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SECTION 4 – BOOM

4-8

USTC

January 15, 2001

4. Retract boom to ensure telescope cylinder is

fully retracted (bottomed).

Note: Open wedge socket may need to be removed to
unreeve cable from around lower boom nose sheave
wheels in next step if crane is configured for 3 or 4-
part line. If socket is removed it will need to be
reinstalled to help lower hoist out of way as in the
following steps.

5. With boom still in lowered position, remove

headache ball/hook block assembly from hoist
cable and unreeve cable from boom nose
sheaves. Also remove upper and lower hoist
cable retaining pins from boom head.

6. Using all applicable safety precautions, operate

the hoist and retract cable onto drum until cable
socket on the end of cable is up over the boom
nose and next to cable socket attach lug on top
of base boom.

7. Using cable socket, pin hoist cable to cable

socket attach lug on top of base boom and re-
move any excess slack in hoist cable.

8. Using all applicable safety precautions, operate

crane and move the boom to the horizontal
position.

9. Remove upper two bolts on the hoist mount that

go through the side plates of base boom.

10. Using all safety precautions start crane and

operate hoist lower lever and gradually lower
hoist till it comes to rest on the turntable.

11. With hoist in resting position, operate hoist to

allow slack in hoist cable to move cable to side
out of way.

12. Shut down crane.

13. Reverse process to reinstall the hoist for opera-

tion.

WARNING: NEVER OPERATE CRANE

WITHOUT PLEXIGLASS SHIELDING IN
PLACE.

Extend/Retract Cable Adjustment Procedure

IMPORTANT: If locking nuts bottom out on
threaded cable adjustment ends on both the extend
and retract cables (no threads remain before
adjustment dimension or torque can be obtained)
cables are stretched and require replacement.

Always replace cables for each boom section in sets,
i.e. all fly and outer-mid section extend cables or all
fly and outer-mid section retract cables.

It is acceptable to cut one inch off of cable adjust-
ment stud with an abrasive cutting saw if extend
cable stud interferes with hoist mounting plate.

Note: Do not torque retract cable ends on boom
nose end of base boom. Torque only extend cables
on hoist end of base boom).

The boom has six extend cables and four retract
cables. Two extend cables extend the fly section and
four extend cables extend the outer-mid section. The
outer-mid and fly sections each use two retract
cables.

1. Lay back hoist. Refer to procedure earlier in

this section.

2. Adjust outer-mid retract cables so lube port

holes at pedestal end of the boom line up with
grease fittings and all slack is removed from
cables.

3. Adjust outer-mid extend cables to remove all

slack.

Lube Ports and Alignment Holes

Figure 4-7. Hoist Layback

Courtesy of Crane.Market

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Summary of Contents for 2500 jbt

Page 1: ...512 942 3000 Sales Fax 717 505 8811 Sales Fax 512 863 3776 Service 800 556 8280 Service 512 942 3022 Service Fax 717 505 8812 Service Fax 512 942 3094 USTC Inc 76 Bowman Road 3000 S Austin Ave York PA 17404 8793 Georgetown TX 78627 1609 2500 2700JBT Cranes Service Manual Courtesy of Crane Market ...

Page 2: ...BER EQUIPMENT IS ONLY AS SAFE AS THOSE WHO OPERATE IT Since safety of personnel and proper use of the machine are of primary concern statements are used throughout this manual to emphasize certain areas The following definitions indicate how a statement will appear in this manual Whenever this symbol is seen in this manual or on the machine personnel safety is a concern Take time to read and under...

Page 3: ...raulic Pump 1 3 Hydraulic Filter 1 3 Hydraulic Tank 1 3 Boom Specifications 1 3 Jibs Optional 1 4 Outriggers And Stabilizers 1 4 A Frame Outriggers 1 4 Out and Down Stabilizers 1 4 Cylinders 1 4 Telescope 1 4 Lift 1 4 A Frame Outrigger 1 4 Out and Down Stabilizer Extend 1 4 Out and Down Stabilizer Jack 1 4 Pressure Settings 1 4 Capacities 1 4 Performance Data 1 5 Hoist Performance 1 5 Functional S...

Page 4: ...tion and Attachment Procedure 4 2 Break In Procedure 4 3 Cable Reeving 4 3 Single Part Line Reeving 4 4 Two Part Line Reeving 4 5 Three Part Line Reeving 4 5 Four Part Line Reeving 4 5 Five and Six Part Line Reeving 4 6 Wear Pads 4 7 Side Wear Pads 4 7 Extend Retract Boom Cables 4 7 Cable Inspection Procedures 4 7 Hoist Layback 4 7 Extend Retract Cable Adjustment Procedure 4 8 Extend Retract Cable...

