Reference Only: Supplement To Service Manual Boom Cable Tensioning

Supplement to Service Manual
Boom Cable Tensioning
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© 2017 Manitowoc
Published 03-23-2017, Control# 641-01
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This Supplement provides information regarding the proper Cable Tensioning
Tensioning of Extend and Retract Cables and Positive Lock
of adjustment hardware on National Crane Boom cable Tensioning Setup Procedure
assemblies. The information provided here supplements the
Tensioning must be done with the boom in the horizontal
Service Manual and must be used in conjunction with all
position.
other manuals.
When tightening/loosening the first (adjustment) nuts on
GENERAL cables, secure cable using the wrench flats at the front of the
cable ends to prevent cable twist. Excess twisting of cables
A boom assembly is considered properly timed when can cause premature failure.
telescoping sections extend equally relative to each other
and bottom out simultaneously at full retraction and do not Ensure boom is completely assembled and fully retracted.
spring back out after retract pressure is returned to neutral. 1. Mark the front of each section with a chalk line as
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Hydraulic extend cylinder construction will dictate which indicated in Figure 1.
extendable section will be the driver that the other extend 2. Extend and retract boom several times to establish
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sections will need to be adjusted to utilizing cable working state of cables.
adjustment.
3. Extend boom so scribed lines are exposed by
A single stage cylinder will control first extendable section. approximately 12 inches.
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A dual stage cylinder will control second extendable section. 4. Measure the extension gaps between each boom
Timing sequence of cables will depend on number of section and scribed line and note values.
sections and the extend cylinder construction. 5. Retract boom so that the scribed lines are exposed by
approximately 6 inches.
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Design intent of the cable tensioning is to balance the
preload of extend and retract cables for each extendable 6. Measure the retraction gaps between each boom
section. In addition, sequencing of the sections during section and scribed line and note values.
retraction requires retract cables of every section to be
indexed relative to each other. 7. Extend and retract the boom a few times and then
repeat measuring the extension gaps.
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8. Adjust all corresponding cables according to Cable

Tightening Sequence instructions.
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8860-5
8860-6
FIGURE 1
Cable Tension Sequence 1. 321 retract cables

2. 123 extend (synchronizing) cables.
Five section boom with two stage cylinder.
3. 234 extend cables
Cable tensioning (See Figure 2) to be in the following order:
4. 432 retract cables.
5. 345 extend cables
GROVE Published 03-23-2017, Control# 641-01 1

6. 543 retract cables. 1. 123 extend cables.
Four section boom with two stage cylinder. 2. 321 retract cables.
Cable tensioning to be in the following order: 3. 234 extend cables.
1. 321 retract cables 4. 432 retract cables.
2. 123 extend (synchronizing) cables. Three section boom with one stage cylinder.
3. 234 extend cables Cable tensioning to be in the following order:
4. 432 retract cables. 1. 123 extend cables.
Four section boom with one stage cylinder. 2. 321 retract cables.
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Cable tensioning to be in the following order:
5 - Section Boom w/ 2 Stage Cylinder Cable Positioning
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1/2/3 EXTEND 2/3/4 EXTEND 3/4/5 EXTEND
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8860-1
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3/2/1 RETRACT 4/3/2 RETRACT 5/4/3 RETRACT
FIGURE 2
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Cable Tightening Sequence 5 Section Boom with Two 4. Tightening until the extension gap between the first and
Stage Extend Cylinder second section and the extension gap between the
second and the third are equal.
Boom must be in horizontal position when adjusting cable
tension (See Figure 2.) Retract boom fully ensuring sections If when tightening the 321 retract cable the third section
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are bottomed out on section stops and do not spring back. starts to go out with the second section the 123
(Reference Tensioning Setup Procedure) synchronizing cable located at the top back of the base
section may need to be loosened.
321 and 123 cable balancing
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Retraction
Extension
1. Measure the retraction gaps between the first and
1. Measure the extension gaps between the first and second section and the second and third section.
second section and the second and third section.
If the retraction gap is greater between the first and second
If the extension gap between first and second section is less section than the retraction gap between the second and third
than the extension gap between the second and third section;
section;
2. Tighten the 123 synchronizing cable located at the back
2. Tighten 321 retract cable located at the front bottom of of the base section the difference in the retraction gap
the base section the difference in the extension gap measurements.
measurements.
3. Extend and retract the boom a few times and then
3. Extend and retract the boom a few times and then repeat measuring the retraction gaps.
The third section should have moved out.
The second section should have moved out.
2 Published 03-23-2017, Control# 641-01

4. Tightening until the retraction gap between the first and At this time the third, second and first extendable sections
second section and the retraction gap between the should extend and retract equally and bottom out against the
second and the third are equal. stops simultaneously.
At this time the second and first extendable sections should 345 and 543 cable balancing
extend and retract equally and bottom out against the stops
simultaneously. Extension
1. Measure the extension gaps between the fourth and fifth
section and the third and fourth section.
Extension
If the extension gap between fourth and fifth section is less
1. Measure the extension gaps between the third and than the extension gap between the third and fourth section;
fourth section and the second and third section.
2. Tighten the 345 extend cable located at the back top of
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If the extension gap between third and fourth section is less the third section the difference in the extension gap
than the extension gap between the second and third measurements.
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section;
2. Tighten the 234 extend cable located at the back top of repeat measuring the extension gaps.
the second section the difference in the extension gap
The fifth section should move outward.
measurements.
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4. Tightening until the extension gap between the fifth and
fourth section is equal to the extension gap between the
fourth and third section.
The fourth section should have moved out.
Retraction
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4. Tightening until the extension gap between the third and
1. Measure the retraction gaps between the fourth and fifth
section and the third and fourth section.
second and third section.
If the retraction gap is greater between the fourth and fifth
Retraction
section than the retraction gap between the third and fourth
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1. Measure the retraction gaps between the second and section;

third section and the third and fourth section.
2. Tighten the 543 retract cable located at the front bottom
If the retraction gap is greater between the third and fourth of the third section the difference in the retraction gap
section than the retraction gap between the second and third measurements.
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section;
2. Tighten the 432 retract cable located at the front bottom repeat measuring the retraction gaps.
of the second section the difference in the retraction gap
The fifth section should have moved in.
measurements.
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4. Tightening until the retraction gap between the fifth and

fourth section is equal to the retraction gap between the
repeat measuring the retraction gaps.
fourth and third section.
The fourth section should have moved in.
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At this time the all extendable sections should extend and

4. Tightening until the retraction gap between the third and retract equally and bottom out against the stops
fourth section is equal to the retraction gap between the simultaneously.

4- Section Boom w/ 2 Stage Cylinder Cable Positioning
1/2/3 EXTEND
TIP
2/3/4 EXTEND
BASE 1ST STAGE

2ND STAGE
3RD STAGE 4th STAGE
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8860-2
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4/3/2 RETRACT
3/2/1 RETRACT
FIGURE 3
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Cable Tightening Sequence 4 Section Boom with Two Retraction
Stage Extend Cylinder
Boom must be in horizontal position when adjusting cable second section and the second and third section.
tension (See Figure 3.) Retract boom fully ensuring sections
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If the retraction gap is greater between the first and second
are bottomed out on section stops. Ensure all sections are
section than the retraction gap between the second and third
fully bottomed out and do not spring back.(Reference
section;
Tensioning Setup Procedure)
2. Tighten the 123 synchronizing cable located at the back
321 and 123 cable balancing of the base section the difference in the retraction gap
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Extension measurements.
1. Measure the extension gaps between the first and 3. Extend and retract the boom a few times and then
second section and the second and third section. repeat measuring the retraction gaps.
If the extension gap between first and second section is less The third section should have moved out.
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than the extension gap between the second and third 4. Tightening until the retraction gap between the first and
section; second section and the retraction gap between the
2. Tighten 321 retract cable located at the front bottom of second and the third are equal.
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the base section the difference in the extension gap At this time the second and first extendable sections should
measurements. extend and retract equally and bottom out against the stops
3. Extend and retract the boom a few times and then simultaneously.
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The second section should have moved out.
Extension
4. Tightening until the extension gap between the first and
1. Measure the extension gaps between the third and
second section and the extension gap between the
fourth section and the second and third section.
If the extension gap between third and fourth section is less
If when tightening the 321 retract cable the third section
than the extension gap between the second and third
starts to go out with the second section the 123
section;
synchronizing cable located at the top back of the base
section may need to be loosened. 2. Tighten the 234 extend cable located at the back top of
the second section the difference in the extension gap
measurements.

The fourth section should have moved out. 2. Tighten the 432 retract cable located at the front bottom
4. Tightening until the extension gap between the third and
measurements.
second and third section. 3. Extend and retract the boom a few times and then
Retraction
The fourth section should have moved in.
1. Measure the retraction gaps between the second and
third section and the third and fourth section. 4. Tightening until the retraction gap between the third and
fourth section is equal to the retraction gap between the
If the retraction gap is greater between the third and fourth
section than the retraction gap between the second and third
section; At this time the all extendable sections should extend and
retract equally and bottom out against the stops
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simultaneously.
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1/2/3 EXTEND 2/3/4 EXTEND
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TIP
BASE 1ST STAGE

2ND STAGE 3RD STAGE
4th STAGE
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8860-3
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3/2/1 RETRACT 4/3/2 RETRACT

FIGURE 4
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Cable Tightening Sequence 4 Section Boom with (1) The third section should have moved out.
Boom must be in horizontal position when adjusting cable second section and the extension gap between the
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tension (See Figure 4.) Retract boom fully ensuring sections second and the third are equal.
Retraction
fully bottomed out and do not spring back.(Reference
Tensioning Setup Procedure) 1. Measure the retraction gaps between the first and
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If the retraction gap is greater between the second and third
Extension section than the retraction gap between the first and second
1. Measure the extension gaps between the first and section;
second section and the second and third section. 2. Tighten the 321 retract cable located at the front bottom
If the extension gap between second and third section is less of the base section the difference in the retraction gap
than the extension gap between the first and second section; measurements.
2. Tighten 123 extend cable located at the back top of the 3. Extend and retract the boom a few times and then
base section the difference in the extension gap repeat measuring the retraction gaps.
measurements. The third section should have moved in.

4. Tightening until the retraction gap between the first and 4. Tightening until the extension gap between the third and
second section and the retraction gap between the fourth section is equal to the extension gap between the
second and the third are equal. second and third section.
At this time the second and first extendable sections should Retraction
extend and retract equally and bottom out against the stops
1. Measure the retraction gaps between the second and
simultaneously.
third section and the third and fourth section.
234 and 432 cable balancing If the retraction gap is greater between the third and fourth
Extension section than the retraction gap between the second and third
section;
1. Measure the extension gaps between the third and
fourth section and the second and third section. 2. Tighten the 432 retract cable located at the front bottom
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If the extension gap between third and fourth section is less measurements.
than the extension gap between the second and third
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section;
2. Tighten the 234 extend cable located at the back top of
the second section the difference in the extension gap The fourth section should have moved in.
measurements.
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4. Tightening until the retraction gap between the third and
3. Extend and retract the boom a few times and then fourth section is equal to the retraction gap between the
repeat measuring the extension gaps. second and third section.
The fourth section should have moved out. At this time the all extendable sections should extend and
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simultaneously.

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TIP
EXTEND CABLE
BASE
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1ST SECTION 3RD SECTION

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8860-4 2ND SECTION
RETRACT CABLE
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FIGURE 5
Cable Tightening Sequence 3 Section Boom with (1) 321 and 123 cable balancing
Extension
Boom must be in horizontal position when adjusting cable
1. Measure the extension gaps between the first and
tension (See Figure 5.) Retract boom fully ensuring sections
fully bottomed out and do not spring back.(Reference If the extension gap between second and third section is less
Tensioning Setup Procedure) than the extension gap between the first and second section;
2. Tighten 123 extend cable located at the back top of the
base section the difference in the extension gap
measurements.

3. Extend and retract the boom a few times and then 2. Tighten the 321 retract cable located at the front bottom
repeat measuring the extension gaps. of the base section the difference in the retraction gap
measurements.
The third section should have moved out.
second section and the extension gap between the
second and the third are equal. The third section should have moved in.
Retraction 4. Tightening until the retraction gap between the first and
second section and the retraction gap between the
At this time the all extendable sections should extend and
If the retraction gap is greater between the second and third
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section than the retraction gap between the first and second
simultaneously.
section;
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OPTION 1
5 5 OPTION 2
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6
3
4
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8859-1 8859-2
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2 2
1 1
FIGURE 6
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Cable Retention NOTE: (OPTION 2) method used ONLY when space

constraints prevent OPTION 1 usage.
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Cable Retention Hardware

When tightening/loosening the first (adjustment) nuts on
Item Description cables, secure cable using the wrench flats at the front of the
cable ends to prevent cable twist.
1 Threaded Cable End
After the cable adjustment procedure is completed for the
2 Nut (Adjustment)
entire boom assembly. The second (torqued) nut must be
3 Nut (Positive Lock) installed on all retract and extend cables.
4 Setscrew The second nut should be hand tightened until it comes in
5 Washer contact with the back of the first nut.
6 Nut (Torqued) Hold the first (adjustment) nut stationary and a torque
wrench to tighten the second (torqued) nut against the first
Nut configuration (see Figure 6) will be First Nut (adjustment) nut to the values indicated in TORQUE
(ADJUSTMENT) and Second Nut (TORQUED). VALUES for Second Nut:

Third (positive lock) nut installation is to be placed on each of
the extend cables. The retract cables do not require the third Metric Series with Coarse Threads
(positive lock) nut. Minimum
The third nut should be hand tightened until the tapped hole Cable end Nut TORQUE
Nut Type
for the set screw is tangent to the end face of the wrench flat. Thread Size Property Nm
Class
Install set screw into Third nut and tighten.
Hex Jam
(OPTION 2) method used ONLY when space constraints M16x2 5 26
(THIN)
prevent OPTION 1 usage (see Figure 6).
Hex Jam
M20x2.5 5 66
TORQUE VALUES for Second Nut: (THIN)
Inch Series with Coarse Threads (UNC)
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Minimum
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Cable end Nut TORQUE
Nut Type
Thread Size Strength ft lbf
GRADE
Hex Jam
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1/2-13 SAE 2 12
(HALF)
Hex Jam
5/8-11 SAE 2 31
(HALF)
Hex Jam
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3/4-10 SAE 2 47
(HALF)
Hex Jam
7/8-9 SAE 2 63
(HALF)
Hex Jam
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1-8 SAE 2 199

(HALF)
Hex Jam
1 ¼-7 SAE 2 203
(HALF)
Hex Jam
1 ½-6 SAE 5 250
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(FULL)
Hex Jam
1 ¾-5 ASTM B 250
(FULL)
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Manitowoc Cranes
1565 Buchanan Trail East PO Box 21
Shady Grove, PA 17256-0021
T 717 597 8121 F 717 593 5999
www.manitowoc.com
Service Bulletin N14-003

√ Information Only
Product Update - Warranty
Product Update - Non Warranty
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Date:
January 23, 2014
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To:
All National Crane Service Managers
Subject:
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Boom Extend Cables Service Manual Update
Model(s) Affected:
All National Crane Cable Extend Booms
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(Including non-current and current production
models)
PURPOSE:
The purpose of this bulletin is to advise of a change being made to the service manual on cable extend
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booms on National Crane Boom Trucks. The current recommendation is to replace the boom extend
cables every five (5) years.
Going forward the recommendation has been changed to replace the extend cables every seven (7) years.
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OPERATIONS REQUIRED:
Please include a copy of this service bulletin in the machines services manuals.
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If you have any questions regarding this Service Bulletin, please contact Manitowoc Crane Care.
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Manitowoc
Crane Care
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OPERATOR MANUAL
Supplement
Crane Warm-up Procedures
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! DANGER
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An untrained operator subjects himself and others to death or

serious injury. Do not operate this crane unless:
• You are trained in the safe operation of this crane. Manitowoc is not
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responsible for qualifying personnel.

• You read, understand, and follow the safety and operating
recommendations contained in the crane manufacturer’s manuals and
load charts, your employer’s work rules, and applicable government
regulations.
• You are sure that all safety signs, guards, and other safety features are
in place and in proper condition.
• The Operator Manual and Load Chart are in the holder provided on
crane.
© 2015 Manitowoc
Published 3-10-2015, Control # 571-00
SECTION CONTENTS
Crane Warm-up Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Swing Drive and Turntable Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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This Supplement provides information regarding the proper Operating the transmission with a sump temperature below
warm-up procedures for operating the crane in colder normal operating temperature is limited to:
temperatures. The information provided here supplements
• operating in the neutral gear or
the Operator and Service Manuals and must be used in
conjunction with these manuals. • driving with an unloaded crane while not exceeding
1500 engine RPM and not exceeding half throttle.
CRANE WARM-UP PROCEDURES Alternate Warm-up Procedures for Truck Mount (TM/
The following procedures detail the actions that must be TMS) Cranes:
taken to properly warm the different crane components 1. Setup the crane on outriggers.
before operating the crane.
2. Engage the transmission and allow crane to run at idle
NOTE: For temperatures below -9°C (15°F) refer to arctic until the temperature of the transmission sump reaches
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lubricants and conditions in the Operator and normal operating temperature.
Service Manuals.
Hoist
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Before starting the crane, ensure the appropriate lubricants
are used to provide lubrication for the prevailing ambient Performing a warm-up procedure is recommended at every
temperatures in which the crane will operate in (a list of startup and is required at ambient temperatures below 4°C
lubricants and their temperature ranges can be found in the (40°F).
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Lubrication section of your crane’s Operator Manual, by
contacting your local Manitowoc distributor, or by contacting Warm-up Procedures:
Manitowoc Crane Care directly). 1. Without operating the hoist function, warm the hydraulic
oil (see Hydraulic Oil System, page 2).
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CAUTION 2. Once the hydraulic system is warm, operate the
unloaded hoist, in both directions, at low speeds several
Crane Damage Hazard!
times to prime all hydraulic lines with warm hydraulic oil
Operating the crane with the incorrect lubricants and and to circulate gear lubricant through the planetary
fluids for the prevailing ambient temperature and/or failing gear sets.
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to adequately warm the crane prior to cold weather

operation can lead to a failure of a crane component or Swing Drive and Turntable Bearing
system.
Warm-up Procedures for Temperatures Above -7°C
Always use Manitowoc recommended lubricants and
(20°F):
fluids for the prevailing ambient temperature and properly
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start and warm the crane using the cold weather 1. Setup the crane on fully extended outriggers, with the
procedures found in this Operator Manual and boom fully retracted and near maximum lift angle with no
supplement before operating the crane at full load. load applied.
2. Rotate the superstructure at a speed of less than one
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Engine RPM for at least one complete revolution in one

NOTE: For National Crane engine warm-up procedures, direction, then rotate the superstructure at a speed of
refer to chassis manufacturer’s manual. less than one RPM for at least one complete revolution
in the opposite direction.
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Warm-up Procedures for All Temperature Ranges:

Warm-up Procedures for Temperatures Below -7°C
1. Upon startup, allow the engine to idle for 3 to 5 minutes (20°F):
before operating with a load.
1. Ensure the boom is fully retracted and near maximum lift
2. Cold Engine Startup: After allowing the engine to warm angle with no load applied.
by idling it for 3 to 5 minutes, slowly increase the engine
speed to provide adequate lubrication to the bearings 2. Rotate the superstructure at a speed of less than one-
and to allow the oil pressure to stabilize. half RPM for at least two complete revolutions in one
direction, then rotate the superstructure at a speed of
Transmission less than one-half RPM for at least two complete
revolutions in the opposite direction.
NOTE: For National Crane transmission warm-up
procedures, refer to chassis manufacturer ’s
manual.
National Crane Published 3-10-2015, Control# 571-00 1

Axles crane’s hydraulic pumps or motors, stop the operation
and engine immediately and contact a Manitowoc
NOTE: For National Crane axle warm-up procedures, refer distributor.
to chassis manufacturer’s manual.
• From 10°C to 4°C (50°F to 40°F): Crane operation with
Hydraulic Oil System a load is allowed with medium engine RPM and medium
function speed (joystick position) until the fluid reaches
Operating Limits and Warm-up Procedures: at least 10°C (50°F).
• From 4°C to -10°C (40°F to 15°F): Crane operation • From 95°C to 10°C (200°F to 50°F): Crane operation
without a load is allowed with medium engine RPM and with a load is allowed with no restrictions.
medium function speed (joystick position) until the fluid
reaches at least 10°C (50°F). It is then recommended • Above 95°C (200°F): No crane operation is allowed. Let
that all crane functions be cycled to remove cold fluid the crane’s hydraulic oil cool by running the engine at
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from all components and cylinders of the hydraulic idle with no functions actuated.
system. If there is any unusual sound coming from the
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OPERATOR AND SERVICE MANUAL
This manual has been prepared for and is considered part of -
900A
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Crane Model Number
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This Manual is divided into the following sections:
SUPPLEMENT
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TABLE OF CONTENTS
SAFETY INFORMATION
OPERATING CONTROLS AND PROCEDURES
MAINTENANCE INSPECTION
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LUBRICATION
SERVICE
SPECIFICATIONS
INSTALLATION CONFIGURATIONS
INSTALLATION PROCEDURES
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OPTIONS
NOTICE
The crane serial number is the only method your distributor or the factory
has of providing you with correct parts and service information.
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The crane serial number is identified on the builder’s decal attached to the
crane frame. Always furnish crane serial number when ordering parts
or communicating service problems with your distributor or the factory.
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! DANGER
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regulations.
• The Operator’s Manual and Load Chart are in the holder provided on
crane.
© 2011 Crane Group
PUBLISHED 10-18-2011 CONTROL # 031-07

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CALIFORNIA
PROPOSITION 65 WARNING
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Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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CALIFORNIA
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PROPOSITION 65 WARNING
Battery posts, terminals, and related accessories contain
chemical lead and lead compounds, chemicals known to
the State of California to cause cancer, birth defects or
other reproductive harm. Wash hands after handling.
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OWNER’S MANUAL
Supplement
900A
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! DANGER
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regulations.
• The Operator’s Manual and Load Chart are in the holder provided on
crane.
© 2011 Manitowoc

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This Supplement provides information regarding the stabilizer to identify when the outriggers and stabilizer beams
Outrigger Monitoring System, which is standard equipment are extended to a point in which they provide maximum
on cranes sold in North America and optional equipment on stability.
cranes sold outside of North America. The information
The OMS utilizes an LED indicator to communicate to the
provided here supplements the Operator’s and Service
operator the position of the outriggers and stabilizers. The
Manuals and must be used in conjunction with the
Outrigger Status Indicator (1, Figure 1) is a bi-color LED
Operator’s and Service Manuals.
located at each control station. When power is on and the
outrigger and stabilizer beams are extended to a point at
OUTRIGGER MONITORING SYSTEM (OMS) which they provide maximum stability (stabilizers beams
(OPTIONAL—STANDARD IN NORTH shall be fully extended on cranes equipped with Rear
AMERICA) Stabilizer Out and Down (RSOD)), the Outrigger Status
Indicator illuminates constant green, indicating a lift can be
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Operation made. If power is on and one or more outrigger or stabilizer
beams are not extended to a position which provides
The Outrigger Monitoring System (OMS) aids the operator in maximum stability, the Outrigger Status Indicator flashes red,
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ensuring that the crane is properly setup on outriggers and indicating a lift should not be made. If the Outrigger Status
stabilizers. The OMS utilizes one sensor in each outrigger Indicator illuminates constant red, there is a fault in the OMS.
and one proximity switch in each horizontally extending
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7962-1
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7962-2
1
FIGURE 1
National Crane c
Maintenance connector (p/n 80009992). Contact your Manitowoc dealer for
further assistance.
Cylinder Length Sensor
Outrigger
Stabilizer Proximity Switch (version 1)
1
1
2
3
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4
3
5
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2
7939-4
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7939-3 6
FIGURE 3
FIGURE 2 Remove
Remove 1. Disconnect electrical connector (1, Figure 3) at switch.
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1. Fully retract outriggers. 2. Remove the two screws (2, Figure 3) securing the
mounting bracket/switch assembly to the stabilizer box.
2. Disconnect electrical connector (1, Figure 2) at sensor.
setscrews securing sensor (2, Figure 2) holding 3. Loosen jam nut (3, Figure 3) securing switch (4) to
3. Remove
mounting bracket; remove switch.
plate.
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4.

Slide sensor (3, Figure 2) out of sensor holding bracket.
Install
1. Fully extend stabilizer beam (horizontally).
Install
2. Thread switch (4, Figure 3) into mounting bracket (5) so
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1. Fully retract outriggers.

that face of switch protrudes 10 mm through bracket.

2. Slide sensor (3, Figure 2) into holding bracket.
3. Using two screws (2, Figure 3), secure mounting bracket/
3. Using the two setscrews and sensor holding bracket, (2, switch assembly to stabilizer box.
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Figure 2) secure sensor to the hydraulic cylinder.

4. Screw switch into stabilizer box until it contacts the
4. electrical connector (1, Figure 2) to sensor.
Connect stabilizer wear pad, then un-screw switch three full turns.
5. Calibrate sensor; refer to Calibrate, page d. 5. Tighten jam nut (3, Figure 3) on switch.
Calibrate 6. Connect electrical connector (1, Figure 3) to switch.
the cylinder length sensor requires a laptop
Calibrating 7. With power on and stabilizer beam fully extended, ensure
equipped with the HED Conductor software and a USB cable LED (6, Figure 3) on proximity switch illuminates; retract
stabilizer beam and ensure LED is not illuminated.
d
Stabilizer Proximity Switch (version 2) Remove
1. Disconnect electrical connector (1, Figure 4) at switch.
2. Remove the two screws (2, Figure 4) securing the
switch (4) to the stabilizer box; remove switch.
Install
1 1. Fully extend stabilizer beam (horizontally).

