish procedures, such as assigning anadditional signal person, to furnish equivalentprotection. This does not apply when lifting per-sonnel in load line supported baskets. Personnelshall not be lifted in load line supported basketswhen the anti-two block devices are not function-ing properly.

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 bemade by actual measurement or marking on theboom.

6. When a level indicator is inoperative or malfunc-tioning, other means shall be used to level thecrane.

7. In situations where inconsistency exists, verifiedweights, measured radii, boom lengths, and au-thorized crane capacities must always take prece-dence over indicator readings.

Figure 1−63Rated Capacity Limiter Computer

1. Computer2. Connectors3. Upper Operator’s Cab Wire Harness4. Bypass Wire Harness

1

43

2

Configuration Selection

In the normal operational mode the system is pro-grammed 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 se-lected. Use the following procedure along withFigure 1−64 to select the crane configuration (the fol-lowing step numbers correspond with the numberedscreens in Figure 1−64).

Note: When selecting configurations allowed onoutriggers all beams must be equally extended; allfully retracted, intermediate extended, or fully ex-tended.

Note: Depending on how the crane is equipped orwhich selections have been made, some screensshown in Figure 1−64 may not appear or may notappear as illustrated. The system cannot be pro-grammed for configurations not allowed by the ca-pacity charts listed in the Crane Rating Manual.

Operator’s Manual


1. From the normal working screen press the CRANESET UP button. The crane set-up screen willchange and graphically display the carrier options.Press the corresponding configuration selectionbutton to select the desired carrier configuration.

WARNINGThe Microguard 434 is not operational when inthe RIGGING/TRAVEL Mode. Return theMicroguard 434 to normal operation beforeoperating the crane.

2. The crane set-up screen will change and graphi-cally display the counterweight options. Press thecorresponding configuration selection button toselect the desired counterweight.

3. The crane set-up screen will change and graphi-cally display the boom mode options. Press thecorresponding configuration selection button toselect the desired boom mode.

4. The crane set-up screen will change and graphi-cally display the auxiliary lifting sheave fitted or notfitted. Press the corresponding configurationselection button to select the desired auxiliary lift-ing sheave.

5. If the crane is equipped with a fly, the crane set-upscreen will change and graphically display anerected attachment. Press the correspondingconfiguration selection button to select the desirederected attachment if required.

6. If an offset fly was previously selected, the craneset-up screen will change and graphically displaythe available offset angles. Press the correspond-ing configuration selection button to select the de-sired offset angle, if required.

7. The crane set-up screen will change and graphi-cally display the rear winch lifting point. Press thecorresponding configuration selection button toselect the desired rear winch lifting point as indi-cated by the flashing arrows. Or press the corre-sponding configuration selection button to selectthe rear winch not in use.

8. If the crane is equipped with a front winch, the craneset-up screen will change and graphically displaythe front winch lifting point. Press the correspond-ing configuration selection button to select the de-sired front winch lifting point as indicated by theflashing arrows. Or press the corresponding con-figuration selection button to select the front winchnot 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 thestowed deduct. Press the corresponding configu-ration selection button to select the desired stoweddeduct if required.

10. The crane set-up screen will change to the normalworking screen and graphically display the craneconfiguration as previously selected. Press thecorresponding configuration selection button toselect the desired parts of line for the rear winch.

11. If the crane is equipped with a front winch and itwas selected, press the corresponding configura-tion selection button to select the front winch.Press the corresponding configuration selectionbutton to select the desired parts of line for the frontwinch.

Note: From the normal working screen, aftercrane setup has been established, only twoselection buttons are active; the winch selectbutton and the parts of line button.

Note: To change winches, push the winch selectbutton to toggle between winches. The winchlifting points cannot be changed without goingthrough the crane setup routine.

Note: The parts of line can be changed for theselected winch by pressing the parts of line but-ton to scroll through the available options forthat winch.

Note: Refer to Figure 1−65 and Figure 1−66 forexamples of some normal working screens.

Operator’s Manual


16000 lb

4000 lb

No Fly

39.5’

67’

2

20

40

None

39.5’

67’

27.5’

B

567’ Fly20�

B

167’ Fly20��

Figure 1−64Configuration Selection Flow Chart

1

5

6 7

3

4

89

11 10

Crane Set Up

Crane Set Up

Crane Set Up

Crane Set Up

Crane Set Up

Crane Set Up

Crane Set Up

Crane Set Up

��

A

B

Crane Set Up

0 lb

2

44

12000 lb

8000 lb

Operator’s Manual


Figure 1−65Normal Working Screen Examples

A

5

In this example the crane is setup on intermediate extended outriggers

(1), boom mode A (2), 8,000 lb counterweight (3), auxiliary head fitted (4),

fly base and tip stowed (5), the front winch available with the aux head

and the rear winch selected (6) with the winch rope reeved over the main

boom (7), with five parts of line (8), two operator alarms have been set (9).

1 2

4

5

6

8

B

1 39.5’ Ofst20�

In this example the crane is setup on fully extended outriggers

(1), boom mode B (2), 12,000 lb counterweight (3), 39.5’ offset

fly erected with 20° offset (4), the rear winch available with the

main boom and the front winch selected (5), with the winch rope

reeved over the 39.5’ offset fly (6), with one part of line (7).

12

4

5

7 6

7

9

12

83

3

Operator’s Manual


Figure 1−66Normal Working Screen Examples

A

3

In this example the crane is setup for stationary on tires (1),

boom mode A (2), 8,000 lb of counterweight (3), front winch

not in use and the rear winch selected (4), winch rope reeved

over the main boom (5), with three parts of line (6).

1

2

4

6

B

1

In this example the crane is setup on fully retracted outrig-

gers (1), boom mode B (2), 8,000 lb of counterweight (3)

fly base and tip stowed (4), front winch not in use and the

rear winch selected (5), with one part of line (6).

1

2

45

6

5

38

38

Operator’s Manual


Figure 1−67Rigging/Travel Mode Screen

�

To Select Rigging/Travel Mode

The CRANE SET UP push-button is also used to selectRIGGING/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 tireconfiguration per the proper procedure.

WARNINGThe Microguard 434 is not operational when inthe RIGGING/TRAVEL Mode. Return theMicroguard 434 to normal operation beforeoperating the crane.

1. From the normal working screen press the CRANESET UP button. The crane set-up screen willchange and graphically display the carrier options.

2. Press the corresponding configuration selectionbutton to select RIGGING/TRAVEL MODE. Referto Figure 1−67.

3. The crane set-up screen will change and graphi-cally display the RIGGING/TRAVEL MODE icon.

To Cancel Audible Alarm And Reset FunctionLimiters

The CANCEL ALARM button is used to cancel the audi-ble alarm when the alarm has occurred as a result of

either an Overload, a Two Block alarm, or an Operatorsettable alarm.

The audible alarm may be canceled by pressing andreleasing the CANCEL ALARM button. The audiblealarm remains canceled until the condition whichcaused the alarm has been removed. For example, ifthe audible alarm was canceled because of an over-load condition, it will remain canceled until the overloadcondition is removed. However, if a different alarm, e.g.two block condition, was to occur when the audiblealarm was still canceled for an earlier overload condi-tion, the new alarm condition would cause the audiblealarm to be re-started.

WARNINGOnce the function limiters have beenby-passed, the crane is no longer protectedagainst the condition that initially caused thefunction limiters to occur.

Note: The CANCEL ALARM feature is a temporaryfunction. 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 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 3 seconds, afterwhich the function limiters will be reset to allow normaloperation. However, should another different alarmcondition 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 limita-tions imposed by the capacity chart. The operator hascontrol over additional alarms which can be set to oper-ate within the normal chart limitations and which are, inaddition 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 1−68.