Page 5: ...ake 5 2 Adjustment 5 2 Disassembly 5 2 Installation 5 3 Gear Reducer Hub 5 4 Hub Disassembly 5 4 Cleaning And Inspection 5 4 Carrier Disassembly 5 5 Primary Carrier Assembly 5 5 Secondary Carrier Assembly 5 6 Hub Assembly 5 6 Swing Bearing 5 7 Bolt Replacement Torque Procedure 5 7 Swing Bearing Wear Tolerance 5 8 SECTION 6 ELECTRICAL General 6 1 Anti Two Block System Operation 6 1 Electrical Syste...

Page 6: ...e Testing 7 2 Main Relief Valve 7 2 Telescope In Relief Valve 7 3 Swing Inlet Relief Valve 7 4 Hoist Relief Valve 7 4 Burst of Speed and Telescope Out Relief Valve 7 5 Cylinders 7 6 Holding Valves 7 6 Dissasembly 7 6 Cleaning and Inspection 7 7 Assembly 7 8 Control Valve 7 10 Hoist Valve 7 11 Manifold Valve 7 12 Hydraulic Filter 7 13 Courtesy of Crane Market ...

Page 7: ...ing Clearance Measurement 5 9 5 7 Bearing Tolerance Check 5 9 6 1 Anti Two Block Positions 6 1 6 2 Electrical Schematic 6 3 6 3 Electrical Power Distribution Diagram 6 4 6 4 Electrical Box Schematic 6 5 6 5 Outrigger Stabilizer Schematic 6 6 6 6 Overload Electrical Schematic 6 7 6 7 Outrigger Stabilizer Wiring 6 8 6 8 Outrigger Stabilizer Switch Wiring 6 9 6 9 A2B with Slow Down Circuit for Platfo...

Page 8: ...ve 7 11 7 10 Manifold Valve 7 12 7 11 Hydraulic Filter 7 13 7 12 Hydraulic Schematic 7 14 7 13 Outrigger Schematic 7 15 7 14 Two Speed Hoist 7 16 7 15 Overload 7 17 7 16 Out and Down Stabilizers with Center Stabilizer 7 18 7 17 Front Center Stabilizer 7 19 7 18 Clam Shell Circuit 7 20 7 19 Emergency Down 7 21 7 20 Hydraulic Schematic with Continuous Rotation 7 22 7 21 Hydraulic Schematic with Cont...

Page 9: ...tenance and operating person nel must be the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided WARNING SINCE MACHINE MANUFACTURER HAS NO DIRE...

Page 10: ... TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT R OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL R KEEP OIL GREASE WATER ETC OFF STANDING SURFACES AND HAND HOLDS R USE CAUTION WHEN CHECKING A HOT PRESSURIZED COOLANT SYSTEM R NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING R BEFORE MAKING ADJUSTMENTS...

Page 11: ... Circle 29 96 in 761 0 mm Ball Diameter 1 37 in 35 mm Bolt Torque 472 lb ft 640 Nm w Loc Wel Patch Dry Control Valve Manufacturer Commercial Intertech Type Dual Inlet Open Center Sections 7 Hoist Valve Manufacturer Commercial Intertech Type Open Center Sections 1 Hydraulic Pump Manufacturer Commercial Intertech Type 3 Section Gear Rated Pump Speed 2400 rpm 1st Section Flow 39 gpm 148 L min 2nd Sec...

Page 12: ... 44 in 1484 mm Rod Diameter 4 00 in 102 mm Nut Torque 1900 2400 lb ft 2576 3254 Nm A Frame Outrigger Bore 4 00 in 102 mm Stroke 56 13 in 1426 mm Rod Diameter 2 75 in 70 mm Nut Torque 1125 1375 lb ft 1525 1864 Nm Out and Down Stabilizer Extend Bore 2 00 in 51 mm Stroke 76 00 in 1930 mm Rod Diameter 1 25 in 32 mm Nut Torque 50 lb ft 68 Nm Out and Down Stabilizer Jack Bore 5 00 in 127 mm Stroke 22 25...

Page 13: ...d to Fully Extended __ sec Minimum 70 sec Maximum 95 sec TELESCOPE IN TELESCOPE IN TELESCOPE IN TELESCOPE IN TELESCOPE IN Extended to Fully Retracted __ sec Minimum 70 sec Maximum 100 sec SWING LEFT 360 SWING LEFT 360 SWING LEFT 360 SWING LEFT 360 SWING LEFT 360 Boom 60 Elevation ______ sec Minimum 40 sec Maximum 50 sec SWING RIGHT 360 SWING RIGHT 360 SWING RIGHT 360 SWING RIGHT 360 SWING RIGHT 36...

