Om 5560B Operators 1006266

5500 Series
Model 5560B
Carrydeck®
Industrial Crane
02
OP
ER 3-
MA ATIO
0
INT N A
25
E
M A N A N ND
12
NU CE
AL
SHUTTLELIFT, INC.
STURGEON BAY, WISCONSIN P/N 1006266
Warning
IMPROPER OPERATION OF THIS MACHINE
CAN CAUSE INJURY OR DEATH.
BEFORE STARTING THE ENGINE, DO THE

FOLLOWING:
1. READ THIS OPERATOR'S MANUAL.
02
2. READ ALL THE SAFETY DECALS ON
THE MACHINE.
0 3-
3. CLEAR THE AREA OF OTHER
25
PERSONS.
LEARN AND PRACTICE SAFE USE OF THE

12
MACHINE CONTROLS IN A SAFE, CLEAR

AREA BEFORE YOU OPERATE THIS
MACHINE ON THE JOB SITE.
It is your responsibility to observe pertinant

laws and regulations and to follow the
manufacturer's instructions on machine
operation and maintenance.
5500 Series Table Of Contents
Model 5560B
Table of
Contents
TABLE OF CONTENTS
SECTION 1 - GENERAL Operating Practices ................................... 3-33
Introduction .................................................. 1-1 Handling A Load .................................. 3-33
The Manual ........................................... 1-1 Attaching A Load ................................. 3-33
Directional Reference ............................ 1-1 Holding The Load ................................ 3-33
Serial Number Plate .............................. 1-1 Moving The Load ................................. 3-33
Reports ................................................. 1-1 Traveling With A Load (Pick
Disclaimer ............................................. 1-1 and Carry ........................................ 3-34
Nomenclature ........................................ 1-2 Elevating Personnel ............................. 3-34
Turning Clearances .............................. 3-35
SECTION 2 - SAFETY
02
Machine Shutdown .............................. 3-35
Safety Practices .......................................... 2-1 Towing A Disabled Machine ................. 3-35
Signal Words ........................................ 2-1
SECTION 4 - CAPACITY CHART
Trained Operator’s ................................. 2-2 3-
New or Additional Operator’s ................. 2-2 Using The Capacity Chart ............................ 4-1
Personal Considerations ........................ 2-2 Operating Boom Radius ........................ 4-1
0
Operational Considerations ................... 2-6 Locating The Lift Capacity ..................... 4-1
Equipment Considerations ................... 2-10 Things To Observe When Using
25
Safety Decals ............................................ 2-11 The Capacity Chart .......................... 4-1

Standard Hand Signals .............................. 2-15 Lifting With The Boom Extension
Installed ........................................... 4-2
Wire Rope Safety ...................................... 2-17
12
Pick And Carry Ranges ......................... 4-2

SECTION 3 - OPERATION
SECTION 5 - ATTACHMENTS
Controls, Switches and Gauges ................... 3-1
Pivoting Boom Head .................................... 5-1
Cab Controls ......................................... 3-1
Boom Head Positions ............................ 5-1
Gauges and Indicators .......................... 3-3
Changing The Boom Head Position ....... 5-3
Panel Switches ..................................... 3-7
Adjusting The Boom Extension Offset ... 5-3
Outrigger Controls ................................. 3-9
Boom Extension .......................................... 5-5
Steering Controls ................................. 3-11
Attaching The Boom Extension ............. 5-5
Four-Wheel Steer Indexing Procedure . 3-12
Adjusting The Boom Extension Angle .... 5-9
Operator’s Cab .......................................... 3-13
Stowing The Boom Extension ................ 5-9
Heater and Defroster ........................... 3-13
Down Haul Weight ..................................... 5-11
Seat Adjustment .................................. 3-13
Wire Rope Wedge Socket Installation ........ 5-13
Seat Belt ............................................. 3-14
Reeving ...................................................... 5-14
Cab Door (Optional) ............................. 3-14
Fire Extinguisher ................................. 3-15
Machine Operation ..................................... 3-16
Fuel Changeover - Dual Fuel ................ 3-16
Starting The Engine ............................ 3-16
Traveling With The Crane ..................... 3-21
Operating The Outrigger Controls ........ 3-23
Operating The Boom Controls ............. 3-26
Issued: 10/27/00
Revised 9/20/03
Table Of Contents 5500 Series
Model 5560B
Table Of Contents (Contd)

SECTION 6 - ADJUSTMENTS SECTION 8 - SPECIFICATIONS
Hydraulic System Adjustments .................... 6-1 Lubricants And Capacities ........................... 8-1
Testing The Relief Valve Settings ........... 6-1 Lubricants ............................................. 8-1
Adjusting The Relief Valve Pressure ...... 6-3 Engine Oil Specifications ....................... 8-2
Boom Adjustments ...................................... 6-7 Fuel Types ................................................... 8-3
Swing Gear and Pinion Adjustment .............. 6-8 Diesel Fuel ............................................ 8-3
Parking Brake Adjustment ........................... 6-8 Gasoline ................................................ 8-3
SECTION 7 - MAINTENANCE Relief Valve Settings .................................... 8-4
General Specifications ................................. 8-4
Introduction .................................................. 7-1
Dimensions ................................................. 8-6
Spark Arresting Mufflers ......................... 7-1
Torque Charts .............................................. 8-7
Safety List ............................................. 7-1
Lubricants .................................................... 7-2
Maintenance Records .................................. 7-2
Special Maintenance .................................... 7-2
02
Preventive Maintenance ............................... 7-4
Maintenance Schedule and Checklist .... 7-4
Lubrication Points ................................. 7-6
Scheduled Maintenance ............................ 7-10
Daily (Walk-Around) Inspection ........... 7-10
3-
50 Hours Of Operation ......................... 7-15
0
100 Hours Of Operation ....................... 7-18
25

1000 Hours Of Operations ................... 7-29
2000 Hours Operation .......................... 7-36
12
Miscellaneous Maintenance ................ 7-37

5500 Series Section 1 - General
Model 5560B
Section 1
General
Introduction
THE MANUAL
This operator’s manual provides the information
you need to correctly operate and maintain the
5500 Series, Model 5560B, Carrydeck Industrial
crane.
IMPORTANT!
Before you operate the crane, carefully read this
manual completely, so you will understand the
02
safety instructions and the operation of the controls
and safety equipment. You must comply with all
DANGER, WARNING, and CAUTION notices.
They are for your benefit. 3- Figure 1-1. Serial Number Plate
DIRECTIONAL
0
REFERENCE
25
All references to the right side, left side, front, SERIAL NUMBER _____________________
and rear are given from the operator’s seat
looking in a forward direction. REPORTS
12
IMPORTANT!
SERIAL NUMBER PLATE A Delivery Report form must be filled out by the
manufacturers distributor, signed by the purchaser,
For easy reference, when contacting the dealer/ and returned to the manufacturer once the product
manufacturer about this machine, record the is sold and/or put into service. This report activates
machine’s serial number in the space provided the warranty period, assuring that your claims
in the next column. The numbers are stamped during the warranty period will be honored and
on the serial plate which is located behind the processed expediently. To guarantee full warranty
operator’s seat. See Figure 1-1. Components, service, make sure your distributor has returned
such as the pump, transmission, engine, axles, the report to the manufacturer. An engine warranty
etc., have their own serial plates that will be form must also be filled out, signed and returned
to the engine manufacturer for full warranty
found on the housing of the component.
coverage.
IMPORTANT!
The replacement of any part of this product with DISCLAIMER
anything other than a manufacturers authorized
replacement part may adversely affect the The manufacturer reserves the right to make
performance, durability, or safety of this product improvements in design or changes in
and will void the warranty. The manufacturer specifications at any time without incurring any
assumes no liability for unauthorized replacement obligation to install them on units previously sold.
parts which adversely affect the performance,
durability, or safety of this product.
1-1
Section 1 - General 5500 Series
Model 5560B
NOMENCLATURE
18 1
17 2
1
16
3
15
14
9
13
12
11 4
10
02
5
9
0 3-
6
25
8
7
4
12
Figure 1-2. Crane Nomenclature
1. Counterweights Location 10. 4th Boom Section