Six alarms are available for operator use.

�Minimum Angle �Maximum Length�Maximum Angle �Left and Right Swing�Maximum Height �Operator Defined Area

Operator’s Manual


MAX

MIN

0

MAX

Figure 1−68Operator 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 whenentering the operator defined bad area. Forsafe operation, adequate distance must bemaintained to allow for operator reaction timeto avoid entering the bad area. It is theresponsibility of the operator to set pointswhich ensure that the crane’s boom,attachment, load, rigging, etc. maintains asafe working distance and complies with localsafety regulations.

Setting Length/Angle/Height/Swing OperatorAlarms1. 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 selectthe desired alarm to be set.

Note: The bottom value displayed in the maxheight 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, thenumerical value displayed will be the previous-ly set alarm value. The previous alarm must firstbe cleared, then set the new alarm. Alarmswhich are not set are indicated by the word OFF.

4. Press the corresponding selection button to set thealarm 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 audio will sound intermit-tently, and a warning message will appear in theCrane Set-up Screen. When exceeding the alarmset point the red lamp will illuminate, the audiblealarm will sound continuously, and a warning mes-sage will appear in Crane Set-Up Screen.

Note: An alarm icon will appear on the normalworking screen to alert the operator that an op-erator alarm has been set. The number of iconsshown indicate how many operator alarms havebeen set.

7. Use the following examples to understand the useof 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 theCrane Rating Manual to ensure safe, stableoperation under conditions described in thefollowing examples.

To Set Minimum Angle Alarm

Example: To have an alarm whenever the boom isbelow a 30 degree angle, use the followingprocedure:

1. From the normal working screen Press the OPER-ATOR ALARM button to access the alarm screen.

2. Press the corresponding button for minimumangle (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 toreturn to the previous menu screen.

6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching30 degree boom angle the pre-alarm (amber) indi-cator lamp will illuminate, the audio will sound inter-mittently, and �!Minimum Angle" will appear in theCrane Set-up Screen. The red lamp will illuminate,the audible alarm will sound continuously, and�!Minimum Angle" will appear in Crane Set-UpScreen whenever the boom is lowered below 30degrees.

To Set Maximum Angle Alarm

Example: To have an alarm whenever the boom isabove a 60 degree angle use the followingprocedure:

1. From the normal working screen press the OPER-ATOR ALARM button to access the alarm screen.

2. Press the corresponding button for maximumangle (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 thealarm setting.

5. Press the EXIT button to return to the normal work-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 alarmpoints have been properly set. When approaching60 degree boom angle the pre-alarm (amber) indi-cator lamp will illuminate, the audio will sound inter-mittently, and �!Maximum Angle" will appear in theCrane Set-up Screen. The red lamp will illuminateand the audible alarm will sound continuouslywhenever the boom is raised above 60 degreesand �!Maximum Angle" will appear in Crane Set-Up Screen.

To Set Maximum Length Alarm

Example: To have an alarm whenever the boom lengthexceeds 50 feet, use the followingprocedure:

1. From the normal working screen press the OPER-ATOR ALARM button to access the alarm screen.

2. Press the corresponding button for maximumlength (top right).

3. Extend the boom to 50 feet.4. Press the corresponding button (middle left) to en-

ter the alarm. The displayed value will be the alarmsetting.


6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching50 foot boom length the pre-alarm (amber) indica-tor lamp will illuminate, the audio will sound inter-mittently, and �!Maximum Length" will appear inthe Crane Set-up Screen. The red lamp will illumi-nate and the audible alarm will sound continuouslywhenever the boom is extended beyond 50 feetand �!Maximum Length" will appear in Crane Set-Up Screen.

To Set Maximum Height Alarm

Example: To have an alarm whenever the boom tipheight exceeds 75 feet, use the followingprocedure:

1. Press the OPERATOR ALARM button to access thealarm screen.

2. Press the corresponding button for maximumheight (top right).

Note: The bottom value displayed in the maxheight 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 alarmsetting.


6. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approaching75 foot boom tip height the pre-alarm (amber) indi-cator lamp will illuminate, the audio will sound inter-mittently, and �!Maximum Length" will appear inthe Crane Set-up Screen. The red lamp will illumi-nate and the audible alarm will sound continuouslywhenever the boom tip height exceeds 75 feet and�!Maximum Height" will appear in Crane Set-UpScreen.

To Set Left And Right Swing Alarms

Example: To have an alarm whenever the LEFTSWING AND RIGHT SWING exceedpre-determined alarm points, use thefollowing procedure:

1. Press the OPERATOR ALARM button to access thealarm screen.

2. Press the corresponding button for the swingalarm (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 bethe right alarm setting.

7. Press the EXIT button to return to the normal work-ing screen or the MENU (Operator Alarm) button toreturn to the previous menu screen.

8. Test the alarm, with no load, to ensure the alarmpoints have been properly set. When approachingthe set alarm point the pre-alarm (amber) indicatorlamp will illuminate, the audio will sound intermit-tently, and �!Swing Alarm" will appear in the CraneSet-up Screen. The red lamp and the audiblealarm will be activated whenever the swing ex-ceeds the alarm points and �!Swing Alarm" will ap-pear in Crane Set-Up Screen.

Note: Both the left and right swing alarms mustbe set for the system to determine the operatorset working area.

Figure 1−69Operator Defined Area Alarm Screens

Exit OFF

00.0

MAX

MIN0

�

Exit

SettableAlarms

OFFMenu

To Set 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 pre-alarm (amber) indicator lamp will illumi-nate, the audio will sound intermittently, and the mes-sage �Bad Area" will appear on the Crane Set-UpScreen. When passing the plane the overload (red)warning lamp will illuminate, the audio alarm will soundcontinuously, and the message �Bad Area" will appearon the Crane Set-Up Screen. Use the following proce-dure, Figure 1−69, and Figure 1−70 to set the opera-tor defined area alarm.

WARNINGThe operator defined area alarm is a warningdevice. All functions remain operational whenentering the operator defined bad area. Forsafe operation, adequate distance must bemaintained to allow for operator reaction timeto avoid entering the bad area. It is theresponsibility of the operator to set pointswhich ensure that the crane’s boom,attachment, load, rigging, etc. maintains asafe working distance and complies with localsafety regulations.

Operator’s Manual


Setting Operator Defined Area Alarm1. From the normal working screen press the OPER-

ATOR ALARM button to access the Operator Alarmscreen.

2. Clear any previously set left and right swing alarmsif required. Refer to �To Clear Operator SettableAlarms" found later in this Section of thisOperator’s Manual.

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 1−69.

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.

5. Position the boom, attachment, load, rigging, etc.to the right alarm point and press the correspond-ing 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 (3.05m) or 30degrees.

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 audio will sound intermittently, andthe message �Bad Area" will appear on the CraneSet-Up Screen. When passing the plane the over-load (red) warning lamp will illuminate, the audioalarm will sound continuously, and the message�Bad Area" will appear on the Crane Set-UpScreen.

WARNINGIf crane or obstacle is moved or if a differentsize load is lifted, the area alarm must bereset.

To Clear Operator Settable Alarms1. From the normal working screen press the OPER-

ATOR ALARM button to access the Operator Alarmscreen.

2. Press the corresponding selection button to selectthe 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 buttonto return to the alarm screen or press the MENUbutton to return to the previous menu screen.