Page 14: ...800 29400 32400 38600 42200 42300 47500 53800 59600 64100 73000 78000 87700 8 9 16 18 30 31 43 49 96 120 17 19 30 35 50 55 75 90 110 120 150 170 260 300 430 470 640 700 800 880 1120 1240 1460 1680 1940 2200 LBf FT 6 7 12 13 22 23 32 36 75 86 13 14 23 25 35 40 55 65 80 90 110 130 200 220 320 350 480 530 600 660 840 920 1100 1260 1460 1640 135 105 19 21 35 40 55 60 85 100 120 135 165 190 285 330 475...

Page 15: ...40 0 1640 0 1900 0 1900 0 2500 0 2500 0 3125 0 3125 0 3750 0 3750 0 4375 0 4375 0 5000 0 5000 0 5625 0 5625 0 6250 0 6250 0 7500 0 7500 0 8750 0 8750 1 0000 1 0000 1 1250 1 1250 1 2500 1 2500 1 3750 1 3750 1 5000 1 5000 0 00604 0 00661 0 00909 0 01015 0 01400 0 01474 0 01750 0 02000 0 0318 0 0364 0 0524 0 0580 0 0775 0 0878 0 1063 0 1187 0 1419 0 1599 0 1820 0 2030 0 2260 0 2560 0 3340 0 3730 0 46...

Page 16: ...SECTION 1 SPECIFICATIONS 1 8 USTC January 15 2001 Courtesy of Crane Market ...

Page 17: ...ch the equipment operates WARNING DO NOT MODIFY IN ANY WAY OR USE UNAUTHORIZED PARTS ON THE MACHINE WITHOUT THE EXPRESS WRITTEN CONSENT OF USTC INC PREPARATION FOR USE To ensure that the equipment is ready for operation at all times it should be inspected systematically so that de fects may be discovered and corrected before any result in serious damage or failure Defects discovered during operati...

Page 18: ...1 Lower Lift Cylinder Pin MPG 50 1 12 Swing Bearing MPG 50 2 Apply MPG rotate turntable 90 and Pinion and Swing Bearing Teeth 500 return reapply MPG and rotate 90 in opposite direction 13 Swing Gear Box EPGL 250 1000 Change oil after first 250 hrs and every 1000 hrs thereafter Oil level to be 1 1 2 from top of hub 14 Jib Sheave Optional MPG 50 15 Outrigger Stabilizer Wear Pads MPG 500 Extend beam ...

Page 19: ...fter allowance for normal stretch and diameter reductions of newly rigged cable f Excessive abrasion scrubbing and peeling of outer wires pitting deformation kinking bird caging or other damage resulting in physical changes to the cable structure g Cracked bent worn or improperly installed wedge socket 5 Inspect hook for security of attachment proper swivel lubrication and for nicks cracks gouges ...

Page 20: ...es annual inspections by an authorized dealer A decal located on the turntable behind the cab affords a place to record stamp inspection dates Notify dealer if inspection is overdue The crane must be thoroughly inspected periodically so as to detect in a timely manner the possibility of damaged or improperly installed parts Frequency of inspection will to a large extent depend upon crane activity ...

Page 21: ... of leakage and security of attachment Check cable attachment to hoist drum 16 Inspect hydraulic electric swivel assembly for obstructions damage and security of attachment Check for pinched wires or hoses and leakage 17 Check telescope cylinder and lines for damage evidence of leakage and security of attachment 18 Check boom structure for damage missing or loose parts hardware and security of att...

Page 22: ...SECTION 2 INSPECTION 2 6 USTC January 15 2001 Courtesy of Crane Market ...

Page 23: ...al system Each malfunction or trouble within an individual group or system is followed by a listing of probable causes which will enable determination of the appli cable remedial action The probable causes and the remedial actions should where possible be checked in the order listed in the tables It should be noted that there is no substitute for a thorough knowledge of the equipment and related s...

Page 24: ...s out of adjustment Attach pins damaged Boom nose lugs damaged Jib attach lugs damaged Jib stowage attach bracket out of adjustment Defective bearing Upper lift cylinder pin damaged or worn Boom pivot pin or bushings damaged or worn Replace applicable cables Replace anchor weldment Replace applicable sheaves or attach pins Adjust cables Replace nuts and applicable cables Adjust cable systems Repla...