2. Using two screws (2, Figure 4) secure the switch (4) to
stabilizer box.
3. Connect electrical connector (1, Figure 4) to switch.
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4. With power on and stabilizer beam fully extended,
4 ensure LED (3, Figure 4) on proximity switch illuminates;
3 retract stabilizer beam and ensure LED is not
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2
illuminated.
SIDE FOLDING SWING-AROUND JIB
O
7939-5 OPERATION
The following note needs added to the Jib Deployment and
Stowing procedures:
FIGURE 4
NOTE: When lowering the boom below horizontal, two
ce
persons may be required. With the telescope
control in neutral, the boom may creep out when
below horizontal.
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National Crane e

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TABLE OF CONTENTS
Supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a
Outrigger Monitoring System (OMS) (Optional—Standard in North America . . . . . . . .c
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .d
Side Folding Swing-Around Jib Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .e
Safety Information
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Alert Symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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Operator’s Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operator’s Qualifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operational Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Load Moment Indication (LMI) Systems (If Equipped) . . . . . . . . . . . . . . . . . . 1-3
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Anti-Two-Block Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Work Area Definition System (WADS) (If Equipped). . . . . . . . . . . . . . . . . . . . 1-4
Crane Stability/Structural Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Load Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Work Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
ce
Wind Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Lifting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Outrigger Lift Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Multiple Crane Lifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
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Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Electrocution Hazard Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Electrical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Special Operating Conditions and Equipment . . . . . . . . . . . . . . . . . . . . . . . 1-10
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Personnel Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
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Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
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Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Transporting the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Travel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Work Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Personal Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Crane Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Job Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Boom Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Parking and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Shut-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
National Crane I
Temperature Effects on Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Overload Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Boom Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Superstructure Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
Carrier Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

Operation
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Truck Cab Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Crane Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Optional Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Crane Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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Equipment Familiarization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Equipment Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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Work Site Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Before Leaving the Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Crane Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Before Making the Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

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Reading and Understanding the Capacity Chart . . . . . . . . . . . . . . . . . . . . . . 2-7
Winch System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Using Multiple Part Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
General Rules when Operating the Winch. . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Lifting the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
ce
Shutting Down and Preparing for Road Travel . . . . . . . . . . . . . . . . . . . . . . 2-13
Optional Winch Burst of Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Anti-Two-Block System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Description/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

ATB Weight Rigging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
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Optional Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Optional Wireline Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . 2-16
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
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System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Hydraulic Capacity Alert System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Main Boom HCA Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Jib HCA Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
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Wireline Jib Min. Angle Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Jib Safety and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Safety Tips for Jib Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Side Folding Swing-Around Jib Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
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Jib Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Jib Jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Adjustable Swing Speed Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Standard Hand Signals for Controlling Crane Operations . . . . . . . . . . . . . . . . . . . 2-27
Optional Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Maintenance & Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Maintenance, Lubrication & Service

Maintenance
Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

II

Weekly Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Monthly Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Wire Rope Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Rope Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Care of the Wire Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Rope Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Adjustments and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Tire Load and Inflation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Lubrication
Lubrication Procedures and Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
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Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
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Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Wire Rope Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Hydraulic Oil Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
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Carwell Rust Inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Protecting Cranes From Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cleaning Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
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Areas of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Service
Service and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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Label Parts When Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
National Crane Fitting O-Ring Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Fatigue of Welded Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Loctite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
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Fasteners and Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Torque Wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
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Using Torque Wrench Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Winch Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Brake Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
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Anti-Two Block Trouble Diagnosis - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Anti-Two Block Trouble Diagnosis - Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Cylinder Disassembly and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Single-Stage Extend Cylinder Disassembly and Repair . . . . . . . . . . . . . . . . . . . . . . 6-2
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Four Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Four Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Four Section Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Four Section Boom Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Additional Maintenance/Disassembled Boom . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Four Section Boom Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
National Crane III

Four Section Top/Bottom Pad Replacement, Assembled Boom . . . . . . . . . . . . . . 6-12
Top Rear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Front Bottom Pad Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Three Section Boom Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Boom Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Three Section Boom Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Internal Cable Sheave Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Three Section Cable Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Three Section Boom Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Boom Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Boom Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Additional Maintenance/Disassembled Boom . . . . . . . . . . . . . . . . . . . . . . . 6-17
Three Section Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
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Three Section Top/Bottom Pad Replacement, Assembled Boom . . . . . . . . . . . . . 6-20
Top Rear Pad Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
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Front Bottom Pad Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Inner Wear Pad Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Inner side Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Inner Boom Pad Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

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Jib Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Jib Jack Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
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Rust Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
(Optional) Oil Cooler Service and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Rotation Gearbox and Brake Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Swing Drive Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
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Lubrication and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Servicing the Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
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Disassembly and Reassembly of Control Valves to Replace Seals . . . . . . 7-12

Replacing Spool Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Control Valve Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Unloader Dump Valve - Air Purging Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
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Hydraulic System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Service Manual for Pump
Service Manual for Load Moment Indicator

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Specifications
Dimensional Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Dimensional Specification Tractor Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Capacity Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Installation
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Typical Locations/Serial Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Minimum Truck Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
Mounting Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
Configuration 1 - 9103A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Configuration 2 - 9103A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Configuration 3 - 990A/969A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Configuration 4 - 990A/969A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

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Configuration 5 - Rear Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Configuration 6 - 9103A New York City Approved . . . . . . . . . . . . . . . . . . . . . 9-7
Configuration 7 - 9103A New York City Approved . . . . . . . . . . . . . . . . . . . . . 9-8
PTO Horsepower Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Direct Mount Pump to PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Auger System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
PTO Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10
Truck Frame Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Truck Frame and Mounting Bolt Requirements for Front Stabilizer . . . . . . . 9-15
Section Modulus Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
Truck Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
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Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Positioning Crane on Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
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PTO, Pump, Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Reinforcing/After Frame Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-20
After Frame Modification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
Crane Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
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Pin Bearing Inspection and Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Pin Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Trunnion Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
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Counterweighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Counterweighting New York City Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Counterweighting Methods for Stability Around the Rear 180°. . . . . . . . . . . . . . . 10-10
Anti-Two-Block Load Moment Indicator Installation and Function Verification . . . 10-12
Initial Crane Run-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
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Boom Rests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

Stability Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Stability Check New York City Approved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Illustrated Parts
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Mounting
Controls & Hydraulics
Frame & Lift Cylinder
Outrigger & Stabilizers
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Boom & Jib
Options
Since cranes have varying quantities and complex options, supplemental information concerning
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Safety, Operation, Service & Maintenance, Specifications, Installation and parts for the options on
this crane are included in this section.
National Crane V

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VI

SAFETY INFORMATION
SAFETY MESSAGES NOTE: Emphasizes operation or maintenance
procedures.
General
GENERAL
The importance of safe operation and maintenance cannot
be overemphasized. Carelessness or neglect on the part of It is impossible to compile a list of safety precautions
operators, job supervisors and planners, rigging personnel, covering all situations. However, there are basic principles
and job site workers can result in their death or injury and that must be followed during your daily routine. Safety is
costly damage to the crane and property. your primary responsibility, since any piece of equipment
is only as safe as the person at the controls.
To alert personnel to hazardous operating practices and
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maintenance procedures, safety messages are used Read and follow the information located in Model Specific
throughout the manual. Each safety message contains a Information near the end of this section.
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safety alert symbol and a signal word to identify the hazard’s
This information has been provided to assist in promoting a
degree of seriousness.
safe working atmosphere for yourself and those around you.
Safety Alert Symbol It is not meant to cover every conceivable circumstance
which could arise. It is intended to present basic safety
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precautions that should be followed in daily operation.
Because you are the only part of the crane that can think and
This safety alert symbol means ATTENTION! reason, your responsibility is not lessened by the addition of
Become alert - your safety is involved! Obey all safety operational aids or warning devices. Indeed, you must guard
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messages that follow this symbol to avoid possible death against acquiring a false sense of security when using them.
or injury. They are there to assist, not direct the operation. Operational
aids or warning devices can be mechanical, electrical,
electronic, or a combination thereof. They are subject to
Signal Words
failure or misuse and should not be relied upon in place of
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good operating practices.

You are the only one who can be relied upon to assure the
DANGER safety of yourself and those around you. Be a professional
and follow the rules of safety.
Identifies hazards that will result in death or serious injury
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if the message is ignored. Remember, failure to follow just one safety precaution could
cause an accident that results in death or serious injury to
personnel or damage to equipment. You are responsible for
the safety of yourself and those around you.
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WARNING
Identifies hazards that may result in death or serious ACCIDENTS
injury if the message is ignored.
Following any accident or damage to equipment, the
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Manitowoc dealer must be immediately advised of the

incident and consulted on necessary inspections and
repairs. Should the dealer not be immediately available,
contact should be made directly with Manitowoc Product
CAUTION Safety at the address below. The crane must not be returned
Identifies hazards that could result in minor or moderate to service until it is thoroughly inspected for any evidence of
injury if the message is ignored. damage. All damaged parts must be repaired or replaced as
authorized by your Manitowoc dealer and/or Manitowoc
Crane Care.
CAUTION If this crane becomes involved in a property damage and/or

personal injury accident, immediately contact your
Without the safety alert symbol, identifies hazards that
Manitowoc dealer. If the dealer is unknown and/or cannot be
could result in property damage if the message is ignored.
reached, contact Product Safety at:
National Crane 1-1

The Manitowoc Company, Inc. OPERATOR’S QUALIFICATIONS
East Buchanan Trail
1565
Shady Grove, PA 17256-0021 Qualified person is defined as one who by reason of
knowledge, training and experience is thoroughly familiar

Phone: 888-777-3378 (888-PSR.DEPT) with crane operations and the hazards involved. Such a
Fax: 717-593-5152 person shall meet the operator qualifications specified in

E-mail: [email protected] Occupational Safety and Health Administration (OSHA)
Regulations (United States Federal Law), in ASME B30.5

OPERATOR’S INFORMATION American National Standard, or in any other applicable
federal, state or local laws.
You must read and understand this Operator’s Manual and

the Load Chart before operating your new crane. You must Ensure that all personnel working around the crane are
also view and understand the supplied safety video. This thoroughly familiar with safe operating practices. You must
manual and Load Chart must be readily available to the
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be thoroughly familiar with the location and content of all
operator at all times and must remain in the cab (if equipped) placards and decals on the crane. Decals provide important

or operator’s station while the crane is in use. instructions and warnings and must be read prior to any
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operational or maintenance function.
The Operator’s Manual supplied with and considered part of
must be read and completely understood by each
your crane You must be familiar with the regulations and standards
person responsible for assembly, disassembly, operation governing cranes and their operation. Work practice

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and maintenance of the crane. requirements may vary slightly between government
regulations, industry standards, and employer policies so a
No personnel shall be allowed to climb onto the crane or
thorough knowledge of all such relevant work rules is
enter the crane cab or operator’s station unless performance
necessary.
of their duties require them to do so, and then only with
of the operator or other qualified person.
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knowledge
Allow No One other than the operator to be on the crane

while the crane is operating or moving, unless they are
seated in a two-man cab.

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An untrained operator subjects himself and others to death
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or serious injury.
You must not operate this machine unless:

• You have been trained in the safe operation of this
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machine.

• You read, understand, and follow the safety and
operating recommendations contained in the

manufacturer’s manuals, your employer’s work rules,
Do not remove the Load Chart, this Operator’s Manual, or and applicable government regulations.
any decal from this crane.
• You are sure the machine has been inspected and
Inspect the crane every day (before the start of each shift). maintained in accordance with the manufacturer’s
routine maintenance and lubrication are being
Ensure that manuals and is operating properly.
dutifully performed. Don’t operate a damaged or poorly
maintained • You are sure that all safety signs, guards, and other
crane. You risk lives when operating faulty
machinery - including your own. safety features are in place and in proper condition.

If adjustments or repairs are necessary, the operator shall Do not attempt to operate the crane unless you are trained
notify the next operator. and thoroughly familiar with all operational functions.

1-2

Controls and design may vary from crane to crane; therefore, supervising the lifting operations shall establish
it is important that you have specific training on the particular procedures, such as assigning an additional signal
crane you will be operating. person to furnish equivalent protection. This does not
apply when lifting personnel in load-line supported
Training is ESSENTIAL for proper crane operation. Never
personnel platforms. Personnel shall not be lifted when
jeopardize your own well-being or that of others by
anti-two-block devices are not functioning properly.
attempting to operate a crane on which you have not been
trained. • When a Boom Length Indicator is inoperative or
malfunctioning, the designated person responsible for
You must be mentally and physically fit to operate a crane.
supervising the lifting operations shall establish the
Never attempt to operate a crane while under the influence
boom lengths at which the lift will be made by actual
of medication, narcotics, or alcohol. Any type of drug could
measurements or marking on the boom.
i m pa i r p h y s i c a l , v is u a l a n d m e n ta l r e a c t i o n s , a n d
capabilities. • When a Level Indicator is inoperative or malfunctioning,
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other means shall be used to level the crane.
As operator of this crane, you are granted the authority to
stop and refuse to lift loads until safety is assured.
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Load Moment Indication (LMI) Systems (If
Equipped)
OPERATIONAL AIDS
Your crane may be equipped with an LMI system which is
Manitowoc remains committed to providing reliable products
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intended to aid the operator. Test daily for proper operation.
that enable users and operators to safely lift and position
Never interfere with the proper functioning of operational
loads. Manitowoc has been an industry leader in the
aids or warning devices.
incorporation of operational aids into the design of its cranes.
Federal law requires that cranes be properly maintained and Under no condition should it be relied upon to replace the
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kept in good working condition. The manuals that Manitowoc use of Load Charts and operating instructions. Sole reliance
provides that are specific for each crane and the upon these electronic aids in place of good operating
manufacturer’s manuals for the operational aids shall be practices can cause an accident.
followed. If an operational aid should fail to work properly, the
Know the weight of all loads and always check the capacity
crane user or owner must assure that repair or recalibration
of the crane as shown on the Load Chart before making any
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is accomplished as soon as is reasonably possible. If

lifts.
immediate repair or recalibration of an operational aid is not
possible and there are exceptional circumstances which NEVER exceed the rated capacity shown on the Load Chart.
ju stify continued sho rt-term use of the crane w hen Always check the Load Chart to ensure the load to be lifted
operational aids are inoperative or malfunctioning, the at the desired radius is within the rated capacity of the crane.
following requirements shall apply for continued use or
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For detailed information concerning the operation and

shutdown of the crane:
maintenance of the load moment indicating system installed
• Steps shall be taken to schedule repairs and on the crane, see the manufacturer’s manual supplied with
recalibration immediately. The operational aids shall be the crane.
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put back into service as soon as replacement parts, if

required, are available and the repairs and recalibration Anti-Two-Blocking Device
can be carried out. Every reasonable effort must be
This crane should have a functional Anti-Two-Block and
made to expedite repairs and recalibration.
Control Lock-Out System. Test daily for proper operation.
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• When a Load Indicator, Rated Capacity Indicator, or

Two-blocking occurs when the load block (hook block,
Rated Capacity Limiter is inoperative or malfunctioning,
headache ball, rigging, etc.) comes into physical contact with
the designated person responsible for supervising the
the boom (boom nose, sheaves, boom extension, etc.). Two-
lifting operations shall establish procedures for
blocking can cause hoist lines (wire rope), rigging, reeving,
determining load weights and shall ascertain that the
and other components to become highly stressed and
weight of the load does not exceed the crane ratings at
overloaded in which case the wire rope may fail allowing the
the radius where the load is to be handled.
load, block, etc. to free fall.
• When a Boom Angle or Radius Indicator is inoperative
Two-blocking is more likely to occur when both the main and
or malfunctioning, the radius or boom angle shall be
auxiliary hoist lines are reeved over the main boom nose and
determined by measurement.
b o o m e x t e n s i o n n o s e r e s p e c t i v e l y. A n o p e r a t o r,
• When an Anti-Block Device, Two-Blocking Damage concentrating on the specific line being used, may telescope
Prevention or Two-Block Warning Device is inoperative or lower the boom allowing the other hoist line attachment to
or malfunctioning, the designated person responsible for contact the boom or boom extension nose, thus causing
National Crane 1-3

damage to the sheaves, or causing the wire rope to fail, block conditions. It is not a replacement for operator
dropping the lifting device to the ground and possibly injuring awareness and competence.
personnel working below.
Never interfere with the proper functioning of operational
Caution must be used when lowering the boom, extending aids or warning devices.
the boom or hoisting up. Let out load line(s) simultaneously
to prevent two-blocking the boom tip(s) and the hook block, Work Area Definition System (WADS) (If
etc. The closer the load is carried to the boom nose the more Equipped)
important it becomes to simultaneously let out wire rope as
the boom is lowered. Keep load handling devices a minimum If your crane is equipped with a WADS, you must read and
of 42 in (107 understand the manufacturer’s Operator’s Manual before
cm) below the boom nose at all times. operating the system. Become familiar with all proper
Two-blocking can be prevented. Operator awareness of the operating procedures and with the identification of symbol
hazards of two-blocking is the most important factor in
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usage.
preventing this condition. An Anti-Two-Block System is
intended to assist the operator in preventing dangerous two- The work area definition system is intended as an aid to the
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operator. It is not a substitute for safe crane operating
practices, experience and good operator judgements.

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CRANE STABILITY/STRUCTURAL models equipped with outriggers that can be pinned at the
STRENGTH mid-extend position (vertical strip, if applicable), the
outriggers must also be pinned when operating from the mid-
To avoid death or serious injury, ensure that the crane is on a extend position.

firm surface with load and crane’s configuration within
Use adequate cribbing under outrigger floats to distribute
capacity as shown on the crane’s Load Chart and notes.
weight over a greater area. Check frequently for settling.
pins and floats are properly installed and outrigger
Ensure all
beams are properly extended before lifting on outriggers. On

1-4

(For cranes with center front stabiliers)
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Carefully follow the procedures in this Operator’s Manual
when extending or retracting the outriggers. Death or serious
injury could result from improper crane setup on outriggers.
KEEP THE BOOM SHORT. Swinging loads with a long line
The operator must select the proper Load Chart and Load can create an unstable condition and possible structural
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Moment Indicating (LMI) System program for the outrigger failure of the boom.
position selected.
Load Charts
Before swinging the superstructure over the side when the
outriggers are retracted, check the Load Chart for backwards Load Charts represent the absolute maximum allowable
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stability. loads, which are based on either tipping or structural

limitations of the crane under specific conditions. Knowing
Long cantilever booms can create a tipping condition when
the precise load radius, boom length, and boom angle
in an extended and lowered position. Retract the boom
should be a part of your routine planning and operation.
proportionally with reference to the capacity of the applicable
Actual loads, including necessary allowances, should be
Load Chart.
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kept below the capacity shown on the applicable Load Chart.

Check crane stability before lifting loads. Ensure the
Load Chart capacities are based on freely suspended loads.
outriggers (or tires if lifting on rubber) are firmly positioned on
solid surfaces. Ensure the crane is level, brakes are set, and You must use the appropriate Load Chart when determining
the load is properly rigged and attached to the hook. Check the capability of the crane in the configuration required to
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the Load Chart against the weight of the load. Lift the load perform the lift.
slightly off the ground and recheck the stability before
Maximum lifting capacity is available at the shortest radius,
proceeding with the lift. Determine the weight of the load
minimum boom length, and highest boom angle.
before you attempt the lift.
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Do not remove the Load Charts from the crane.

Unless lifting within On Rubber capacities, outrigger beams
and jack cylinders (plus center front stabilizer, if equipped)
Work Site
must be properly extended and set to provide precise
leveling of the crane. Tires must be clear of the ground Prior to any operation, you must inspect the entire work site,
before lifting on outriggers. including ground conditions, where the crane will travel and
operate. Be sure that the surfaces will support a load greater
than the crane’s weight and maximum capacity.
Be aware of all conditions that could adversely affect the
stability of the crane.
Wind Forces
Wind can have a significant affect on loads that may be lifted
by a crane. Wind forces act differently on a crane depending
National Crane 1-5

upon the direction from which the wind is blowing (e.g., wind a loss of control in handling the load. Manitowoc
on the rear
of the boom can result in decreased forward recommends that, if the wind speed (velocity) is between 20
stability, wind on the underside of the boom can result in mph (32 km/h) to 30 mph (48 km/h), the load capacities shall
decreased backward stability, wind on the side of the boom be reduced to account for the size and shape of the load and

can result in structural damages, etc.). To assist you in the wind direction in relation to the machine for all boom and
determining prevailing wind conditions, refer to Table 1-1. boom extension lengths. Further, operation of the crane in
wind velocities over 30 mph (48 km/h) is not recommended.
Wind forces can exert extreme dynamic loads. Manitowoc
recommends that a lift not be made if the wind can cause

Table 1-1

Wind Force
Wind Velocity Visible Indicator

Beauford
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Designation mph (km/h) Effects of wind as observed on land
Scale
Zero (0) Calm less than 1 (<2) No wind; smoke rises vertically
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1 Light Air 1-3 (2-5) Wind direction seen by smoke but not by wind vanes

2 Light Breeze 4-7 (6-11) Wind felt on face; leaves rustle; wind vane moves slightly
3
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Gentle Breeze 8-12 (13-19) Leaves/small twigs in constant motion: wind extends flag
Moderate
4 13-18 (21-29) Raises dust & loose paper; moves small branches
Breeze
Reduce crane load ratings and operating parameters at 20 mph (32 km/h)
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Small trees in leaf begin to sway; on ponds, crested wavelets
5 Fresh Breeze 19-24 (31-39)
form
Large branches in motion; telegraph wires whistle; umbrellas
6 Strong Breeze 25-31 (40-50)
used with difficulty
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Cease all craning operations at 30 mph (48 km/h); lower & retract boom

7 Moderate Gale 32-38 (52-61) Whole trees in motion; walking against wind is inconvenient

Lifting Operations (hook block, boom extension, etc.) must be considered part
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of the load.

Before lifting, position the crane on a firm surface, properly
extend and set the outriggers, and level the crane. Measure the load radius before making a lift and stay within
Depending on the nature of the supporting surface, approved lifting areas based on the range diagrams and
adequate cribbing may be required to obtain a larger bearing working area diagrams on the crane’s Load Chart.
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surface. Always keep the load as near to the crane and as close to
The crane is equipped with a bubble level that should be the ground as possible.

used to determine whether the crane is level. The load line Do not overload the crane by exceeding the capacities
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can also be used to estimate the levelness of the crane by shown on the appropriate Load Chart. Death or serious
checking to be sure it is in-line with the center of the boom at injury could result from the crane tipping over or failing
all points on the swing circle. structurally from overload.
extension, or auxiliary boom nose is to be used,
If the boom The crane can tip over or fail structurally if:
ensure the electrical cable and the weight for the Anti-Two-
Bl ock S w it ch a r e p r o p er l y in sta ll ed an d th e L M I is • The load and crane’s configuration is not within the
programmed for the crane configuration. Refer to the LMI capacity as shown on the applicable Load Chart and
handbook supplied with the crane. notes.

Verify the crane’s capacity by checking the Load Chart • The ground is soft and/or the surface conditions are
against the weight of the load. Then, lift the load slightly at poor.

first to ensure stability before proceeding with the lift. • Outriggers are not properly extended and set. On
Be sure the load is properly rigged and attached. Always models equipped with outriggers that can be pinned at
determine the weight of the load before you attempt to lift it the mid-extend position, the outriggers must also be
and remember that all rigging (slings, etc.) and lifting devices pinned when operating from the mid-extend position.

1-6

• Cribbing under the outrigger pads is inadequate. lift off the ground during operation of the crane within the
capacity limits of the Load Chart, yet the crane will not have
• The crane is improperly operated.
reached instability. The “balance point” for stability testing
Do not rely on the crane’s tipping to determine your lifting according to SAE and Manitowoc criteria is a condition of
capacity. loading wherein the load moment acting to overturn the
crane is equal to the maximum moment of the crane
Be sure the hoist line is vertical before lifting. Do not subject
available to resist overturning. This balance point or point of
the crane to side loading. A side load can tip the crane or
instability for a crane does not depend on “lifting” of an
cause it to fail structurally.
outrigger but rather on comparison of the “opposing” load
Load Chart capacities are based on freely suspended loads. moments.
Do not pull posts, pilings, or submerged articles. Be sure the
The occurrence of an outrigger lifting from the ground is often
load is not frozen or otherwise attached to the ground before
attributed to the natural flex in the crane’s frame. This may
lifting.
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happen when lifting a load in certain configurations within the
If you should encounter a tipping condition, immediately capacity limits of the Load Chart and is not necessarily an
lower the load with the hoist line and retract or elevate the indication of an unstable condition.
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boom to decrease the load radius. Never lower or extend the
Provided the crane is properly set up, the crane is in good
boom; this will aggravate the condition.
working condition, that all operator’s aids are properly
Use tag lines whenever possible to help control the programmed, that the qualified crane operator adheres to
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movement of the load. the instructions found in the applicable Load Chart,
Operator’s Manual and decals on the crane, the crane
When lifting loads, the crane will lean toward the boom and should not be unstable.
the load will swing out, increasing the load radius. Ensure the
crane’s capacity is not exceeded when this occurs. Multiple Crane Lifts
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Do not strike any obstruction with the boom. If the boom Multiple crane lifts are not recommended.
should accidentally contact an object, stop immediately.
Inspect the boom. Remove the crane from service if the Any lift that requires more that one crane must be precisely
boom is damaged. planned and coordinated by a qualified engineer.
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Never push or pull with the crane boom. If it is necessary to perform a multi-crane lift, the operator
shall be responsible for assuring that the following minimum
Avoid sudden starts and stops when moving the load. The safety precautions are taken:
inertia and an increased load radius could tip the crane over
or cause it to fail structurally. • Secure the services of a qualified engineer to direct the
operation.
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Use only one hoist at a time when lifting loads.

• Use one qualified signal person.
Always use enough parts-of-line to accommodate the load to
be lifted. Lifting with too few parts-of-line can result in failure • Coordinate lifting plans with the operators, engineer, and
of the wire rope. signal person prior to beginning the lift.
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• Maintain communication between all parties throughout

Counterweight the entire operation. If possible, provide approved radio
On cranes equipped with removable counterweights, ensure equipment for voice communication between all parties
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the appropriate counterweight sections are properly installed engaged in the lift.
for the lift being considered.
• Use cranes and rigging of equal capabilities and use the
Do not add material to the counterweight to increase same boom length.
capacity. United States Federal law prohibits modification or
• Use outriggers on cranes so equipped.
additions which affect the capacity or safe operation of the
equipment without the manufacturer’s written approval. • Be certain cranes are of adequate lifting capacity.
[29CFR 1926.1434]
• Calculate the amount of weight to be lifted by each crane
and attach slings at the correct points for proper weight
Outrigger Lift Off
distribution.
Regarding “lifting” of an outrigger pad during craning
• Ensure the load lines are directly over the attach points
activities, be advised that the rated loads for these cranes,
to avoid side loading and transfer of loading from one
as indicated on the crane’s Load Chart, do not exceed 85%
crane to the other.
of the tipping load on outriggers as determined by SAE J765
OCT80 “Cranes Stability Test Code.” An outrigger pad may • Do not travel. Lift only from a stationary position.
National Crane 1-7

ELECTROCUTION HAZARD operator, are responsible for alerting all personnel of
dangers associated with electrical power lines and
To avoid death or serious injury, keep all parts of the crane, equipment. Do not allow unnecessary personnel in the
rigging and load at least 20 feet (6 meters) away from any vicinity of the crane while operating. Permit no one to lean
e n e r g i z e d p o w e r l i n e . Yo u m u s t f o l l o w t h e O S H A against or touch the crane. Permit no one, including riggers
requirements set forth in 29CFR 1926.1407 through and load handlers, to hold the load, load lines, tag lines, or
1926.1411. rigging gear.
This crane is not designed or equipped for use within 10 feet If the load, wire rope, boom, or any portion of the crane
(3 mete rs) of energized power lines [Refer to
contacts or comes too close to an electrical power source,
29CFR1926.1410 Table A]. If operation within 10 feet (3 everyone in, on, and around the crane can be seriously
meters) of any power lines cannot be avoided, the power injured or killed.
utility must be notified and the power lines must be de-
energized and grounded before performing any work. Most overhead power lines are not insulated. Treat all
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overhead power lines as being energized unless you have
If contact is ever accidentally made with a power line and any reliable information to the contrary from the utility company
crane, its rigging or load, never touch the crane or
part of this
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or owner.
even approach or come near the crane.
The rules in this Operator’s Manual must be followed at all
Electrocution can occur even without direct contact with the times, even if the electrical power lines or equipment have
crane. been de-energized.