Operator’s Manual


Figure 1−70Operator Defined Area Alarm

Operator’s Manual


Figure 1−71Typical Crane Attachment Setup (Provided For Correct Identification Of Attachments)

4

3

2

1

1. Offset Lattice Fly Tip Section2. Offset Lattice Fly Base Section3. Auxiliary Lifting Sheave4. Four Section Boom5. Front Winch6. Rear Winch

5 6

Operator’s Manual


Entering And Exiting TheUpper Operator’s CabEntering or leaving the upper operator’s cab could behazardous if certain aspects are not taken into consid-eration. A ladder is mounted on each side of the carrierto provide easy access to the carrier deck and upperoperator’s cab. Numerous hand grips are also at-tached to the upper operator’s cab as well as texturedtread areas on the surface of the carrier deck, to pro-vide safe entry to the cab . Use these features to makeclimbing on the crane as safe as possible. Remain inthree point contact with the crane at all times (twohands and one foot or two feet and one hand).

Inside the cab, two separate features are provided toprevent accidental operation of the hydraulic controlswhile entering or leaving the operator’s seat.

1. Function Lockout SwitchThis switch is used to disable the hydraulic func-tions which are operated by the control levers andboom telescope foot pedal. Move the switch tothe �DISABLE" position to prevent inadvertent op-eration of these controls. To allow normal opera-tion of the swing, winch, boom hoist, and tele-scope functions, move the function lockout switchto the �OPERATE" position. This switch must al-ways be moved to the �DISABLE" position beforeentering or leaving the operator’s seat.

2. Movable Left Hand Side ConsoleThe left hand side console is hinged at the rear toallow the operator to pivot the console up, out ofthe way while entering or exiting the upper opera-tor’s cab. A counterbalance spring holds the con-sole securely in position during normal operationand makes movement of it as effortless as possi-ble.

Lifting the left arm rest enables the console to pivotup, out of the way for ease of entry and exit. It alsoperforms the same duty as the function lockoutswitch, described above, disabling all hydraulicfunctions related to the control levers and boomtelescope foot pedal. Make sure the side consoleis rotated up, out of the way before attempting toenter or exit the upper operator’s cab.

One more feature which is available to ease entryand exit of the upper operator’s cab, is the adjust-able operator’s seat. Lift the left hand arm rest upout of the way and move the seat and/or consoleback as required to allow safe entry. This featurealso provides operator comfort during crane op-eration as well.

Figure 1−72Left Console Warning Label

To prevent personal injury do not attemptto enter the operator’s cab prior to raisingthe left console stand.

WARNING

Break-In PeriodOperate a new crane at half throttle for the first twenty(20) hours of operation. A break-in period under mod-erate loads will assist in providing long, trouble-freeperformance.

Before Starting OperationsBefore starting daily operations, make the followingchecks and inspections.

Engine

Check fuel, oil, and cooling systems for proper fluid lev-els. Check for leaks. Repair or fill as required. Refer tothe engine manufacturer’s manual for additional de-tails.

Gear Cases

Visually inspect all gear cases for leaks or damage. Ifleaks or damage exists, repair and fill case to proper lu-brication level.

Hydraulic System

Check all hoses for chafing, bulging, or other damage.Replace as necessary. Inspect hydraulic system for ex-ternal leaks. Repair as needed. Check hydraulic reser-voir oil level. Add oil if necessary. Refer to Section 2 ofthis Operator’s Manual for additional information.

Lubrication

Lubricate the crane as outlined in Section 2 of this Op-erator’s Manual.

Note: Operators may have nothing to do with lubri-cation or maintenance of the crane, but it could beadvantageous for them to be familiar with it. Knowl-edge of preventive maintenance makes the opera-tor more aware of malfunctions in the crane so re-pairs can be made with a minimum of downtime.

Operator’s Manual


Tires And Wheels

Check tire inflation. Inflate to pressures per the GrossWeight Rating Plate for highway travel, or per the CraneRating Manual for pick and carry operations, whichev-er is applicable. Check wheel lug nut torque, each day,for the first five (5) days of operation and periodicallythereafter. Refer to Section 3 of this Operator’s Manualfor additional information.

Wire Rope And Sheaves

Inspect all wire rope and sheaves for damage or dete-rioration. Replace as necessary. Refer to Section 5 ofthis Operator’s Manual for additional information.

General Inspection

Visually inspect the entire crane for loose or missingcotter pins or bolts, or damaged fly chords or lattices.Check for oil or fluid leaks. Make repairs as needed.

Electrical System

Check the operation of all lights, windshield wipers,horns, turn signals, etc. Repair as needed.

Brakes

Start the engine and allow the air system pressure toreach its normal operating range, 100−120 psi(690−827kPa). Check park brake and service brakeoperations. Adjust or repair as needed.

Controls

Check all controls for proper operation and adjust-ment. Repair as needed.

Fire Extinguisher

A fire extinguisher is located under the left control con-sole of the upper operator’s cab and directly behind thedriver’s seat in the carrier cab. Refer to Figure 1−33and Figure 1−43. They are A B C type fire extinguish-ers, meaning they are capable of extinguishing mosttypes of fires. The operator should be familiar with theirlocation, the clamp mechanism used to secure them inplace, and foremost the operation of the devices. Spe-cific instructions, regarding operation, are given on thelabel attached on the fire extinguisher. A charge indica-tor on the fire extinguisher monitors the pressure withinthe tank. Check the indicator daily to ensure the fire ex-tinguisher is adequately charged and ready for use.

Engine Starting Procedure

WARNINGThis manual must be thoroughly read andunderstood by the operator before startingthe engine. Crane damage or personal injurycould result from improper operatingprocedures.

Before attempting to start the engine, the operatorshould carefully read and understand the engine start-ing instructions in the engine manufacturer’s manualand this Operator’s Manual. Attempting to start or runthe engine before studying these instructions may re-sult in engine damage. The operator should learn andobey all applicable �Rules of the Road" and if not al-ready a competent driver, obtain instructions to attainthese necessary skills. With the crane fully servicedand the operator familiar with all gauges, switches,controls, and having read and fully understood this en-tire manual, start the engine using one of the followingprocedures.

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

To Start The Engine From TheCarrier Cab1. 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. Shift the transmission to neutral. (The engine will

not start unless the transmission is in neutral.)4. Move throttle selector switch to �Lower" position.5. 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 tothe crane.

Operator’s Manual


6. Turn the ignition switch to the �On" position to ener-gize the engine electrical system and allow thegauges to go through their self test routine.

7. Turn the ignition switch to the �Start" position. Re-lease the ignition switch immediately after the en-gine starts. If engine fails to start in 30 seconds, re-lease the ignition switch and allow the starter motorto cool a few minutes before trying to start again. Ifengine fails to start after four attempts, refer to en-gine manufacturer’s manual for instructions.

8. Warm Up − Run the engine at low throttle with noload while engine is warming up. Observe the fol-lowing instruments for proper indications.a. Engine Oil Pressure − If there is no engine oil

pressure after 10−15 seconds of running time,shutdown the engine immediately and repairthe problem to avoid major engine damage.Refer to engine manufacturer’s manual forproper oil pressure operating range.

b. Battery Gauge − Observe indicator to ensurebattery and electrical system is working prop-erly. The gauge should indicate 12.5 to 14.0volts while engine is running. (It should read12.0 volts when the key is on, without the en-gine running.)

c. Air Pressure Warning Light − Normal operat-ing range is 100−120 psi (690−827kPa).When air pressure is sufficient for safe carrieroperations, the low air pressure warning lightand alarm will turn off. Do not attempt to oper-ate crane until air pressure warning light andalarm are off.

9. When the engine has thoroughly warmed up, afterall pressures and temperatures are within operat-ing ranges, and all daily checks have been made,the crane is ready for operation.