Page 25: ...ontrol valve out of adjustment Change oil using recommended viscosity and flush system Loosen valve and check mounting Replace mounting if bent Remove valve and repair or replace Remove valve and repair or replace Check pressure delivery to and from valve and repair or replace Repair or replace control rod or lever Remove and repair valve Remove valve and repair or replace Remove line and clear ob...

Page 26: ... pump drive shaft Low hydraulic oil level Restricted or broken suction line Worn or chipped pump gears Worn or broken pump drive shaft Replace poppet spring Replace shift rail Replace shift fork or tighten set screw in shift fork Replace worn gears Check shift linkage for proper adjustments Adjust shift linkage to permit full shift Check backlash and refer to setting the backlash Replace worn gear...

Page 27: ...er control valve Hydraulic lines incorrectly connected to cylinder Malfunctioning crossover valve Malfunctioning outrigger valve Excessive oil leak past piston seal Relief valve in control valve set too low Replace switch Add oil Remove line and clear obstruction or replace line Repair or replace pump Check pressure delivery from control valve and repair or replace valve Connect hydraulic lines pr...

Page 28: ...ce anti two block Add oil Remove line and clear obstruction or replace lines Repair or replace pump Repair or replace control cable Check pressure delivery from control valve and repair or replace valve Low hydraulic oil level Restricted or broken supply line Malfunctioning hydraulic pump Worn valve spool Low hydraulic oil level Restricted or broken hydraulic line Malfunctioning hydraulic pump Con...

Page 29: ...l TROUBLE PROBABLE CAUSE REMEDY Table 3 4 Hydraulic Components continued Hoist will not raise load or load handling device Hoist will not raise load or load handling device continued Hoist lowers load with control lever in neutral Hoist chatters while raising or lowering load Boom will not elevate Repair or replace hoist motor Repair or replace sticking valve Disassemble hoist and repair or replac...

Page 30: ...ged Malfunctioning holding valve on cylinder Defective cylinder packing Worn control valve spool Malfunctioning holding valve on cylinder Add oil Remove line and clear obstruction or replace line Repair or replace pump Repair or replace control cable Repair or replace check valve Repair or replace cylinder Check pressure delivery from control valve and repair or replace valve Connect hydraulic lin...

Page 31: ...eplace swing brake Replace counterbalance valve Hydraulic oil level low Restricted or broken supply line Malfunctioning hydraulic pump section Control cable broken kinked or disconnected Worn control valve spool Malfunctioning swing motor Malfunctioning swing brake Malfunctioning drive hub Relief valve in control valve inlet set too low Restricted or broken supply line Worn control valve spool For...

Page 32: ...r broken supply line Malfunctioning hydraulic pump Worn control valve spool Worn or defective swing motor Swing circuit relief vale set too low Check valve in telescope section stuck in closed position Control cable broken kinked or disconnected Hydraulic oil level low Malfunctioning hydraulic pump Worn control valve spool Hydraulic lines incorrectly connected at control valve Excessive oil leakin...

Page 33: ... Lack of lubricant on boom sections Wear pads out of adjustment or worn One or more boom sections distorted Check pressure delivery from control valve and repair or replace valve Connect hydraulic lines properly Check for presence of pilot pressure at return valve and repair or replace Adjust or replace relief valve Remove and repair telescope cylinder Remove and repair cylinder Repair or replace ...

Page 34: ...ning horn button switch or loose terminal connections Malfunctioning horn Relay in ground electrical box defective Determine cause of circuit overload or short and correct before replace fuse Check switch for correct operation with test meter Replace or repair as necessary Check for defective horn with test meter Replace as necessary Replace relay Courtesy of Crane Market ...

Page 35: ... every 2000 hours whichever occurs first CAUTION WEAR GLOVES TO PROTECT HANDS WHEN HANDLING CABLE The periodic inspection shall cover the entire length of cable The inspection frequency shall be based on such factors as expected cable life as determined by experience with similar installations severity of environment percentage of capacity lifts frequency rates of operation and exposure to shock l...

Page 36: ...A good indicator of stretched extend retract cables is if the adjusting nuts are bottomed out If no adjustment remains the cables have stretched and need replacement Also check for cracked bent worn severely cor roded or improperly installed cable ends Inspect sheave grooves for excessive wear IMPORTANT To establish a basis for judging the proper time for cable replacement a dated cable condition ...

Page 37: ...obtain the maximum amount of permissible rope pull multiple parts of line must be run See the Permissible Main Rope Pull section of the Load Capacity Chart for different ratings for each configuration LOAD LINE SHORT PIECE OF WIRE ROPE MUST NOT EXCEED LENGTH OF WEDGE SEIZING ON FREE END OF ROPE LOAD LINE LIVE END MUST BE ON THIS SIDE OF SOCKET CLAMP TORQUE ROPE SIZE in TORQUE lb ft 7 16 1 2 9 16 5...