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Crane operation is dangerous when close to an energized The safest way to avoid electrocution is to stay away from
electrical power source. Exercise extreme caution and electrical power lines and electrical power sources.

prudent judgement. Operate slowly and cautiously when in
the vicinity of power lines. It is not always necessary to contact a power line or power
source to become electrocuted. Electricity, depending on
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Before operating this crane in the vicinity of electrical power magnitude, can arc or jump to any part of the load, load line,
lines or equipment,
notify the power utility company. Obtain or crane boom if it comes too close to an electrical power
positive and absolute assurance that the power has been source. Low voltages can also be dangerous.
turned off.
Thoroughly read, understand, and abide by all applicable
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This crane is not insulated. Always consider all parts of the federal, state, and local regulations.
load and the crane, including the wire rope, hoist cable,
pendant cables, and tag lines, as conductors. You, the

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1-8

Set-Up and Operation not assure that electrical contact will not occur. Even if codes
or regulations require the use of such devices, failure to
During crane use, assume that every line is energized (“hot” follow the rules listed here may result in serious injury or
or “live”) and take the necessary precautions. death. You should be aware that such devices have
Set up the crane in a position such that the load, boom, or limitations and you should follow the rules and precautions
any part of the crane and its attachments cannot be moved to outlined in this manual at all times even if the crane is
within 20 ft (6 m) of electrical power lines or equipment. This equipped with these devices.
includes the crane boom (fully extended to maximum height, Insulating links installed into the load line afford limited
radius, and length) and all attachments (boom extensions, protection from electrocution hazards. Links are limited in
rigging, loads, etc.). Overhead lines tend to blow in the wind their lifting abilities, insulating properties, and other
so allow for lines’ movement when determining safe properties that affect their performance. Moisture, dust, dirt,
operating distance. oils, and other contaminants can cause a link to conduct
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A suitable barricade should be erected to physically restrain electricity. Due to their capacity ratings, some links are not
the crane and all attachments (including the load) from effective for large cranes and/or high voltages/currents.
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entering into an unsafe distance from electrical power lines The only protection that may be afforded by an insulated link
or equipment. is below the link (electrically downstream), provided the link
Plan ahead and always plan a safe route before traveling has been kept clean, free of contamination, has not been
under power lines. Rider poles should be erected on each scratched or damaged, and is periodically tested (just before
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side of a cro ssing to assure sufficient clearance is use) for its dielectric integrity.
maintained. Boom cages and boom guards afford limited protection from
electrocution hazards. They are designed to cover only the
boom nose and a small portion of the boom. Performance of
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boom cages and boom guards is limited by their physical
size, insulating characteristics, and operating environment
(e.g. dust, dirt, moisture, etc.). The insulating characteristics
of these devices can be compromised if not kept clean, free
of contamination, and undamaged.
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Proximity sensing and warning devices are available in

different types. Some use boom nose (localized) sensors
and others use full boom length sensors. No warning may be
given for components, cables, loads, and other attachments
located outside of the sensing area. Much reliance is placed
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upon you, the operator, in selecting and properly setting the

sensitivity of these devices.
Never rely solely on a device to protect you and your fellow
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workers from danger.

United States OSHA regulations require a flagman when
operating in close proximity to energized power lines. Some variables you must know and understand are:
Appoint a reliable and qualified signal person, equipped with • Proximity devices are advertised to detect the existence
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a loud signal whistle or horn and voice communication of electricity and not its quantity or magnitude.
equipment, to warn the operator when any part of the crane • Some proximity devices may detect only alternating
or load moves near a power source. This person should current (AC) and not direct current (DC).
have no other duties while the crane is working.
• Some proximity devices detect radio frequency (RF)
Tag lines should always be made of non-conductive energy and others do not.
materials. Any tag line that is wet or dirty can conduct
electricity. • Most proximity devices simply provide a signal (audible,
visual, or both) for the operator; this signal must not be
Do not store materials under power lines or close to ignored.
electrical power sources.
• Sometimes the sensing portion of the proximity devices
Electrocution Hazard Devices becomes confused by complex or differing arrays of
power lines and power sources.
The use of insulated links, insulated boom cages/guards,
proximity warning devices, or mechanical limit stops does
National Crane 1-9

Do not depend on grounding. Grounding of a crane affords Consultant. Also refer to local, state, and federal codes
lit tl e o r n o p r ot e cti on fro m e lec tric al h az ar d s. T h e and regulations.
effectiveness of grounding is limited by the size of the
When operating cranes equipped with electromagnets, you
conductor (wire) used, the condition of the ground, the must take additional precautions. Permit no one to touch the
magnitude of the voltage and current present, and numerous
magnet or load. Alert personnel by sounding a warning
other factors.
signal when moving a load. Do not allow the cover of the
Electrical Contact electromagnet power supply to be open during operation or
at any time the electrical system is activated. Shut down the
If the crane should come in contact with an energized power crane completely and open the magnet controls switch prior
source, you
must: to connecting or disconnecting magnet leads. Use only a
non-conductive device when positioning a load. Lower the
1. Stay in the crane cab. Don’t panic.
magnet to the stowing area and shut off power before

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2. Immediately warn personnel in the vicinity to stay away. leaving the operator’s cab (if equipped) or operator’s station.
3. Attempt
to move the crane away from the contacted
PERSONNEL HANDLING
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power source using the crane’s controls which are likely
to remain functional. The American Society of Mechanical Engineers issued a

4. Stay in the crane until the power company has been new American National Standard entitled, Personnel Lifting

contacted and the power source has been de-energized. Systems, ASME B30.23-2005. This standard provides,
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No one must attempt to come close to the crane or load “lifting and lowering of personnel using ASME B30 Standard
until the power has been turned off. hoisting equipment s hall be under tak en only in
circumstances when it is not possible to accomplish the task
Only as a last resort should an operator attempt to leave the by less hazardous means. Unless all of the applicable
contacting a power source. If it is absolutely
crane upon
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requirements of this volume are met, the lifting or lowering of
necessary to leave the operator’s station, jump completely personnel using ASM E B30 Standard eq uipment is
clear of the
crane. Do not step off. Hop away with both feet prohibited.” This new standard is consistent with the U.S.
together. Do not walk or run. Department of Labor, Occupational Safety and Health
Following any contact with an energized electrical source, Administration (OSHA) regulations for Construction that
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the Manitowoc dealer must be immediately advised of the state, in 29CFRI926.1431: “General requirements. The use
incident and consulted on necessary inspections and of a crane or derrick to hoist employees on a personnel
repairs. Thoroughly inspect the wire rope and all points of platform is prohibited, except when the erection, use, and
contact on dismantling of conventional means of reaching the worksite,
the crane. Should the dealer not be immediately such as a personnel hoist, ladder, stairway, aerial lift,
available, contact Manitowoc Crane Care. The crane must
elevating work platform or scaffold, would be more
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not be returned to service until it is thoroughly inspected for

any evidence of damage and all damaged parts are repaired hazardous or is not possible because of structural design or
or replaced as authorized by your Manitowoc dealer or worksite conditions.” Additional requirements for crane
Manitowoc Crane Care. o pe r a t io n s a r e sta t ed in A SM E B 3 0 .5 , M ob i le An d
Locomotive Cranes, and in OSHA regulations
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Special Operating Conditions and 29CFRI910.180 for General Industry and 29CFRI926.1431
for Construction.
Equipment
Use of a Manitowoc crane to handle personnel is acceptable
Never operate the crane during an electrical thunderstorm.
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provided:
When operating
near transmitter/communication towers
• The requirements of the applicable national, state and
where an electrical charge can be induced into the crane or
local regulations and safety codes are met.
load:

• A determination has been made that use of a crane to
• The transmitter shall be deenergized OR,
handle personnel is the least hazardous means to
• Tests shall be made to determine if an electrical charge perform the work.
will be induced into the crane or load.
• The crane operator shall be qualified to operate the
•

The crane must be provided an electrical ground. specific type of hoisting eq uipment used in the
personnel lift.
• If taglines
are used, they must be non-conductive.
• The crane operator must remain at the crane controls at
• Every precaution must be taken to dissipate induced all times when personnel are off the ground.

voltages. Consult a qualified RF (radio frequency)
1-10

• The crane operator and occupants have been instructed And Locomotive Cranes, and ASME B30.23, Personnel
in the recognized hazards of personnel platform lifts. Lifting Systems, are available by mail from the ASME, 22
Law Drive, Fairfield, New Jersey, 0700-2900
• The crane is in proper working order.
• US DOL/OSHA Rules and Regulations are available by
• The crane must be equipped with a boom angle
mail from the Superintendent of Documents, PO Box
indicator that is visible to the crane operator.
371954, Pittsburgh, PA, 15250-7954.
• The crane's Load Chart is affixed at the operator’s
station and readily accessible to the operator. The total ENVIRONMENTAL PROTECTION
weight of the loaded personnel platform and related
rigging shall not exceed 50 percent of the rated capacity Dispose of waste properly! Improperly disposing of waste
for the radius and configuration of the crane. can threaten the environment.
• The crane is level within one percent of level grade and Potentially harmful waste used in Manitowoc cranes includes
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located on a firm footing. Cranes with outriggers shall — but is not limited to — oil, fuel, grease, coolant, air
have them all deployed following manufacturer's conditioning refrigerant, filters, batteries, and cloths which
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specifications. have come into contact with these environmentally harmful
substances.
• The crane's Operator's Manual and other operating
manuals are at the operator ’s station and readily Handle and dispose of waste according to local, state, and
accessible to the operator. federal environmental regulations.
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• The platform meets the requirements as prescribed by When filling and draining crane components, observe the
applicable standards and regulations. following:
• For wire rope suspended platforms: • Do not pour waste fluids onto the ground, down any
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drain, or into any source of water.
- The crane is equipped with a hook that can be
closed and locked, eliminating the throat opening. • Always drain waste fluids into leak proof containers that
are clearly marked with what they contain.
- The crane is equipped with a functional Anti-Two-
Block Device. • Always fill or add fluids with a funnel or a filling pump.
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- The platform is properly attached and secured to the • Immediately clean up any spills.
load hook.
MAINTENANCE
• For boom mounted platforms:
The crane must be inspected prior to use on each work shift.
- Use only Manitowoc approved personnel platforms
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The owner, user, and operator must ensure that routine

attached to the boom.
maintenance and lubrication are being dutifully performed.
- The platform is properly attached and secure. Never operate a damaged or poorly maintained crane.
To avoid death or serious injury: Manitowoc continues to recommend that cranes be properly
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maintained, regularly inspected and repaired as necessary.

• NEVER use this crane for bungee jumping or any form
Manitowoc reminds crane owners to ensure that all safety
of amusement or sport.
decals are in place and legible. Manitowoc continues to urge
• NEVER handle personnel on the loadline unless the crane owners to upgrade their cranes with load moment
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requirements of applicable national, state and local indicator (LMI) and control lever lockout systems for all lifting
regulations and safety codes are met. operations.
• NEVER permit anyone to ride loads, hooks, slings or Shut down the crane while making repairs or adjustments.
other rigging for any reason.
Always perform a function check after repairs have been
• NEVER get on or off a moving crane. made to ensure proper operation. Load tests should be
performed when structural or lifting members are involved.
• NEVER allow anyone other than the operator to be on
this crane while the machine is operating or traveling. Follow all applicable safety precautions in this manual when
performing crane maintenance as well as crane operations.
The following standards and regulations regarding personnel
handling are available by mail at the following addresses: Keep the crane free of mud, dirt, and grease at all times.
Dirty equipment introduces hazards, wears-out faster, and
• ASME (formerly ANSI) B30 Series American National makes proper maintenance difficult. Cleaning solutions used
Safety Standards For Cableways, Cranes, Derricks,
Hoists, Hooks, Jacks, and Slings; ASME B30.5, Mobile
National Crane 1-11

should be non-flammable, non-toxic and appropriate for the • Do not attempt to repair or tighten any hydraulic hose or
job. fitting while the engine is running, or when the hydraulic
system is under pressure.
Routine maintenance and inspection of this crane must be
performed by a qualified person(s) according to the • Never disconnect any hydraulic lines unless the boom is
recommendations in the Manitowoc Crane Care fully lowered, the engine is shut off, and the hydraulic

Maintenance and Inspection Manual. Any questions pressure is relieved. To relieve hydraulic pressure, stop
regarding procedures and specifications should be directed the engine and move the hydraulic controls in both
to your Manitowoc
dealer. directions several times.
• Hot hydraulic fluid will cause severe burns. Wait for the
Service
and Repairs fluid to cool before disconnecting any hydraulic lines.
• Hydraulic fluid can cause permanent eye injury. Wear

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appropriate eye protection.
Moving Parts:
WARNING
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• Do not place limbs near moving parts. Amputation of a
Fall Hazard!
body part may result. Turn off the engine and wait until
Working at elevated heights without using proper fall the fan and belts stop moving before servicing crane.
protection can result in severe injury or death.

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• Pinch points, which result from relative motion between
Always use proper fall protection as required by local,
mechanical parts, are areas of the machine that can
state or federal regulations.
cause personal injury or death. Do not place limbs or
your body in contact with pinch points either on or
Service and repairs to the crane must only be performed by a
around the machine. Care must be taken to prevent
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qualified person. All service and repairs must be performed
m o t io n b e t w e e n p in c h p o i n ts w h e n p e r f o r m i n g
in accordance with manufacturer’s recommendations, this
maintenance and to avoid such areas when movement
manual, and the service manual for this machine. If there is
is possible.
any question regarding maintenance procedures or

specifications, contact your Manitowoc dealer for assistance. • Do not allow persons to stand near extending or
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lowering outriggers. Foot crushing could occur

Qualified person is defined as one who by reason of

knowledge, training and experience is thoroughly familiar Before performing any maintenance, service or repairs on
with the crane’s operation and required maintenance as well the crane:

as the hazards involved in performing these tasks.
• The boom should be fully retracted and lowered and the
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Training and qualification of maintenance and repair load placed on the ground.

personnel are crane owner’s responsibility.
• Do not get under a raised boom unless the boom is
Any modification,
alteration, or change to a crane which blocked up safely. Always block up the boom before
affects its original design and is not authorized and approved doing any servicing that requires the boom to be raised.
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by Manitowoc
is strictly prohibited. All replacement parts
• Stop the engine and disconnect the battery.
must be Manitowoc approved. Such action invalidates all
warranties and makes the owner/user liable for any resultant • Controls should be properly tagged. Never operate the
accidents. crane if it is tagged-out nor attempt to do so until it is
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restored to proper operating condition and all tags have

Hydraulic Fluid:
been removed by the person(s) who installed them.
• Do not use your hand or any part of your body to check
After maintenance or repairs:

for hydraulic fluid leaks when the engine is running or
the hydraulic system is under pressure. Fluid in the • Replace all guards and covers that have been removed.
hydraulic
system can be under enough pressure that it
• Remove all tags, connect the battery, and perform a
will penetrate the skin, causing serious injury or death.
function check of all operating controls.
Use a piece of cardboard, or piece of paper, to search

for leaks. Wear gloves to protect your hands from • Consult with Manitowoc Crane Care to determine if load
spraying fluid. testing is required after a structural repair is performed.
•

If any hydraulic fluid is injected into the skin, obtain
Lubrication
medical attention immediately or gangrene may result.
The crane must be lubricated according to the
manufacturer’s recommendations for lubrication points, time

1-12

intervals, and types. Lubricate at more frequent intervals length of rope equal to thirty (30) times the rope
when working under severe conditions. diameter.
Exercise care when servicing the hydraulic system of the • For running ropes other than rotation resistant: six (6)
crane, as pressurized hydraulic oil can cause serious injury. broken wires in one rope lay or three (3) broken wires in
The following precautions must be taken when servicing the one strand.
hydraulic system:
• One valley break where the wire fractures between
• Follow the manufacturer’s recommendations when strands in a running rope is cause for removal.
adding oil to the system. Mixing the wrong fluids could
• Abrasion of the rope resulting in wear of the individual
destroy seals, causing component failure.
outside wires of 1/3 of the original wire diameter.
• Be certain all lines, components, and fittings are tight
• Any kinking, bird caging, crushing, corrosion, or other
before resuming operation.
damage resulting in distortion of the rope structure.
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Tires • Rope that has been in contact with a live power line or
has been used as a ground in an electric circuit (eg.
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welding) may have wires that are fused or annealed and
must be removed from service.
• In standing ropes, more than three (3) breaks in one
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WARNING rope lay in sections beyond the end connection or more
Possible equipment damage and/or than two (2) broken wires at an end connection.
personal injury!
• Core deterioration, usually observed as a rapid
Driving the crane with a tire and split-rim assembly under reduction in rope diameter, is cause for immediate
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inflated at 80% or less of its recommended pressure can removal of the rope.
cause the wheel and/or tire to fail. Per OSHA Standard
1910.177(f)(2), when a tire has been driven under inflated The following is a brief outline of the basic information
at 80% or less of its recommended pressure, it must first required to safely use wire rope.
b e c o m pl e t e ly d e f l at e d , r e m o ve d f r o m th e a x le , • Wire ropes wear out. The strength of a wire rope begins
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disassembled, and inspected before re-inflation. to decrease when the rope is put to use and continues to
decrease with each use. Wire rope will fail if worn-out,
Inspect the tires for nicks, cuts, embedded material, and overloaded, misused, damaged or improperly
abnormal wear. maintained.
Ensure all lug nuts are properly torqued. • The nominal strength, sometimes called catalog
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Ensure pneumatic tires are inflated to the proper pressure strength, of a wire rope applies only to a new, unused
(refer to the Load Chart). When inflating tires, use a tire rope.
gauge, clip-on inflator, and extension hose which will permit • The nominal strength of a wire rope should be
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standing clear of the tire while inflating. considered the straight line pull which will actually break
a new unused rope. The nominal strength of a wire rope
Wire Rope should never be used as its working load.
Use only the wire rope specified by Manitowoc as indicated • Each type of fitting attached to a wire rope has a specific
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on the crane’s Load Chart. Substitution of an alternate wire efficiency rating which can reduce the working load of
rope may require the use of a different permissible line pull the wire rope assembly or rope system.
and, therefore, require different reeving.
• Never overload a wire rope. This means never use the
NOTE: Wire rope may be purchased by contacting wire rope where the load applied to it is greater than the
Manitowoc Crane Care. working load determined by the rope manufacturer.
Always make daily inspections of the wire rope, keeping in • Never “shock load” a wire rope. A sudden application of
mind that all wire rope will eventually deteriorate to a point force or load can cause both visible external and internal
where it is no longer usable. Refuse to work with worn or damage. There is no practical way to estimate the force
damaged wire rope. Wire rope shall be taken out of service applied by shock loading a rope. The sudden release of
when any of the following conditions exist: a load can also damage a wire rope.
• For rotation-resistant running ropes: more than two (2) • Lubricant is applied to the wires and strands of a wire
broken wires in a length of rope equal to six (6) times the rope when it is manufactured. The lubricant is depleted
rope diameter, or more than four (4) broken wires in a when the rope is in service and should be replaced
National Crane 1-13

periodically. Refer to the Service Manual for more • When a wire rope has been removed from service

information. because it is no longer suitable for use, it must not be
reused on another application.
• In the U.S.A., regular inspections of the wire rope and

keeping of permanent records signed by a qualified When installing a new rope:
person are required by OSHA for almost every wire rope
• Keep all parts of your body and clothing away from
application. The purpose of the inspection is to
rotating hoist drums and all rotating sheaves.
determine whether or not a wire rope may continue to be
safely
used on the application. Inspection criteria, • Never handle the wire rope with bare hands.
including number and location of broken wires, wear and
• Follow proper instructions for removing rope from a reel.
elongation,
have been established by OSHA, ANSI,
ASME and similar organizations. See the Service • Apply back tension to the storage/payoff reel of the new
Manual for inspection procedures. rope to insure tight, even spooling onto the hoist drum.

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When inspecting wire ropes and attachments, keep all • Operate the new rope - first through several cycles at
parts of your body and clothing away from rotating hoist light load and then through several cycles at
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drums and all rotating sheaves. Never handle the wire intermediate load to allow the rope to adjust to operating
rope with bare hands. conditions.

Some conditions that lead to problems in wire rope When using a wedge socket:
systems
include:
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• Always inspect socket, wedge, and pin for correct size
- Sheaves that are too small, worn or corrugated and condition.
cause damage to a wire rope.
• Do not use parts that are damaged, cracked, or
- Broken wires mean a loss in strength. modified.

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- Kinks permanently damage a wire rope and must be • Assemble the wedge socket with live end of rope aligned
avoided. with the centerline of pin and assure proper length of tail
(dead end) protrudes beyond the socket.
- Wire ropes are damaged by knots. Wire rope with
knots must never be used.
Sheaves
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- Environmental factors such as corrosive conditions

and heat can damage a wire rope.
- Lack of lubrication can significantly shorten the

useful life of a wire rope.
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- Contact with electrical wires and resulting arcing will

damage a wire rope.
•
An inspection should include verification that none of the
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specified removal criteria for this usage are met by

checking for such things as:
- Surface wear; nominal and unusual.

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- Broken wires; number and location.

- Reduction in diameter.
Inspect the boom nose and hook block sheaves for proper
- Rope stretch (elongation). operation, excessive wear, and damage every 50 hours or

- Integrity of end attachments. weekly. Inoperable, damaged and/or worn sheaves cause
rapid deterioration of wire rope.
- Evidence of abuse or contact with another object.
Ensure sheaves carrying ropes that can be momentarily
- Heat damage. unloaded are equipped with close fitting guards or other

- Corrosion. devices to guide the rope back into the groove when the load
is reapplied. Ensure sheaves in the lower load block are
NOTE: A more detailed wire rope inspection procedure is equipped with close fitting guards that will prevent the ropes
given in the Service Manual. from becoming fouled when the block is lying on the ground
with loose ropes.
1-14

To attain maximum wire rope life and minimize hook block allow the radiator time to cool before removing the radiator
rotation, it is recommended that even numbers of parts-of- cap.
line be used in multiple-part reeving whenever possible.
Shut down the engine and disconnect the battery before
The use of nylon (nylatron) sheaves, as compared with performing maintenance. If unable to do so for the task
metallic sheaves, may change the replacement criteria of required, keep hands clear of the engine fan and other
rotation-resistant wire rope. moving parts while performing maintenance.
NOTE: The use of cast nylon (nylatron) sheaves will Be careful of hot surfaces and hot fluids when performing
substantially increase the service life of wire rope. maintenance on or around the engine.
However, conventional rope retirement criteria
Do not use ether to start the engine on cranes equipped with
based only upon visible wire breaks may prove
intake manifold grid heaters.
inadequate in predicting rope failure. The user of
cast nylon sheaves is therefore cautioned that a
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retirement criteria should be established based TRANSPORTING THE CRANE
upon the user’s experience and the demands of his Before transporting the crane, check the suitability of the
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application. proposed route with regard to the crane height, width, length,
and weight.
Batteries
Check load limits of bridges on the travel route and ensure
Battery electrolyte must not be allowed to contact the skin or
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they are greater than the combined weight of the crane and
eyes. If this occurs, flush the contacted area with water and transporting vehicle.
consult a doctor immediately.
When loading or unloading the crane on a trailer or railroad
When checking and maintaining batteries, exercise the car, use a ramp capable of supporting the weight of the
following procedures and precautions:
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crane.
• Wear safety glasses when servicing batteries. Ensure the crane is adequately secured to the transporting
• If equipped, disconnect battery with the battery vehicle.
disconnect switch before disconnecting the ground Before transporting the crane on a road or highway, first
battery cable.
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check state and local restrictions and regulations.

• Do not break a live circuit at the battery terminal. When using hookblock tie downs, excessive loading can be
Disconnect the ground battery cable first when removing applied by pulling the cable too tight, particularly when
a battery and connect it last when installing a battery. reeved with multiple part lines. When the cable is hooked
• Do not short across the battery posts to check charge. into the hookblock tie down, the cable should be merely
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Short circuit, spark, or flame could cause battery “snugged-up” with slack provided at the center line of sheave
explosion. to anchor point. Care must be exercised anytime any crane
function is being performed while the cable is hooked into the
• Maintain battery electrolyte at the proper level. Check hookblock tie down. Do not draw cable taut.
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the electrolyte with a flashlight.

• If applicable to your crane, check battery test indicator TRAVEL OPERATION
on maintenance-free batteries.
Only the crane operator shall occupy the crane when
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• Check battery condition only with proper test equipment. traveling.

Batteries shall not be charged except in an open, well-
When traveling, the boom should be completely retracted
ventilated area that is free of flame, smoking, sparks,
and lowered to the travel position and the turntable pin swing
and fire.
lock should be engaged. If equipped with boom rest, lower
Engine the boom into the boom rest and engage the turntable lock.
Strictly adhere to the guidelines and restrictions in the Load
Fuel the crane only with the engine turned off. Do not smoke
Chart for pick and carry operations.
while fueling the crane. Do not store flammable materials on
the crane. This machine is manufactured with no axle suspension
system. Traveling at high speeds, especially on rough
Be familiar with the location and use of the nearest fire
ground, may create a bouncing affect that can result in loss
extinguisher.
of control. If bouncing occurs, reduce travel speed. (RT and
Be careful when checking the engine coolant level. The fluid Shuttle Lift Only)
may be hot and under pressure. Shut down the engine and
National Crane 1-15

Death or serious injury could result from being crushed by Check load limit of bridges. Before traveling across bridges,
revolving tires. ensure they will carry a load greater than the crane’s weight.
If it is necessary to take the crane on a road or highway,

“Stunt” driving and “horse-play” are strictly prohibited. Never check state and local restrictions and regulations.
allow anyone to hitch a ride or get on or off a moving crane.
instructions in this manual when preparing the Keep lights on, use traffic warning flags and signs, and use
Follow the front and rear flag vehicles when necessary. Check state and
crane for travel. local restrictions and regulations.

If using a boom dolly/trailer, thoroughly read and understand Always drive the crane carefully obeying speed limits and
all the steps and safety precautions in this manual for setup highway regulations.

and travel.
Stay alert at the wheel.
When driving
the crane, ensure the cab is level, if equipped
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with a tilting cab. If equipped, ensure that the hoist access platform hand rail
and step are in the travel configuration.
hook block and other items before moving the
Secure the
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crane. Slopes:

Watch clearances when traveling. Do not take a chance of - Pick and carry on level surfaces only.
running into overhead or side obstructions. - Refer to the Operation Section for more detailed

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When moving in tight quarters, post a signal person to help information on traveling on slopes.
guard against collisions or bumping structures. - Driving across a slope is dangerous, as unexpected

Before traveling a crane, check suitability of proposed route changes in slope can cause tip over. Ascend or
with regard descend slopes slowly and with caution.
to crane height, width, and length.
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Never back up without the aid of a signal person to verify the - Ascend or descend slopes with the boom pointing

area behind the crane is clear of obstructions and/or up the slope.
personnel. - When operating on a downhill slope, reduce travel

On cranes equipped with air-operated brakes, do not attempt speed and downshift to a low gear to permit
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to move the crane until brake system air pressure is at compression braking by the engine and aid the
operating level. application of the service brakes.