2. Main Winch Location 11. 3rd Boom Section
3. Engine Location 12. 2nd Boom Section
4. Outriggers (4) 13. 1st Boom Section
5. Rear Axle 14. Main Control Valve Location
6. Operator’s Cab 15. Swing Motor and Gearbox Location
7. Front Axle 16. Lift Cylinders (2)
8. Hook Block 17. Crowd Assembly Location (Inside Boom)
9. Anti-Double Blocking System or LMI 18. Mast
System
1-2
5500 Series Section 2 - Safety
Model 5560B
Section 2
Safety
Safety Practices
Your safety and the safety of others in the work
area depends upon your knowledge and
understanding of all correct operating practices
WARNING
and procedures for this machine. The signal word “Warning” denotes a hazard
exists on or near the machine which can cause
SIGNAL WORDS injury or death if the proper precautions are not
taken.
CAUTION
02
The signal word “Caution” denotes a reminder
of safety practices or directs attention to unsafe
This symbol means “Attention! Become Alert!

3- practices on or near the machine which could
result in personal injury if the proper precautions
are not taken.
0
Your Safety is Involved!” The symbol is used
with the following signal words to attract attention
GENERAL
25
to safety messages found on safety decals and

throughout this manual. The message that follows It is impossible to compile a list of safety
the symbol contains important information about precautions covering all situations. However,
12
Safety. To avoid possible death or injury, carefully there are basic safety precautions that MUST
read and follow the messages! Be sure to fully be followed during your daily routine. Safety is
understand the potential causes of death or injury. YOUR PRIME RESPONSIBILITY, since any
Signal Word piece of equipment is only as safe AS THE
PERSON AT THE CONTROLS.
A signal word is a distinctive word on safety
decals and throughout this manual that alerts With this thought in mind, this information has
the viewer to the existence and relative degree been provided to assist you, the operator, in
of the hazard. promoting a safe working atmosphere for
yourself and those around you. It is not meant to
DANGER
cover every conceivable circumstance which
could arise. It is intended to present basic safety
precautions that should be followed in daily
The signal word “Danger” denotes an extremely operation.
hazardous situation exists on or near the
machine which would result in high probability
IMPORTANT!
of death or irreparable injury if proper precautions The information in this manual does not replace
are not taken. any safety rules and laws used in your area.
Before operating this crane, learn the rules and
laws in your area. Make sure the machine has
the correct equipment according to these rules
and laws.
2-1
Section 2 - Safety 5500 Series
Model 5560B
TRAINED OPERATORS NEW OR ADDITIONAL

OPERATORS
IMPORTANT!
This crane should only be operated by personnel At the time of original purchase, the purchaser
who have met the requirements of ASME B30.5 of this crane was instructed by the seller on its
(Latest Revision). safe and correct use. If this crane is to be used
by an employee, or is loaned or rented to
Because you, the operator, are the only part of someone other than the purchaser, make sure
the crane that can think and reason, your that the new operator reads and understands
responsibility is not lessened by the addition of this Operator’s Manual that is provided with the
operational aids or warning devices. Indeed, you crane, before operating the crane.
must guard against acquiring a false sense of Also, make sure that the operator has completed
security when using them. They are there to a walk-around inspection of the crane
assist, NOT direct the operation. Operational aids (Page 7-10), is familiar with the decals and
or warning devices can be mechanical, electrical, safety equipment on the crane, and has
electronic, or a combination thereof. They are demonstrated the correct use of all controls.
subject to failure or misuse.
02
You are the only person who can be relied upon PERSONAL
to ensure the safety of yourself and those around CONSIDERATIONS
you. Be a PROFESSIONAL and follow the 3-
RULES of safety.
1. Seat Belt
REMEMBER failure to follow just one safety
0
Always adjust the seat and lock it in position,
precaution can cause an accident to people or and fasten the seat belt securely before you
25
equipment. start the engine.

Ensure that you and those working with you are
aware of any special dangers when you are
12
operating the crane. Be especially careful of

dangerous ground objects, including buildings,
near the crane.
NOTICE!
DO NOT attempt to operate the crane under the w0003
influence of alcohol or drugs. Persons involved
in the operation of heavy equipment must possess
sound judgement. Persons whose judgment is The operator’s seat is equipped with a
impaired due to mind altering substances may seat belt. Use this belt at all times when
cause damage to the crane, its load and yard operating the machine.
facilities, as well as themselves. An accident
could be fatal.
2. Clothing and Gear
IMPORTANT! DO NOT wear loose clothing or jewelry that
Operators of all hydraulic cranes must be guided can get caught on controls or moving parts.
solely by the capacity chart recommendations Wear the protective clothing and personal
concerning load, boom length, load radius, and safety gear issued or called for by the job
other factors listed on the capacity chart, such conditions. Hard hat, safety shoes, ear
as outrigger position and level terrain. protectors, reflective clothing, safety goggles,
and heavy gloves may be required.
2-2
Model 5560B
3. Mounting/Dismounting
Use the recommended hand holds and steps
with at least three points of support when
getting on or off the crane.
DO NOT get off the crane until you
• place the travel selector lever in
(N) Neutral, w0002
• engage the parking brake, EXHAUST FUMES CAN BE FATAL.

• lower load to ground, When operating in enclosed areas with
a gasoline or diesel engine, provide
• lower the boom, adequate ventilation.
• turn engine off.
CALIFORNIA PROPOSITION 65.
Diesel engine exhaust contains
chemicals known to the State of
02
California to cause cancer, birth defects
or other reproductive harm.
3- B. Explosive Fuel
Engine fuel is flammable and can cause
0
a fire and/or explosion. Avoid personal
injury or death by keeping sparks, open
25
flames, and smoking materials away

from the crane and fuel during refueling
or fuel system servicing. Know the
location of the fire extinguishers on the
12
job site and how to use them.
WARNING
w0018
1100257
DO NOT jump off the crane.

DO NOT dismount while the crane is in
motion.
FIRE HAZARD
Engine fuel is flammable and can
4. Chemical Hazards cause a fire or explosion. Death
or personal injury could occur.
A. Exhaust Fumes Do not put fuel in tank with engine
running.
Engine exhaust fumes can cause injury Keep open flames away.
or death. When operating in an enclosed Do not use smoking materials during
refueling or servicing.
area, provide good ventilation to replace 1004361
hazardous exhaust fumes with fresh
air. w0049
2-3
Model 5560B
C. Hydraulic Fluid
• DO NOT use your hand or any part
of your body to check for hydraulic
fluid leaks when the engine is running
or the hydraulic system is under
pressure. Fluid in the hydraulic system
is under enough pressure that it can
penetrate the skin causing serious
injury or death. Use a piece of
cardboard, or piece of paper, to search
for leaks. Wear gloves to protect
your hands from spraying fluid.
• If anyone is injured by, or if any