Page 38: ...end of cable extends beyond boom nose 3 If not already done reeve hoist cable through base and mid boom cable guides on top of boom 4 Remove upper and lower hoist cable retaining pins on boom nose 5 Reeve hoist cable through the boom nose over the upper sheave wheel and lower right sheave wheel 6 If not already done install cable socket onto the end of the hoist cable 7 Attach cable socket to the ...

Page 39: ...edge socket pin securing the wedge socket to the boom nose lug or hookblock headache ball assembly 5 Remove lower hoist cable retaining pin from the boom nose 6 The headache ball hookblock assembly must be configured as a single or double sheave hook block assembly The hoist cable can either be reeved through the headache ball hookblock assembly after removing the open wedge cable socket as in Ste...

Page 40: ...oom nose 10 Reinstall anti two block counterweight around the hoist cable and adjust counterweight chain length to activate cut off switch before two blocking occurs Five and Six Part Line Reeving If it is desired to handle higher loads than the four part lined is rated for the crane can be equipped with a single sheave snatch block to allow for five and six part line reeving The snatch block hang...

Page 41: ...e adjusted to make the boom extend straight When the boom is fully ex tended the boom must be within 1 2 in of straight when measured side to side Fully extend the boom Attach one end of a string centered on top of the boom at the pedestal end and the other at the nose end If the boom string does not trace along the center of the boom add or remove shims under side wear pads at nose end to cause t...

Page 42: ...n resting position operate hoist to allow slack in hoist cable to move cable to side out of way 12 Shut down crane 13 Reverse process to reinstall the hoist for opera tion WARNING NEVER OPERATE CRANE WITHOUT PLEXIGLASS SHIELDING IN PLACE Extend Retract Cable Adjustment Procedure IMPORTANT If locking nuts bottom out on threaded cable adjustment ends on both the extend and retract cables no threads ...

Page 43: ...SECTION 4 BOOM 3120933 Rev 0 USTC 4 9 Figure 4 8 Internal Boom Cable Reeving Outer Mid Retract Cable Fly Retract Cable Outer Mid Extend Cable Fly Extend Cable Courtesy of Crane Market ...

Page 44: ...nd reeve cable for the configuration required i e one part line two part line etc Refer to reeving instructions earlier in this manual 16 Reinstall hoist Extend Retract Cable Replacement When the extend cables require replacement and the boom is not scheduled to be completely disassembled it is possible to attach a wire to one end of the old cable before pulling the cable out Once the old cable is...

Page 45: ...SECTION 4 BOOM 3120933 Rev 0 USTC 4 11 Lift Cylinder Rod Keeper Rod Keeper Rod Keeper Pivot Pin Sleeve Boom Pivot Pin Lift Cylinder Pin Lift Cylinder Pin Figure 4 9 Boom Removal Courtesy of Crane Market ...

Page 46: ...etract lift cylinder using crane hydraulics Insert pin through boom and lift cylinder Secure pin with rod keeper Torque keeper bolt per Torque Chart Boom Disassembly The boom has four sections which extend proportion ally using a telescope cylinder connected to each of the sections through a series of extend and retract cables Wear pads are provided inside the nose end and on the outside of the pe...

Page 47: ...protected prior to installation Re place pins as necessary Inspect upper and lower boom nose sheaves for wear ovality scoring or other damage Replace sheaves as necessary Inspect all sheaves boom nose extend and re tract cables for excessive groove wear burrs or other damage Replace sheaves as necessary Inspect extend and retract cable sheave pins for scoring tapering ovality and evidence of corre...

Page 48: ...ction retract cables to fly section using clamps at the pedestal end Use mechanic s wire to hold middle of cable in approximate location of sheaves inside outer mid section Lay bullet end of extend cables in approximate position at pedestal end 3 Attach ramp to fly section Using mechanic s wire hold ramp up as high as possible Pull cable ends top and bottom in towards center of fly section to prev...

Page 49: ...the nose end insert the top wear pad and two bottom wear pads and shims Attach cable guide assembly to top of base section opposite top wear pad Shim bottom wear pads as necessary to provide 1 16 in clearance Be sure to orient bottom wear pads toward outside edge of sec tion 21 Insert four side wear pads loosely to inside of base section Shims will be added after boom is assembled 22 Install lower...

Page 50: ...i mately 25 ft Set Park Brake 2 Lay back hoist Refer to hoist layback proce dure 3 Evenly remove four nylon insert lock nuts from extend cables Note If a single nut is removed completely with tension on any remaining cables the free cable will retract into boom and completely boom disassembly will be required 4 Remove six socket head bolts which secure the cable retainer block to the base section ...