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1-16

WORK PRACTICES or walking/working surfaces could cause a slipping accident.
A shoe that is not clean might slip off a control pedal during
Personal Considerations operation.
Always adjust the seat and lock it in position, and fasten the Do not allow ground personnel to store their personal
seat belt securely before you start the engine. belongings (clothing, lunch boxes, water coolers, and the
like) on the crane. This practice will prevent ground
Do not wear loose clothing or jewelry that can get caught on personnel from being crushed or electrocuted when they
controls or moving parts. Wear the protective clothing and attempt to access personal belongings stored on the crane.
personal safety gear issued or called for by the job
conditions. Hard hat, safety shoes, ear protectors, reflective Job Preparation
clothing, safety goggles, and heavy gloves may be required.
Before crane use:
Crane Access
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• Barricade the entire area where the crane is working and
keep all unnecessary personnel out of the work area.
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• Ensure that the crane is properly equipped including
access steps, covers, doors, guards, and controls.
WARNING
Fall Hazard! • Conduct a visual inspection for cracked welds, damaged
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components, loose pins/bolts, and wire connections.
Working at elevated heights without using proper fall
Any item or component that is found to be loose or
protection can result in severe injury or death.
damaged (broken, chipped, cracked, worn-through, etc.)
Always use proper fall protection as required by local, must be repaired or replaced. Inspect for evidence of
state or federal regulations. improper maintenance (consult your Service Manual).
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You must take every precaution to ensure you do not slip • Check for proper functioning of all controls and operator
and/or fall off the crane. Falling from any elevation could aids (e.g. LMI).
result in serious injury or death. • Check all braking (e.g. wheel, hoist, and swing brakes)
Never exit or enter the crane cab or deck by any other means and holding devices before operation.
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than the access system(s) provided (i.e., steps and grab You must ensure that the outriggers and stabilizers are
handles). Use the recommended hand-holds and steps to properly extended and set before performing any lifting
maintain a three-point contact when getting on or off the operations. On models equipped with outriggers that can be
crane. pinned at the mid-extend position, the outriggers must also
be pinned when operating from the mid-extend position.
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If necessary, use a ladder or aerial work platform to access

the boom nose. Clear all personnel from the outrigger area before extending
Do not make modifications or additions to the crane’s access or retracting the outriggers. Carefully follow the procedures
system that have not been evaluated and approved by in this Operator’s Manual when extending or retracting the
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Manitowoc Crane Care. outriggers. Death or serious injury could result from improper
crane set up on outriggers.
Do not step on surfaces on the crane that are not approved
or suitable for walking and working. All walking and working Be familiar with surface conditions and the presence of
surfaces on the crane should be clean, dry, slip-resistant, overhead obstructions and power lines.
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and have adequate supporting capacity. Do not walk on a

surface if slip-resistant material is missing or excessively Working
worn. Operator shall be responsible for all operations under his/her
Do not use the top of the boom as a walkway. direct control. When safety of an operation is in doubt,
operator shall stop the crane’s functions in a controlled
Do not step on the outrigger beams or outrigger pads (floats) manner. Lift operations shall resume only after safety
to enter or exit the crane. concerns have been addressed or the continuation of crane
Use the hoist access platform (if equipped) when working in operations is directed by the lift supervisor.
the hoist area. Know the location and function of all machine controls.
Wear shoes with a highly slip-resistant sole material. Clean Make sure all persons are away from the crane and the
any mud or debris from shoes before entering the crane cab/ Travel Select Lever is in the “N” (Neutral) position with the
operator’s station or climbing onto the crane superstructure. parking brake engaged before starting the engine.
Excessive dirt and debris on the hand-holds, access steps,
National Crane 1-17

Sparks from the crane’s electrical system and/or engine
exhaust can cause an explosion. Do not operate this crane
in an area with flammable dust or vapors, unless good
ventilation
has removed the hazard.
Carbon monoxide fumes from the engine exhaust can cause
in an enclosed area. Good ventilation is very
suffocation
important when operating the crane.

Before actuating swing or any other crane function, sound
the horn and verify that all personnel are clear of rotating and

moving parts.
Never operate the crane when darkness, fog, or other

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visibility restrictions make operation unsafe. Never operate a
crane in thunderstorms or high winds.

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Always be aware of your working environment during
operation of the crane. Avoid contacting any part of the crane

with external objects.
C l e a r a l l p e r s o n n e l f r o m t h e c o u n t e r w e i g h t a n d
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superstructure area before removing the counterweight.

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Lifting
Use enough parts of line for all lifts and check all lines,
slings, and chains for correct attachment. To obtain
maximum lifting capacities, the hook block must be set up
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Keep unauthorized personnel clear of the working area

during operation. with enough parts of line. Too few parts of line can result in
failure of the wire rope or hoist. No less than three wraps of
Only the crane operator shall occupy the crane when in wire rope should remain on the hoist drum. When slings, ties,

operation. hooks, etc., are used, make certain they are correctly
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You must always be aware of everything around the crane positioned and secured before raising or lowering the loads.
while lifting or traveling. If you are unable to clearly see in the Be sure the rigging is adequate before lifting. Use tag lines
direction of motion, you must post a look out or signal person when possible to position and restrain loads. Personnel
before moving the crane or making a lift. Sound the horn to
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using tag lines should be on the ground.

warn personnel
Be sure good rigging practices are being used. Refuse to
Operate the crane only from the operator’s seat. Do not use any poorly maintained or damaged equipment. Never
reach in a
window or door to operate any controls. wrap the hoist cable around a load.
Operate the crane slowly and cautiously, looking carefully in If using a clam bucket, do not exceed 80% of the crane’s
of movement.
the direction capacity.
A good practice is to make a “dry run” without a load before Make certain the boom tip is centered directly over the load
making the first lift. Become familiar with all factors peculiar before lifting.
to the job site.
Ensure that all slings, ties, and hooks are correctly placed
wire rope is properly routed on the hook block
Ensure the and secured before raising or lowering the load.
and boom nose and that all rope guards are in place.
Be sure the load is well secured and attached to the hook
with rigging of proper size and in good condition.

1-18

Check the hoist brake by raising the load a few inches, If the boom should contact an object, stop immediately and
stopping the hoist and holding the load. Be sure the hoist inspect the boom. Remove the crane from service if the
brake is working correctly before continuing the lift. boom is damaged.
When lowering a load always slow down the load’s descent When lifting a load the boom may deflect causing the load
before stopping the hoist. Do not attempt to change speeds radius to increase—this condition is made worse when the
on multiple-speed hoists while the hoist is in motion. boom is extended. Ensure weight of load is within crane’s
capacity on Load Chart.
Watch the path of the boom and load when swinging. Avoid
lowering or swinging the boom and load into ground Avoid sudden starts and stops when moving the load. The
personnel, equipment, or other objects. inertia and an increased load radius could tip the crane over
or cause it to fail structurally.
Lift one load at a time. Do not lift two or more separately
rigged loads at one time, even if the loads are within the Use tag lines (as appropriate) for positioning and restraining
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crane’s rated capacity. loads. Check the load slings before lifting.
Never leave the crane with a load suspended. Should it Be sure everyone is clear of the crane and work area before
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become necessary to leave the crane, lower the load to the making any lifts.
ground and stop the engine before leaving the operator’s
Never swing over personnel, regardless of whether load is
station.
suspended from or attached to the boom.
Remember, all rigging equipment must be considered as
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part of the load. Lifting capacities vary with working areas. If Hand Signals
applicable, permissible working areas are listed in the Load
A single qualified signal person shall be used at all times
Chart. When swinging from one working area to another,
when:
ensure Load Chart capacities are not exceeded. Know your
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crane! • Working in the vicinity of power lines.
Stop the hook block from swinging when unhooking a load. • The crane operator cannot clearly see the load at all
times.
Swinging rapidly can cause the load to swing out and
increase the load radius. Swing the load slowly. Swing with • Moving the crane in an area or direction in which the
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caution and keep the load lines vertical. operator cannot clearly see the path of travel.
Look before swinging your crane. Even though the original At all times use standardized hand signals - previously
setup may have been checked, situations do change. agreed upon and completely understood by the operator and
signal person.
Never swing or lower the boom into the carrier cab (if
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applicable). If communication with the signal person is lost, crane

movement must be stopped until communications are
Do not pull posts, pilings, or submerged articles. Be sure the
restored.
load is not frozen or attached to the ground before lifting.
Keep your attention focused on the crane’s operation. If for
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Never push or pull loads with the crane’s boom; never drag a
some reason you must look in another direction, stop all
load.
crane movement first.
Do not subject crane to side loading. A side load can tip the
Obey a signal to stop from anyone.
crane or cause it to fail structurally.
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National Crane 1-19

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1-20

BOOM EXTENSION the ground. When a qualified person at a jobsite determines
that it is not practical to lower the boom to the ground, we
To avoid death or serious injury, follow the procedures in this recommend the following additional instructions be followed:
manual during erection, stowage, and use of the boom
extension. • The crane should be left in the smallest, most stable,
valid operational conf iguration that the job site
Install and secure all pins properly. practically allows.
Control movement of boom extension at all times. • The crane can not be left running, with a load on the
Do not remove right side boom nose pins unless boom hook, or in erection mode, or in wind conditions in
extension is properly pinned and secured on front and rear excess of allowed values.
stowage brackets. • The boom should be retracted as far as is practical, the
crane configured in as stable a configuration as possible
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( bo om an gle , sup er stru ctu re o r ien tat ion , bo om
extension angle, etc.)
DANGER
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• In high winds the boom and boom extensions should be
Boom Extension Hazard! lowered, or secured. Changing weather conditions
To avoid death or serious injury, follow procedures in Load including but not limited to: wind, ice accumulation,
Chart, safety, and operation manuals during erection, p r ec ip ita ti on , fl oo d in g , l ig ht i ng , et c. sh o ul d b e
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stowage and use of boom extension. Install and secure all co n si de r e d w h en d e te r m in i ng t h e l o ca t io n a n d
pins properly and control boom extension movement at all configuration of a crane when it is to be left unattended.
times.
SHUT-DOWN
Do not remove all the pins from both front and rear stowage
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brackets unless the boom extension is pinned to the right Use the following steps when shutting down the crane:
side of the boom nose. • Engage the parking brake.
Properly inspect, maintain, and adjust boom extension and • Fully retract and lower the boom.
mounting.
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• Engage the swing lock pin or 360 degree swing lock.

When assembling and disassembling boom extension
sections, use blocking to adequately support each section • Place controls in neutral position.
and to provide proper alignment. • Shut down the engine and remove the ignition key.
Stay outside of boom extension sections and lattice work. • Chock the wheels, if not on outriggers.
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Watch for falling or flying pins when they are being removed. • Lock the operator’s cab (if applicable) and install vandal
guards, if used.
PARKING AND SECURING
In cold weather, never park the crane where the tires can
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become frozen to the ground.
! WARNING COLD WEATHER OPERATION

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Tipping Hazard! Cold weather operation requires additional caution on the

When parking the crane and leaving it unattended follow part of the operator.
the instructions in Section 3 of this manual.
Check operating procedures in this manual for cold weather
Failure to comply with these instructions may cause death starting.
or serious injury
Don’t touch metal surfaces that could freeze you to them.
When parking on a grade, apply the parking brake and chock Clean the crane of all ice and snow.
the wheels.
Allow ample time for hydraulic oil to warm up.
Section 3 of this manual provides instructions for parking and
securing a crane when it is to be left unattended. These In freezing weather, park the crane in an area where it
instructions are intended to allow the crane to be placed in cannot become frozen to the ground. The drive line can be
the most stable and secure position. However, Manitowoc damaged when attempting to free a frozen crane.
recognizes that certain jobsite conditions may not permit the If applicable to your crane, frequently check all air tanks for
boom and boom extension of a crane to be fully lowered to water in freezing weather.
National Crane 1-21

If applicable to your crane, always handle propane tanks movement of the boom may be undetected by the operator
according to the supplier’s instructions. unless a load is suspended for a long period of time. To
minimize the effects of thermal contraction or “Stick-slip” it is
Never store flammable materials on the crane.
recommended that the telescope control lever is activated
If cold weather starting aids are provided on your crane, use periodically in the extend position to mitigate the effects of
them. The cooling oil.
use of aerosol spray or other types of starting
fluids containing ether/volatiles can cause explosions or fire.
If a load and the boom is allowed to remain stationary for a
period of time and the ambient temperature is cooler than the
TEMPERATURE EFFECTS ON HYDRAULIC trapped oil temperature, the trapped oil in the cylinders will
CYLINDERS
cool. The load will lower as the telescope cylinder(s) retracts
allowing the boom to come in. Also, the boom angle will
Hydraulic oil expands when heated and contracts when
decrease as the lift cylinder(s) retracts causing an increase
cooled. This is a natural phenomena that happens to all
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in radius and a decrease in load height.
liquids. The coefficient of expansion for API Group 1
hydraulic oil is approximately 0.00043 cubic inches per cubic This situation will also occur in reverse. If a crane is set up in
nl
inch of volume for 1°F of temperature change. Thermal th e m or n ing w it h co ol oil a nd t h e da yti me a mb ien t
contraction will allow a cylinder to retract as the temperature heats the oil, the cylinders will extend in similar

hydraulic fluid which is trapped in the cylinder cools. proportions.
The change
in the length of a cylinder is proportional to the Table 1-2 has been prepared to assist you in determining the
O
extended length of the cylinder and to the change in approximate amount of retraction/extension that may be
temperature
of the oil in the cylinder. For example, a cylinder expected from a hydraulic cylinder as a result of change in
extended 25 ft in which the oil cools 60°F would retract the temperature of the hydraulic oil inside the cylinder. The
approximately 7 3/4 in (see chart below). A cylinder chart is for dry rod cylinders. If the cylinder rod is filled with

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extended 5 feet in which the oil cools 60°F would only retract hydraulic oil, the contraction rate is somewhat greater.
approximately 1 1/2 in. The rate at which the oil cools
NOTE: Operators and service personnel must be aware
depends on many factors and will be more noticeable with a
that load movement, as a result of this phenomena,
larger difference in oil temperature verses the ambient
can be easily mistaken as leaking cylinder seals or

temperature.
faulty holding valves. If leaking seals or faulty
en
Thermal contraction coupled with improper lubrication or holding valves are suspected to be the problem,
improper wear pad adjustments may, under certain refer to Service Bulletin dealing with testing
conditions, cause a “stick-slip” condition in the boom. This telescope cylinders. (Bulletin 98-036 applies to
condition could result in the load not moving
“stick-slip” TMS700 and bulletin G06-005A applies to RT890
smoothly. Proper boom lubrication and wear pad adjustment and RT9130.
er
to permit the boom sections to slide freely. Slow

is important
Table 1-2: BOOM DRIFT CHART (Cylinder length change in inches)

ef

3 3
Coeff. = 0.00043 (in /in / °F)
STROKE Temperature Change (°F)
R
(FT.) 10 20 30 40 50 60 70 80 90 100
5 0.26 0.52 0.77 1.03 1.29 1.55 1.81 2.06 2.32 2.58
10 0.52 1.03 1.55 2.06 2.58 3.10 3.61 4.13 4.64 5.16
15 0.77 1.55 2.32 3.10 3.87 4.64 5.42 6.19 6.97 7.74

20 1.03 2.06 3.10 4.13 5.16 6.19 7.22 8.26 9.29 10.32
25 1.29 2.58 3.87 5.16 6.45 7.74 9.03 10.32 11.61 12.90
30 1.55 3.10 4.64 6.19 7.74 9.29 10.84 12.38 13.93 15.48
35 1.81 3.61 5.42 7.22 9.03 10.84 12.64 14.45 16.25 18.06
40 2.06 4.13 6.19 8.26 10.32 12.38 14.45 16.51 18.58 20.64
45 2.32 4.64 6.97 9.29 11.61 13.93 16.25 18.58 20.90 23.22
50 2.58 5.16 7.74 10.32 12.90 15.48 18.06 20.64 23.22 25.80
55 2.84 5.68 8.51 11.35 14.19 17.03 19.87 22.70 25.54 28.38
60 3.10 6.19 9.29 12.38 15.48 18.58 21.67 24.77 27.86 30.96
3 3
Length change in inches = Stroke (Ft.) X Temperature Change ( °F) X Coeff. (in /in / °F) X 12 in/ft
1-22

OVERLOAD INSPECTION
This information supplements the Load Moment Indicator
(LMI) manual supplied with each Grove crane.
WARNING
When the LMI system has acknowledged an overload on
Overload Hazard!
your crane, you must carry out specified inspections on the
crane. To avoid an accident caused by overload damage to your
crane:
These inspections apply only to overloads up to 50%. For
overloads of 50% or higher, crane operation must be • Perform the inspections outlined in this publication
stopped immediately and Crane Care must be contacted for for overloads up to 50%.
corrective action. • Stop operating the crane and contact Manitowoc
Crane Care immediately for overloads of 50% and
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higher.
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NOTE: If your crane is equipped with CraneSTAR, an
overload warning will be posted to the web site for
review by the crane owner.
Overload warnings do NOT indicate real time
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events! Warnings could be sent 24 hours (or more)
after the actual event.
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National Crane 1-23

Boom Inspection

1

9, 10
4

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8
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2, 3
1

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5

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9, 10

6
7
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1-24

Overload less than 25%
Sheaves,
1 Inspect all for damage.
Rope Guides
Collar-Wear
2 Pads, Pad Inspect for damage.
Retainers
Overload from 25% to 49%
Sheaves,
1 Inspect all for damage.
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Rope Guides
Collar-Wear
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2 Pads, Pad Inspect all for damage.
Retainers
3 Collar-welds Inspect all for damage.
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4 Pinning Areas Inspect all for cracks.
Telescopic Inspect for bent or twisted sections. Check the boom
5
Sections for straightness.
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Lift Cylinder
6 Inspect for bends or cracked welds.
Head Area
Turret-Base
7 Inspect for cracked welds.
Section
en
Inspect for bent or twisted section. Check for

8 Jib Section
straightness.
9 Welds Inspect for cracks.
Inspect for cracked paint which could indicate twisted,
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10 Paint
stretched, or compressed members.
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National Crane 1-25

Superstructure Inspection

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2
3
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5 4
1
6

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7
8

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10,11

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9

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1-26

1 Lift Cylinder Inspect for leaking.
See topic in Introduction section
2 Wire Rope Inspect all for damage.
of Service Manual.
Turntable See topic in Swing section of
3 Check bolts for proper torque.
Bearing Service Manual.
1 Lift Cylinder Inspect for leaking.
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See topic in Introduction section
2 Wire Rope Inspect all for damage.
nl
of Service Manual.
Turntable See topic in Swing section of
Bearing Service Manual.
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4 Hoist/Drums Inspect each for damage.
5 Hoist Brakes Brakes must hold rated line pull.
Bearing Main
6 Boom Pivot Inspect for deformation, cracked welds.
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Pin
Lift Cylinder-
7 Inspect pin and welds.
Lower Mount
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8 Turret Area Inspect for deformation, cracked welds.

Mounting
Studs
er

11 Paint
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National Crane 1-27

Carrier Inspection

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3

1

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2

4
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3
1
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5, 6

2

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3 4
1
2
1-28

Stabilizer
1 Inspect for leaking.
Cylinders
Outrigger
2 Inspect for deformation and cracked welds.
Pads
Stabilizer
1 Inspect for leaking.
Cylinders
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Outrigger
Pads
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Outrigger
Beams
Outrigger
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Boxes
6 Paint
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National Crane 1-29

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1-30

OPERATION
CONTROLS
TRUCK CAB CONTROLS Operation Below -40°F

For crane operation below -40°F, capacities shall
Power Take-Off
be derated 2 percent of the rated load shown on the
Manual Shift Control – The PTO’s are engaged
capacity charts for each degree below -40°F.
when the knobs on dash or floor are pulled out and dis-
engaged when the knobs are pushed in. The truck gear
CRANE CONTROLS
shift lever must be in neutral and the clutch depressed
The unit is equipped with control stations on each
whenever the knobs are moved.
side of the main frame. Placards on the control knobs
Air Shift Control – The PTO is engaged when the
or next to the lever indicate the direction to actuate the
switch is moved to apply air to PTO and disengaged
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controls for the various unit functions. Each station is
when switch is in off position. The truck gear shift lever
complete and provides complete control of boom rota-
must be in neutral and clutch depressed when switch is
nl
tion, boom elevation, boom extension, winch, outriggers,
moved. The transmission selector lever must be re-
engine foot throttle, the engine emergency stop switch
turned to “N” for stationary vehicle operation. The power
and a horn switch. All control handles except the outrig-
take-off may be disengaged while in any transmission
ger controls are positioned in the same order at both
range provided that the load has first been removed from
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control stations. The hydraulic system pressure gauge
the PTO.
is located at only one operator’s station.
Electric Shift Control – Full torque electric shift
PTO’s are controlled by a switch. To operate, disengage
Control Functions
the clutch, shift to fourth or fifth gear, and operate the
Turn – Operate the lever to RIGHT to rotate the boom
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switch down to engage the PTO or up to disengage the
in a clockwise direction. Operate the lever to LEFT to
PTO. Return the gear shift to neutral and engage the
rotate the boom in a counterclockwise direction as
clutch.
viewed from the top of the crane.
Power Shift Control – If the vehicle is equipped
A mechanical rotation stop pulls the turn control le-
with automatic transmission, the power take-off must
en
ver back to the center position when engaged. The

be engaged with the engine at idle. Refer to transmis-
boom rotation is stopped over the front of the chassis.
sion manufacturer’s instructions for special procedures.
On rear mounted cranes, rotate the boom over the pas-
senger side of the chassis when stowing and unstowing
Park Brake
to prevent immediate contact with the mechanical rota-
The truck brake must be firmly set before leaving
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tion stop.
cab to begin operation. If the ground surface is icy or
slick or is sloped, you may be required to help immobi-
Swing Speed Adjustment – Located on turn mo-
tor inside frame. Turn knob in to increase maximum
lize the truck with wheel chocks.
swing speed. Turn knob out to decrease maximum
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swing speed.
Cold Weather Operation
The following recommendations are for operating
Boom – Operate the lever to DOWN to lower the
boom. Operate the lever to UP to raise the boom.
National cranes in very low (i.e., sub-zero) temperatures.
Cranes should have appropriate hydraulic oil, lubri-
Boom Telescope – Operate the lever to OUT to ex-
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tend the boom. Operate the lever to IN to retract the

cants, and other auxiliary items required for operation
boom.
in sub-zero temperatures. Operate individual crane func-
tions to ensure they are sufficiently warmed prior to per-
Winch—Operate the lever to DOWN to payout and
lower the loadline. Operate the lever to UP to reel in and
forming a lift
raise the loadline. Refer to winch system operation sec-
Operation of cranes at full rated capacities in tem-
tion for additional information.
peratures between -18°C (0°F) and -40°C (-40°F) or
lower should be accomplished only by competent op-
erators who possess the skill, experience, and dexterity ! DANGER
to ensure smooth operation. Shock loading shall be
Payout loadline before extending boom. Fail-
avoided.
ure to do so may cause the loadline to break or dam-
Operation Below -40°C age the crane.
For crane operation below -40°C, capacities shall
Stabilizers – Up/Down – Operate the lever to
be derated 3.67 percent of the rated load shown on the
DOWN to lower and UP to raise.
capacity charts for each degree below -40°C
2-1
NATIONAL CRANE 900A SERIES
Stabilizers – Extend/Retract – Operate the lever Boom Length Indicator – Located on either side
to EXTEND to move beams out and to RETRACT to move of the second boom section. The letters on the interme-
beams in. diate boom lengths correspond to the letters on the ca-
Outriggers
– Operate the lever to UP to raise the pacity chart. The length indicators are used to define
outrigger legs. Operate the lever to DOWN to lower the boom length and with the capacity chart and load radius
outrigger legs. are used to determine the maximum loads that may be
Foot Throttle – Depress the foot throttle to accel- safely lifted. Actual radius must be measured from the
erate the truck engine speed. Release to return to idle centerline of rotation.

speed. Increasing truck speed increases operating Load Radius – Horizontal distance from the center
speed. of rotation of the turret to the center of the loadline hook

Kill Switch – Operate the switch to kill the truck or load with the load suspended. Use boom angle and
engine under emergency conditions. Switch must be re- boom length as a reference to determine loadline or
set to on to operate truck from cab. load radius. When lifting maximum rated load, always
Horn – Operate horn button to warn fellow workers know the weight of the load and measure the radius

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on construction site of pending movement of crane. with the load suspended.
Pressure Gauge – Observe pressure gauge while
booming up or down at end of stroke to determine sys- OPTIONAL HCA SYSTEM
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tem pressure. Note: LMI required on cranes with jibs Note: HCA system cannot be used with jibs and/
and/or man baskets. or man baskets.
LMI Display Console – Acts as interface between HCAS Load Range Gauge – Aid in determining
operation and load moment system. It’s used to import the load condition of crane. The gauge has three colors
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operating conditions and display boom and load infor- on the dial face: (1) Green – OK; (2) Yellow – Caution;
mation. Refer
to LMI manual in this owners manual. and (3) Red – Overload. Do not use the Load Range
LMI CPU – Processes load information to give op- Gauge with a jib. Refer to “Hydraulic Capacity Alert
erator crane
capacities and boom information. Refer to System” for more information
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LMI manual in this owners manual. HCAS Overload Light – Indicator light illuminates
ATB Light – Indicator light illuminates when a two when HCAS detects crane overload and boom down,
block condition is detected. extend out and winch up functions disabled.
Override Key Switch – Turn key switch to enable ATB Light – Indicator light illuminates when a two
block condition is detected.
or disable HCAS and ATB override. Some units may be
en
equipped with a Manual Reset Valve option that does Override Key Switch – Turn key switch to enable

not have Override Key Switch. or disable HCAS and ATB override. Some units may be
Capacity Chart – This chart shows capacities of equipped with a Manual Reset Valve option that does
crane at various operating areas and winch capacities not have Override Key Switch.
with appropriate reeving. Override Button – With Override Key Switch in on
er
Boom Angle Indicator – Located on either side of position, depress button to override HCAS and ATB sys-
the base boom section and used to determine main tem. Do not use override to continue lifting operations
boom angle with respect to horizontal. For reference in an overload or two blocked condition.
only.
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2-2

!
BOOM
WINCH
TELESCOPING
TURN
O/R THIS SIDE
O/R OTHER SIDE
FUSE
OVERLOAD LIGHT *
OVERRIDE BUTTON *
ATB LIGHT *
O/R OTHER SIDE

O/R THIS SIDE
PRESSURE GAUGE
KILL SWITCH
* HCA LOAD HORN
RANGE GAUGE BOOM
WINCH
TELESCOPING
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CROSS-FRAME O/R THIS SIDE TURN
CROSS-FRAME O/R EXT/RET
CROSS-FRAME O/R OTHER SIDE
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HCA LOAD RANGE GAUGE *
CROSS-FRAME O/R OTHER SIDE

CROSS-FRAME O/R EXT/RET
CROSS-FRAME O/R THIS SIDE
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* OPTIONAL HCA SYSTEM
BOOM ANGLE
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INDICATOR
LMI CENTRAL
PROCESSING
UNIT (CPU)
LMI DISPLAY
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CONSOLE
CAPACITY
CHART
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LEVEL
INDICATOR
* OVERRIDE SWING
KEY SWITCH
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ADJUSTMENT
KNOB
COVER
BOOM
LENGTH
INDICATOR
FOOT
THROTTLE
2-3

"

=!
!>

All members of the crew should become thoroughly ! "
familiar with
the location and operation of controls, the
correct operating procedure, the maximum lifting ca- &
34
$$
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5
36%
4$&

pacities and the safety precautions applicable to the unit $
#$
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$
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$
7

before operating. This crane is a complex piece of equip- 8

3'$
3
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9'
ment and can be overloaded in many ways. Carefully '3'
6$
3
$&
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53
7

follow the operating procedures outlined below and in $
$&
6&8
the instructional pages of the load rating chart at the
station. If the operator cannot see the load handling device
operator’s
approaching the boom nose, he shall have an assistant
(signal person) watch the load handling device. The
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=!
+,
operator shall be prepared to stop the machine immedi-
Perform the following checks prior to placing the unit
ately should the LMI (or optional HCA system) not func-

in operation:
nl
tion properly. If the LMI (or optional HCA system) is not
• Inspect for any unusual conditions such as pools
functioning properly, lifting the anti-two-block weight will
of hydraulic fluid or lubricating oil under the chas-
not activate the red warning light or the audible alarm
sis, any outrigger which may have crept down or
(optional for the HCA system), and will not lock the crane
up and any signs of damage or improper main-
O
movements hoist up, telescope out, and boom down.
tenance.
Check the anti-two-block alarm light and the audible
• Check
that the tires are inflated to the proper
alarm by performing one of the following tests:
pressure.
• Manually lift the weight attached to the anti-two-
• Check
the level of the hydraulic reservoir.
block switches. When the weight is lifted, the
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• Check the operation of the “stop” and horn cir-
audible alarm for the LMI (or optional audible
cuits.
alarm for the optional HCA system) should sound
• Check for missing and loose bolts.
and the anti-two-block alarm light should light.
• Check for damaged structural members and
• Slowly raise the main boom load handling de-
welds.
en
vice to create a potential two-block condition.