hydraulic fluid is injected into the
skin, obtain medical attention
immediately or gangrene may result.
02
• DO NOT attempt to repair or tighten
any hydraulic hose or fitting while the
engine is running, or when the
hydraulic system is under pressure. 3-
• NEVER disconnect any hydraulic
0
lines unless the boom is fully lowered,
the engine is shut off, and the hydraulic
25
pressure is relieved.
w0017
• HOT HYDRAULIC FLUID WILL D. Battery
12
CAUSE SEVERE BURNS. Wait for

the fluid to cool before disconnecting The following WARNING is intended to
any hydraulic lines. supplement and does not replace the
warnings and information provided on
the battery by the battery manufacturer.
• Hydraulic fluid can cause permanent
eye injury. Wear appropriate eye
protection. When jump starting the crane, carefully
follow instructions found under Jump
Starting on page 3-19.
w0019
1100263
2-4
Model 5560B
Keep sparks, flames, and lit cigarettes

away from the battery at all times. Lead
acid batteries generate explosive
gases. Severe chemical burns can
result from improper handling of the
battery electrolyte. Wear safety eye
glasses and protective clothing to prevent
electrolyte from coming in contact with
eyes, skin, or clothing. For Battery
Electrolyte First Aid, see page 7-38.
E. Radiator
NEVER remove the radiator cap while the
cooling system is hot. The system is under
pressure and the coolant can cause severe
burns or eye injury. Wear protective clothing
and safety glasses. Always turn the cap 1100264
slowly to the first stop, and allow the pressure
02
w0021
to escape before removing the cap completely.
0 3-
25
12
1100259
w0020
5. Moving Parts
1100262
DO NOT place limbs near moving parts. w0022
Amputation of a body part may result. Turn
off the engine and wait until the fan and belts
stop moving before servicing crane.
Pinch points which result from relative motion
between mechanical parts, are areas of the
machine that can cause personal injury or
death. DO NOT place limbs or your body in
contact with pinch points either on or around
the machine. Care must be taken to prevent
motion between pinch points when performing
maintenance and to avoid such areas when
movement is possible.
DO NOT allow persons to stand near extending
or lowering outriggers. Foot crushing could 1100267
occur. w0023
2-5
Model 5560B
6. Falling Load and Boom Hazard OPERATIONAL

NEVER allow anyone to walk or stand under CONSIDERATIONS
a raised load. A falling load can kill.
Before lifting a load be sure it is within capacity
of the crane. Overweight loads may fall,
causing property damage, personal injury or
death.
DO NOT get under a raised boom unless the
boom is blocked up safely. Always block up
the boom before doing any servicing that
requires the boom to be raised.
Worn-out, damaged or abused wire rope and
sheaves may cause a load to fall.
1100258
w0025
02
1. Preparation and Prevention
3-Know the location and function of all machine

controls.
Make sure all persons are away from the
0
crane and the Travel Select Lever is in the
“N” (Neutral) position with the parking brake
25
engaged before starting the engine.

DO NOT operate the crane unless:
12
1200143A
• all safety equipment is in proper working
w0024 condition,
• all covers and shields are in place, and
• all safety and instructional decals are in
place and readable.
1200143C
w0026
2-6
Model 5560B
IMPORTANT 4. Limitations
Always install new decals whenever the old
decals are destroyed, lost, painted over, or illegible. Understand the crane’s limitations and keep
When individual parts are replaced that have the crane under control.
decals attached, be sure to install new decals
with a new part. Replacement decals are available 5. Check Controls
from your dealer.
Check brakes, steering and all controls for
This machine is manufactured with no axle proper operation. If a malfunction is found,
suspension system. Traveling at high speeds, shut down the crane and report the malfunction
especially on rough ground, may create a for resolution.
bouncing affect that can result in loss of control.
If bouncing occurs, reduce travel speed. 6. Machine Failure
2. Work Site If a failure that causes loss of control, such

as steering, service brakes or engine occurs,
stop the crane’s motion as quickly as possible
Holes, obstruction, debris, and other work
and shutdown the engine and crane. Keep
area hazards can cause injury or death.
the crane securely parked until the malfunction
Always walk around and look for these and
is corrected or the machine can be safely
02
other hazards before operating the crane in
towed. See towing on page 3-35.
a new work area.
Prevent accidents when moving the machine 3- 7. Attachment Points
around the job site. Know the rules for
movement of people and machines on the Use the approved attachment point when
job site. Follow the instructions of signals using the crane for towing. If a cable or chain
0
and signs. Refer to pages 2-13 for standard is used, keep people away from the tow line.
25
hand signals for controlling crane operations.

8. Electrocution Hazard
3. Clearances
Never operate this or any equipment in an
12
area in which overhead power lines, overhead

or underground cables, or a power source
exists without first notifying the appropriate
power company or utility company to de-
energize the lines.
Never operate this machine, or any part of
the load, closer to any electrical power line or
power source than the distance specified or
required by Federal, State/Provincial, local
or other applicable safety codes or regulations.
In addition, United States OSHA regulations
require a flagman when operating in close
proximity to energized power lines.
NEVER operate this machine without first
consulting Federal, State/Provincial, local,
1100255 w0027 or other applicable safety codes or regulations.
It is the employer’s responsibility to implement
Always check clearances carefully before
the above precautions and to provide the
driving under electrical lines, bridges, etc.
employees with all safety devices, or means
Refer to specifications at rear of manual for
that may be necessary or required for any
unit dimensions and weights.
particular use, operations, setup, or service.
2-7
Model 5560B
NOTICE!
ELECTROCUTION HAZARD. It is not necessary
to come in contact with a power line for electrical
energy to ground through the machine. If electricity
does ground through the machine, remain in the
cab. DO NOT ALLOW ANYONE TO TOUCH
THE MACHINE STRUCTURE; injury or death
could occur.
1200144
w0028
02
0 3-
25
a0038
12
ELECTRICAL CONDUCTOR CLEARANCE CHART
Minimum Vertical Minimum Lateral Clearance From

Conductor Clearance From Clearance From Insulation Covered
Voltages Conductors Conductors
50,000 V or less 10' (3.1 m) 10' (3.1 m) 4' (1.3 m)
Over 50,000 V 10' (3.1 m) plus 0.4" 10' (3.1 m) plus 0.4" 10' (3.1 m)
up to and including (10.2 mm) for each (10.2 mm) for each
345,000 V 1,000 V over 1,000 V over
50,000 V 50,000 V
Over 345,000 V 16' (4.9 m)

up to and including
750,000 V
2-8
Model 5560B
9. Lifting Personnel
Use only an approved work platform for lifting
and lowering personnel. NEVER transport
personnel in a work platform for even a short
distance.
Serious injury or death can occur if these
rules are not obeyed. Riders can fall and be
crushed, or run over. Avoid accidents.
w0053
DO NOT exceed the rated lift capacity of the

crane, as structural damage and unstable
machine conditions will result.
If proper operating procedures are not followed,
this crane could tip over. If a machine ever
becomes unstable and starts to tip over,
BRACE YOURSELF and STAY WITH THE
02
1100256
MACHINE. KEEP SEAT BELT
w0029 FASTENED. HOLD ON FIRMLY and LEAN
AWAY FROM THE POINT OF IMPACT.
10. Tip Over Hazard 3- Indecision and trying to escape from a tipping
machine can result in death or injury.
Traveling with a suspended load and the
0
boom raised is dangerous and can cause tip
over. Keep the load as low as possible or
25
place the load on the crane’s deck. Travel

with extreme caution and at the slowest
possible speed.
12
DO NOT side-pull with the boom, either by

traveling with the crane in forward or reverse
motion, or by means of the hydraulic swing
control or cable control, while the unit is in a
fixed position.
Keep the machine under control at all times.
Avoid jerky turns, starts, or stops. Reduce
operating speed on rough ground and slopes.
w0030 Use extreme caution when accelerating or
1100254 decelerating on slippery or unstable surfaces.
Vehicles equipped with traction differentials
are inherently more sensitive to side slip.
w0054
2-9
Model 5560B
11. Slopes 14. Ventilation

DO NOT park the crane on an incline and Sparks from the electrical and engine exhaust
leave it unattended. can cause an explosion. DO NOT operate
this crane in an area with flammable dust or
Driving across a slope is dangerous, as vapors, unless good ventilation has removed
unexpected changes in slope can cause tip the hazard.
over. Ascend or descend slopes slowly and
with caution. Carbon monoxide fumes from the engine
exhaust can also cause suffocation in an
Ascend or descend slopes with the boom enclosed area. Good ventilation is very
and load pointing up the slope. important when operating the crane.
When operating on a downhill slope, reduce
travel speed and downshift to a low gear to
permit compression braking by the engine
and aid the application of the service brakes.
12. Falling Load Hazard
02
DO NOT downshift at a high ground speed.
You may drop the load off the deck due to a
sudden slowing. w0002
3- EXHAUST FUMES CAN BE FATAL.