Page 51: ...ylinder and retract cables inside boom assembly Be sure cylinder sheaves stay vertical no twisting as cylinder is inserted into boom assembly CAUTION WHEN USING SLING TO LIFT CYLINDER USE BLOCKS TO PREVENT PINCHING AND DEFORMATION OF CABLE WHEN REPOSITIONING SLING USE BLOCKING TO PREVENT LAYING CYLINDER ON CABLES 5 When telescope cylinder is approximately six feet from being completely in boom ass...

Page 52: ...orts along the way Con tinue until retract cables are inside wear pad locations 3 Insert side wear pads inside outer mid section loosely without shims Install upper and lower wear pads shimming bottom wear pads to 1 16 clearance Be sure to orient lower pads toward outside edge of section 4 Slide remainder of fly section and any other sections completely into base section 5 Lay extend cables in gro...

Page 53: ... speed will not be attainable Refer to the Operating and Safety Manual for information on PTO selection COUNTERBALANCE VALVE A dual counterbalance valve mounted on the inside of the turntable balances the pressure between left and right swing Without the counterbalance valve the swing motor would drive the pump backwards until the boom stopped rotating When one side is pressurized the off side rec...

Page 54: ...ake The brake should engage and stop rotation in one to two seconds To adjust loosen the set screw on flow control valve If the turntable continues to rotate turn the adjust ment knob counterclockwise If the turntable stops abruptly less than one second turn the adjustment knob clockwise After adjusting tighten the set screw Disassembly CAUTION DO NOT CLAMP OR OTHERWISE RESTRAIN COVER FROM MOVING ...

Page 55: ...ase by tapping out the output end with a soft hammer Installation Note Unless otherwise specified use automatic transmission fluid ATF Type F as a lubricant for the swing brake 1 If removed install shaft seal and bearing in the case 2 Install shaft in brake case Tap shaft into place with a soft hammer 3 Install friction pack in the brake case Install spacer first and friction discs and spacers Not...

Page 56: ...g surfaces are not damaged Discard o ring seal 3 Remove input thrust washer and carefully re move input gear segment Discard thrust washer 4 Remove primary carrier assembly together with sun gear Be careful not to damage gear teeth 5 Remove and discard bolts retaining bearing retainer plate to output shaft 6 Place hub in a suitable hydraulic press with the pinion gear portion of the output shaft d...

Page 57: ...hing roll pin 4 Remove the planet gear and washers from the carrier and if necessary remove and discard the bearing from the planet gear 5 Using a suitable punch gently tap roll pin from planet pin and carrier housing 6 Repeat steps 1 through 5 for remaining planet gears Primary Carrier Assembly 1 Using the press install bearing into planet gear making sure teh bearing cage is installed squarely 2...

Page 58: ...ed holes in retainer plate If needed align holes in retainer plate directly over holes in shaft and shims 4 If necessary gently tap planet pin into position with a soft mallet ensuring that roll in holes are aligned and planet gear rotates freely 5 Position a new roll pin in the carrier hole and drive the pin into the hole until the end of the pin is flush with carrier surface Again ensure that pl...

Page 59: ...alant on magnetic plug and install into oil fill hole in cover 22 Stick a shaft into input gear and turn by hand to be sure unit runs smoothly and easily SWING BEARING The swing bearing carries all the load from the boom The bearing is manufactured with a certain clearance which must be maintained to obtain a smooth rotation with low torque requirements Bearing mounting bolts must also be monitore...

Page 60: ...nctional Note The following procedure serves only to illustrate how a relative clearance measurement may be acquired to evaluate the integrity of a swing bearing The only true method to determine the integrity of the bearing is to compare the original clearance between the inner and outer race as manufactured to the current measurement on the bearing in question If the condition of the bearing is ...

Page 61: ... the opposite side of the boom 3 With the boom at horizontal and fully retracted place a suitable 5 ton hydraulic jack between the deck and the boom Raise the boom enough to reverse the load on the swing bearing 4 At the rear center of the pedestal measure and record the distance between the swing bearing and pedestal If the distance is greater than 0 072 in 1 829 mm then it may be necessary to re...

Page 62: ...SECTION 5 SWING DRIVE 5 10 USTC January 15 2001 Courtesy of Crane Market ...

Page 63: ...pe out and hoist up func tions in the event that the sheave block contacts the anti two block counterweight suspended on the hoist cable beneath the boom nose The normally open NO switch mounted to the boom nose is held closed by the counterweight This switch opens when the hookblock comes into contact with and raises the counterweight The switch opens the circuit to the solenoid valve thus direct...