• Check all rope guides and cable keepers.
When the load handling device lifts the weight,
• Check all sheaves for free turning.
the audible alarm should sound, the anti-two-
• Check the loadline cable for kinks, broken
block alarm light should light and the motion of
strands or other damage in accordance with in-
the load handling device should be stopped.
structions in the “Lubrication & Maintenance”
er
Lower the load handling device slightly to elimi-

section.
nate this condition.
• Check to see that the hydraulic hoses and fit-
• Slowly extend (telescope) the boom to create a
tings
are in good condition and show no signs of potential two-block condition. When the load
leaking. The hoses should be free from cuts
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handling device lifts the weight, the audible alarm

and
abrasions and there should be no evidence should sound, the anti-two-block alarm light
of binding. Any damage or leakage should be
should light and the boom telescope out func-
repaired
immediately.
tion should be stopped. Lower the load handling
• Check LMI and anti-two-block system for proper
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device slightly to eliminate this condition.

operation.

$*
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6'
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1. Check the electrical wiring connecting the vari-
63'$
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parts of the system for physical damage.
ous
8
2. Check the anti-two-block switches and weights
for
free movement. • If the crane is equipped with a boom extension
that is deployed and rigged for work, repeat the
test procedure for the boom extension anti-two-
block switch.
2-4

• Check that the display of the main boom length that outriggers can be fully extended and leg comes
agrees with the actual boom length. down on firm level surface. Particular care must be
• Check that the display of the main boom angle taken in selecting a site position to the location of over-
agrees with the actual boom angles. head power lines so that proper clearance conditions
• Check that the display of the operating radius of can be maintained. Ideally, one should select a location
the crane agrees with the actual radius. at which the boom could not come within minimum rec-
• Check the load display by lifting a load of known ommended distance of the power lines at full extension.
weight. The accuracy of the load indication shall It is best to select a location on the site such that
be within the tolerance of SAE J159. most of the lifting can be done over the outrigger sup-
port or rear of the truck.
$
After being properly checked, the LMI is operational.
"
+

The operator shall be thoroughly familiar with all con- 1. Position the truck so that the outriggers can be
trols of the LMI and he shall properly set the reeving extended without encountering obstructions. Set
y
Switch before operating the crane. The proper function the truck park brake securely and turn front
of the system shall be checked by lifting a load of known wheels into the curb. Wheel chocks may be
weight and comparing the load to the information dis- required under certain conditions.
nl
played on the LMI. 2. With the gear shift in neutral, depress clutch (if
Rated loads include the weight of the hook block, equipped with a manual transmission), and en-
slings, and auxiliary load handling devices. Their com- gage the power takeoff by pulling out the shifting
bined weights shall be subtracted from the listed load knob.
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capacities as stated on the load capacity chart to obtain 3. Bring the hydraulic system up to operating tem-
the net load to be lifted. perature (oil reservoir warm to the touch) by al-
lowing the system to operate by actuating the
! " outrigger retract switch with all outriggers fully
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retracted.
3
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If operating on sloping ground provide blocks. When
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! port the outrigger and stabilizer pads with bearing pads.
5$8 Some concrete and asphalt surfaces are relatively thin
and cannot support outrigger or stabilizer loading. Con-
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crete can break through and cause instability.

! " Variation in chassis, outrigger and mounting con-
figurations will cause outrigger foot loading to differ on
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each crane, however, outrigger foot loads can be as
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high as 50,000 pounds (22 697 kg) when outriggers are

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6
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at full span [154 psi (1.06 MPa) on standard outrigger
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pads]. Support surface bearing capacities vary by a large
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amount—from 833 psi (5.7 MPa) on bed rock down to
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14 psi (0.1 MPa) on soft clay. Loose sand or soft as-
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phalt will support even less load. It is imperative that
5
3$%8 the operator take proper precautions to insure the
outrigger foot has adequate cribbing for existing soil
2,

conditions.
Always seek the best possible work site when park-
ing the crane. An ideal parking location at a job site is
firm, level, dry ground or pavement located in close prox-
imity to the work station. Avoid uneven, rocky or muddy
terrain, steep grades or locations with unnecessary over-
head obstructions. Location should be selected such
2-5

If specific outrigger foot loading is required for an 3. Rear Mount Units Equipped with Rear Stabilizer
individual crane, contact National Crane with actual chas- A rear stabilizer is required when loads are to be
sis weights and crane details. lifted over the rear of the vehicle. Before con-
1. When
Lifting Over the Rear of the Truck ducting any boom operations, extend both
outriggers until the chassis weight is removed
from the wheels. Level the crane side-to-side
using the level indicator located at either control
station as a reference. Then extend and lower

the HO outriggers to level the crane front-to-back.
Again refer to the level indicator to insure that
the crane is properly leveled. After the crane is
180°
leveled side-to-side and front-to-back, extend the
rear stabilizer leg until firm contact is made with
the ground. Always keep the load as close to the

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ground as possible.
! "

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Before conducting any boom operations, extend

$
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both outriggers until the chassis weight is re-
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moved from the wheels. Level the crane from
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side-to-side. A level indicator is provided at ei-
ther control station. Then extend and lower the 4. Check to ensure that the jib, if so equipped, is

stabilizers to level the crane front-to-back. Again stowed correctly on the first section boom.
refer to the level indicator to insure that the crane
is properly leveled. Always keep the load as close
!, "
+

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to the ground as possible. 1. Check all controls for proper operation by oper-

2. When Lifting Over the Front of the Truck and the ating each system through one complete cycle.
Vehicle is Equipped with a Front Stabilizer This is particularly important after the unit has
been serviced or repaired. If any abnormal op-
en
erations are detected, correct the condition be-

fore continuing.
2. During all operations, the controls should be
metered when beginning or terminating a move-
ment to prevent sudden starting or stopping
er
360° which imposes undue shock loads on the equip-

ment. This metering can be performed by me-
tering the control lever and the foot throttle.
3. Check the operating area for electric powerlines.
ef

A front stabilizer is required when loads are to be
R
lifted over the front of the vehicle. Before con-

ducting any boom operations, extend both
outriggers until the chassis weight is removed
the wheels. Level the crane side-to-side
from
using the level indicator located at either control

station as a reference. Then extend and lower
the rear stabilizers to level the crane front-to-
Again refer to the level indicator to insure
back.
that the crane is properly leveled. After the crane
is leveled side-to-side and front-to-back, extend
the front stabilizer leg(s) until firm contact is made
with the ground. Always keep the load as close
to the ground as possible.
2-6

"

"
+
10. The loads are lifted in the proper area around
+ the truck.
The structures and components of your unit are de- A stability test should have been performed on this
signed to provide satisfactory service if the unit is not crane and can be repeated by referring to the Installa-
loaded in excess of the maximum rated loads specified tion Section.
on the load chart. Overloading can create serious po- All capacities are given in direct relationship to the
tential safety hazards and can also shorten the service boom length and loaded radius at which the load is be-
life of your unit. It is important that you know the weight ing handled. All radii are measured from the centerline
and radius of any load that you are attempting to handle. of rotation to the loadline with the load suspended. All
This should be done by use of a dynamometer and tape variances of loads and radii of operation are shown on
measure or by contacting your supervisor. the load capacity chart mounted on the main frame.
Overloading a crane Boom angle should be used as reference only to aid in
can cause many types of determining radius. The correct loaded radius must be
,
failure depending on the measured and not exceeded during any point of the lift-
Q
y
configuration and working ing operation. The placard is located at the operators
"
position of the crane, i.e. platform for the purpose of informing the operator when
Q
structural damage to al- a load can or cannot be handled. Load ratings cannot
nl

most any part of the crane, be interpolated between load points shown on the chart
winch or cable failure and

in the boom areas. When boom length or radius or both
tipping the unit over. are between points listed on capacity chart, the small-
The load chart shows the maximum rated loads in- est load shown at either the next larger radius or boom
O
cluding load (weight being lifted), load handling equip- length shall be used. Capacities of the jib cannot be
ment such as slings, buckets, and downhaul weights, interpolated between angles nor at reduced lengths
etc. which can be handled by the crane and the winch. because the strength of the jib and its attachment point
The weight of the load handling equipment and boom to the boom does not increase when the boom is short-
ce
attachments must be deducted from the maximum load ened.
rating shown on the load chart to determine the payload
which can be lifted. Additional reduction may be neces- "
sary to make allowance for such factors as the effects 1. The equipment can be hazardous if improperly
of freely swinging loads, wind, ground conditions, out- maintained or operated. Read and comply with
en
of-level conditions and operating speeds. the Operator’s Manual supplied with this machine
The ratings shown on the outrigger full span load for information on safety, operation and mainte-
chart are maximum loads and are based on the struc- nance before operating this machine. If these
tural integrity of the crane in shaded areas, the stability manuals are missing, order replacements from
of the crane in nonshaded areas. The stability or non National Crane through the distributor.
er
shaded areas represent a stability tipping factor of 85% 2. Rated loads shown on the capacity chart pertain
(Note: For New York City approved units the stability or to this machine as originally manufactured and
non shaded areas represent a stability tipping factor of equipped. Modifications to the machine or use
75%) when: of equipment that is not factory specified or ap-
ef
1. All outriggers are extended with positive contact proved can be hazardous. Refer to capacity de-
on firm, level surface, the tires are free of the duction chart for weights which must be deducted
ground and the machine is level within 1°. from rated loads when accessories are attached
2. The proper amount of counterweight has been to boom or loadline.
R
installed, if required.
3. The unit is mounted in accordance with factory $7
instructions on a vehicle with proper specifica- 1. Inspect vehicle and crane including crane op-
tions. eration prior to use each day.
4. The weight of load handling devices is consid- 2. Load ratings shown on the chart are maximum
ered as a part of the load being lifted. allowable loads with the crane mounted on a fac-
5. The correct loadline reeving is used for the load tory approved truck and all outriggers set on a
to be lifted. firm level surface so the crane is level. This crane
6. Adverse environmental conditions such as wind is not rated for use without outriggers.
are not present. 3. Depending on the nature of the supporting sur-
7. The operator controls the loads smoothly. face, structural supports under the outrigger
8. Tires are inflated to the proper pressure. floats may be necessary to spread the load to a
9. The load to be handled does not exceed the larger bearing surface.
maximum capacity at the boom length and 4. Always level the crane with the level indicator
loaded radius. located at the operator stations located on ei-
ther side of the crane frame.
2-7

$ capacity chart, the smallest load shall be used.
1. Operation of this equipment in excess of maxi- 9. It is safe to attempt to telescope or retract any
mum load rating and disregard of instructions is load listed if rating is not exceeded. Capacities
hazardous.
Always refer to the capacity chart at retracted boom length cannot be telescoped
for load and area limits before operating the without exceeding ratings.
crane.
Rated loads at rated radius shall not be 10. Always pay out loadline before extending boom
exceeded. Over loading this crane may cause to avoid damaging loadline or crane structure.
structural collapse or instability. Do not rely on 11. Loads lifted must be within safe winch capacity

the LMI or HCAS system to weigh the load and as well as safe crane capacity. Multiple part rope
control limiting boom angle and radius. Use the reeving must be used on loads exceeding winch

system as a backup to safe operation. single part rated pull. Jibs are rated for single
2. Use the angle indicator as a reference only. part use only.

When lifting maximum loads, measure radius. 12. Do not operate the boom over personnel or al-
3. Rated loads do not exceed 85% of the tipping low them to walk or stand beneath the boom or
as determined by SAE Crane Stability Test
y
load load.
Code J765a when mounted on a factory recom- 13. Do not allow personnel on truck bed or crane

mended truck (Note: For New York City approved frame area when operating crane.
nl
units rated loads do not exceed 75% of the tip- 14. Do not allow personnel to ride on hook, hook
load as determined by SAE Crane Stability
ping block, load or any device attached to the loadline.
Test Code J765a when mounted on a factory rec- Use only National Crane approved baskets.
ommended
truck). Structural limited ratings on 15. Operate controls slowly and smoothly to avoid
O
the capacity chart are shaded. Stability limited damage to crane or personnel.
loads
are not shaded. Machine will not always 16. Boom must be in carrying rack and outriggers
tip before structural damage occurs. fully retracted for travel.
4. Rated
loads include the weight of the hook block, 17. Do not operate crane within 10 feet (3.05m) of
ce
slings, other lifting live power lines.
devices and boom
,
accessories. 3$
Q
Their weights 1. Load Radius-Horizontal distance from the
"
must be sub- centerline of rotation before loading to the cen-
en
Q
tracted from the ter of the vertical load line or block with load ap-

listed rated load to plied.
determine the net

2. Loaded Boom Angle-Loaded boom angle is the

load that can be angle between the first section boom and the
lifted. horizontal, after lifting the rated load at the rated
er

5. Rated loads are based on freely suspended radius. The boom angle before loading should
loads. Always position the boom tip directly over be greater to account for deflections. The loaded
the
load before lifting. No attempt shall be made boom angle combined with the boom length give
to push down with the boom or move the load only an approximation of the operating radius.
ef
sideways
in any direction by pulling or dragging 3. Working Area-Area measured in a circular arc
the load. above the center line of rotation as shown on
6. The
user shall operate at reduced ratings to al- the Working Area diagram. If no decal is present
low for adverse job conditions such as soft or the work area is 360°.
R
uneven ground, high winds or erratic operation

which produce swinging (side) loads, experience
of personnel, two machine lifts, or other hazard-
conditions for safe operation.
ous
7. When boom length or radius or both are between

points listed on capacity chart, the smallest load FULL CAPACITY
shown at either the next larger radius or boom 180°
WORK AREA

length shall be used.
8. Do not exceed jib capacities at any reduced
boom
length. If jib is between angle ratings on

2,

"!

2-8

4. Freely Suspended Load-Load hanging free with The following examples are for illustrative purposes
no direct external force applied except by the only. The examples utilize the capacity chart shown.
loadline. The load chart ratings, component weights and dimen-
5. Side Load-Horizontal side force applied to the sional data may not be the same as the actual unit. Al-
lifted load either on the ground or in the air. ways use actual information from the crane and job site
6. Boom Length-Length of the boom, from boom when planning a lift.
pivot pin to wire rope on last main boom section.
K6
X
A decal on either side of the boom shows when
A load is to be lifted from the ground and weighs
certain boom lengths are reached. The letters
5000 pounds (2267 kg) at a radius of 20' (6.09 m). It will
on the intermediate boom lengths correspond to
be placed on the roof of a building at a radius of 40'
the letters on the capacity chart.
(12.19 m) and a height of 65' (19.81 m) above the ground
7. Range Diagram-Corresponds to the pictorial in
on the opposite side of the truck.
the Capacity Chart. It shows the operating ra-
dius and height of the unloaded boom tip at all $
X8 Determine the load.
y
boom lengths and angles. It should be used as Load = 5000 lb (2267 kg)
a guide to position unloaded loadline and to de- 1 Part Load Block = 150 lb (68 kg)
termine approximate height to which the load can Sling = 30 lb (14 kg)
nl
be lifted. 5180 lb (2349 kg)
The following procedure is a typical method which $
Z8 Starting Radius
must be used to determine the crane’s ability to handle Given = 20 ft (6.09 m)
a load. The crane is equipped with a standard winch:
O
$
[8 Ending Radius
1. Determine the weight of the load and load han-
Given = 40 ft (12.19 m)
dling equipment.
2. Determine the radius from center line of crane $
\8 Refer to crane Capacity Chart.
rotation to position of load.
Starting point: Assuming the boom is fully retracted
ce
3. Determine the radius from centerline of crane
[27.5' (8.38 m) boom length], the capacity at a 20' (6.09
rotation to center of point where load is being
m) radius is 14,800 pounds (6,713 kg).
moved to.
In order to get the load on the roof, the load must be
4. Refer to Capacity Chart for crane and determine
hoisted from the ground, swung around the rear of the
that load and radius of lifting are within capacity
en
truck (deadspot in rotation is over the cab) and boom

of crane.
extended to full 90' (27.43 m). At this point measure to
5. Refer to Capacity Chart for winch to determine
ensure load is at 40' (12.19 m) radius. Raise or lower
winch reeving is proper.
boom to achieve radius. Hoist load to a height that will
clear the top of the building and rotate to the point load
er
is to be placed. Lower the load using the winchline to

the roof.
Ending Point: The load rating at the ending point is
5850 pounds (2653 kg). The boom will be at 90' (27.43
ef
m) extension and the loaded radius is 40' (12.19 m).

The crane has enough capacity at each end of the
lift to allow the lift to be made.
$
]8 Lastly refer to winch Capacity Chart.
R
• Crane is reeved for single part line.

• Allowable load for single part line is 7700 pounds
(3492 kg) well above the 5180 pounds (2349 kg)
to be lifted.
Operator should now proceed to lift the load as
smoothly as possible.
2-9

K6
Z K6
[
Assume a load of 9000 pounds (4082 kg) at 10' A load of 2900 pound (1315 kg) is to be lifted from
(3.04 m) radius on the ground beside the truck to be the roof of a building at a radius of 30' (9.14 m) and a
picked up, swung over and placed on the truck bed at height of 115' (35.05 m) and placed on the ground on
an 8' (2.43 m) radius from the crane. Crane is reeved the other side of the truck at a radius of 50' (15.24 m).
for single part.
$
X8 Weight of load and load handling equip-
$
X8 Weight of load and load handling equipment.

ment. Load = 2900 lb (1315 kg)
Load = 9000 lb (4082 kg) 1 Part Line Block = 150 lb (68 kg)
1 Part Line Block = 150 lb (68 kg) Slings = 30 lb (14 kg)
Slings = 50 lb (22 kg) 3080 lb (1397 kg)
9200 lb (4173 kg)
$
Z8 Starting Radius
$
Z8 Starting Radius Given = 30 ft (9.14 m)

y
Given = 10 ft (3.04 m)
$
[8 Ending Radius
$
[8
Ending Radius Given = 50 ft (15.24 m)
nl
Given = 8 ft (2.43 m)
$
\8 Refer to Crane Capacity Chart.
Refer to crane Capacity Chart.
$
\8
To reach the load on the roof, the jib must be uti-
The crane capacity at the 10' (3.04 m) point is 30,600 lized to clear the roof with the load. 6$$*

$
pounds (13,879 kg). Of course, at the 8' (2.43 m) ra-
O
$$6$
$
%)
$&
(5
'$
%
%
'%7
dius, the capacity would be substantially more. There- $%
(5
$
36$
3'%
$

$&
fore, the crane capacity is adequate. $
3
$&
6'8 Both the retracted 25' (7.62 m)
jib length and extended 44' (13.41 m) jib length have
$
]8
Refer to winch Capacity Chart. the necessary capacity at a 30' (9.14 m) radius. Only
ce
The capacity of a 1 part line is 7700 pounds (3492 the retracted 25' (7.62 m) jib has the capacity at the 50'
is less than load to be lifted. Crane must be
kg), which (15.24 m) radius to accomplish the task.
reeved for 2 part to lift the 9,000 pound (4082 kg) load. Starting Point: With the 25' (7.62 m) jib deployed
and the boom fully extended, the capacity is 4,850
$*
4
$
4&
$)

X];\
'%
en
pounds (2199 kg) at a 30' (9.14 m) radius and boom

^_`]
<j8
angle of 75°.
Actually when one puts on the 2 part block, the load Ending Point: With the main boom still fully ex-
block weighs
approximately 305 pounds (138 kg) rather tended, the capacity is 3,150 pounds (1428 kg) at a ra-
than the 150 pounds (68 kg) figured in Step 1 so actual dius of 50' (15.24 m) and boom angle of 64.5°.
er
load lifted is 9355 pounds (4343 kg). Load [9,000 pounds

$*
&
$)
3
$&
(5
6
$&
6
(4082 kg)] + 2 part block [305 pounds (138 kg)] + slings
#
4$&
$&
6
56
$$%8
$
4$&
[50 pounds (22.67 kg)].
(5
5)
%'
4&
6
56

3')
K$%%
%
$
4$&
(5
5)
56

4&
6
56

ef
$
3')
K$%%8

$
K%
$%
(5
7
$
$
)
%'%
56
$&8

$
]8 Refer to winch Capacity Chart.
R
The capacity of a 1 part line is 7700 pounds (3492

kg) which is well above the 3,080 pounds (1397 kg) to
be lifted.
$*
&
+
%

"'
%
$
#%
'$
%$
3
#%
%$
4&
$
4$&

(5
%)%8
&
+)%'
$)
$
)$6
4
$
#$
$&

36
5
$%

#%
%$8
The operator should proceed to lift the load as

smoothly as possible.

2-10

877725

80°
2ND JIB
*
70° 140
44FT 2+ 1. Operate with jib by radius when main boom is
\\
x fully extended. If necessary increase boom
60°
!
angle to maintain loaded radius.
1ST JIB 2. Operate with jib by boom angle when main boom
25FT 120
50° is not fully extended. Do not exceed rated jib
capacities at any reduced boom lengths.
3. Capacities do not exceed 85% stability.
42°
90 100 4. Shaded areas are structurally limited capacities.
78 40°
38°
80 !
"

2+
66
y
2+
"
!
54 ^
{Xqj
30°
60
nl
42 z 01 MAIN BOOM - NO JIB STOWED
x
02 MAIN BOOM - JIB STOWED
20° +
40 03 25 FT TELE JIB
27
04 44 FT TELE JIB
10° 11 MAN BASKET ON MAIN BOOM
12 MAN BASKET ON 25 FT TELE JIB
O
20
13 MAN BASKET ON 44 FT TELE JIB
A B C D 0°
-10°
0
0 20 40 60 80 100 120
RADIUS IN FEET
STRUCTURAL LENGTH LIMIT
ce

"
Zq

A

B
C

D Z] \\
! ! ! \Z ! ]\ ! __ ! q` ! ! ! x ! x
^j " ^5j " ! " ! " ! " ! " ^5j ^j " ^5j " ^5j
^5j ^5j ^5j ^5j
en
5 77 52,000 30 75 4,850 77.5 3,300

8 70.5 35,900 35 72.5 4,350 75 3,250
10 66 30,600 75 26,900 79 25,300 40 70 3,900 73 3,200
12 60.5 25,900 72 23,000 77 21,600 45 67 3,500 71 3,050
14 55.5 21,600 69 20,100 74 20,100 78 18,100 50 64.5 3,150 69 2,750
16 50 19,300 66 17,800 72.5 16,700 76 15,700 78.5 14,700 55 61.5 2,800 66.5 2,400
20 38.5 14,800 59.5 14,600 67.5 14,500 72.5 13,600 75.5 12,500 78 11,500 60 59 2,500 64 2,150
er
25 51.5 11,300 61.5 11,000 68 11,000 71.5 10,300 74.5 9,300 65 56 2,200 61.5 1,900
30 41.5 9,050 55 8,900 62.5 9,000 67.5 8,600 71 7,800 70 52.5 1,750 59 1,700
35 30 7,050 48.5 7,350 58 7,200 64 7,150 68 6,700 75 49 1,400 56.5 1,550
40 41 6,100 52.5 6,000 59.5 5,850 64.5 5,850 80 45.5 1,100 54 1,400
45 31.5 4,900 46.5 5,100 55 4,900 61 4,900 85 42 800 51.5 1,250
50 17.5 3,850 40 4,350 50.5 4,250 57 4,250 90 38 550 48 1,000
ef
55 32.5 3,550 45 3,650 53 3,700 95 45 800

60 22 2,650 39.5 3,100 48.5 3,250 100 42 600
65 33 2,550 44 2,800
70 24.5 1,950 39 2,350
=!
75 11 1,050 33.5 1,950
^
5
j
80 26.5 1,550
R
Downhaul weight ______ 150

85 16.5 950
One sheave block _____ 305
0 6,400 0 3,000 0 1,600 0 700
Two sheave block _____ 355

Three sheave block ____ 575
2+

x 700 400 300 200 200 100
2
^ 5j
X

Z

[

\

]

_

q

• Do not deadhead line block
against boom tip when extend-
ing boom.
• Keep at least 3 wraps of
loadline on drum at all times.
• Use only 9/16" diameter
rotation resistant cable with
38,500 lb breaking strength on
this machine.
MAX. PULL MAX. PULL MAX. PULL MAX. PULL MAX. PULL MAX. PULL MAX. PULL • Maximum capacity with "burst
7,700 lb 15,400 lb 23,100 lb 30,800 lb 38,500 lb 46,200 lb 52,000 lb of speed" is 3,000 lb.
2-11

X

Z

[

\

]

_

q

MAX. PULL MAX. PULL MAX. PULL MAX. PULL MAX. PULL MAX. PULL MAX. PULL
lb
7,700 15,400 lb 23,100 lb 30,800 lb 38,500 lb 46,200 lb 52,000 lb
y
(3492 kg) (6985 kg) (10 477 kg) (13 970 kg) (17 463 kg) (20 955 kg) (23 586 kg)

nl
"
X

2 +
!
operation.
The winch is mounted at the rear of the first section 3. Make certain the winch cable is not twisted or kinked
O
boom. It has capacities totally independent of the rest and that cable is properly seated on the drum and
of the crane and can normally pull more than the crane in the sheaves.