13. Visual Obstructions When operating in enclosed areas
with a gasoline or diesel engine,
Dust, smoke, fog, etc. can decrease vision
0
provide adequate ventilation.
and cause an accident. Always stop or slow
25
the crane until the obstruction clears, and

the work area is visible again.
EQUIPMENT
CONSIDERATIONS
12
DO NOT modify, alter or permit anyone to

modify or alter the crane or any of its
components.
2-10
Model 5560B
Safety Decals
There are a number of specific safety decals installed on the machine. The location of each is reviewed
here. Study and remember the locations of all safety messages.
All safety decals should be kept clean and readable. Clean decals with a mild detergent and water only.
Never use a solvent to clean decals. Damage to the decal will result.
For your own safety and the safety of others, it is your responsibility to replace any missing, damaged
or otherwise unreadable caution decals. If a component with a decal is replaced, be sure a new decal
is installed.
p0296
02
0 3-
25
12
p0725
p0295
Figure 2-1. Safety Decals On Inside Wall Of The Cab
2-11
Model 5560B
p0360
p0364
Figure 2-2. Safety Decal Next to Seat
Figure 2-5. Safety Decal Near Battery
02
p0197
p0298
0 3-
25
p0361
12
p0365
p0362
Figure 2-6. Safety Decals In Engine

Figure 2-3. Safety Decals On Mast
Compartment
(Both Sides)
p0363
p0726
p0299
Figure 2-4. Safety Decals On Outriggers Figure 2-7. Safety Warnings Near Fuel and
(4 Places) Hydraulic Tanks
2-12
Model 5560B
Standard Hand Signals
SWING: Arm extended, point, with STOP: Arm extended, palm down, EMERGENCY STOP: Both arms
finger in direction of swing of boom. move arm back and forth extended, palms down, move arms back
horizontally. and forth horizontally.
02
0 3-
25
12
TRAVEL (Both Tracks): Use both

fists in front of body, make a
TRAVEL: Arm extended forward, DOG EVERYTHING: Clasp hands circular motion about each other,
hand open and slightly raised, in front of body. indicating direction of travel,
make pushing motion in direction of forward or backward. (FOR LAND
travel. CRANES ONLY)
TRAVEL (One Track Only): Lock

the track on side indicated by
raising fist. Travel opposite track in
RETRACT BOOM (Telescoping
direction indicated by circular EXTEND BOOM (Telescoping
Boom): Both fists in front of body with
motion of other fist, rotated vertically Booms): Both fists in front of body
thumbs pointing toward each other.
in front of the body. (FOR LAND with thumbs pointing outward.
CRANES ONLY)
2-13
Model 5560B
HOIST: With forearm vertical, LOWER: With arm extended USE MAIN HOIST: Tap fist on head,
forefinger pointing up, move hand in downward, forefinger pointing down, then use regular signals.
small horizontal circle. move hand in small horizontal circle.
02
0 3-
25
USE WIPLINE (Auxiliary Hoist): RAISE BOOM: Arm extended, LOWER BOOM: Arm extended,
12
Tap elbow with one hand; then use fingers closed, thumb pointing fingers closed, thumb pointing
regular signals. upward. downward.
MOVE SLOWLY: Use one hand to give RAISE THE BOOM AND LOWER LOWER THE BOOM AND RAISE
any motion signal and place other hand THE LOAD: With arm extended, THE LOAD: With arm extended, thumb
motionless in front of hand giving the thumb pointing up, flex fingers in and pointing down, flex fingers in and out
motion signal, (Hoist slowly shown as out as long as load movement is as long as load movement is desired.
example) desired.
2-14
Model 5560B
Wire Rope Safety

WIRE ROPE DESCRIPTION The greatest differences in wire ropes are found
in the strands, which may vary widely in the
A wire rope is a machine, by definition: "An pattern and number of wires which are laid
assemblage of parts that transmit forces, motion together.
and energy one to another in some
predetermined manner and to some desired The wires of the rope may be made of various
end." metals, including steel, iron, stainless steel,
monel, and bronze. The materials of which
A typical wire rope may contain dozens, even wires are made is the primary determination of
hundreds, of individual wires which are formed rope strength. High-carbon steel is used in the
and fabricated to operate at close bearing crane’s wire rope.
tolerances one to another. When a wire rope
bends, each of its many wires slide and adjust Carbon steel wire ropes come in various
in the bend to accommodate the differences in grades. The term "Grade" is used to designate
length between the inside and the outside of the the nominal strength of the wire rope. The most
02
bend. The sharper the bend, the greater the common grades are Traction Steel (TS), Plow
movement. Steel (PS), Improved Plow Steel (IPS), Extra
Improved Plow Steel (EIPS) and Extra Extra
Every wire rope has three basic components
(Figure 2-8): (1) The wires which form the
3- Improved Plow Steel (EEIPS). The wire rope
used on the crane is an EIPS Grade.
strands and collectively provide rope strength;
0
(2) the strands, which are laid helical around the One cannot determine the grade of wire rope
by its feel or appearance. To be sure you are
25
core, and (3) the core, which forms a foundation

for the strands. The core used in the crane’s using the proper rope, always obtain the wire
wire rope is an Independent Wire Rope Core rope from your Shuttlelift dealer.
(IWRC), which is actually a smaller rope, or a
12
strand similar to the outer strands of the rope. WIRE ROPE SAFETY
The IWRC core adds about 7.5% to the nominal
strength of the wire rope. The following information is not a complete
discussion of wire rope. What follows is a brief
outline of the basic information required to safely
use wire rope.
1. Wire rope WILL FAIL IF WORN-OUT,
OVERLOADED, MISUSED, DAMAGED or
IMPROPERLY MAINTAINED.
2. In service, wire rope loses strength and
work capability. Abuse and misuse
STRAND
increases the rate of loss.
3. The NOMINAL STRENGTH, sometimes
called CATALOG strength, of a wire rope
applies ONLY to a NEW, UNUSED rope.
Figure 2-8. Wire Rope
2-15
Model 5560B
4. The Nominal Strength of a wire rope IF IN DOUBT, REPLACE THE ROPE. An