To Start The Engine From The UpperOperator’s Cab1. Walk around the crane to verify that there are no

persons under, or in close proximity to the crane.2. Check the carrier cab to assure that the transmis-

sion is in neutral, the park brake is engaged, themain hydraulic pump is engaged, and the ignitionswitch is in the �LOCK" position.

3. Move the throttle selector switch to the �Upper"position.

4. In the upper operator’s cab, sound the horn twicein succession, wait 10−15 seconds while making avisual check to verify that there are no persons un-der, or in close proximity to the crane.

5. Turn the ignition switch to the �On" position to ener-gize the engine electrical system and allow thegauges to go through their self test routine.

6. Turn the ignition switch to the �Start" position. Re-lease the ignition switch when the engine starts. Ifthe engine fails to start in 30 seconds, release theignition switch and allow the starter motor to cool afew minutes before trying to start the engine again.If the engine fails to start after four attempts, refer tothe engine manufacturer’s manual for instructions.

7. Warm Up − Run the engine at low throttle with noload while the engine is warming up. Observe theengine oil pressure gauge for proper indications. Ifthere is no engine oil pressure after 10−15 sec-onds of running time, shutdown the engine imme-diately and repair the problem to avoid major en-gine damage. Refer to engine manufacturer’smanual for proper oil pressure operating range.

8. When the engine has thoroughly warmed up, afterall pressures and temperatures are within operat-ing ranges, and all daily checks have been made,the crane is ready for operation.

Engine Shutdown Procedure FromThe Carrier Cab1. Throttle the engine back to idle. Engage the park

brake and shift the transmission to neutral.2. Turn the ignition switch to the �Lock" position.

Note: If the ignition switch is in the �On" posi-tion in the upper operator’s cab, it must bemoved to the �Off" position before the enginewill shutdown.

3. Remove the ignition keys from both cabs and lockthe doors if the crane is to be left unattended.

Engine Shutdown Procedure FromThe Upper Operator’s Cab1. 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. Turn the ignition switch to the �Off" position.

Note: If the ignition switch is in the �On" posi-tion in the carrier cab, it must also be turned tothe �Off" position before the engine will shut-down.

5. Remove the ignition keys from both cabs and lockthe doors if the crane is to be left unattended.

Operator’s Manual


Figure 1−73Battery Cable Connections

Power Source

2

1

3

Make connections in numerical order.Disconnect in reverse order.

4

Frame Ground

Jump Starting The CraneThe crane has four (4) 12V batteries. The batteries arelocated on the left side of the crane next to the fuel tank.

WARNINGTo avoid serious personal injury and/orequipment damage, follow these proceduresin the order they are given.

Wear protective clothing and shield your faceand eyes when working around batteries.Batteries contain sulfuric acid which burnsskin, eyes, and clothing.

Do not jump start a damaged battery. Be surevent caps are tight and level. If anothervehicle is used, be sure booster vehicle andcrane are not touching.

The gases around the battery can explode ifexposed to open flames or sparks. Anexplosion could result in serious personalinjury and/or equipment damage.

Battery posts, terminals, and related accesso-ries contain lead and lead compounds. Washhands after handling.

1. Check all battery terminals and remove any corro-sion before attaching jumper cables.

2. Connect one end of the first jumper cable to the12V positive (+) terminal of the discharged battery.

3. Connect the other end of the first cable to the 12Vpositive (+) terminal of the 12V power source orbooster battery.

4. Connect one end of the second jumper cable to thenegative (−) terminal of the 12V power source orbooster battery.

Figure 1−74Do not use an open flame near the battery.

Wrong

5. Connect the other end of the second cable to agood metallic surface on the carrier frame.

6. If another vehicle is used to jump start the crane,start the booster vehicle. Run the booster vehicle’sengine at a moderate speed.

7. Turn on the key switch to allow discharged batter-ies to charge for a few minutes prior to attemptingto start the disabled crane.

8. Start the disabled crane. After the crane is started,remove jumper cables in reverse order.

9. Let the crane’s engine run for a few minutes tocharge the discharged batteries.

10. Check the battery gauge in the operator’s cab.The gauge reading should be increasing toward14 volts.

Note: If the batteries are severely discharged,voltage may increase slowly.

Operator’s Manual


Cold Weather AidsThese options are offered to aid in engine start up andoperator comfort in extremely cold weather conditions.Each system operates independently of the otherwhich allows use of more than one of them at the sametime. The following is a brief description of each sys-tem and operating instructions.

Hydraulic Pump DisconnectThe pump disconnect is used to disengage the mainhydraulic pump when not in use. Disconnecting themain pump greatly reduces cranking resistance. Thepump should be disconnected for cold weather start-ing. Refer to �Steering Column, Pump Disconnect,And Foot Operated Controls" found earlier in this Sec-tion for proper operating procedure.

Electric Engine Block PreheaterAn electric engine block preheater is available for thiscrane. It is provided to make engine start-up easier inextremely cold weather by keeping the entire enginewarm. The unit is designed for all night operation but ifweather conditions are not severe, it can be used for 30minutes before engine start-up, with good results.

The electric engine block preheater uses electricalpower to heat the coolant and circulate it through theengine. The electric engine block preheater powercord is located on the right side of the engine. Refer toFigure 1−75.

Figure 1−75Electric Engine Block Preheater

1. Preheater Cord

1

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

park brake, shift the transmission to neutral, andshutdown the engine.

2. Plug preheater cord into 110V to 120V electricalsource.

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

Note: Unplug the engine block preheater beforestarting the engine.

To Stop The Electric Engine Block Heater1. Unplug preheater cord from electrical source.

Operator’s Manual


Figure 1−76Ether Start System

1. Ether Fuel Cylinder2. Cylinder Clamp3. Metering Orifice

4. Valve5. Ether Injector Relay (EIR)

5

2

1

3

4

Ether Start SystemThe ether start system is a fully-automatic engine start-ing fluid system designed to spray a controlled amountof ether into the air intake system during and immedi-ately after cranking. The engine control module (ECM)determines when the system should function. TheECM sends a signal to the ether injection relay (EIR)which activates the valve assembly to inject ether.Whenever the engine does not start within a normal pe-riod of cranking the ether fuel cylinder may be empty.Check the low cylinder indicator located on the EIR andreplace the cylinder as required. The ether fuel cylinderis located just inside the engine access door on the leftside of the crane. Refer to Figure 1−76.

Note: The EIR requires a constant power supply inorder to preserve the memory of the amount ofether used. There is an internal backup circuit thatallows the EIR to retain its memory for 72 hourswithout a battery connection. If the battery is dis-connected for longer than 72 hours, the EIR will re-set. The ether fuel cylinder should be replaced tosynchronize the counter with the amount of etherleft in the cylinder.

WARNINGWhen maintaining or troubleshooting etherstart system, always make sure the area iswell ventilated and away from heat, openflames, or sparks. Wear goggles to avoid eyeinjury. When opening ether fuel line ordisconnecting atomizer, make sure it ispointed away from you. The ethyl ether fuelused in this system is extremely flammable,toxic, harmful, and can be fatal.

Operator’s Manual


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

brake, shift the transmission to neutral, and shut-down the engine.

2. Clean all dirt from the neck of the fuel cylinder andtop of the valve. Refer to Figure 1−76.

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

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

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

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

7. Install the new gasket into the valve.

Note: Replace gasket inside valve each time acylinder is replaced. Read the entire cylinder la-bel for additional information on cylinder andvalve gasket installation.

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

9. Install the cylinder by turning the cylinder clock-wise until the cylinder dirt and moisture seal o-ringcontacts the valve.

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

10. Tighten an additional 1-1/2 turns. Do notovertighten.

Figure 1−77Ether Injector Relay

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

net over the reset area 3 or 4 times. The lampshould flash indicating a reset. Refer toFigure 1−77.