itself can withstand. Therefore, care must be taken to 4. Before lifting a load, always make certain that three
insure that the load being lifted is within boom rating. full wraps of rope will remain on the drum at all times
of the heavier loads on the capacity chart, it
ce
To lift some throughout the lift.
will be necessary to multiple part reeve the winch block 5. When lifting a load approaching the rated winch load,
the lifting capacity of the winch (the speed is
to increase raise the load a few inches and return the control to
proportionately slower) and remain in the strength limi- neutral to determine if the brake is working prop-
tations of the winch and wire rope. erly.
en
On a crane equipped with an LMI system, the maxi- 6. Do not drag loads in any direction with the winch

mum allowable load indicated on the LMI display, when 7. Never attempt to lift loads which are not loose and
a single part of line is selected, will exceed the maxi- free, i.e. frozen down material or poles out of ground.
mum pull value listed on the parts of line chart provided 8. Maintain tension on the loadline at all times to pre-
on the crane’s capacity chart. The higher maximum vent the cable from becoming twisted or kinked or
er
allowable load is provided to allow full winch perfor- improperly seated on the winch drum or sheaves.
mance, to the stated single part of line maximum pull
value provided
on the crane’s capacity chart, without "
+

the LMI system activating the kick-out function. # After the vehicle and crane have been properly set
ef
3$
%
$&$
K%
$&
6K6'6
'
#'
$% up and it has been determined the load to be lifted is

$&
?
$)
&$
3
$&
$
3
within the ratings of the crane and winch reeving sys-
#%8 tem, again check the work area for electric power lines
and other obstructions so that proper clearances can
R
"
!

be maintained. (See Safety Rules.) If load is not visible
The winch load rating chart on each machine pro- to operator throughout lift, a person must be appointed
vides the information for pull limitations on the winch to use hand signals as shown on the last page of this
applicable part reevings. These ratings are
with various section. Proceed with lifting the load.
based on providing the proper operating safety factor 1. Rotate, extend or move up or down until boom
on the wire
rope supplied with the machine. Therefore, tip is directly over the load.
any replacement rope must meet the rope specification 2. The crane is normally equipped with a rotation
sections of this manual (Figure 1). stop. It is important that you be aware of the
position of the stop before lifting in order to as-
"

2+
"
2 + sure maximum rotation and prevent excessive
operate the winch control to payout the
1. Always handling of the load.
loadline while extending the boom. This will main- 3. During operations, the controls should always be
tain clearance between the boom tip and loadline metered when beginning or terminating move-
hook. ment to prevent sudden starting or stopping,
2. Do not rely on anti-two-block system to eliminate which imposes undue shock loads on the equip-
two blocking. Use the system as a backup to safe ment. This is especially true when handling
2-12

heavy loads. The control should be slightly actu- for the unit.
ated to begin movement and then slowly in-
creased to desired operating speed. The results
2 +

obtained from metering the oil flow with the con-
trol lever can also be aided by carefully coordi- The “Burst of Speed” will increase winch line speed
nating the throttle control. 60% over normal operation by diverting oil from the multi-
4. Lower loadline and attach load. bank control valve to the winch valve.
5. Control load by use of a non-conductive tag line. The “BOS” is engaged by operating the winch con-
6. Do not leave crane unattended with the boom trol valve lever while pulling up on the BOS handle be-
elevated in operating position. Always secure the low the winch knob. The “BOS” feature should only be
boom in the boom rest before leaving the work operated in a temporary manner to reduce oil heat build
area. up, prevent truck PTO overloading, and provide inde-
pendent operation of the crane and winch (normal winch
+ "
2

"

speed will not decrease when crane functions are used).

y
If the “BOS” feature is run continuously or with an over-
1. Completely retract boom and place securely in load, damage to the crane or truck could occur. To start
boom rest. the “BOS” smoothly, first pull up on the BOS handle then
nl
2. Secure loadline block so that it cannot swing operate the winch lever. To stop the “BOS” smoothly,
freely. return the winch lever to its neutral position then release
3. Anti-Two Block (ATB) Switch to prevent damage
to the ATB switch, consider the following (See
O
WINCH
page 14):
With loadline hook stowed properly, BOS
verify downhaul weight is resting
against the terminator wedge socket
bracket. Slack in the chain
ce
assembly must be present in order
for weight to be removed from ATB s
WINCH
witch.
Utilize entire length of chain. The
en
quick link provided, attaching the

downhaul weight assembly to the
ATB switch, must be installed in the
last link of the assembly opposite the
downhaul weight. CONTROL
er
DO NOT SHORTEN CHAIN AT ANYTIME.

If slack in the chain assembly is still
not present, add straps between an
chor point and hook block to achieve
ef
weight removal from the ATB switch.

4. Retract all outriggers/stabilizers. Optional front
stabilizer should always be retracted first, before
main outriggers are retracted.
R
5. Secure any loads or lifting devices on truck bed $*Maximum Capacity with “BOS”
or body. • One Part Line - 3000 lbs. (1361 kg)
6. Disengage Power Take Off (PTO). • Two Part Line - 6000 lbs. (2722 kg)
7. Release park brake before moving truck. • Three Part Line - 9000 lbs. (4082 kg)
8. When traveling on the road, check all under- • Maximum line speed on third layer - 206 FPM
passes to be sure there is sufficient clearance (62mpm), fourth layer - 225 FPM (68 mpm)
2-13

72
,
!

| on the switch. At this point the contacts in the switch
With untrained or inexperienced or distracted op- open, breaking electrical continuity through the circuit
erators, two blocking the winch cable is a very real pos- provided by the internal anti-two-block cord routed with
sibility. When the winch cable and end attachments a reel or through the boom. When this continuity is bro-
contact the underside of the sheave case, whether by ken, the unloader cartridges de-energize and divert the
winching up or extending the boom without paying out function oil to tank.
the winch cable, the winch cable can be damaged by An audible and visual warning of the two block con-
crimping or over tensioning. dition is provided by the display console of the LMI sys-
The anti-two-block system provided on your National tem. See LMI operators handbook for additional infor-
Crane can help prevent cable damage by sensing the mation.
position of the winch cable end attachments with re- If the machine is equipped with an optional Hydrau-
y
spect to the sheave case and disabling the functions lic Capacity Alert (HCA) system, an indicator light pro-
that can cause a two block condition. vided on the console will alert the operator when a two
nl
The anti-two-block system consists of normally block condition is detected
open, work port unloader valves in the main and winch Normal functioning is restored by winching down

control valves. When the cartridge solenoid is ener- (or retracting boom) until the weight is once again sus-
gized, the crane functions normally, when de-energized, pended freely. Occasionally if the winch up and boom
the oil to the boom extend, boom down, and winch up
O
extend functions are operated at maximum speed in
crane functions are diverted to tank. These solenoids the dump mode, the back pressure induced in the cir-

are controlled by a limit switch, which is attached to the cuit will cause the winch up or boom extend functions to
boom or jib sheave case. This switch is held in the creep slightly (with no load on the hook). Such a condi-
closed position by a chain suspended weight. The
ce
tion is not cause for alarm, as the back pressure is not
weight, which is looped around the winch cable, causes of sufficient magnitude to damage the cable or end con-

the contacts to remain closed until the winch cable end nections.
attachments contact the weight and release the tension

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2-14

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sition can be used as an aid in determining the load
The hydraulic capacity alert system is a hydrauli- condition of the crane. The lift control lever must be
cally operated, maximum capacity sensing device that moved from boom up position to the neutral position to
will stop all of the normal crane functions that cause get the most accurate reading when using load range
overload when maximum capacity is exceeded. In the gauge.
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event that an over capacity condition occurs, the hy-
draulic capacity alert system is actuated by sensing ex- !

cessive pressure in the lift cylinder which causes the The capacity alert system will operate as stated in
boom down, extend out and winch up functions to be- the System Description Section. Once an over-capacity
come inoperative. These are the functions that increase condition is reached, the system will not allow the op-
the over capacity condition. This system allows for con- erator to move the load to a greater radius. The truck
y
tinued operation of the winch down, boom up and boom may have to be repositioned closer to the load in order
retract functions, the functions that normally allow the to set the load at the desired location.
nl
operator to bring the load to a shorter operating radius When trip pressure is reached, the pressure sens-
or set the load down in order to eliminate an over ca- ing switch breaks electrical continuity to the work port
pacity condition. Once the excessive cylinder pressure unloader solenoid in the main control valve. When power
has been reduced by bringing the load to a shorter ra- is removed from this solenoid, the unloader valves al-
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dius or setting the load down, normal operation can be low the oil flowing to winch up, telescope out and boom
resumed. This hydraulic capacity alert system uses the down to flow to tank. This path to tank will prevent fur-
work port unloader solenoids in the anti-two-block sys- ther operation of these functions. When the overload
tem as the hydraulic system dump circuit. condition is corrected by winching down, retracting the
The hydraulic capacity alert system has an over-
ce
boom, or raising the boom, the pressure sensing switch
ride switch or button located on the operator’s console allows the work port unloader solenoids to be powered
that momentarily overrides the hydraulic capacity alert thereby allowing the crane to function normally.
and anti-two-block systems and restores power to crane During the operation at near capacity loads, care
functions. Two indicator lights located near the override must be taken to operate the controls smoothly or the
en
alert the operator of function power loss and discrimi- system may be shocked into the dump mode prema-
nate between the hydraulic capacity alert and the anti- turely.
two-block systems as the cause of power loss. If crane Caution should be exercised when operating near
is equipped with optional audible alert, an audible alarm 80° of boom elevation. If the boom lift cylinder is fully
will sound in an overload condition.
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actuate the override switch and boom down approxi-
mately 5°. Some units may be equipped with a Manual
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HYDRAULIC CAPACITY ALERT Reset Valve Option that can be used to unlock the unit
ANTI–TWO–BLOCK from 80°. See Controls & Hydraulics Section for addi-
OVERRIDE tional description of this system.
The override system consists of a key switch and a
R
! " momentary push button switch. The key switch provides

power to the momentary push button switch located on
HOLDING THIS OVERRIDE TO the console. To momentarily override, activate key switch
INCREASE LOADING OR TWO BLOCK and depress push button on console. This will activate
THE CRANE WILL RESULT IN the anti-two-block solenoid and return power to winch
up, telescope out, and boom down functions. The over-
+

x
ride switch is not to be used during normal use of the
TO CORRECT THE CONDITION CAUSING
crane or as an aid in using the crane in an overload or
THE CRANE SHUTDOWN REFER
anti-two blocked condition.
TO OWNERS MANUAL
876452 The load range gauge is provided to aid the opera-
tor when operating near the rated capacity of the crane.
The hydraulic capacity alert system provides a load The gauge only provides accurate indication when the
range gauge at each operator station. This gauge has lift control lever is in neutral. The gauge movement is
three colors on the dial face: (1) Green – OK; (2) Yellow not proportional to the load on the hook. It is not un-
– Caution; and (3) Red – Overload. The gauge is usual for the indicator to be in the red area at less than
plumbed directly to the lift cylinder and the indicator po- rated load condition when operating the lift control, es-
pecially during boom down operation.
2-15

2
+

!
+
!
boom down, extend out and winch up functions to be-
The Hydraulic Capacity Alert (HCAS) is available in come inoperative. These are the functions that increase
two configurations:
a Single (Boom only) or Dual (HCAJ) the over capacity condition. This system allows for con-
(Boom and Jib) The HCAS and HCAJ systems work tinued operation of the winch down, boom up and boom
identically to monitor boom capacity conditions. The retract functions, the functions that normally allow the

HCAJ system has the added ability to monitor Jib op- operator to bring the load to a shorter operating radius
erations (when the Jib is deployed) or set the load down in order to eliminate an over ca-

The HCAS System is “non-selectable”. The system pacity condition. Once the excessive cylinder pressure
is permanently set to the monitor the Boom (without Jib has been reduced by bringing the load to a shorter ra-
deployed) dius or setting the load down, normal operation can be
In the HCAJ System the Crane Operator can select resumed.

y
either “BOOM” or “JIB” on a two position switch on the When the Dual Hydraulic Capacity Alert Selector
Operators Console. The Boom and Jib CANNOT be Switch is set to “Jib”, the HCAJ is actuated when the
monitored at the same time, the system will only moni- Boom Angle is reduced to below 75° and will prevent
nl
tor one system at a time. increasing the sensed over capacity condition. Normal
operation will be restored when the Boom angle is in-
creased to 75°.
The Hydraulic Capacity Alert System has an over-
O
ride switch or button located on the operator’s console
that momentarily overrides the hydraulic capacity alert
and anti-two-block systems and restores power to crane
functions. Two indicator lights located near the override
ce
switch alert the operator of function power loss and dis-
criminate between the hydraulic capacity alert and the

anti-two-block systems as the cause of power loss. If
The Hydraulic Capacity Alert System is a hydrauli- crane is equipped with optional audible alert, an audible

cally operated, maximum capacity sensing device that alarm will sound in an overload condition.
$
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will stop all of the normal crane functions that cause $&
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overload when maximum capacity is exceeded. In the %

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event that an over capacity condition occurs, the Hy- The Hydraulic Capacity Alert System provides a load

draulic Capacity Alert System is actuated by sensing range gauge at each operator station. This gauge has
excessive pressure in the lift cylinder which causes the three colors on the dial face: (1) Green – OK; (2) Yellow
er
– Caution; and (3) Red – Overload. The gauge is

plumbed directly to the lift cylinder and the indicator po-
sition can be used as an aid in determining the load
HYDRAULIC CAPACITY ALERT condition of the crane. The lift control lever must be
ef
ANTI–TWO–BLOCK moved from boom up position to the neutral position to

OVERRIDE get the most accurate reading when using load range
gauge.
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HOLDING THIS OVERRIDE TO
INCREASE
LOADING OR TWO BLOCK
THE CRANE WILL RESULT IN
+

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TO CORRECT THE CONDITION CAUSING
THE CRANE SHUTDOWN REFER
TO OWNERS MANUAL
876452

2-16

+
!
tem solenoid will deactivate and the boom will remain
Once an over-capacity condition is reached, the sys- locked at 80°. To correct this condition, momentarily
tem will not allow the operator to move the load to a actuate the override switch and boom down approxi-
greater radius. The truck may have to be repositioned mately 5°. Some units may be equipped with a Manual
closer to the load in order to set the load at the desired Reset Valve Option that can be used to unlock the unit
location. from 80°. See Controls & Hydraulics Section for addi-
When trip pressure is reached, the pressure sens- tional description of this system.
ing switch opens the circuit that contain the Anti-Two The override switch is a momentary two position
Block Solenoid. When power is removed from this so- switch normally in the off mode. The momentary on po-
lenoid, the oil flowing to winch up, telescope out and sition is used to override the anti-two-block and hydrau-
boom down is allowed to flow to tank. This path to tank lic capacity alert systems when they are activated. In
will prevent further operation of these functions. When the override position, the switch powers the anti-two-
the overload condition is corrected by winching down, block solenoid returning flow back to winch up, telescope
retracting the boom, or raising the boom, the pressure out, and boom down momentarily. &
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sensing switch allows the solenoid to be powered
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With the HCAJ selector switch set to the “JIB” posi- $4
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tion and the Boom angle less than 75°, electrical conti- The load range gauge is provided to aid the opera-
nuity is broken to a mercury switch in the Wireline Jib tor when operating near the rated capacity of the crane.
Min. Angle Switch. This allows the oil flowing to Winch The gauge only provides accurate indication when the
O
Up, Telescope Out, and Boom Down to flow to tank, lift control lever is in neutral. The gauge movement is
preventing further operations of these functions. When not proportional to the load on the hook. It is not un-
the overload is removed by booming up, the mercury usual for the indicator to be in the red area at less than
switch is energized and oil is no longer dumped to tank. rated load condition when operating the lift control, es-
ce
During the operation at near capacity loads with both pecially during boom down operation.
the HCAS and HCAJ, care must be taken to operate The dual hydraulic capacity alert selector switch located on
the controls smoothly or the system may be shocked the operators console must be set to the proper position.
into the dump mode prematurely. The switch selects between two separate compensating
Caution should be exercised when operating near pressure switches. One pressure switch is set for sensing
en
80° of boom elevation. If the boom lift cylinder is fully overload pressures when BOOM is selected. The other
extended and pressurized above trip pressure, the sys- pressure switch is set for sensing when JIB is selected.
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If this crane is equipped with two Hydraulic Capacity

Alert systems, one for main boom and one for jib, the
Hydraulic Capacity Alert selector switch must be in
“JIB” position when lifting loads with the Jib.
R
Lifting loads with the jib while the main boom Hydrau-
lic Capacity Alert system is active will result in
DEATH OR SERIOUS INJURY.
2-17

+
!
x! plumb the system according to the sche-
The dual hydraulic capacity alert system should be matic and illustrated parts page or replace
checked for proper adjustment during initial crane start faulty pressure gauge.

up and quarterly thereafter. The procedure for proper
adjustment should be performed as follows:
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Before loosening any fittings, support the

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%('$6$. 6. When the pressure reaches capacity load pres
1. Set the HCA Selector Switch to BOOM if sure, the overload system should activate and
installed. boom extension will stop. This is defined as trip
2. Remove the frame or console back cover de pressure.

y
pending on crane model. 7. Trip pressure should be reached as the boom
extension reaches the chosen radius. If the over
! "
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load system trips before the chosen radius is
loosening any fittings, support the boom. reached or allows extension beyond the chosen
Before radius, adjustment is required.
a. If the system is activated before trip

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3. Start the truck and set the crane up for operation pressure is reached, lower the load,
loosen the locking nut on the compensat-
prescribed in the Safety and Operation
as
ing pressure switch and turn the switch
Section.
4. Ensure the Dual Hydraulic Capacity Selector head clockwise to increase trip pressure.

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Switch is properly set. NOTE
5. Select a test weight that is equal to crane capacity
at an intermediate boom length and radius. Work Pressure switch trip pressure is very sensitive
with loads which have load boom angles near 30°. to the number of turns on the switch head.
Starting with the boom at the chosen reference Turning the switch one-fourth turn changes
en
angle and a radius less than the chosen radius, the switch trip pressure by approximately 500
pick the weight up with the winch and begin psi.
extending the boom. 8. When the system reaches trip pressure, turn the
a. As the boom is extending, lower the switch head counterclockwise until the system
load with the winch to keep the load near solenoid is deactivated and tighten the locking nut.
er
the ground. a. Retract the boom until the pilot pressure

b. Monitor the load range gauge located in is reduced enough to reactivate the
the console as the boom is extending. system solenoid. The hydraulic capacity
The gauge is plumbed directly into the lift cyl- alert indicator light will go out when the
ef
inder pilot line and the pressure reading should solenoid is reactivated.
increase to what is defined as capacity load b. Check the trip pressure setting by
pressure as the selected intermediate boom extending the load until the chosen radius

length and radius is reached. is reached. As the chosen radius is
R
The intermediate boom length is determined reached, the system solenoid should be
by a line and corresponding dimension decal
deactivated and the indicator light should
on the side of the second section boom. The come on.
chosen radius is measured from the centerline
c. Readjust switch head if trip pressure is
of rotation to the load line. not correct.
c. If the gauge reading does not increase 9. Once proper adjustment is verified, return the
while extending, lower the load to the boom to a firmly supported position, stop the
ground and check the system plumbing truck engine and replace covers.
according to the hydraulic schematic. Re-

2-18

Jib HCA Adjustment jib compensating pressure switch.
8. Check Rated Radius:
1. Set HCA Selector Switch to JIB position. a. Raise the test weight with the winch
2. Remove the console cover depending on the crane b. Boom down very slowly until the jib
model. compensating pressure switch trips.
3. Start the truck and set the crane up for operation, c. Measure the radius of the test weight and
including erecting the jib, as prescribed in the Safety and verify that it does not exceed the rated
Operation section. radius as specified on the capacity chart.
4. Set up a test weight that is equal to the jib load 9. If the radius is not correct, adjust the Jib Pressure
rated capacity. Compensating Switch.
5. With the jib erect and the boom fully extended. a. To increase the allowable radius of the
Elevate the boom to 80°. test weight:
a. Raise the test weight with the winch. i. Turn the set screw Clockwise to
6. Set the Jib Compensating Pressure Switch: increase the radius.
a. Boom down to rated radius. b. To decrease the allowable radius of the
y
b. Remove the acorn nut from the jib test weight:
compensating pressure switch and loosen i. Turn the set screw Counter-
nl
the locking nut. Clockwise to decrease the radius
i. Slowly turn the set screw 10. Repeat Steps 7,8, and 9 until the jib compensating
counter clockwise until the pressure switch is properly set.
pressure switch trips. HCA 11. After proper adjustment is verified, tighten the
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system trip will be indicated locking nut on the jib Compensating Pressure
when the HCA Indicator Light Switch and install the acorn nut.
becomes lit. 12. Return the boom to a firmly supported position.
13. Stop the Truck Engine .
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7. Boom up to reduce the radius of the test weight. 14. Replace the console cover.
a. Lower the test weight to the ground,
using the winch if necessary, to reset the
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1. Jam Nut 2. Acorn Nut
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1. Boom 2. Jib
2-19

Wireline Jib Min. Angle Switch 5. Ensure that the Mercury Switch retainer is firmly
attached to the Junction Box.
6. Loosen the Junction Box Mounting Screws and adjust
Adjustment the angle of the junction box.
1. Elevate the boom to 80°. a. Adjust the angle of the Mercury Switch
2. Set HCA Selector Switch to Jib position. Junction Box Assembly to achieve 75° boom
angle
3. Boom down very slowly until the Jib Compensat-
b. Tighten the mounting screws
ing Pressure Switch trips. 7. Repeat steps 5 and 6 until 75° boom angle is achieved.
4. Remove the Junction Box Cover. 8. Replace the Junction Box Cover

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2-20

The LMI or (optional) Hydraulic Capacity Alert Systems are intended to be used
as aids to prevent most overload conditions.
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stability overloads to the crane or winch caused by:
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1. Freely swinging loads or operating in an out-of-level condition which
will result in excessive side loading.
2. Side loading due to pulling sideways on the boom with boom rotation
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or load hoist. Load must always be directly under boom tip.
3. Sudden load movements from erratic operation of the crane functions
which will result in excessive shock loading.
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4. Improper loadline reeving for loads larger than single line pull capacity.
5. Extending the boom without first paying out the loadline which can
result in deadheading (two blocking) the loadline against the boom tip.
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6. Loads in excess of capacity when operating with a jib deployed.

7. Loads with lift cylinder fully retracted.
8. Excessive induced loading during auger system operation.
er
9. Operation without outriggers and stabilizers fully deployed or inad-

equate footing for the outriggers and stabilizers.
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2-22

x
Also, on manually extendable jib options:
1. The anti-two-block switch weight and cord must 1. Extension retaining pin, E, must always be in-
be attached to the jib when deployed. stalled when operating.
2. Do not lift load with the boom tip when the jib is 2. All swing around (stow and unstowing) opera-
pinned on the boom tip. tions shall be done with jib retracted and pinned.
3. a. Operate with jib by radius when main boom 3. Extendable section may slide out of 1st section
is fully extended. If necessary, increase boom jib when pin, E, is removed. Keep personnel
angle to maintain loaded radius. clear of area.
b. When radius is between points
listed on capacity chart, the load shown at the
"72 "

x

next longer radius shall be used.
4. a. Operate with jib by boom angle when main )6$
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boom is not fully extended. Do not exceed 1. Using boom telescope function, fully retract
rated jib capacities at any reduced boom boom.
y
lengths. 2. Using lift function, lower boom to allow for easier
b. When angle is between points listed on ca- access to jib deployment pins C1 and C2.
pacity chart, the load shown at next lower 3. Install pins C1 in upper and lower jib ears. Install
nl
boom angle shall be used. retainer spring clips. These pins will be used as
5. Ensure jib is stowed correctly. a pivot point to swing jib into the deployed posi-
a. Removal of swing around pins, C, without tion.
proper installation of stow pin A and pin B, 4. Locate the stowed position of pins C2. If in jib
O
may allow jib to fall off. attachment holes or boom sheave case jib holes,
b. Extending boom with jib stowed and failure to remove pins from storage location .
remove swing pin, C, will damage unit upon 5. Remove t-handle Pin B from top ear of jib.
extension. 6. Remove stow Pin A from ramp/bracket assem-
ce
6. Only attempt to swing jib to working or stowed bly on jib and stow in Stow Loop D and install
position when boom is horizontal, stow pin A and spring clip.
pin B, are removed and swing pins, C, are in 7. Using lift function, raise boom to a horizontal po-
place. Jib could swing uncontrollably if boom is sition.
not horizontal. 8. Attach tag line to sheave case end of jib.
en
7. Crane shall be fully set up according to proper 9. Using telescope function, slowly extend boom
set-up procedures outlined previously when approximately one foot. This procedure will pull
stowing or unstowing jib. the jib out of the stow bracket.
8. Operate boom and turn functions very slowly and
carefully when using jib since jibs can increase !
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boom length by 50%.