SHOULD BE CONSIDERED the straight line inspection should include verification that
pull which will ACTUALLY BREAK a NEW none of the specified removal criteria for this
UNUSED rope. The Nominal Strength of a usage are met by checking for such things
wire rope SHOULD NEVER BE USED AS as:
ITS WORKING LOAD.
• Surface wear; nominal and unusual.
5. WIRE ROPES WEAR OUT. The strength
of a wire rope begins to decrease when the • Broken wires; number and location.
rope is put to use and continues to decrease • Reduction in diameter.
with each use.
• Rope stretch (elongation).
6. NEVER OVERLOAD A WIRE ROPE. This
means NEVER USE the wire rope where • Integrity of end attachments.
the load applied to it is greater than the
• Evidence of abuse or contact with another
working load determined by Shuttlelift, Inc. object.
7. NEVER "SHOCK LOAD" a wire rope. A • Heat damage.
sudden application of force or load can
02
cause both visible external and internal • Corrosion.
damage. There is no practical way to In addition, an inspection should include
estimate the force applied by shock loading condition of sheaves, drums and other
a rope. The sudden release of a load can
also damage a wire rope.
0 3- apparatus with which the wire rope makes
contact.
8. Lubricant is applied to the wires and strands
IMPORTANT!
25
of a wire rope when it is manufactured. The

A more detailed wire rope inspection procedure
lubricant is depleted when the rope is in
is given in Maintenance Section 7.
service and should be replaced periodically.
Refer to Section 7, Preventive Maintenance,
12
for lubrication intervals. 10. When a wire rope has been removed from
service because it is no longer suitable for
9. In the U.S.A., regular INSPECTIONS of the use, it must not be reused on another
wire rope and keeping of PERMANENT application.
RECORDS SIGNED BY A QUALIFIED
PERSON ARE REQUIRED BY OSHA FOR 11. Every wire rope user should be aware of the
ALMOST EVERY WIRE ROPE fact that each type of fitting attached to a
APPLICATION. The purpose of the wire rope has a specific efficiency rating
inspection is to determine whether or not a which can reduce the working load of the
wire rope may continue to be safely used wire rope assembly or rope system, and this
on the application. Inspection criteria, must be given due consideration.
including number and location of broken 12. Some conditions that lead to problems in
wires, wear and elongation, have been wire rope systems include:
established by OSHA, ANSI, ASME and
similar organizations. Refer to Section 7 for • Sheaves that are too small, worn or
inspection procedures. corrugated causes damage to a wire rope.
• Broken wires mean a loss in strength.
2-16
Model 5560B
• Kinks permanently damage a wire rope

and must be avoided.
• Wire ropes are damaged by knots. Wire
rope with knots must never be used.
• 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.
• Contact with electrical wires and resulting
arcing will damage a wire rope.
02
0 3-
25
12
2-17
Model 5560B
This Page Intentionally

Left Blank
02
0 3-
25
12
2-18
5500 Series Section 3 - Operation
Section 3
Model 5560B
Operation
Controls, Switches, Gauges

CAB CONTROLS HOIST CONTROL
(See Figure 3-1)
SWING CONTROL
(See Figure 3-1) The hoist control raises and lowers the drop
block or hook and ball.
The swing control operates the boom/mast
rotation function. The boom and mast will rotate BOOM CONTROL
continuously through a full 360° circle. (See Figure 3-1)
TELESCOPE The boom control raises or lowers the boom
CONTROL (See Figure 3-1) assembly.
02
The telescope control extends and retracts the
boom sections.
3- Hoist Boom
Control Control
0
Swing Telescope
Control Control
25
12
Outrigger
Controls
Steering Accelerator
Select Pedal
Control
Brake
Pedal
Steering
Wheel
p0693
Figure 3-1. Cab Controls
3-1
Section 3 - Operation 5500 Series
Model 5560B
OUTRIGGER CONTROLS STEERING SELECT CONTROL

(See Figure 3-1) (See Figure 3-1)
This set of controls extend/retract and lower/ This control selects the two modes of steering
raise the outriggers. For more information, see (2-Wheel Steering and 4-Wheel Steering). For
page 3-9. more information, see page 3-11.
ACCELERATOR PEDAL TRAVEL SELECT LEVER

(See Figure 3-1) (See Figure 3-2)
Controls the travel speed and hydraulic work Selects the forward and reverse travel of the
function speeds of the crane. Pressing down on crane, as well as the speed ranges.
the accelerator pedal increases the engine
speed. The pedal is spring-loaded to return to TURN SIGNAL AND
idle speed. FLASHER (See Figure 3-2)
BRAKE PEDAL Used to indicate turning direction. Activates
(See Figure 3-1) hazard lights.
02
Pressing down on the brake pedal applies the
service brakes located in the front and rear axles
and slows and stops the crane.
0 3-
25
12
Travel Select
Lever
Turn Signal
and Flasher
p0694
Figure 3-2.
3-2
°
Model 5560B
A reading of less than 14 volts with the engine

GAUGES AND speed above low idle, indicates a problem in
INDICATORS the charging system. The system should be
INSTRUMENT PANEL checked by an authorized Shuttlelift dealer.
GAUGE (Figure 3-3)
HOURMETER
(See Figure 3-4)
The hourmeter registers the total hours the

The instrument panel gauge is four gauges in
engine has been operated. Use this gauge to
one. It registers the amount of fuel in the tank
perform preventive maintenance scheduling.
(Fuel Gauge), the engine oil pressure (Oil
Pressure Gauge), the engine temperature
(Temperature Gauge) and the amount of
electrical system voltage (Voltmeter).
Fuel Gauge Oil Pressure

Gauge
02
0 3-
p0695
25
Figure 3-4. Hourmeter
CRANE LEVEL INDICATOR

12
Temperature (See Figure 3-5)

Voltmeter
Gauge
p0261
This is bubble-type indicator, that allows the
operator to level the crane when using the
Figure 3-3. Instrument Panel Gauge
outrigger controls. Refer to page 3-9 .
NORMAL OPERATING PRESSURES

Diesel Engine - 50 - 70 psi (350 - 480 kPa)
Gasoline/L.P.G. Engine - 45 psi (311 kPa)
NORMAL OPERATING TEMPERATURE
Diesel Engine - 160° - 190° F (72° - 88° C)
Gasoline/L.P.G. Engine - 160° - 190° F (72° - 88° C)
NORMAL VOLTAGE RANGES

Engine above low idle - 14 to 16 volts
Engine stopped - 10 to 14 volts)
A reading of less than 10 volts with the engine
p0263
stopped or at low idle, indicates a low battery
charge. Figure 3-5. Crane Level indicator
3-3
Model 5560B
LOW BRAKE PRESSURE TRANSMISSION LOW OIL

WARNING LIGHT (See Figure PRESSURE WARNING
3-6) LIGHT (See Figure 3-6)
When illuminated (red), the light indicates that When illuminated (Red), this light indicates when
there is a loss in brake pressure. At this point the transmission oil pressure is below normal
there is still enough pressure to stop the crane. operating pressure. If the light illuminates, shut
Immediately stop the crane and shut off the down the engine immediately and do not restart
engine. Do not drive the crane until the problem it until the problem has been repaired.
has been repaired. The light will illuminate briefly
when the brake system charges during TRANSMISSION OIL HIGH
operation. TEMPERATURE WARNING
LIGHT (See Figure 3-6)
WARNING When illuminated (Red), this light indicates when
the transmission oil temperature has risen above
When the low brake pressure warning normal operating temperature. If the light
02
light is illuminated, immediately stop and illuminates, shut down the engine immediately
shutdown the crane. DO NOT drive the and wait until the transmission cools and the
crane with the warning light illuminated. warning light goes out. Only then may the engine
Brake failure is possible and result could 3-
be started and work continued. If the light
be serious personal injury and property illuminates again, shut down the engine and have
damage. the transmission inspected and repaired.
0
OPTIONAL AXLE LOCKOUT
25
Engine Oil Low Engine Warning