Note: The magnet must be capable of lifting aminimum of two pounds.

Operator’s Manual


Figure 1−78Diesel Cab Heater

1. Heater Control Knob2. Diesel Cab Heater

3. Diesel Cab Heater Fuel Tank4. Drain Valve

1

2

3

4

Diesel Cab HeaterA diesel cab heater may be used to heat the upper op-erator’s cab. Refer to Figure 1−78. The diesel fueltank for the system is mounted to the left side of the up-per revolving frame behind the upper operator’s cab.

WARNINGDiesel exhaust fumes can beharmful. Start and operatediesel cab heater in a wellventilated area. If it isnecessary to operate in anenclosed area, vent theexhaust to the outside.

To Start The Diesel Cab Heater

Turn the control knob to the desired temperature set-ting.

To Stop The Diesel Cab Heater

Turn the control knob to the �OFF" position. The heateris equipped with a purge thermostat which permits theheater to continue to run for a short period of time in or-der to burn the fuel from the lines.

To Drain Water

Water should be drained from the diesel cab heater fueltank every 50 hours of heater operation.1. Park crane on a firm, level surface, engage park

brake, shift transmission to neutral, and shutdownthe engine.

2. Install a drain hose to the fitting on the drain valve.Place a suitable container below drain valve.

3. Open drain valve.4. Continue draining until clear fuel is visible.5. Close drain valve.6. Properly dispose of fuel.

Operator’s Manual


1. Hydraulic Cab Heater Control Switch2. Needle Valve

3. Hydraulic Cab Heater4. Hydraulic Cab Heater Oil Reservoir

5. Hydraulic Oil Cooler

Figure 1−79Hydraulic Cab Heater

1

2

3 4 5

Hydraulic Cab HeaterA hydraulic cab heater may be used to heat the upperoperator’s cab. The heater is located behind the op-erator’s seat and the control switch is located on the leftside of the Rated Capacity Limiter panel. Refer toFigure 1−79. The hydraulic cab heater oil reservoir forthe system is mounted on the left side of the upper re-volving frame just behind the upper operator’s cab.

To Start The Hydraulic Cab Heater1. Rotate the needle valve clockwise until it will not ro-

tate anymore.2. With the engine running, move the heater switch to

the �LOW" or �HIGH" position.

To Stop The Hydraulic Cab Heater1. Move 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 oftime, rotate the needle valve counterclockwiseuntil it will not rotate anymore.

Operator’s Manual


Figure 1−80Hand Signals

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 thepermission of the Publisher the American Society of Mechanical Engineers, 345 E. 47th Street, New York, New York 10017.

Hand SignalsHand Signals are important for communications be-tween the designated signalman and the operator. Ahand signal chart is shown in Figure 1−80. A copy isalso located on the right hand side of the carrier, on thehydraulic reservoir.

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 andtheir signals obeyed by the operator. Obey a stop sig-nal from anyone.

Crane OperationCranes are used primarily for making heavy lifts. In or-der to do this properly, certain procedures must be fol-lowed. The following is a suggested procedure formaking typical lifts:1. Determine 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 proper capacity, working areas andworking range chart located in the Crane RatingManual. Find the shortest boom length and loadradius that will accomplish the job.

Operator’s Manual


3. Do not swing upper while on tires, use outriggers.Position crane so a minimum swing is necessary.

4. The crane must be supported by a firm, solid levelsurface before starting to lift. All capacities in theCrane Rating Manual are based on the crane beinglevel in all directions. If the crane is not level, outswing or side swing of the load will greatly reducelifting capacities and could cause crane damage oran accident. If the ground is soft, use mats.

5. If outriggers are used, the following points must beobserved:a. The outrigger beams must all be equally ex-

tended (all fully extended, intermediately ex-tended, or fully retracted) to lift the loadsshown in the Crane Rating Manual. Serious re-ductions in lifting capacity will result if allbeams are not in the same position and thiscould lead to serious crane damage or an acci-dent.

b. The bumper outrigger must be properly set.c. Outrigger pontoons must be on solid, smooth

footing, flush with the ground (no hills or val-leys under pontoons), otherwise pontoonsmay be damaged or destroyed. If there is anydoubt, use mats.

d. All capacities listed for the crane on outriggersare based on the outrigger jacks being used toraise the crane so that all tires are clear of theground and the crane level. A bubble level isprovided in the upper operator’s cab and ateach outrigger ground control station to assistthe operator in leveling the crane.

6. When making lifts on tires, all tires must be inflatedto pressures as listed in the Crane Rating Manual.Do not make lifts which exceed Crane RatingManual specifications.

7. Raise the boom and swing over the load. Extendthe boom to the desired length. Make sure powerboom sections are properly extended.

8. 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 neverbe 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 wirerope capacity chart located in the Crane Rat-ing Manual for the number of parts of lineneeded for a given lift.

d. When lifting loads, care should be taken to pre-vent sudden loading or unloading of the winchrope. Ease into the load. Lift load a few inchesoff the ground and hold to check the winchbrakes.

9. 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. Makesure the load being lifted remains within the liftingcapacity of the crane at the boom length and ra-dius being used.

10. Control the load at all times. Use hand lines toguide the load. Do not guide loads into place withyour hands. Swing slowly and smoothly. Avoidjerks when starting or stopping swings.

During OperationThe operator must remain alert to possible malfunc-tioning of the crane while operating. If the crane doesmalfunction, lower the load and shutdown the craneuntil 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 forproper operating ranges.

2. Watch the hydraulic system oil temperaturegauge. If the temperature exceeds maximum tem-perature, shutdown the crane until the problem iscorrected. Refer to �Hi Performance Hydraulic Oil"chart in Section 2 of this Operator’s Manual for themaximum temperature for each viscosity of hy-draulic oil.

3. Listen for any unusual noises in the hydraulic sys-tem, power train, or the speed reducers. If any,correct problem.

4. Watch for oil leaks or any loss of control. If any de-velop, correct before continuing operation.

5. Make sure all controls work freely and easily, withno sticking or binding. Lubricate or adjust as nec-essary.

6. If working on outriggers, periodically check theoutriggers to make sure the crane is level and sta-ble. If working without outriggers, make sure thetires are inflated to the proper pressure and theboom is positioned directly over the rear of the car-rier with the travel swing lock engaged. Refer toCrane Rating Manual for proper tire pressure.

7. Heed all warning and caution labels. Observegood safety practices at all times.

Operator’s Manual


Pick And Carry OperationTravel during pick and carry operations is restricted tospeeds of 1.0 mph (1.6km/h) or less on a firm, level sur-face. Lifts are to be made off the main boom only, withthe crane prepared as follows:

WARNINGDo not travel above the maximum speedslisted. Crane damage, property damage,and/or personal injury may result.

1. Inflate the tires to the pressure listed in the CraneRating Manual for 1.0 mph (1.6km/h) maximumspeed. Refer to Section 3 of this Operator’s Manualfor tire inflation procedure.

2. Move the air ride suspension switch in the carriercab to the �DOWN" position.

3. Level the crane on fully extended outriggers withthe tires clear of the ground.

4. Position the upper over the rear and engage thetravel swing lock. Release the 360° swing lock, ifequipped.

CAUTIONDo not leave swing park brake or 360° swinglock knob in the engaged position during pickand carry operations. Failure to release thesedevices during this operation may result indamage to the swing speed reducer.

5. Properly store the fly.6. Retract all outrigger jacks just clear of the ground

but leave the outrigger beams fully extended.7. Attach as many hand lines as necessary to prevent

the load from swinging during travel.8. Carefully attach the load to the winch rope and lift it

only as high as necessary.9. Carefully travel at no more than 1.0 mph (1.6km/h).