Page 64: ...te power between the various components located in the main electrical box OVERLOAD SYSTEM The overload system includes an optional shut down function on some models The shut down function operates by activating a solenoid valve that dumps oil to the reservoir The overload system monitors the pressure difference between the extend and retract ports If the machine is overloaded the system will not ...

Page 65: ...SECTION 6 ELECTRICAL 3120933 Rev 0 USTC 6 3 Figure 6 2 Electrical Schematic 1282312 Rev N Courtesy of Crane Market ...

Page 66: ...SECTION 6 ELECTRICAL 6 4 USTC January 15 2001 Figure 6 3 Electrical Power Distribution Diagram 1282312 Rev N Page 2 Courtesy of Crane Market ...

Page 67: ...SECTION 6 ELECTRICAL 3120933 Rev 0 USTC 6 5 Figure 6 4 Electrical Box Schematic 0254930 Rev I Courtesy of Crane Market ...

Page 68: ...SECTION 6 ELECTRICAL 6 6 USTC January 15 2001 Figure 6 5 Outrigger Stabilizer Schematic 1282315 Rev C Courtesy of Crane Market ...

Page 69: ...SECTION 6 ELECTRICAL 3120933 Rev 0 USTC 6 7 Figure 6 6 Overload Electrical Schematic 1282314 Rev K Courtesy of Crane Market ...

Page 70: ...SECTION 6 ELECTRICAL 6 8 USTC January 15 2001 Figure 6 7 Outrigger Stabilizer Wiring 4932612 Rev B Courtesy of Crane Market ...

Page 71: ...SECTION 6 ELECTRICAL 3120933 Rev 0 USTC 6 9 Figure 6 8 Outrigger Stabilizer Switch Wiring 0257474 Rev Courtesy of Crane Market ...

Page 72: ...SECTION 6 ELECTRICAL 6 10 USTC January 15 2001 Figure 6 9 A2B with Slow Down Circuit for Platform Installation Wiring 0257289 Rev A Courtesy of Crane Market ...

Page 73: ...SECTION 6 ELECTRICAL 3120933 Rev 0 USTC 6 11 Figure 6 10 Radio Remote Control 4933062 Rev A Courtesy of Crane Market ...

Page 74: ...SECTION 6 ELECTRICAL 6 12 USTC January 15 2001 Figure 6 11 Clam Shell 1282077 Rev A Courtesy of Crane Market ...

Page 75: ...chalk line to mark outer mid section at end of base section 3 Raise boom to maximum elevation 80 4 Shut down hydraulic system by disengaging Power Take Off PTO and turning off truck engine 5 With engine off move telescope control lever to retract boom If boom starts to retract holding valve is defective and requires replacement 6 If boom does not retract complete steps 7 through 10 CAUTION HYDRAUL...

Page 76: ...r 9 Check to see whether boom has lowered more than eight inches If boom has lowered and oil is leaking around rod end cap of cylinder seals in cylinder are defective and require replacement If boom has lowered and oil is leaking from the holding valve the valve is either improperly adjusted or defective and requires replacement CAUTION ENSURE THAT HYDRAULIC LINES ARE CONNECTED PROPERLY 10 Connect...

Page 77: ... pressure set ting If pressure is too high turn the adjustment screw counterclockwise to decrease the pres sure setting 5 Tighten jam nut while holding the adjusting screw or install the acorn nut 6 Repeat step 3 to ensure that the pressure set ting is correct Telescope In Relief Valve The telescope in function has a separate relief valve on the retract side of the telescope section 1 Attach a 0 4...

Page 78: ...ove the acorn nut or loosen the jam nut on the relief valve cartridge to access the adjustment screw If the pressure is too low turn the adjustment screw clockwise to increase the pressure setting If pressure is too high turn the adjustment screw counterclockwise to decrease the pres sure setting 6 Tighten jam nut while holding the adjusting screw or install the acorn nut 7 Repeat step 4 to ensure...

Page 79: ...tween the main control valve and the hoist control valve and plug 3 Using all applicable safety practices start the truck engine engage the PTO and set the outrig gers Operate the crane at low engine speed 4 Operate the appropriate control lever and note the pressure reading on the gauge IMPORTANT For telescope out relief valve testing be sure the outriggers and stabilizers are set The boom must b...

Page 80: ...ers vary depending upon the application The procedures described herein are general If specific questions arise contact the USTC Customer Service Department If not equipped with cylinder disassembly tools refer to a specialty hydraulic shop IMPORTANT Perform cylinder disassembly and assembly on a clean work surface in a dirt free environment Dissasembly 1 Connect a suitable auxiliary hydraulic pow...