Pressure and Light (Gasoline/
WARNING LIGHT (See Figure 3-7)
Engine High Dual Fuel Engine)
Temperature When illuminated (Red), this light indicates when
12
Warning Light
Diesel Engine)
the rear axle lockouts are engaged. Axle lockout
Low Brake System
must be disengaged whenever the crane is
Pressure Warning traveling over rough terrain.
Light
Transmission Oil
Low Pressure
Warning Light
Transmission Oil
High Temperature
Warning Light p0265
Figure 3-6. Warning Lights
IMPORTANT!
If an engine or transmission warning light
illuminates during operation, shut down the
engine immediately to inhibit damage to either
the engine or the transmission.
p0473
Figure 3-7. Axle Lockout Warning Light
3-4
Model 5560B
ENGINE LOW OIL To start the engine the ignition switch must first
be turned to the OFF position, then back to the
PRESSURE AND HIGH
start position.
TEMPERATURE WARNING
LIGHT (Optional - Diesel) ENGINE WARNING LIGHT
(See Figure 3-6) (Gasoline/Dual Fuel Engine)
When illuminated (Red), this light indicates when (See Figure 3-6)
the engine oil pressure is lower or the engine This light is used to indicate problems in engine
water temperature is higher than normal operation. The light will illuminate, flash or blink
operating conditions and the engine has been to indicate problems that are occurring before
shutdown. The engine will start again as soon and during engine operation. The following table
as one or both conditions have been corrected. indicate engine problem blink codes:
Table 3-1 Engine Warning Light Codes
02
Condition Lamp Status Indication
Engine not running Lamp lit for over 12 seconds No Error Codes
Engine not running
Engine running Lamp off
3-
After 10 seconds, lamp flashes Shows Error Codes (See Table 3-2)
Normal Operation
Engine running Lamp blinks slowly Charging system problem (low
0
voltage)
Engine running Lamp blinks quickly Overheat/over speed/low Oil
25
pressure (Stop engine and find fault)

Engine running Lamp flashes code See Error Codes, Table 3-2
12
Table 3-2. Error Codes
After 10 seconds in standby mode (engine not running), the lamp will blink to display any known errors.
The light will blink in 1/4 second intervals to indicate the following errors. In case of multiple codes,
there will be a 1-1/4 second pause between codes.
Number of Flashes Error Indication
3 Kambda Sensor Signal Problem
4 Accelerator Pedal Sensor Open
5 Air Temperature Sensor Problem
6 Engine Temperature Sensor Problem
7 Map Sensor Problem
8 Battery Voltage Problem
IMPORTANT!
These codes will also display if an error is apparent during normal operation.
3-5
Model 5560B
BOOM ANGLE INDICATOR

(See Figure 3-7)
The boom angle indictor is a plumb arrow and a
decal with angular graduations from 0° to 80°. It
is located on both sides of the boom and is visible
from the operator’s cab. Use the indicator to
determine the boom angle when reading the
capacity chart. (Refer to “Using the Capacity
Chart,” on page 4-1.
p1386
Figure 3-9. Load Indicator/ Rated Load

Capacity Limiter Indicator Panel
LSI RATED CAPACITY LIMITER
02
(RCL) - OPTIONAL
The rated capacity limiter is simiar to the
p0696
3-
standard Load Indicator, but instead of warning
the operator when a load limit is exceeded it
stops the telescope out function and the boom
0
raise function when the load limit has been
3-8. Boom Angle Indicator
25
exceed. It uses a similar indicator panel as the

Load Indicator (Figure 3-9) and the same
LSI LOAD INDICATOR DISPLAY transmitter and load pin, but the system also
includes boom angle and boom length sensors
12
PANEL (STANDARD WITH UNIT WITH

and transmistter that sends boom angle and
SERIAL NUMBER 124504-03 AND length infromation to the display panel. For
AFTER) operating instructions, refer to the Universal User
Manual furnished with the crane.
The load indicator panel (Figure 3-9) displays
load and capacity related information and warns
the operator when a limit is exceeded. The OPTIONAL LOAD MOMENT
operator is warned by a flashing light on the INDICATOR DISPLAY PANEL
display panel. (WYLIE) (Figure 3-9A)
In conjunction with the display panel (receiver), Provides visual indications of angle, load, radius,
there is a transmitter and load pin attached to capacity, etc. and allows the operator to set limits
the boom head that sends the load information on these indications.
to the display panel.
The display panel includes a digital display
For operating instructions and battery changing screen, LED illuminated bar graph, eight
instructions, see the LSI “Users Manual” indicator warning lights, audible alarm and an
supplied with the crane. operations key pad.
See transmitter changeover instructions in For operating instructions, refer to the LMI
Section 5 for moving the transmitter to the down Operator’s Manual furnished with the crane.
haul block when single part line in used.
3-6
Model 5560B
PANEL SWITCHES
OPTIONAL DUAL FUEL SWITCH
(See Figure 3-10)
Cranes with a dual fuel engine can switch

between gasoline and liquid petroleum gas
(L.P.G.). Move the switch Up to use gasoline;
move the switch down to use L.P.G. See change
over instructions on page 3-14
WORK LIGHT/HEAD LIGHT

SWITCH (See Figure 3-10)
p0301
A three-position switch controls the crane’s
lights.
Figure 3-9A. Load Moment Indicator
Up position illuminates the work lights,
02
head and tail lights and the instrument
panel lights.
0 3-
25
Head/Work
Light Switch
Dual Fuel
Switch
12
Auxiliary
Winch Switch
Parking Brake
Switch
Heater/Defroster
Windshield
Switch
Wiper Switch
Ignition
Switch
p0697
Figure 3-10. Instrument Panel Switches
3-7
Model 5560B
Center position turns off all lights. HEATER/DEFROSTER

Down position illuminates the head and SWITCH (Optional)
tail lights and the instrument panel lights. (See Figure 3-10)
PARKING BRAKE SWITCH This switch is used simultaneously start both

(See Figure 3-10) the heater and defroster fans. It is a three-position
switch.
The parking brake switch is used to engage and
disengage the parking brake. The up position is for SLOW fan speed.
To ENGAGE the parking brake, move The center position is OFF.

the switch lever down. The down position is for FAST fan speed.
To DISENGAGE the parking brake,
move the switch lever up.
COLD START SWITCH
IGNITION SWITCH (Optional) (Figure 3-11)
(See Figure 3-10)
02
The cold start switch (Figure 3-11) is used to
The key included with this machine is necessary
actuate a cold start ether cylinder to aid the
for operation of the ignition switch.
starting of the diesel engine in cold weather.
Turn the key clockwise to the first position (Run)
to energize the electrical system.
0 3-
Refer to “Diesel Engine Starting Procedure” on
page 3-16.
Turn the key fully clockwise (Start) to engage

the engine starting motor to crank the engine
25
when the travel select lever is in the (N) Neutral

position. The switch is spring loaded to return Cold Start
Switch
from the Start position to the Run position and
12
must be held in place for normal starting.
AUXILIARY WINCH SWITCH

(Optional) (See Figure 3-10)
This switch operates the optional winch attached
to the front end of the crane.
p0695
To UNWIND rope from the winch, move
the switch lever up. Figure 3-11.
To WIND rope on the winch, move the

switch lever down.
WINDSHIELD WIPER
SWITCH (Optional)
(See Figure 3-10)
Pull the switch lever down to turn on the
windshield wiper motor.
3-8
Model 5560B
OPTIONAL AXLE LOCKOUT OUTRIGGER CONTROLS