Take extra care due to the increased overall widthcaused by the extended outrigger beams. The out-riggers or pontoons must not be allowed to hit anyobstructions. Maintain a safe distance from all per-sonnel and obstructions. Travel only on a firm,level surface.

10. Once the desired destination is reached, shift thetransmission to neutral and apply the park brake.

Traveling The CraneTruck cranes are designed for highway and job sitetravel. Certain conditions must be met for safe travel.Refer to the following outlined procedures before trav-eling the crane.

WARNINGDo not travel above the maximum speedslisted. Crane damage, property damage,and/or personal injury may result.

Job Site TravelJob site travel is limited to speeds less than 5.0 mph(8.0km/h) on a firm, smooth, and level surface. Thecrane may be traveled on the job site with no load perthe following procedure:1. Inflate the tires to pressure listed in the Tire Inflation

Label for 5.0 mph (8.0km/h) maximum speed. Re-fer to Section 3 of this Operator’s Manual for tireinflation procedure.

2. Move the air ride suspension switch in the carriercab to the �DOWN" position.

3. Level the crane on fully extended outriggers.4. Position the upper and attachments in one of the

following arrangements:a. The upper over the front or rear. The boom

sections fully retracted and the fly stored.b. The upper over the rear. The boom sections

fully retracted. The fly base erected and the flytip stored or the fly base and tip erected.

Note: The fly must be in the 2� offset posi-tion.

c. The upper over the front. Boom fully retracted.9,000 lb counterweight or more located on up-per. Fly base erected with fly tip stored, or flybase and tip erected.

5. Boom down fully. Engage the travel swing lock.Release the 360° swing lock, if equipped.

CAUTIONDo not leave the swing park brake or the 360°swing lock knob in the engaged position whentraveling the crane. Failure to release thesedevices during this operation may result indamage to the swing speed reducer.

6. Retract all outrigger jacks just clear of the groundbut leave the beams fully extended.

7. If desired, place the air ride switch, in the carriercab, in the �Up" position.

8. Carefully travel at no more than 5.0 mph (8.0km/h).Take extra care due to the increased overall widthcaused by the extended outriggers. The outrig-gers or pontoons must not be allowed to hit any ob-structions. Maintain a safe distance from all ob-structions, structures and power lines.

Operator’s Manual


Highway TravelHighway travel is considered to be any travel of thecrane over 5.0 mph (8.0km/h). The following condi-tions and precautions must be met for any highwaytravel.

Note: If road weight or axle load limitations are afactor, the crane may be equipped with a counter-weight removal system or boom dolly/trailer kit.Use these systems as necessary to meet roadweight or axle load limitations. Refer to the GrossAxle Weight Rating (GAWR) plate for axle load lim-its.

1. If equipped, the fly must be secured in the storedposition on boom.

2. Inflate the tires to pressure listed on the Gross AxleWeight Rating (GAWR) plate for speeds over 5.0mph (8.0km/h). Refer to Section 3 of this Opera-tor’s Manual for tire inflation procedure.

3. Move the air ride suspension switch in the carriercab to the �UP" position.

4. The boom must be fully retracted, over the front ofthe crane and in the boom rest, unless a boom dol-ly/trailer is being used, with the travel swing lockengaged. Release the 360° swing lock, ifequipped.

CAUTIONDo not leave the swing park brake or the 360°swing lock knob in the engaged position whentraveling the crane. Failure to release thisdevice during this operation may result indamage to the swing speed reducer.

5. Secure hook block to prevent excessive swinging.6. All outriggers must be fully retracted (jacks and

beams) with all outrigger position pins in the re-tracted position and all main outrigger pontoonsremoved from jacks and stored properly.

7. All upper control levers must be in the neutral posi-tion. The upper ignition key must be turned off, keyremoved and all doors and windows locked.

8. Do not allow anyone to ride in the upper operator’scab during any highway travel.

9. Disengage the main hydraulic pump.10. Obey all �Rules of the Road" and travel carefully.

Counterweight RemovalAccess to certain job sites may require the crane totravel on roads with strict vehicle load limitations. In or-der to meet such limitations the crane is designed sothe counterweights can be lowered on and pinned tothe carrier deck to balance axle loadings or removedand transported separately. Removing the counter-weights can reduce the weight of the crane by as muchas 16,000 lb (7�258kg). Refer to the Crane RatingManual for the exact weight of the counterweight.

To Remove The Counterweights1. Park the crane on a firm, level surface, engage the

park brake, and shift the transmission to neutral.2. Properly level the crane on outriggers with the tires

clear of the ground.3. Fully retract all boom sections. If equipped, prop-

erly store the fly on the boom.4. Swing the upper over the rear of the carrier. En-

gage the travel swing lock and boom up to 30°.5. Remove the lock pins which secure the counter-

weights to the upper frame. Refer to Figure 1−81.

Note: Counterweights have to be raised (cylin-ders retracted) to relieve pressure on the lockpins to ease removal.

6. Pull the counterweight cylinder control lever to low-er (extend cylinders) the counterweights to thestorage lugs on the carrier deck.

WARNINGTo avoid personal injury, do not stand undercounterweights during lowering or raising ofthe counterweights.

7. Remove the lock pin which secures the counter-weights to the counterweight removal cylinder.

Note: If all counterweights are not to be re-moved, remove only the two counterweightconnecting pins above the counterweights tobe removed.

8. Pull the counterweight cylinder control lever to re-tract (raise) the cylinders away from the counter-weights.

9. Remove the cylinder travel lock brackets from thestored position and install them in the travel posi-tion.

10. Install the connecting pins to secure the counter-weights to the counterweight storage lugs on thecarrier deck.

Operator’s Manual


Figure 1−81Counterweight Removal System

1. Lock Pins With Keepers − Counterweights to Upper Frame2. Counterweight Removal Cylinder Control Lever (Shown Opposite)3. Counterweights Installed4. Connecting Pin With Keepers − Counterweight to Counterweight5. Carrier Deck Storage Lugs6. Lock Pin With Keepers − Counterweight to Counterweight Removal Cylinder7. Cylinder Travel Lock Bracket in the Traveling Position − Counterweights Removed8. Cylinder Travel Lock Bracket in the Stored Position − Counterweights Installed9. Auxiliary Counterweight10. Lifting Ring11. Connecting Bolt

VIEW A−ACounterweights Pinned to Upper

VIEW A−ACounterweights Lowered to Carrier Deck

A

A

1 2

5

6

4

8

3

7

9 10

10

11

DO NOT have more

than (2) two

counterweights on

deck when lowering

boom into rest.

INFORMATION

COUNTERWEIGHT CONTROL

NEUTRAL

PULL TOLOWER

PUSH TORAISE

INFORMATION

KEEP CLEAROF MOVINGCOUNTERWEIGHTTO PREVENTSERIOUS BODILYINJURY.

WARNING

KEEP CLEAROF MOVINGCOUNTERWEIGHTTO PREVENTSERIOUS BODILYINJURY.

WARNING

Operator’s Manual


11. If required, remove the counterweights from thecarrier deck. The boom may be used to lift thecounterweights onto a transport vehicle. Refer tothe Crane Rating Manual for lifting loads with nocounterweight.

Note: If the crane is equipped with the auxiliarycounterweights, remove the connecting boltsand remove each one using the swivel liftingrings. Refer to Figure 1−81.

To Install The Counterweights1. Park the crane on a firm, level surface, engage the

park brake, and shift the transmission to neutral.2. Properly level the crane on outriggers with all tires

clear of the ground.3. If required, install the counterweights onto the car-

rier deck. The boom may be used to lift the coun-terweights onto carrier deck. Refer to the CraneRating Manual for lifting loads with no counter-weight.