9. Area where jib swings around must be clear of
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obstructions and power lines when stowing and $
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unstowing jib. K$8
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10. Use safety glasses when pounding pins with

10. Using tag line, swing jib into deployed position.
hammer.
11. Remove cable keeper pins from boom sheave
11. Do not extend/retract boom unless boom is hori-
case and jib. Remove hook block. Pivot jib
zontal when stow pin A and pin B are removed
R
slightly to allow for loadline to be removed from

during stowing or unstowing procedures.
boom sheave case. Remove loadline from boom
12. Always put spring clips in pins to ensure that they
sheave case and place in an area to minimize
will stay in place.
possible damage.
13. When the jib is stowed, the boom can not be
12. Pivot jib into place, visually aligning the upper
fully retracted if a boom tip attachment option is
C2 pin holes. Install upper C2 pin and keeper. A
installed.
slight hammer strike may be necessary to install
pins. Always use proper eye protection during
this step.
13. Using jib jack, position jib so that lower C2 pin
holes are in alignment and install lower C2 pin
and keeper.
14. Using winch function, unspool enough loadline
to reeve loadline over jib sheave case. Keep
slight tension on loadline to avoid bird caging of
loadline on winch drum.
2-23

15. Route loadline over jib sheave and install keeper. 10. Using extend function, extend boom approxi-
Install line block to end of loadline. mately 1 foot.
16. Remove anti-two-block weight/chain assembly 11. Using tag line attached to jib sheave case, slowly
from
boom tip switch and install on jib tip switch. swing jib into stow position (parallel with 1st sec-
17. Disconnect twist lock quick coupler on anti-two- tion boom). Pins C1 are the jib pivot points dur-
block
cord going to boom anti-two-block switch ing this operation.
and attach to quick coupler on jib anti-two-block
wire on rear of jib between the upper and lower
!
jib ears.
18. Install pin B and keeper into jib ears.
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19. Unwrap ATB cord on side of jib to allow manu- )
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568
ally extending jibs to be deployed without dam-
to the cord.
age 12. Install t-handle pin B through jib ear and boom
20. For manually extendable jibs, pull extension re- sheave case holes. This pin will keep the jib as-
sembly in line (parallel) with the 1st section boom.
y
tention pin E, and extend second section out by
pulling on sheave case. The second section jib, Pin B %
$ retain the jib in its stowed posi-
as it extends, will hit a mechanical stop that al- tion on the 1st section boom.
nl
lows for extension pin E installation. Install pin 13. Using boom telescope function, slowly retract
keeper.
and boom. The ramp/bracket assembly on the side
21. Make ATB cord connections as required. of the 1st section jib will engage the hook on the
side of the 1st section boom, first lifting the jib

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$4
%' and then engaging the jib stow bracket and the
1. Using lift function, lower boom so that jib tip is boom hook completely upon full retraction of the
boom.
close to the ground .
2. For 14. Install stow pin A with spring clip into the ramp/
manually extendable jibs, pull extension re-
ce
tention pin and fully retract extendable 2nd sec- bracket assembly on the jib. Complete engage-
tion jib into the 1st section. Retraction of 2nd ment of stow brackets and proper installation of
pin A is critical for secure jib stow attachment.
section may be facilitated by attaching loadline
wedge socket to attachment point F on the jib 15. Remove pins C1 from upper and lower jib ears.

sheave case. Slowly activate the winch up func- A slight hammer strike may be necessary to re-
en
tion until the 2nd section is fully retracted move pins. Always use proper eye protection

3. Reinstall extension retention pin through the 1st during this step.
and 2nd section jib assembly and install spring 16. Reinstall loadline over boom sheave case.

clip.
4. Remove loadline from jib sheave case. Place !
er

loadline in area to avoid possible damage from
stow procedure. ')
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5. Disconnect twist lock anti-two-block wire connec- 3')
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$4
5<$;
(5
$4
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tor at rear of 1st section jib. Connect twist lock 6$

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connector to anti-two-block switch connector on $&

$8
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boom tip. Move anti-two-block weight assembly
to boom tip switch. 4

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6. Attach tag line to sheave case end of jib. $4
5<$
6$)
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7. Remove spring clips from pins C2 on both up- &<

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per and lower jib ears.
8. Remove pins C2 from upper and lower jib ears. )

$&'&
6$
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Do not remove C1 pins at this time. C1 pins will 56
$8
be used as a pivot point to swing jib into stow

position. A slight hammer strike may be neces- x
!
sary to remove pins. Always use proper eye pro- 1. Lubricate sheave pin on jib with grease gun con-
taining chassis grease weekly.

tection during this step. Utilization of the jib jack
at this time will aid in pin hole alignment to facili- 2. Check for free rotation of jib sheave daily when
tate using jib.
pin removal.
9. Using lift function, raise boom to a horizontal po-
sition.

2-24

x
x,
peated. To relieve the jack, use the flattened end of

The jib pin alignment device consists of a hydraulic jack handle to slowly turn relief valve counter clockwise
jack mounted horizontally on the underside of the jib. A no more than one full turn.
handle for the jack is provided and is installed above After all jib pins are installed, relieve jack. The jib
the jack on the side of the jib. pin alignment device is also useful when removing the
The purpose of the jib pin alignment device is to aid “fourth” pin. Use the jib jack to relieve jib weight in-
in installing the fourth or “last” jib pin when setting up a duced pressure on the “fourth” pin and it will be much
jib. This device has been designed to line up the bot- easier to remove.
tom jib pin hole on the left side of the crane. Once the jib has been erected or stowed, it is im-
To use the device, follow the proper procedure out- portant that the jack handle be properly placed back on
lined in the Owner’s Manual to install both jib pins on its stowage hooks and that the cotter key be properly
y
the right side of crane and the top pin on the left side. placed in the stowage hook to retain the handle on the
Next remove jack handle and using the flattened end, hook.
close jack release valve by turning handle clockwise 6$$*
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until it is firmly closed. Insert the round end of the handle 9'<)

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into the handle sleeve and pump jack until ram contacts
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boom sheave case. Continue to pump slowly until jib &)%'
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pin hole is exactly aligned with hole in boom ear. At this When jib is stowed on side of crane, always leave
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time the final jib pin can be easily tapped into position. ram and handle sleeve pushed all the way down to re-
If hole alignment is “over shot” due to jacking too duce exposure to rusting.
far, the jack can simply be relieved and the process re-
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2-25

x
2 "

The Series 900A is equipped with an adjustable

swing speed valve. This valve allows the operator to
limit the maximum swing speed of the machine to suit
operator preference or varying applications.
An adjustment dial is located on the swing holding

valve mounted on the swing motor inside the crane
frame. The valve has an adjustment screw with a lock

collar. Loosen the lock collar when adjusting the speed,
then tighten the lock collar to maintain swing speed limit SWING SPEED
setting. Turning the knob counterclockwire reduces the ADJUSTMENT
VALVE
rotation speed. The adjustment dial allows the maxi-
speed to be reduced as follows:
y
mum swing
K6$

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3 !K8
4
% $
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Closed 45 sec. 100%
1 48 sec. 90%
2
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53 sec. 80%
3 61 sec. 70%
4 89 sec. 50%

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2-26

+
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2 "8 Arm extended, point with 8 Arm extended, palm down, !"
8 Both arms +8 With forearm vertical, 28 With arm extended
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finger in direction of swing of move arm back and forth extended, palms down, move forefinger pointing up, move hand downward, forefinger pointing
boom. horizontally. arms back and forth horizontally. in small horizontal circle. down, move hand in small
horizontal circle.
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+8 Tap fist on 8 Arm extended forward, "
+ "8 Clasp hands
^$&
<j8 Use
2+
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head; then use regular signals. hand open and slightly raised, in front of body. both fists in front of body, making +$j8 Tap elbow with one hand;
making pushing motion in a circular motion about each then use regular signals.
direction of travel. other, indicating direction of
travel, forward or backward. (For
land cranes only.)
en
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!8 Arm extended, 2
!8 Arm extended,
^
<j8 Lock the
!
^ z
!
^
fingers closed, thumb pointing fingers closed, thumb pointing track on side indicated by raised 6j8 Both fists in front of 6j8 Both fists in front of
upward. downward. fist. Travel opposite track in body with thumbs pointing toward body with thumbs pointing
ef
direction indicated by circular each other. outward.

motion of other fist, rotated
vertically in front of body. (For
land cranes only)
R
z
!

!
[8]
7
Z
+
!
2+
+

!
2 8 Use one hand to
+
!

2 2
+
!

give any motion signal and place +
8 With arm extended, +
8 With arm extended,
other hand motionless in front of thumb pointing up, flex fingers in thumb pointing down, flex fingers
hand giving the motion signal. and out as long as load movement in and out as long as load
(Hoist slowly shown as example.) is desired. movement is desired.
2-27

+

!
!
x!
schematic and illustrated parts page or replace
The hydraulic capacity alert system should be faulty pressure gauge.
checked for proper adjustment during initial crane start-
up and quarterly thereafter. The procedure for proper ! "
adjustment should be performed as follows:

1. Remove the console cover depending on crane 3

)
3$$;
'$
$&
568
model.
When the pressure reaches capacity load pres-
sure, the overload system should activate and
! " boom extension will stop. This is defined as trip
pressure. This point should be at or very close
3

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3$$;
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568
to the red/yellow color change on the load range
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2. Start the truck and set the crane up for operation gauge.
as prescribed in the “Safety and Operation” Sec- 4. Trip pressure should be reached as the boom

nl
tion. extension reaches the chosen radius. If the over-
3. Select a test weight that is equal to crane capac- load system trips before the chosen radius is

ity at an intermediate boom length and radius. reached or allows extension beyond the chosen
Work with loads which have loaded boom angles radius, adjustment is required. If the system is
30°. Starting with the boom at the chosen
O
near activated before trip pressure is reached, lower
reference angle and a radius less than the cho- the load, remove acorn nut and loosen the lock-
radius, pick the weight up with the winch and
sen ing nut on the compensating pressure switch and
begin extending the boom. As the boom is ex- turn the setscrew clockwise to increase trip pres-

tending, lower the load with the winch to keep sure.
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the load near the ground. Monitor the load range 5. When the gauge reaches trip pressure, turn the

gauge located in the console as the boom is ex- setscrew counterclockwise until the system so-
tending. The gauge is plumbed directly into the lenoid is deactivated and tighten the locking nut.
lift
cylinder pilot line and the pressure reading Retract the boom until the pilot pressure is re-
en
should increase to what is defined as capacity duced enough to reactivate the system solenoid.
load
pressure as the selected intermediate boom The hydraulic capacity alert indicator light will go
length and radius is reached. The intermediate out when the solenoid is reactivated. Check the
boom
length is determined by a line and corre- trip pressure setting by extending the load until
sponding dimension decal on the side of the sec- the chosen radius is reached. As the chosen ra-
er
ond section boom. The chosen radius is mea- dius is reached, the system solenoid should be

sured from the centerline of rotation to the deactivated and the indicator light should come
loadline. on. Readjust switch head if trip pressure is not
If the gauge reading does not increase while ex- correct.
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tending, lower the load to the ground and check 6. Once proper adjustment is verified, return the
system plumbing according to the hydraulic
the boom to a firmly supported position, stop the
schematic. Replumb the system according to the truck engine and replace covers.

R
2-28

+ "
The following step-by-step analysis will be helpful in isolating and correcting almost every service problem if fol-
lowed in a step-by-step systematic manner. Use this information with the Hydraulic Schematic and the Illustrated Parts
Catalog to identify parts and follow flow paths. Start at top box and work downward step by step – don’t try to start in the
middle or skip steps.
Boom Creeping Down
Control Valve Centered
y
Yes No
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Cap Sensing Line Between Control Valve in
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Counterbalance Valve and Meter in Position
Compensating Pressure
Switch
Yes No
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Still Creeps Stops Creep
Center Valve Control Valve in Down
Position Normal
Operation
en
Incorrect Counterbalance Replace

Setting Compensating
Bad Counterbalance Valve Pressure Switch
Leaking Cylinder Seals
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2-29

Overload Trips and
will not Reset
Has Overload Condition

been Eliminated

Yes No
Loadline Downhaul Weight Lifting Eliminate Overload

Anti-Two-Block Weight

Lower Loadline Weight

Do Crane Functions Boom Down,
y
Telescope Out, Winch up work
nl
Yes No

Problem Solved Boom Lift Cylinder
Fully Extended

O
Yes No

Actuate Momentary Key Switch
and Boom Down 5o with No Load

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Crane Functions Boom Down,
Telescope Out, Winch up work
Solved Yes No
Problem
en
12v Across Compensating

Pressure Switch
No Yes
er
Fuse OK 12v to Solenoid

No Yes Trouble Shoot No Yes
Wiring
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Resistance Across
Replace Fuse 12v to Compensating Solenoid Coil
Pressure Switch
No Yes Sticking Spool 12 Ohm Replace

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Functions Operate Clean or Replace Solenoid Valve
No Yes
Replace Wiring Some Functions
Still Don't Work

Problem Solved
Check Valves Sticking
Clean or Replace

!

1. Refer to Hydraulic Schematic and System Description to gain a thorough understanding of the capacity alert
system before proceeding with any maintenance.

2. System adjustment must be checked every three months for accuracy. Refer to the preceding section on Sys-
tem Adjustment.
3. Always be sure the boom is adequately supported and no hydraulic pressure remains in the lines before the pilot
pressure line fittings are loosened.
2-30

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R

CARWELL© RUST INHIBITOR
Protecting Cranes From Corrosion • Exposure to harsh environmental hazards such as
alkaline, acids, or other chemicals that can attack the
Manitowoc Crane Group's cranes are manufactured to high crane's paint finish.
quality standards, including the type of paint finish
demanded by today's industry. In partnership with our paint While the surfaces of the crane that are easily seen have the
supplier, we are also doing our part to help prevent biggest impact on the appearance of the crane, particular
premature corrosion of cranes. attention should be given to the undercarriage of the crane to
minimize the harmful effects of corrosion.
National Crane will be treated with a rust inhibitor called
Carwell T32-CP-90. While a rust inhibitor cannot guarantee Exercise special care and increase the frequency of cleaning
that a machine will never rust, this product will help protect if the crane is operated:
y
against corrosion on National Cranes that are treated with • on roads where large quantities of salt or calcium are
this product. applied to treat icy and snowy road surfaces;
nl
Carwell T32-CP-90 is a treatment, not a coating. It contains • in areas that use dust control chemicals;
no silicones, solvents, CFCs or anything that would be
classified as hazardous under OSHA Regulation 29CRF-19- • anywhere there are increased levels of wetness -
10.1200. The product is a liquid blend of petroleum especially near salt water;
O
derivatives, rust inhibitors, water-repelling and water- • during prolonged periods of exposure to damp
displacing agents. Special equipment is used to spray a light conditions (e.g., moisture held in mud), where certain
film onto the entire undercarriage and various other areas of crane parts may become corroded even though other
each new crane prior to shipment. When applied the product parts remain dry; or
has a red tint to allow applicators to view coverage during
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application. This red tint will turn clear on its own within • in high humidity, or when temperatures are just above
approximately 24 hours after application. the freezing point.
Once applied, Carwell T32-CP-90 can appear to leave a Cleaning Procedures

slightly “oily” residue on painted surfaces and until the red
en
tinting fades could initially be mistaken for a hydraulic oil To help protect against corrosion of National Crane,
leak. While the product is not harmful to painted surfaces, Manitowoc Crane Care recommends washing the crane at
glass, plastic or rubber, it must be removed using standard least monthly to remove all foreign matter. More frequent
steam-cleaning techniques. cleaning may be needed when operating in harsh
environmental conditions. To clean the crane, follow these
Carwell works in various ways: (1) it eliminates the moisture
er
guidelines:
containing salt, dirt and other pollutants by lifting and
removing them from the metal surface; (2) the film creates a • High pressure water or steam is effective for cleaning
barrier to repel further moisture from coming in contact with the crane's undercarriage and wheel housings. Keeping
the metal; and (3) it penetrates crevices. these areas clean will not only help retard the effects of
ef
corrosion, but will also improve the ability to identify

In addition to the factory-applied Carwell coating, National
potential issues before they grow into larger problems.
crane owners must provide proper maintenance and care to
help ensure long-term protection of their crane against
R
corrosion. This procedure provides information and

guidelines to help maintain the paint finish on National CAUTION
Cranes. High pressure water can be forced into spaces and
The most common causes of corrosion include the following: infiltrate beyond seals. Avoid pressure washing in the
vicinity of electrical controls, panels, wiring, sensors,
• Road salts, chemicals, dirt, and moisture trapped in the hydraulic hoses and fittings, or anything that can be
hard-to-reach areas; damaged by high pressure cleaning/spraying.
• Chipping or wear of paint, cased by minor incidents or
moving components; • Rinse the dirt and dust off before washing the crane.
Dirt can scratch the crane's finish during washing/
• Damage caused by personal abuse, such as using the cleaning.
decks to transport rigging gear, tools, or cribbing; and
• Hard to clean spots caused by road tar or bugs should
be treated and cleaned after rinsing and prior to
washing. Do not use solvents or gasoline.
4-5
• Wash using only soaps and detergents recommended • Consider touching up the spots with a brush technique

for automotive paint finishes. to cover the bare metal. This will retard the effects of
corrosion and enable you to do the repair at a later time
• Rinse all surfaces thoroughly to prevent streaking
by soap residue. during a normal maintenance interval.
caused
• Spots should be touched up with quality paint. Primers
• Allow the crane to dry thoroughly. You can accelerate
tend to be porous; using a single coat of primer only will
drying by using compressed air to remove excess water.
allow air and water to penetrate the repair over time.
NOTE: Polishing and waxing (using an automotive-type
wax) is recommended to maintain the original paint
finish. Application
•
Depending upon the environment in which a crane is used

y
and/or stored, the initial factory application of Carwell T32-
Inspection and Repair
CP-90 should help inhibit corrosion for up to approximately
•
Immediately following cleaning, Manitowoc Crane Care 12 months.
nl
recommends an inspection to detect areas that may
It is recommended that Carwell T32-CP-90 be periodically
have become damaged by stone chips or minor
reapplied by the crane owner after that time to help continue
mishaps. A minor scratch (one that has not penetrated
to protect against corrosion of the crane and its components.
substrate surface) can be buffed with an
O
to the
automotive-type scratch remover. It is recommended However, if a crane is used and/or stored in harsh
that a good coat of automotive wax be applied to this environments (such as islands, coastal regions, industrial
area afterwards. areas, areas where winter road salt is regularly used, etc.),
reapplication of Carwell T32-CP-90 is recommended sooner
• All identified spots and/or areas that have been
ce
than 12 months, e.g., repeat treatment in 6-9 months.
scratched through to the metal should be touched up
and repaired as soon as possible to prevent flash • Do not apply to recently primered and painted areas for
rusting. To repair a major scratch (down to bare metal) or at least 48 hours after paint is properly dried and cured.
minor damage, follow these procedures: For minor touch up areas a 24 hour period is needed for

cure time before applying Carwell.
en
NOTE: Manitowoc Crane Care recommends that a

qualified body repairman prepare, prime and paint NOTE: Unit must be completely dry before applying
any major scratch(es) or minor damage. Carwell.
• Do not allow product to puddle or build-up on weather
stripping, rubber gaskets, etc. Unit should not have
er
CAUTION puddles or runs evident anywhere.

To the extent any damage is structural in nature, • To ensure proper coverage of Carwell, the product
Crane Care must be contacted and consulted
Manitowoc needs to be fogged on the unit.
as to what repairs may be required.
ef
• Use of pressure pots to apply the Carwell to the unit

• For scratches and marks in highly visible areas: being processed is recommended.
• Sand to remove the scratch and feather outward from • Carwell T32-CP-90 is available in 16 ounce spray
R
the mark to blend the repair into the original surface. bottles from Manitowoc Crane Care (order part number
Body putty may be applied as necessary to hide the 8898904099).
defect; then sand smooth. • After application of the Carwell is complete, wash or
• all bare metal with a primer that is compatible with
Cover clean film residue from lights, windshield, grab handles,
the original paint finish ladders/steps and all access areas to crane, as
necessary.
•

and allow to dry thoroughly.
Please contact Manitowoc Crane Care should you have any
• Prepare
the surface prior to applying the finish coat of questions.
paint.
Areas of Application
• Apply a finish coat paint using accepted blending
techniques. Use of original paint colors is recommended • The underside of the unit will have full coverage of the
to insure the best color match possible. rust inhibitor. These are the only areas that a full coat of

For scratches and marks in areas of low visibility: the rust inhibitor is acceptable on the painted surfaces.

4-6
Areas include; Valves, hose end and fittings, Swivel, unpainted fasteners and hardware, valves, slew ring, all
pumps, axles, drive lines, transmission, all interior bare metal surfaces.
surfaces of the frame
• Boom applications areas are; pivot pins, hose end and
• Frame application areas are; hose ends and fittings, all fittings, jib pins and shafts, all bare metal surfaces,
unpainted fasteners and hardware, all bare metal headache ball / hook block pins and fasteners.
surfaces, outrigger pads, and back up alarms.
• All hardware, clips, pins, hose connections not painted
• Superstructure applications are; hose end and fittings, will have Carwell applied.
wire rope on hoist roller tensioning springs on hoists, all
15
6 16
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9 11
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10

Item Description

Item Description 8 Hook Block/Headache Ball
er
1 Hoist Plumbing Connections 9 O/R Hose Connections

All Hardware, Clips, Pins, Hose Connections 10 O/R Pins, Clips
2
not painted O/R Pins, Clips 11 Power Train Hardware
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3 Pivot Shaft 12 Entire underside of unit

4 Hose Connections 13 Turntable Bearing Fasteners,Pins
5 Mirror Mounting Hardware
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14 Valve Bank, Hose Connections

6 Wire Rope 15 Clips for Optional Jib
7 Boom Nose Pins, Clips 16 Hanger Hardware for Optional Jib

4-8

The information supplied in this section of the ing and covering apply when access covers or inspec-
manual is designed to assist you in service and repair tion plates are removed.
of your National Crane. Inspection, lubrication and gen- Clean and inspect all parts. Be sure all passages
eral maintenance information are found in two previous and holes are open. Cover all parts to keep them clean.
sections of this manual. Before attempting to perform Be sure parts are clean when they are installed. Leave
any service work, the machine must be shut down as new parts in their containers until ready for assembly.
outlined under “Adustments and Repairs” in the Mainte-
nance section of this book. +
!
Generally, a study of the hydraulic schematics in Contaminants in a hydraulic system affect opera-
y
conjunction with a systematic procedure to locate and tion and will result in serious damage to the system com-
correct the problem will enable a skilled mechanic to ponents. Dirty hydraulic systems are a major cause of
nl
determine the problem and correct it. If at any time you component failures.
cannot find or correct the problem, contact your local If evidence of foreign particles is found in the hy-
distributor or National Crane Product Support Depart- draulic system, flush the system.
ment.
'
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5<; Disassemble and assemble hydraulic components
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8
This information is on the serial number placard Clean all metal parts in a nonflammable cleaning
located on the crane frame. fluid. Then lubricate all components to aid in assembly.
The following general suggestions should be help- Inspect all sealing elements (O-ring, gaskets, etc.)
ful in analyzing and servicing your crane. Use the fol- when disassembling and assembling the hydraulic sys-
ce
lowing systematic approach should be helpful in finding tem components. Installation of new sealing elements
and fixing problems: is always recommended.
1. Determine the problem. When installing metal hydraulic tubes, tighten all
2. List possible causes. bolts finger tight. Then, in order, tighten the bolts at the
en
3. Devise checks. rigid end, the adjustable end, and the mounting brack-
4. Conduct checks in a logical order to determine ets. After tubes are mounted, install the hoses. Con-
the cause. nect both ends of the hose with all bolts finger tight.
5. Consider the remaining service life of compo- Position the hose so it does not rub the machine or an-
nents against the cost of parts and labor neces- other hose and has a minimum of bending and twisting.
er
sary to replace them. Tighten bolts in both couplings.

6. Make the necessary repair. Due to manufacturing methods, there is a natural
7. Recheck to ensure that nothing has been over- curvature to a hydraulic hose. The hose should be in-
looked. stalled so any bend is with this curvature.
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8. Functionally test the new part in its system. In case of replacement hoses with angled stem re-
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4) usable fittings, the hose curvature must be taken into
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An important item in preserving the long life of the
crane is keeping dirt out of working parts. Enclosed
compartments, seals, and filters have been provided to
keep the supply of air, fuel and lubricants clean. It is
important that these enclosures be maintained.
Whenever hydraulic, fuel, lubricating oil lines are dis-
connected, clean the adjacent area as well as the point
of disconnect. As soon as the disconnection is made,
cap, plug or tape each line or opening to prevent entry
of foreign material. The same recommendation for clean-
5-1
i
t

2+
! "

a When removing or disconnecting a group of wires
a or cables, tag each one to ensure proper identification
l
during re-assembly.
S When shims are removed, tie them together and
of identify them as to location. Keep shims clean and flat
v until they are reinstalled.
W
b 2 "

Sensitive truck computer system and crane’s LMI
$ computer system components may be damaged by
welding on the truck or crane. The following precau-
y
tions should be taken:
• Disconnect truck battery cables (positive and
nl
negative)
• Attach welding ground lead as close as possible
to area to be welded.

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"
7 "

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7 "

7 "

(REF) (REF)
O-RING O-RING B
B
FACE BOSS
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8 > ^66j ^66j 88 ^66j ^66j >
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**897063 9/16-18 .07 .301 .250 4 .351 .072 7/16-20 888412*
(1.78) (7.64) (8.92) (1.83)

**897064 11/16-16 .07 .364 .375 6 .458 .078 9/16-18 888414*
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(1.78) (9.24) (11.63) (1.98)

**897065 13/16-16 .07 .489 .500 8 .644 .087 3/4-16 888415*
(1.78) (12.42) (16.36) (2.21)

**897066 1-14 .07 .614 .625 10 .755 .097 7/8-14 888416*
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(1.78) (15.60) (19.18) (2.46)

**897067 1 3/16-12 .07 .739 .750 12 .924 .116 1 1/16-12 888417*
(1.78) (18.77) (23.47) (2.95)

**897068 1 7/16-12 .07 .926 1.000 16 1.171 .116 1 5/16-12 888419*
(1.78) (23.52) (29.74) (2.95)

**897069 1 11/16-12 .07 1.176 1.250 20 1.475 .118 1 5/8-12 888420*
(1.78) (29.87) (37.46) (3.00)

**897070 2-12 .07 1.489 1.500 24 1.720 .118 1 7/8-12 888421*
(1.78) (37.82) (43.69) (3.00)

* 888422 O-Ring Boss Seal Kit (12 EA) ** 897234 O-Ring Face Seal Kit (12 EA)

5-2

Fatigue of Welded Structures Application of Medium Strength Loctite
Experience has shown that highly stressed welded NOTE: The fastener may be re-used; the adhesive may be
structures when repeatedly subjected to varying stresses re-applied over cured adhesive residue.
caused by twisting, shock, bending, and intentional and/or The following procedure covers the proper application and
unintentional overloads, often become subject to weld curing method for medium strength Loctite adhesive/sealant
cracking which may be attributed to fatigue of the welded (Loctite #242) and primer (Locquic Primer T7471).
joint. This condition is not uncommon in construction
equipment. Primer Application
Equipment should be periodically inspected for evidence of NOTE: It is not necessary to bathe the threads in primer.
weld fatigue. The frequency of these inspections should
1. Ensure the threaded surface, both male and female, is
increase with the age of the equipment and the severity of
clean and free of dirt and oil. Apply a light spray coating
y
the application.The following are known high stress areas
of primer to both male and female parts to be joined to
applicable to Grove machines, and a visual inspection of
clean and accelerate the curing process.
these areas should be made part of an owner’s planned
nl
preventive maintenance program: 2. Allow the part to dry prior to adhesive/sealant
application.
• Telescopic Boom: wear pad retaining structures,
hydraulic cylinder attaching points, boom pivot shaft Adhesive/Sealant Application
O
retaining structures.
• Outrigger pads, beams, boxes and attachment Bead Application
structures.
• Main frame: generally in the area of doubler plates and
ce
crossmembers; at the junction of front and rear frame
members on truck cranes.
• Turntable bearing connection—where bearing is welded 4203
to the crane superstructure or chassis. FIGURE 5-1
en
• Counterweight support structures. 1. Apply a bead perpendicular to the thread, several

threads wide, in the approximate area of threaded
• Chassis axle and suspension mounting structures. engagement (see Figure 1-3).
• Hydraulic cylinder end connections. 2. In a blind hole application, a bead of several drops of
adhesive should be applied into the bottom of the hole to
er
The above is provided only as a guide, and your inspection

plan should not be limited to the areas listed. A thorough be hydraulically forced up during engagement.
visual inspection of all weldments is good practice. 3. After application and engagement of mated threads,
Anyone requiring more detailed inspection instructions and/ fixturing will occur within five (5) minutes if primed prior
ef
or repair procedures may request same by contacting your to engagement. Fixturing may take up to 30 minutes on
local Manitowoc distributor. unprimed parts.
4. Time required to achieve full strength is 24 hours.
Loctite Maximum ultimate strength is achieved using no primer
R
with this specific threadlocking adhesive.
Fasteners and Torque Values

! CAUTION
Use bolts of the correct length. A bolt which is too long may
Skin and/or Eye Hazard!
bottom before the head is tight against the part it is to hold. If
Loctite type adhesives contain chemicals that may be
a bolt is too short, there may not be enough threads engaged
harmful if misused. Read and follow the instructions on
to hold the part securely. Threads can be damaged. Inspect
the container.
them and replace fasteners, as necessary.
Always follow the directions on the Loctite container, as not Torque values should correspond to the type bolts, studs,
all Loctite types are suitable for all applications.Various types and nuts being used.
of Loctite are specified throughout the Service Manual. The The torque tables are provided by Manitowoc for reference
following types of Loctite brand adhesives are available from when performing maintenance.
the Parts Department of the local Manitowoc distributor.
5-3
Use of proper torque values is extremely important. Improper NOTE: If multipliers and/or special tools are used to reach
torquing can seriously affect performance and reliability. hard to get at areas, ensure torque readings are
accurate.
Identification of fastener grade is always necessary. When
marked as a high strength bolt (grade 5, 8, etc.), the Torque wrenches are precision instruments and must be
mechanic must be aware that he/she is working with a highly handled with care. To ensure accuracy, calibrations must be
stressed component and the fastener should be torqued made on a scheduled basis. Whenever there is a possibility
accordingly. that a torque wrench may have been either overstressed or
damaged, it should immediately be removed from service
NOTE: Some special applications require variation from
until recalibrated. When using a torque wrench, any erratic or
standard torque values. Reference should always
be made to component overhaul procedures for jerking motion can result in the application of excessive or
improper torque. ALWAYS use a slow, even movement and
recommendations.
STOP when the predetermined value has been reached.

y
Special attention should be given to the existence of
When using step wrenches, calculated wrench settings are
lubricant, plating, or other factors that might require variation
valid only when the following conditions are met:
from standard torque values.
nl
• Torque wrenches must be those specified and forces
The use of lubricants on zinc-flake coated parts shall be
must be applied at the handle grip. The use of handle
prohibited since this will change the required torque value.
extensions will change applied torque to the bolt.