SWITCH (Figure 3-12)
This switch engages and disengages the rear
axle lockouts. For normal operation, the axle
lockouts should be engaged. Disengage the axle
lockouts when traveling over rough terrain.
w0023
1100267
DO NOT allow any persons to stand near

extending or lowering outriggers. Foot crushing
could occur.
02
NOTICE!
p0473 3- For maximum lift and stability, fully extend and
lower the outriggers. Be sure the crane is level
Figure 3-12. Axle Lockout Switch before lifting a load. The bubble indicator
0
Figure 3-13) located below the outrigger controls
is to be used to determine when the crane is
25
This switch engages and disengages the

optional rear axle lockouts. The axle lockout must level. The bubble must be in the center of the
be engaged when lifting on rubber and when indicator circle. Use the outriggers to level the
crane. If this is not possible, reposition the crane
traveling in crab steer. When traveling on rough
12
until the bubble is centered.

terrain the axle lockouts must be disengaged.
The up position ENGAGES the axle
lockouts. When the axle lockouts are
engaged a red warning light will
illuminate (See Figure 3-7).
p0473
The down position DISENGAGES the
axle lockouts and turns off the warning
light.
p0263
Figure 3-13. Bubble Indicator
3-9
Model 5560B
OUTRIGGER SWITCHES
OUTRIGGER SELECT SWITCHES
Standard Outriggers (Figure 3-14)
This switch selects which outriggers are to be
operated.
The left position allows for the operation
of only the left outriggers.
The center position allows for operation
of all outriggers.
p0698
The right position allows for the operation
of only the right outriggers. Figure 3-14A. Optional Outrigger Switches
02
OUTRIGGER EXTEND/RETRACT AND
LOWER/RAISE CONTROL (Figure 3-15)
This control is used to extend/retract and lower/
3-
raise the outriggers. It is a four-way electrical
switch, similar to a four-way joy stick.
0
Moving the control handle DOWN,
25
lowers the outriggers.

Moving the control handle UP, raises the
outriggers.
12
p0722
Figure 3-14. Standard Outrigger Switch Moving the control handle LEFT, extends
the outriggers.
Optional Independent Outriggers Moving the control handle RIGHT,

(Figure 3-14A) retracts the outriggers.
These switches select which outriggers are to

extended and lowered. The top switch operates
the front outriggers and the bottom switch
operates the rear outriggers.
The left position on both switches allows
for the operation of only the left
outriggers.
The center position on both switches
allows for the operation of both
outriggers.
p0268
The right position on both switches
Figure 3-15. Outrigger Extend/Retract
allows for the operation of only the right
and Lower/Raise Control
outriggers.
3-10
Model 5560B
STEERING CONTROLS 1. Two-Wheel Steer Mode Without Crab

Steering (see Figure 3-17)
The crane is typically operated in two steering
modes. The front wheels steer the crane. The
rear wheels remain in the fixed forward
Two-Wheel Steer position. This mode is used for highway
travel and traveling at higher speeds.
Two-Wheel Steer Mode With Crab
Four-Wheel Steer
Steering Option (see Figure 3-17A)
The rear wheels steer the crane. The
When equipped, it can also be front wheels remain in the fixed forward
operated in crab steer mode. position. This mode is used for highway
travel and traveling at higher speeds.
These modes are selected using the Steering
Selector Switch shown in Figures 3-16 and
3-16A.
02
2-Wheel
Steer Mode
0 3-
25
4-Wheel
Steer Mode a0610
Figure 3-17. Two-Wheel Steer Mode

12
Without Crab Steering

p0699
Figure 3-16. Steering Select Switch

p0269
(Two-Wheel and Four-Wheel Steering)
Crab Steer
Mode
2-Wheel
Steer Mode
a0564
4-Wheel
Steer Mode Figure 3-17A. Two-Wheel Steer Mode
With Crab Steering
Figure 3-16A. Steering Select Switch - Optional

(Two-Wheel, Four-Wheel and Crab Steering)
3-11
Model 5560B
2. Four-Wheel Steer Mode (Figure 3-18)

IMPORTANT!
DO NOT travel at high speed with the crane in
the four-wheel steer mode. Possible tipping may
occur when turning.
The front wheels steer in the direction
that the steering wheel is turned and
rears wheels turn in the opposite
direction. This mode allows for an
extremely short turning radius. It enables
the rear wheels to follow the track of the
front wheels. This is an advantage in a0566
muddy or sandy conditions.

3-18A. Optional Crab Steer Mode
FOUR-WHEEL STEERING
INDEXING PROCEDURE
02
Units without Crab Steering
0 3-
1. Place the steering select switch in the four-
wheel steer mode.
2. Turn the steering wheel until the rear wheels
are in a straight forward position.
25
a0565
3. Place the steering select switch in the two-
3-18. Four-Wheel Steer Mode wheel steering mode and align the front
12
steering wheels in a straight forward position

3. Optional Crab Steer Mode (Figure 3-18A)
4. The crane should now be properly indexed
and the steering select switch can now be
placed in the four-wheel steering mode.
Units with Optional Crab Steering
1. Place the steering select switch in the four-
wheel steer mode.
2. Turn the steering wheel until the front wheels
are in a straight forward position.
All wheels steer in the same direction.
This mode permits the operator to move 3. Place the steering select switch in the two-
the machine sideways. This feature is wheel steering mode and align the rear
especially helpful in tight areas on the steering wheels in a straight forward position
job.
4. The crane should now be properly indexed
and the steering select switch can now be
placed in the four-wheel steering mode or
crab steering mode.
3-12
Model 5560B
OPERATORS CAB
HEATER AND DEFROSTER
The cab heater (furnished as an option
with enclosed cabs) is located under the
operator’s seat (Figure 3-19). The
windshield defroster vent is located on
top of the instrument panel (Figure 3-20).
p0510
Figure 3-21. Heater Shut-Off Valve - Diesel

Engine Shown
02
To operate the heater and defroster, use the
heater and defroster switch located on the
instrument panel (See page 3-7). Select the
3- desired fan speed.
Position the vent (Figure 3-19) on the heater for
desired amount of air flow.
0
SEAT ADJUSTMENT
25
p0281
Figure 3-19. Heater Location Adjust the operator’s seat correctly. Full foot
pedal control must be obtained with your back
12
firmly against the seat back.

SEAT FORE & AFT ADJUSTMENT -
To adjust the seat, move the control lever
(Figure 3-22) to the right. Move the seat
to proper position and then move the
control lever back to the left to lock the
seat position.
p0282
Figure 3-20. Defroster Vent Location
IMPORTANT!
Be sure the shut-off valve in the hot water supply
p0283
line is open. The shut-off valve is located on the
engine (Figure 3-21)
Figure 3-22. Seat Adjustment
3-13
Model 5560B
SEAT BELT OPENING THE DOOR FROM

The operator’s seat is equipped with a seat belt.
INSIDE
Use this belt at all times when operating the Pull the door handle back to release the cab door
machine. latch (Figure 3-24).
w0003
02
The operator’s seat is equipped with
a seat belt. Use this belt at all times p0285
when operating the machine. 3- Figure 3-24. Opening Door - Inside
0
LOCKING THE CAB DOOR
CAB DOOR (Enclosed Cab)
25
The cab door can be locked from the outside.