Note: If the crane is equipped with the auxiliarycounterweights, place each one on the top coun-terweight using the swivel lifting rings. Install theconnecting bolts and torque to 200 ft lb (271Nm),then install counterweights to the upper. Refer toFigure 1−81.

4. Swing the upper over the rear of the carrier. En-gage the travel swing lock and boom up to 30°.

5. Remove the cylinder travel lock brackets from thetravel position and install them in the stored posi-tion. Refer to Figure 1−81.

6. Pull the counterweight cylinder control lever to ex-tend (lower) the counterweight removal cylindersto align connecting lugs on the top counterweight.

7. Install the lock pins and keeper pins to secure thecounterweights to the counterweight removal cyl-inder.

8. Remove the connecting pins which secure thecounterweights to the storage lugs on the carrierdeck.

9. Push the counterweight cylinder control lever to re-tract (raise) the cylinders and lift the counter-weights.

WARNINGTo avoid personal injury, do not stand undercounterweights during lowering or raising ofthe counterweights.

10. Continue to lift the counterweights until the lugs onthe top counterweight align with the lugs on the up-per frame.

11. Install the lock pins and keepers which secure thecounterweights to the upper frame.

12. Lower counterweights (extend cylinders) slightly totransfer the weight of the counterweights from thecylinders to the upper frame.

Traveling With BoomDolly/TrailerA boom dolly/trailer can be used to reduce the weighton each of the carrier axles by supporting a portion ofthe weight of the boom during highway travel, if high-way codes allow the use of this equipment. The fly mayalso be partially supported by the dolly/trailer if it isproperly stored on the boom. The crane must beequipped with the boom dolly/trailer kit to provide thenecessary hydraulic plumbing required to allow theboom to float freely on the dolly/trailer. The boom dolly/trailer is for highway use only.

WARNINGWhen initiating a turn with the boom dolly/trailer,the tip of the boom may swing outside theturning radius of the dolly/trailer axles. In somecases the tip of the boom will move into the lineof traffic. The tip of the boom must be properlyflagged before roading the crane. Allow ampletime to complete a turn before oncoming trafficapproaches.

The dolly/trailer must be equipped with an air brakesystem. Pressurized air for this system is supplied tothe dolly/trailer through outlets on the rear of the carrier.Push in on the boom dolly/trailer air control valve knob,on the carrier cab dash, to pressurize the outlets. Pull itout to shutoff the air supply to the dolly/trailer. Refer toFigure 1−34. Electrical hook-ups for lights are alsoavailable on the rear of the carrier.

WARNINGThe counterweights must be removed from theupper when traveling the crane with a boomdolly/trailer. Crane may tip over when initiatinga turn when the counterweights are left installedon the upper. The counterweights may betransported on the carrier deck or on the boomdolly/trailer. If the counterweights aretransported on the boom dolly/trailer, they mustbe equally positioned on the sides of thedolly/trailer e.g. 4,000 lb (1 814kg) on one sideand 4,000 lb (1 814kg) on the other side. Ensurethat the counterweights are properly securedon the carrier deck and dolly/trailer.

Operator’s Manual


Figure 1−82Typical Boom Dolly/Trailer

1. Counterweight Storage Locations2. Boom

3. Boom Dolly/Trailer4. Control Air Line (Blue)

5. Electrical Cable6. Supply Air Line (Red)

2

34

5

6

1

1

A

A

Boom Dolly/Trailer Installation1. Properly prepare the crane for highway travel. See

�Traveling the Crane", in this Section of this Opera-tor’s Manual for instructions.

2. Using a signalman, back the crane to the dolly/trail-er.

3. Hook up the air lines and plug in the electricalcable. Refer to Figure 1−82.

4. Position the fully retracted boom at a 45° angle.Swing the boom over the dolly/trailer as required.Lower the boom onto the dolly/trailer.

WARNINGWhen swinging over the side on tires maintain45° boom angle. Crane may tip overbackwards causing personal injury and/orcrane damage.

5. Adequately secure the boom to the dolly/trailer.6. Shutdown the engine and disengage the main

pump.

7. Turn the needle valves at the boom hoist cylinderand boom hoist control valve counterclockwise, asfar as possible, to open the valves and allow theboom to float freely on the dolly/trailer. Refer toFigure 1−83.

WARNINGCheck that the boom is properly supported bythe dolly/trailer before opening the needlevalves.��The boom could drop suddenlycausing damage or injury.

All needle valves must be fully open beforetraveling the crane with a boom dolly/trailer.Crane damage could result.

8. Release the travel swing lock and the swing parkbrake. Also release the 360° swing lock, ifequipped.

Operator’s Manual


Figure 1−83Boom Hoist Float Valves

1. Swing Speed Reducer2. Boom Hoist Control Valve

3. Boom Hoist Cylinder4. Needle Valves − 2 Places

1

24

3

4

CAUTIONDo not leave any swing lock device in theengaged position when traveling the cranewith a boom dolly/trailer. Failure to releasethese devices during this operation may resultin damage to the swing speed reducer.

9. Push in on the boom dolly/trailer air control valve,on the carrier dash, to supply air to the dolly/trailer.Refer to Figure 1−34.

Note: If the boom dolly/trailer air system is notalready pressurized, allow ample time for thesystem to charge before attempting to move thedolly/trailer.

10. Flag (lights if traveling at night) the end of the boombefore roading the crane. Obey all �Rules of theRoad" and travel carefully.

Boom Dolly/Trailer Removal1. Park the boom dolly/trailer where desired and ap-

ply the park brake. Shutdown the engine. Blockthe wheels of the dolly/trailer.

2. Turn the needle valves at the boom hoist cylinderand boom hoist control valve clockwise, as far aspossible, to close the valves and allow normalboom hoist operation. Refer to Figure 1−83.

WARNINGAll needle valves must be fully closed beforeoperating the crane. The boom could fallcausing damage or injury.

3. Engage the main hydraulic pump and start the en-gine. Pull out on the boom dolly/trailer air controlvalve, on the carrier cab dash, to shutoff the airsupply to the dolly/trailer. Refer to Figure 1−34.

4. Disengage the boom from the dolly/trailer.5. Raise the fully retracted boom to a 45° boom

angle. Swing the boom directly over the front of thecarrier and place it in the boom rest. Engage thetravel swing lock.

WARNINGWhen swinging over the side on tires do notexceed 45° boom angle. Crane may tip overbackwards causing personal injury and/orcrane damage.

6. Disconnect the electrical cable and air lines fromthe rear of the carrier. Cap the outlets and the airhoses using the storage hardware and bracketsprovided. Refer to Figure 1−82.

7. Carefully drive the crane away from the dolly/trailer.

Operator’s Manual


Lifting The CraneThe entire crane can be lifted or the components maybe removed from the crane and lifted individually. Referto Figure 1−84 for the centers of gravity and weightsfor the entire crane and the individual components.The following conditions and precautions must be metbefore lifting the crane or removing any component.

1. The crane must be parked on a firm, level surfacewith the travel swing lock engaged and the boom inthe boom rest.

2. Use lifting equipment, shackles, slings, etc., ofsuitable size and strength. All lifting equipmentmust be inspected before lifting the crane. The in-spection must be recorded and dated in accor-dance with current OSHA regulations.

3. The weights and locations of all centers of gravityinclude all possible options (heaviest crane) withthe fly base and fly tip stowed on the boom. Usethe centers of gravity as a starting point. Centerhoist line on the center of gravity, lift a few inchesand adjust the hoist line to keep the crane/compo-nents level at all times.