O
When maximum recommended torque values have been
• All handles must be parallel to the step wrench during
exceeded, the fastener should be replaced.
final tightening. Multiplier reaction bars may be
installed bolts and nuts of Grade 8 or Class 10.9
Previously misaligned no more than 30 degrees without causing
and higher may not be reused. serious error in torque.

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When referring to the applicable torque charts, use values as • Multiplier bar handles must be propped or supported
close as possible to the torque values shown to allow for within the outer 1/4 of the handle length, or serious

wrench calibration tolerance. under or over tightening will occur.
Torque Wrenches To convert pounds-foot (lb-ft) of torque to newton meters

(Nm), multiply the pounds-foot quantity by 1.3558.
en
Flexible beam type wrenches, even though they might have

a pre-set feature, must be pulled at right angle and the force To convert pounds-inch (lb-in) of torque to newton meters
must be applied at the center of the handle. Force value (Nm), multiply the pounds-inch quantity by 0.11298.
readings must be made while the tool is in motion. Rigid
Torque Values
handle type, with torque limiting devices that can be pre-set
er
to required
values, eliminate dial readings and provide more The following tables list the torque values for both ASME
reliable, less variable readings. standard and metric fasteners. The tables list the values for
grade 5 and grade 8 zinc-flake coated, untreated (black)

finish and stainless steel fasteners.
ef

R
5-4

SAE Grade 1 SAE Grade 5 SAE Grade 7 SAE Grade 8
and Grade 2 HHCS HHCS HHCS
HHCS
y
Socket Head Socket Head Serrated
Capscrew Shoulder Flange Head
nl
Screw
FIGURE 5-2
O
Table 5-1: UNC (Course) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners
Bolt Diameter - Inches

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Torque Values (Pounds-Foot, Maximum/Minimum)
SAE Grade 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2
5 7 14 25 40 61 88 121 213 342 512 — 884 1532
Zinc-Flake
8 10 20 36 57 86 124 171 301 483 723 — 1433 2488
en
9.0 19 32 52 78 114 156 270 416 606 813 1141 2028

5
7.7 17 30 48 72 106 144 249 384 560 751 1053 1865
Untreated
12.5 26 48 73 120 161 234 385 615 929 1342 2043 3276
8
11.5 24 44 67 110 143 216 355 567 857 1234 1885 3024
er
NOTE: Studs shall be torqued using capscrew values when grade is known.
Table 5-2: UNF (Fine) Thread: Torque Values for Zinc-Flake Coated and Untreated Fasteners
ef
Bolt Diameter - Inches

Torque Values (Pounds-Foot, Maximum/Minimum)
SAE Grade 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1-1/8 1-1/4 1-1/2
R
5 8 15 28 44 66 95 132 229 364 543 — 944 1654

Zinc-Flake
8 11 22 39 61 94 134 186 323 514 766 — 1530 2682
10 21 36 57 88 126 182 312 458 658 882 1251 2288
5
9 19 34 53 81 116 167 287 421 606 814 1155 2105
Untreated
14.5 26 53 85 125 177 250 425 672 1009 1500 2092 3640
8
13.5 24 49 79 115 163 230 393 620 931 1380 1925 3360
NOTE: Studs shall be torqued using capscrew values when grade is known.
5-5
Table 5-3: Metric Fasteners, Coarse Thread, Zinc-Flake Coating

Bolt Diameter - Metric
Torque Values (Nm)
M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33 M36
Grade
0.157 0.197 0.236 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18 1.18 1.18
8.8 2.6 5.2 9.0 21.6 42.4 73.1 116 178 250 349 467 600 877 1195 1608 2072
10.9
3.7 7.5 12.5 31.5 62.0 110 170 265 365 520 700 900 1325 1800 2450 3150
12.9 4.3 9.0 15.0 36.0 75.0 128 205 315 435 615 830 1060 1550 2125 2850 3700

Table 5-4: Metric Fasteners, Coarse Thread, Untreated

y

nl
Torque Values (Nm, Maximum/Minimum)
M4 M5 M6 M7 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30
Grade
0.157 0.197 0.236 0.276 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
3.1 6.5 11 19 27 53 93 148 230 319 447 608 774 1134 1538

O
8.8
2.8 5.9 10 17 25 49 85 136 212 294 413 562 714 1046 1420
4.5 9.2 16 26 38 75 130 212 322 455 629 856 1089 1591 2163
10.9
4.1 8.5 14 24 35 69 120 195 298 418 581 790 1005 1469 1997

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5.4 11 19 31 45 89 156 248 387 532 756 1029 1306 1910 2595
12.9
4.9 10 17 28 42 83 144 228 357 490 698 949 1206 1763 2395

Table 5-5: Metric Fasteners, Fine Thread, Zinc-Flake Coating

en

Torque Values (Nm)
M8x1 M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3
Grade

0.157 0.197 0.236 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
er
8.8 23 46 44 75 123 185 270 374 496 635 922 1279 1707 2299

10.9 34 71 66 113 188 285 415 575 770 980 1425 2025 2500 3590
12.9 41 84 79 135 220 335 485 675 900 1145 1675 2375 2900 4200
ef
Table 5-6:
Metric Fasteners, Fine Thread, Untreated

Torque Values (Nm, Maximum/Minimum)
R
M8x1
M10x1 M10x1.25 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M24x2 M27x2 M30x2 M33x2 M36x3
Grade
0.157 0.197 0.236 0.315 0.394 0.472 0.551 0.630 0.709 0.787 0.866 0.945 1.06 1.18
8.8 29 57 57 100 160 248 345 483 657 836 1225 1661 — —
27 53 53 92 147 229 318 446 607 771 1130 1534 — —
10.9
41 81 81 1140 229 348 491 679 924 1176 1718 2336 — —
38 75 75 130 211 322 451 627 853 1085 1587 2157 — —
49 96 96 168 268 418 575 816 1111 1410 2063 2800 — —
12.9
45 90 90 156 246 386 529 754 1025 1302 1904 2590 — —

5-6

Table 5-7: UNC (Course) Thread: Torque Values for Table 5-8: Metric Course Thread: Torque Values for
Stainless Steel Fasteners with Oil Lubrication Stainless Steel Fasteners with Oil Lubrication
Torque Value Torque

Size Value
lb-in lb-ft Size
#5 (0.125) 6.9 —
Nm
#8 (0.164) 18 — M2.5 0.4
#10 (0.190) 21 — M3 0.9
1/4 68 — M4 1.5
5/16 120 10 M5 3.1

M6 5.3
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3/8 210 17.5
7/16 340 28 M8 13.0
M10 27.0
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1/2 — 39
5/8 — 74 M12 45.0
3/4 — 114 M14 71.1
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M16 109
NOTE: Stainless steel fasteners tend to gall while being
M18 157
tightened. To reduce this risk, lubricate the threads
with oil or molybdenum disulfide and torque at low M20 220
speeds without interruptions. Do not use excessive
NOTE: Stainless steel fasteners tend to gall while being
ce
pressure. Impact wrenches are not recommended.
tightened. To reduce this risk, lubricate the threads
with oil or molybdenum disulfide and torque at low
speeds without interruptions. Do not use excessive
pressure. Impact wrenches are not recommended.
en
Weld Studs
Unless otherwise specified the following grade 2 torque
values (± 10%) apply.
er
Table 5-9: Weld Stud Torque Values

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T-2-4
R
5-7
"
=
2 +
z
1. Torque
wrench extensions are designed to ex-
tend the range or versatility of torque wrenches.
Torque
wrench scale readings or limit settings
shall be computed with the following formulas
when an extension handle is employed. The

sketch below shows which formula is to be used,
adding “A” or subtracting “A” when calculating

the torque wrench setting.
TW = Ta x L or TW = Ta x L
L+A L–A

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Ta = Torque required (specified)
= Wrench scale reading or limit setting of
TW
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torque wrench
L = Length of torque wrench in inches (center
of drive tang to handle pivot pin or center
of hand grip - extension handles are con-
O
sidered part of wrench length, when used)
A = Length of adapter extensions in inches.
THIS SIDE ADD “A”

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Ta
TW Ta

THIS SIDE SUBTRACT “A”
er
2. If the offset C/L is not in line with the torque

wrench C/L, then you must measure the distance
from
the C/L of the torque wrench to the C/L of
the offset by using a square. Then apply this di-
ef
mension
to the torque wrench setting formula.
See sketch below.
3. If offset is positioned at right angles to the torque

wrench, then the offset will not change the effec-
R
tive length. Therefore, TW-wrench setting and Ta-

applied torque, will be the same value as if no
offset were used.

ACTUAL DIMENSION “A”
5-

2 +

To check or fill winch drum and rotation gearbox with oil, remove fill plug and bushing. The oil should be level with
this opening. If more oil is needed, refer to one of the manufacturer’s recommended lubricants listed in this manual.
BREATHER
OIL LEVEL
OIL LEVEL &
FILL PLUG
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1234567890123456
1234567890123456
1234567890123456
1234567890123456
1234567890123456
1234567890123456
1234567890123456
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1234567890123456
1234567890123456
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,

To check or fill brake fluid, elevate boom to 45° & remove brake fluid level plug, the fluid should be level with this
opening. If more fluid is needed, refer to Manufacturer’s Service Manual for list of lubricants.
er
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R
BRAKE FLUID
LEVEL PLUG
BRAKE FLUID
FILL & VENT
45°
BRAKE
FLUID
LEVEL
1234567890123
1234567890123
1234567890123
1234567890123
5-

"
The following chart lists malfunctions which may occur during equipment operation, followed im-
by possible cause and possible solution. These are not all inclusive but are designed to
mediately
help isolate the problem and should be checked before calling the factory Service Department.

• Load too heavy. • Check Capacity Chart.
$
$ • PTO not engaged. • Engage PTO.
• Low hydraulic fluid supply. • Check and fill as required.
• Suction line blocked. • Drain tank and hose and remove blockage.

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• Broken hydraulic pressure line. • Replace as required.
• Defective hydraulic pump. • See Pump Service Manual.
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• Incorrect relief valve setting. • Adjust relief.

• Relief valve sticking. • Clean relief.

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• Pump not operating at proper speed. • Check PTO ratio, pump size and engine
&)%'
speed for proper oil flow.
)$6
• Low hydraulic fluid supply. • Check and fill as required.
36

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• Relief valve sticking. • Remove and clean.
• Relief setting too low. • Readjust to proper setting.
• Worn pump, motor or cylinder. • Replace bad part.
• Plugged filter. • Change filter.
en
• Valve spools not fully open. • Ajust linkage so valve has full throw.

• Boom holding valves out of adjustment. • Adjust or clean as required.
• Oil temperature too high. • Reduce engine speed, slow cycle time to
cool oil or add oil cooler option.
er
• Hydraulic oil too cold or dirty. • Warm oil or use less viscous oil.
• Line restricted. • Check lines; clean and repair as necessary.

• Internal control valve crack. • Replace valve.
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• Load too heavy. • Check Capacity Chart and reduce load.

4 • Loose turntable bearing. • Torque bearing mounting bolts.
R
6# • Loose swing gearbox mounting bolts. • Tighten bolts.

$

) • Worn gears or bearing. • Replace worn parts or adjust gearbox
spacing.
• Operator control of lever too erratic. • Operate controls smoothly.
• Motor counterbalance valves dirty or not • Clean or replace counterbalance valves not
set properly. set at 600 psi.
• Brake not holding properly. • Check for no pressure in brake pilot line
when turn is in neutral.

• Replace worn brake parts or shim brake to
proper torque.

• Brake releasing at wrong time or erratically. • Bleed air from brake with bleed screw on
side of brake.

5-

"
^$'%j

4
4 • Attempting to swing up too much of incline. • Level machine.
$
$' • Turn circuit relief valves sticking. • Clean and check circuit pressure.
• Turntable bearing drag. • Lubricate thoroughly as rotating boom.
• Brake not releasing properly. • Check for 200 + PSI brake pilot pressure.
Clean pilot line or adjust motor counterbal-
ance valves.
• Adjust or clean brake for proper release.
y
K# • Excessive pump speed. • Adjust foot throttle or check for too high
nl
'6
PTO ratio.
%' • Low oil temperature. • Allow unit to warm up.
$
• Low hydraulic oil supply. • Check and fill.
O
• Suction line kinked, collapsed or blocked. • Clear blockage.
• Hydraulic oil too thick. • Warm oil or use oil more applicable to
environment.
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• Relief valve chattering. • Dirt in relief valve or damaged relief.
• Hydraulic tubing vibration. • Check for loose tubing.
• Tank breather plugged. • Clean breather.
en
)% • Not getting oil to cylinders. • Clean and replace as required.

%3$ • Worn or damaged piston seals. • Replace as required.
• Air in hydraulic oil. • Cycle operate crane cylinder to remove air.
• Loose holding valve. • Tighten valve.
er
• Dirt in holding or check valve. • Clean valve.
2&
4 • Load too heavy. • Check load and change to applicable
ef
$
3$
multipart reeving.
&%
% • Relief valve setting too low. • Check and adjust if required.
• Motor worn excessively. • Replace motor.
R
• Counterbalance valve defective or leaking. • Clean and replace as necessary.

• Anti-two-block system defective. • Repair anti-two-block system.
• Brake worn out. • Repair or replace brake.
2& • Gearbox grease low. • Check and fill as required.

5K
&$ • Duty cycle too high. • Reduce cycle time or speed of winch.
'<
• Kill switch on crane control console de- • Pull up kill switch.
4
$
$$ pressed. • Check all other normal motor vehicle
systems as outlined by normal practice.
5-

"
^$'%j

6 • Boom sections need lubrication. • Grease boom.

&$$ • Wear pads not shimmed correctly. • Reshim as described in boom assembly

%' section.
K$|

$$
• Worn wear pads. • Replace pads.
%?$ • Extension cables out of adjustment. • Readjust cables and tension properly.

$ • Extend or retract cables broken. • Disassemble and inspect and replace
) cables.
y

6
4 • Proportioning cables not attached. • Reconnect, replace and/or adjust cables.
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$
K$% • Anti-two-block system shut down. • Lower hook, and extend load.
• Defective anti-two-block system. • Check anti-two-block system; repair if
defective.
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5-
72
,

"
7

$74
<
)$6
3
$
&'$
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4&
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56
K$%
Check for voltage across

leads of limit switch with
weight supported
YES NO
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Check limit switch or actuator
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arm for sticking - Repair or Fuse blown
replace switch
NO YES
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Test HCAS & ATB relays for
proper operation (see Replace fuse
Schematic)
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NORMAL FAULTY
RELAY OPERATION RELAY OPERATION
en
Examine solenoid valve for

sticking spool due to corrosion, Replace relay
burrs, contamination, etc.
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5-
72
,

"
7

^ j
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3'$
4&
4&$

3)
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12 volts at limit switch

YES NO

Fuse blown
y
NO YES
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proper operation (see Replace fuse

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Schematic)
NORMAL FAULTY
RELAY OPERATION RELAY OPERATION

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Continuity check lead
wires Replace relay

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Limit switch contacts closed

with weight suspended
NO YES
er

Replace limit switch or
check actuator arm for Check for 12 volts at
solenoid valve
free movement
ef
NO YES

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proper operation (see Check continuity

Schematic) across solenoid valve
NORMAL FAULTY
RELAY OPERATION RELAY OPERATION NO YES

Continuity check lead Check valve for sticking
Replace relay Replace solenoid
wires spool - Clean or replace

5-1

72
,

"
7
+
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)$6
3
$
&'$
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4&
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56
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56
K$%
HYDRAULIC ELECTRICAL
Check to ensure ATB

Do all three functions fail to electrical system is working
shut down properly. Refer to ATB
electrical diagnosis
y
YES NO
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Examine solenoid valve for
Work with individual section
sticking spool due to corrosion,
which fails to shut down
burrs, contamination, etc.
O
Disconnect drain line from
outlet end of unloader valve
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Operate function at low
engine RPM
Oil flow from open port in

en
unloader valve
NO YES
er
Poppet is not shifting.

Remove unloader and flush Remove unloader and flush
to dislodge contamination to dislodge contamination.
that is blocking orifice Inspect to see that poppet is
ef
free to shift in housing
Reinstall, retest and replace

R
unloader if problem persists
Reconnect drain line to outlet

end of unloader valve
$*

3
$&
$
$
3
$&
'%
##

#58
5-1
72
,

"
7
+
^ j
$74
<
)$6
&'$
%4

3'$
4&

4&$

3)
'%%
Purge air from unloader

circuits. See procedure in
this manual

YES
y
Functions operate correctly ? Problem solved
NO

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Are all three functions
shut down ?
YES NO

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Examine solenoid valve Work with individual
for sticking spool section that is shut down

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Disconnect drain line from
outlet end of unloader valve

en
Install cap fitting to plug outlet

end of unloader valve

Operate function
er

Function operates correctly

ef
YES NO
Oil is passing through the The poppet in the unloader

R
check valve in another is not seated. Remove

unloader unloader and flush to
dislodge contamination

Cap each of other
unloaders in turn to identify Reinstall, retest and replace
the unloader with the faulty unloader if problem persists
check valve

Flush to remove

contamination otherwise
replace unloader valve

$*

3
$&
$
$
3
$&
'%
##

#58
5-1

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CONFIGURATION 5 – REAR MOUNT (69’, 90’, 103’ CONFIGURATION 6 – REAR MOUNT (125’ BOOM)
BOOMS)
This configuration allows the rear mount installa-
tion of the Series 900A. This configuration is 360° stable This configuration allows the rear mount installa-
and allows the effective use of close working area to lift tion of the Series 900A. This configuration is 360° stable
the heavier capacity loads. and allows the effective use of close working area to lift
the heavier capacity loads.
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360° 360°
FULL CAPACITY FULL CAPACITY
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Requires a 16,000 lb (7257 kg) GAWRF, 40,000 lb

(18 143 kg) GAWRR and 56,000 lb (25 401 kg) GVWR, Requires a 18,000 lb (8165 kg) GAWRF, 40,000 lb
R
overframe outriggers, rear stabilizer, and heavy duty rear (18 143 kg) GAWRR and 56,000 lb (25 401 kg) GVWR,
mount sub-base. The maximum bed length is 16' (4.87 overframe outriggers, rear stabilizer, and heavy duty rear
m). Counterweight may have to be added to ensure mount sub-base. The maximum bed length is 18' (5.5
unit stability if the truck does not meet minimum weight m). Counterweight may have to be added to ensure
requirements. Truck frame must have 15.9 in3 (260 cm3) unit stability if the truck does not meet minimum weight
section modulus and 1,749,000 in-lb (197 610 N·m) RBM requirements. Truck frame must have 15.9 in3 (260 cm3)
from rear of crane through the front outriggers. Truck section modulus and 1,749,000 in-lb (197 610 N·m) RBM
frame must have or be capable of being lengthened to from rear of crane through the front outriggers. Truck
an AF of 112 inches (2844 mm). frame must have or be capable of being lengthened to
an AF of 120 inches (3048 mm).
*Actual scale weights prior to installation of crane,
heavy duty sub-base and behind cab stabilizers. *Actual scale weights prior to installation of crane,
heavy duty sub-base and behind cab stabilizers.
9-7
CONFIGURATION 7 - 9103A NEW YORK CITY CONFIGURATION 8 - 9103A NEW YORK CITY
APPROVED APPROVED
This configuration allows the installation of the Se- This mount requires front stabilizer for full capacity
ries 9103A
on a chassis by using the sub-base for a 22' 360° around the truck. Front stabilizer gives the ma-
bed. In most cases, the chassis will not require rein- chine a solid base helping the operator control loads.
forcing.
SFO

RSOD
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3" (76 mm) MIN
64" 192"
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(1625 mm) (4876 mm)
MIN MIN
*9800 lb *11250 lb
(4445 kg) (5102 kg)

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360°
FULL CAPACITY
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WORK AREA

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Requires 18,000 lb (8164 kg) GAWRF, 34,000 lb Requires 18,000 lb (8164 kg) GAWRF, 34,000 lb
(15 422 kg) GAWRR, 52,000 lb (23 856 kg) GVWR, (15 422 kg) GAWRR, 52,000 lb (23 856 kg) GVWR,
R
RSOD rear stabilizers and sub-base for 22' bed. Full standard sub-base for 22' bed, SFO and RSOD rear
capacity work area is rear 180° of vehicle from outrigger stabilizers. Truck must have 20.0 in.3 (327 cm3) section
to outrigger. Truck frame must have or be capable of modulus and 2,200,000 in-lb (248 566 N·m) RBM or be
being reinforced to 20.0 in. 3 S.M. (327 cm 3) and capable of being reinforced to this strength under the
crane frame through to the front suspension. Normally
2,200,000 in-lb (248 566 Nm) RBM under the
crane frame. a tapered frame cannot be reinforced to this require-
ment. Additional truck frame requirements must be met
from the crane frame through the front suspension to
the SFO attachment point (See “Truck Frame and
Mounting Bolt Requirements for Front Stabilizer” in this
section).
*Actual axle scale weights prior to installation of

crane, torsion box and stabilizers.
9-8

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+,
The chassis weight, before the crane is mounted, is ORDGGRZQ VRWKHORDG ZLOOVZLQJRXW XQWLOWKH
intended for use only as a guideline in determining the ORDGHGUDGLXVLVUHDFKHG$VWKHERRPLVORZ
total weight
required for the unit to be stable with an 85% HUHGNHHSZLQFKLQJWKHORDGXSWRNHHSLWDERXW
tipping factor (i.e. when lifting capacity load, the unit is LQFKHVRIIWKHJURXQG
at 85% of tipping or less).
$
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In order to ensure the stability of the unit with an 6ORZO\URWDWHWKHERRPWKURXJKRXWWKHZRUNDUHD
85% tipping factor, a live load stability test must be per- $VWKHERRPLVURWDWHGWKHERRPZLOOKDYHWREH
formed on each completed unit. Proceed as follows: UDLVHGDQGRUORZHUHGWRPDLQWDLQWKHORDGHGUD
1. Test the unit for stability on a firm level surface. GLXVEHFDXVHRIVXEEDVHIOH[XUH
2. A Series 900A crane requires RSOD stabilizers 2QXQLWVQRWHTXLSSHGZLWKIURQWVWDELOL]HUVWLS
for stability. With the boom stowed, set the unit SLQJIURPVWDELOL]HUVXSSRUWWRIURQWZKHHOVXS
level on the outriggers and stabilizers.
up SRUW ZLOO RFFXU DV WKH ORDG RU ERRP LV VZXQJ
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3. When stability testing this unit, select the load at DURXQGWKHIURQW'RQRWDWWHPSWWROLIWUDWHGORDGV
specified boom extension and radius listed
the DURXQGWKHIURQWRIWKHWUXFNXQOHVVWKHXQLWLV
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10-16

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Reference Only: Supplement To Service Manual Boom Cable Tensioning

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Reference Only: Supplement To Service Manual Boom Cable Tensioning

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What are the steps for cable tensioning?

What are the steps for cable tensioning?

Supplement to Service Manual

Boom Cable Tensioning

THIS PAGE BLANK

8. Adjust all corresponding cables according to Cable

Cable Tension Sequence 1. 321 retract cables

GROVE Published 03-23-2017, Control# 641-01 1

Cable tensioning to be in the following order: 3. 234 extend cables.

1. 321 retract cables 4. 432 retract cables.

5 - Section Boom w/ 2 Stage Cylinder Cable Positioning

3/2/1 RETRACT 4/3/2 RETRACT 5/4/3 RETRACT

2 Published 03-23-2017, Control# 641-01

1. Measure the retraction gaps between the second and section;

4. Tightening until the retraction gap between the fifth and

At this time the all extendable sections should extend and

GROVE Published 03-23-2017, Control# 641-01 3

BASE 1ST STAGE

234 and 432 cable balancing

4 Published 03-23-2017, Control# 641-01

1/2/3 EXTEND 2/3/4 EXTEND

BASE 1ST STAGE

3/2/1 RETRACT 4/3/2 RETRACT

second section and the second and third section.

GROVE Published 03-23-2017, Control# 641-01 5

3- Section Boom w/ 1 Stage Cylinder Cable Positioning

1ST SECTION 3RD SECTION

8860-4 2ND SECTION

6 Published 03-23-2017, Control# 641-01

Cable Retention NOTE: (OPTION 2) method used ONLY when space

Cable Retention Hardware

GROVE Published 03-23-2017, Control# 641-01 7

Inch Series with Coarse Threads (UNC)

1-8 SAE 2 199

8 Published 03-23-2017, Control# 641-01

Service Bulletin N14-003

An untrained operator subjects himself and others to death or

responsible for qualifying personnel.

to adequately warm the crane prior to cold weather

Engine RPM for at least one complete revolution in one

Warm-up Procedures for All Temperature Ranges:

National Crane Published 3-10-2015, Control# 571-00 1

2 Published 3-10-2015, Control# 571-00

An untrained operator subjects himself and others to death or

© 2011 Crane Group

PUBLISHED 10-18-2011 CONTROL # 031-07

serious injury. Do not operate this crane unless:

1. Fully retract outriggers.

Figure 2) secure sensor to the hydraulic cylinder.

1 1. Fully extend stabilizer beam (horizontally).

SIDE FOLDING SWING-AROUND JIB

Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Personnel Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Optional Hydraulic Capacity Alert System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Wireline Jib Min. Angle Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Jib Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24