Page 81: ... seal and wiper seal s Cleaning and Inspection 1 Clean all parts thoroughly in an approved com mercial cleaning solvent 2 Inspect cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary 3 Inspect threaded portion of rod for damage Dress threads as necessary 4 Inspect inner surface of cylinder barrel tube for scoring ...

Page 82: ...ter groove Ensure correct orientation 6 Place the piston on the cylinder rod ensuring that o ring is not damaged or dislodged 7 Using suitable protection for the rod clamp cylinder rod in a vise or holding fixture as close to the piston as possible Push piston onto rod until it contacts the spacer end and install lock nut Torque lock nut according to table 8 Remove the cylinder rod from the holdin...

Page 83: ...SECTION 7 HYDRAULICS 3120933 Rev 0 USTC 7 9 Figure 7 6 Control Valve Linkage Courtesy of Crane Market ...

Page 84: ...rough linkages to the control handles The control valve can be accessed inside the pedes tal through the pedestal side covers for adjustments and hose replacement If the valve must be replaced or other components require access the console weldment can be removed To remove the console weldment the hoses must be disconnected from the valves mounted on the inside of the console weld ment IMPORTANT A...

Page 85: ...et section The hoist valve is located on the inside of the console weldment above the main control valve The hoist valve can be accessed by removing the side covers from the pedestal To remove the valve disconnect the hoses and the linkage from the valve Remove the bolts securing the valve to the console weldment IMPORTANT Clean area around valve and valve to prevent dirt and contamination from en...

Page 86: ...additional 24 gpm to the hoist control valve The solenoid valve cartridges can be removed and cleaned if necessary Four check valves are also removable for cleaning Figure 7 10 Manifold Valve The solenoids are interchangeable To test one of the solenoids they can be interchanged if the opposing solenoid is known to be working If the solenoid fails but the cartridge is operational replace the solen...

Page 87: ...n before the oil is returned into the tank The filter is equipped with a gauge which indicates the pressure differential between the entry and exit of the oil into the filter When the gauge indicates in the red it should be replaced If the element is not replaced and becomes clogged a bypass opens in the filter head to release unfiltered oil into the tank IMPORTANT Do not operate the crane with a ...

Page 88: ...SECTION 7 HYDRAULICS 7 14 USTC January 15 2001 1282489 Rev G Sheet 1 Figure 7 12 Hydraulic Schematic Courtesy of Crane Market ...

Page 89: ...SECTION 7 HYDRAULICS 3120933 Rev 0 USTC 7 15 Figure 7 13 Outrigger Schematic 1282489 Rev G Sheet 2 Courtesy of Crane Market ...

Page 90: ...SECTION 7 HYDRAULICS 7 16 USTC January 15 2001 Figure 7 14 Two Speed Hoist 1282489 Rev G Sheet 3 Courtesy of Crane Market ...

Page 91: ...SECTION 7 HYDRAULICS 3120933 Rev 0 USTC 7 17 Figure 7 15 Overload 1282330 Rev C Courtesy of Crane Market ...

Page 92: ...SECTION 7 HYDRAULICS 7 18 USTC January 15 2001 Figure 7 16 Out and Down Stabilizers with Center Stabilizer 2792296 Rev Courtesy of Crane Market ...

Page 93: ...SECTION 7 HYDRAULICS 3120933 Rev 0 USTC 7 19 Figure 7 17 Front Center Stabilizer 2792287 Rev Courtesy of Crane Market ...

Page 94: ...SECTION 7 HYDRAULICS 7 20 USTC January 15 2001 Figure 7 18 Clamshell Circuit 1282076 Rev D Courtesy of Crane Market ...

Page 95: ...SECTION 7 HYDRAULICS 3120933 Rev 0 USTC 7 21 Figure 7 19 Emergency Down 2792484 Rev Courtesy of Crane Market ...

Page 96: ...SECTION 7 HYDRAULICS 7 22 USTC January 15 2001 Figure 7 20 Hydraulic Schematic with Continuous Rotation 1282502 Rev F Courtesy of Crane Market ...

Page 97: ...SECTION 7 HYDRAULICS 3120933 Rev 0 USTC 7 23 Figure 7 21 Outrigger Hydraulic Schematic with Continuous Rotation 1282502 Rev F Sheet 2 Courtesy of Crane Market ...

Page 98: ...SECTION 7 HYDRAULICS 7 24 USTC January 15 2001 Powered by TCPDF www tcpdf org Courtesy of Crane Market ...

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