4. Removal of any components from the crane willshift the center of gravity of the entire crane. Adjusthoist line to account for the removal of any compo-nent.

5. The hook block and ball are not included in the to-tal weight of the crane.

6. When lifting the entire crane, extend outriggersbeams to the intermediate position and installslings around the beams. Protect slings from anysharps edges.

7. Do not reeve load lines through the fly when liftingthe entire crane or damage may result

8. Use only nylon straps to lift fly base or fly tip to pre-vent damage to them. Protect the straps fromsharp edges.

9. Do not allow the hoist lines to contact boom whilelifting crane. Damage to the boom may result.

Towing The CraneAlways use good judgment and reliable equipmentwhen towing the crane. Use extra caution when towingthe crane on the highway and in traffic. When makingconnections between the crane and towing vehicle, besure none of the connections will cause damage toeither vehicle. Pay particular attention to tie rods, brakelines, steering cylinders and steering lines.

Always exercise safety and follow all local codes whentowing the crane. Prepare the crane as follows beforetowing it.1. If equipped, store the fly on the boom.2. The boom must be fully retracted and over the front

of the crane with the travel swing lock engaged.Release the 360° swing lock.

CAUTIONDo not leave the 360° swing lock engagedwhen towing the crane. Failure to release the360 degree swing lock during this operationmay result in damage to the swing speedreducer.

3. Secure the hook block to prevent excessive swing-ing.

4. All outriggers must be fully retracted (jacks andbeams) with all pontoons removed from jacks andstored properly.

5. All control levers in the upper operator’s cab mustbe in the neutral position.

6. The hydraulic pump must be disconnected.7. Shift the transmission to neutral.

CAUTIONFailure to disconnect the drive tube, or lift thedriving wheels, before pushing or towing thecrane can cause serious transmissiondamage.

8. Remove the drive tube between the transmissionand axle.

9. Unlock the steering column by turning the ignitionswitch to the �On" position. Turn on the hazardflashers.

10. Release the park brake when the crane is attachedto the towing vehicle and ready to be towed.

Operator’s Manual


Figure 1−84Lifting The Crane

DESCRIPTION WEIGHT

CARRIER 43,600 lb (19 777kg)

UPPER 13,800 lb (6 260kg)

BOOM HOIST CYLINDER 2,710 lb (1 229kg)

BOOM W/ FOOT PIN 20,600 lb (9 344kg)

COUNTERWEIGHTS 16,000 lb (7 258kg)

AUXILIARY ARM 110 lb (50kg)

FLY BASE 1,590 lb (721kg)

FLY TIP 790 lb (358kg)

TOTAL CRANE 99,200 lb (44 997kg)

Fly TipSheave

CL 13’ 8"(4.2m) Fly Tip

21’ 7"(6.6m)

Fly Base

BoomFully Retracted0° Boom Angle

19’ 9"(6.0m)

Fly Base SheaveCL

Boom Foot PinCL

7’ 1"(2.2m) 5’ 6"

(1.7m)

Upper

Counterweights

2’ 5"(6.3cm)

AuxiliaryArm

AuxiliaryArm Sheave

CL

Boom HoistCylinder Boom

Hoist Pin

CL

Carrier

Total Crane

7’ 3"(2.2m)

12’ 8"(3.9m)

4’ 1"(1.2m)

Tow & TieDown PointsLift Point

OfRotation

CL

Lift Point

Tow & TieDown Points

Operator’s Manual


Transporting The CraneWhen transporting the crane, precautions should betaken in securing the crane to the trailer, barge, or othermeans of conveyance. The towing shackles are therecommended tie down points. If the crane is notequipped with towing shackles, chains may be loopedaround the outrigger boxes or the axle housings andused to secure the crane down.

CAUTIONIf chains are wrapped around the axlehousing, be certain the chains will not damagethe tie rods, brake lines, steering cylinders, orsteering lines.

If chains are wrapped around the outrigger box collar,be certain the chains will not damage the hydrauliclines and fittings. The chains should be wrappedaround the outrigger box, not the outrigger beam.

Always exercise safety and follow all local codes whenloading, unloading or transporting the crane.

WARNINGDo not use the towing shackles as a means oflifting the crane. These shackles are notintended to be used to lift the crane and maybreak if subjected to the entire weight of thecrane. Severe personal injury or extensiveequipment damage may result from thispractice.

Prepare the crane as follows before transporting it:1. If equipped, store the fly on boom.2. The boom must be fully retracted and over the front

of the crane with the travel swing lock engaged.Release the 360° swing lock.

CAUTIONDo not leave the 360° swing lock engagedwhen transporting the crane. Failure torelease the 360° swing lock during thisoperation may result in damage to the swingmechanism.

3. Secure the hook block to prevent excessive swing-ing.

4. All outriggers must be fully retracted (jacks andbeams) with all pontoons removed from jacks andstored properly.

5. Engage the park brake and shift the transmissionto neutral.

6. All control levers in the upper operator’s cab mustbe in the neutral position.

7. Lock all windows and doors. Remove the keysfrom the crane.

8. Depending on the specific situations, furtherpreparations may be needed to protect the cranefrom the environment or vandalism. See �CraneStorage" for further suggestions.

Crane StorageAnytime the crane is going to be left unattended, itshould be prepared so that it will not be damaged bythe elements, be an attraction to vandals, or a playthingfor children.

Short Term Storage1. Do not leave the crane where it will be a traffic haz-

ard.2. Lower all loads to the ground.3. The 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. Shift the transmission to neutral, engage the park

brake and shutdown the engine. Block the wheelsto prevent the crane from rolling if on tires.

8. If the crane is on outriggers, the outriggers must beproperly set and supported so the crane will re-main level.

9. In cold weather, locate the crane where it will notfreeze to the ground.

10. Lock all windows and doors. Remove the keysfrom the crane.

Operator’s Manual


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 full of oil.5. Inflate tires to pressures shown on the Gross

Weight Rating Plate. Check tire pressures periodi-cally during storage to make sure they do not goflat. Refer to Section 3 of this Operator’s Manual forcorrect procedure. If possible block the crane upso the tires are clear of the ground. Make sure theblocking is placed so the crane cannot fall off it. Ifthis is not possible, set the crane on planks so thetires will not sink in the ground. Block the tires toprevent the crane from rolling.

6. Fully retract all hydraulic cylinders, if possible. Ifequipped, store the fly. Cover all cylinder rods, ma-chined and unpainted surfaces with a coat ofgrease.

7. Leave all control levers in neutral.8. Engage the park brake and shift the transmission

to neutral.9. Cover all open areas around the engine, cab, etc.

to prevent entry of water. Cover the entire enginearea with a tarp if possible.

10. 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 drainthe engine block.

11. If in a location where vandalism may occur, lock thecab doors. Cover all cab glass with plywood orboards to prevent glass breakage. Provide ameans of locking the engine access doors, fueltank and hydraulic reservoir.

12. Drain all moisture from the air reservoirs to preventrust and deterioration.

13. Store the crane so it does not provide a playthingfor children. Such a unit can be an �attractive nui-sance" for children to play on. If they fall off it or getentangled, serious injury may result.

14. While in storage, the crane should be �exercised"every 60 days to ensure the working condition ofthe crane. Uncover all closed-up areas and re-move any tarp/cover from the engine. Start the en-gine and operate all switches, control cables, andhydraulic functions several times to circulate lubri-cants and to keep all mechanisms and linkagesoperative.

Operator’s Manual


997 - section 01.pdf

Documents

upper operators cab

cruise controls

engine brake controls

carrier cab seat

operators manualisection

carrier cab fuse box

engine brake operation

operating safety