OPENING THE CAB DOOR Insert the key and turn it to the left to lock the
FROM OUTSIDE door. Turn the key to the right to unlock the
12
door. The door key number is stamped on the

Pull on the door latch out to release the door lock if additional keys are required.
from the cab (Figure 3-23).
OPENING SIDE WINDOWS
Both side windows are opened by sliding the
window to the opened position.
p0284
Figure 3-23. Opening Door - Outside
3-14
Model 5560B
FIRE EXTINGUISHER
(Optional)
The fire extinguisher is located in the cab and is
attached to the right and rear of the operator’s
seat (Figure 3-25). Study the manufacturer’s
instructions printed on the fire extinguisher for
its proper use.
a0567
If the machine equipped with a fire

extinguisher, maintain a charged fire
extinguisher AND KNOW HOW TO USE
IT.
02
0 3-
25
p0292
Figure 3-25. Fire Extinguisher

12
3-15
Model 5560B
Machine Operation
FUEL CHANGEOVER STARTING THE ENGINE
INSTRUCTIONS - DUAL
FUEL ENGINES NORMAL ENGINE STARTING
NOTICE!
CAUTION
Never leave the engine running while the crane
is unattended. Shut off the engine to inhibit
unauthorized persons from operating the controls.
Flammable Liquids. When switching NOTICE!
from Liquid Petroleum Gas (L.P.G.) to Walk around the crane and warn all personnel
liquid fuel, be sure that there is no who may be servicing the machine or are in the
spillage of liquid fuel from the carburetor machine’s path prior to starting. Do not start
float system. Fire or explosion is possible until all personnel are clearly away from the
from spilled fuel. crane.
02
1. Enter the cab and adjust the operator’s seat
1. Place the dual fuel switch to desired fuel for comfortable operation.
selection, L.P.G. or gasoline.
0 3-
2. Fasten the seat belt.
25
12
w0003

a seat belt. Use this belt at all times
Figure 3-26. Dual Fuel Switch
when operating the machine.
4. Start engine using normal engine starting 3. Check that the parking brake is engaged
procedures. (Figure 3-27).
3-16
Model 5560B
IMPORTANT!
If the crane is equipped with shutdown gauges
and the engine starts but will not keep on running,
check to see if the engine oil low pressure and
engine high temperature light warning light is
illuminated. If it is, either the engine oil pressure
is low or the engine cooling system temperature
is high. The engine will not start until the problem
is repaired.
6. Check the engine oil pressure gauge for
proper operating pressure. See page 3-3. If
the gauge is not registering the proper oil
p0288
pressure, shut down the engine immediately.
Figure 3-27. Parking Brake Switch Locate what is causing the low oil pressure
and repair it before starting the engine again.
4. Place the travel select lever in the neutral 7. Check the brakes, steering and all controls
position (Figure 3-28). for proper operation. If a malfunction is found,
02
shut down the engine immediately and park
the crane until the malfunction is corrected
or the crane can be safely towed. See page
3- 3-35.
8. Disengage the parking brake before you
0
travel with the crane. See Travel Instructions
on page 3-21.
25
Engine Starting Procedures

NOTICE!
12
DO NOT crank the starter motor continuously

p0723 for more than 30 seconds. Damage to the
starter motor could occur.
Figure 3-28. Travel Select Lever.
NOTICE!
Check the engine oil pressure gauge immediately
NOTICE
after the engine starts. If the oil pressure does
Do not bypass the crane’s neutral-start system.
not increase to approximately 10 psi (60 kPa),
The neutral start system must be repaired if it
stop the engine and find the cause.
malfunctions.
IMPORTANT!
5. Start the engine. Follow the engine starting
DO NOT operate the engine at full RPM or
procedures that follow. apply a full load until the engine is warm. During
cold weather, it may be necessary to run the
engine at a higher speed to keep the correct
operating temperature.
3-17
Model 5560B
The diesel engine in this crane is not normally

equipped with a metering cold starting aid.
However, one is available as an option from
Shuttlelift and is recommended when the crane
is to be operated in temperatures below 10° F
(-29° C).
NOTICE!
Temperature ranges will vary when using different
oil weights. Consult the engine manufacturer’s
manual for the variables.
1. If necessary, apply a starting aid to the
p0695
engine. Refer to “Applying Starting Fluid to
the Engine” below.
Figure 3-29. Cold Start Switch
2. Depress the accelerator pedal halfway to the
floor.
WARNING
02
3. Turn the ignition switch to the START
position to crank the engine. Release the
switch when the engine starts. If the engine
fails to start on the first try, wait until the 3-
starter motor comes to a complete stop;
then again press the accelerator pedal
0
halfway and crank the engine with the ignition
key.
25
w0050
APPLYING STARTING FLUID TO
THE DIESEL ENGINE Ether is poisonous. Do not store ether
12
cylinders in the operator’s compartment.

APPLYING FLUID USING A METERED Breathing ether fumes or repeated
INJECTION-TYPE STARTING AID (Optional) contact with skin can cause serious
personal injury. Use ether only in well
An ether injection kit is available as an option ventilated areas.
from Shuttlelift for injecting pre-measured
amounts of ether into the engine’s intake
WARNING
manifold using a switch in the cab.
1. Push down on the cold start switch on the
instrument panel (see Figure 3-29) to inject
a metered amount of fluid into the engine.
2. If the engine does not start after the first
injection of starting fluid, repeat injecting fluid
until the engine starts.
w0051
NOTICE!
Avoid injecting too much starting fluid into the Do not smoke while changing ether
engine. Too much fluid will cause engine damage cylinders or where ether cylinders are
by washing lubricant from the cylinder bores. stored. Keep ether cylinders away from
open flames.
3-18
Model 5560B
1. Remove the intake cover from the air
WARNING cleaner.
2. Spray a small amount of starting fluid into
the intake opening.
3. Start the engine.
4. If the engine does not start, repeat the
w0052 procedure until the engine starts or it is
Discard spend ether cylinders per determined it will not start.
manufacturer’s instructions. Do not NOTICE!
puncture or burn. Ether cylinders can Avoid injecting too much starting fluid into the
burst causing serious personal injury. engine. Too much fluid will cause engine damage
by washing lubricant from the cylinder bores.
APPLYING FLUID FROM A SPRAY
CANISTER TOWING OR PUSHING THE
CRANE TO START THE ENGINE
02
WARNING If the battery is discharged, DO NOT try to start
the engine by towing or pushing the crane.
NEVER use starting fluid near an open 3- Damage to the transmission will occur. Instead
flame, or with an electric pre-heater, or use a booster battery to jump start the engine.
with flame heating equipment. Serious
JUMP STARTING THE ENGINE
0
injury or death could occur from
25
explosion. Follow the recommended jump starting

procedure below when using booster batteries
DO NOT breath starting fluid fumes. to start the engine.
12
Serious injury or death could result from

1. Wear eye protection.
the toxic fumes.
2. Engage the parking brake.
DO NOT use excessive amounts of
3. Place the travel select lever in the Neutral
starting fluid. Serious injury or death
(N) position.
could result from a backfire of flame,
which could ignite the starting fluid 4. Stop all electrical loads (lights, heaters, etc.).
canister and cause an explosion.
NOTICE!
Two people are recommended to be present
when attempting to start the engine using a
starting fluid without a metered starting fluid
system. One is to operate the ignition switch,
while the other sprays the starting fluid into the
air cleaner intake. Avoid soaking the air cleaner
element with fluid. This is extremely important,
because a backfire of flame can completely
destroy the air cleaner element, as well as
p0399
cause other damage to the engine and possible
personal injury. Figure 3-30. Battery Location
3-19
Model 5560B
5. Lift the access cover and locate the battery IMPORTANT!

(Figure 3-30). If the battery has removable If a battery charger is used, disconnect the field
fill caps, remove the fill caps being careful connection from the alternator before connecting
not to contaminate the battery fluid. the battery charger to the battery. Do not install
the field connection until the battery charger is
Removing the battery caps reduces the
removed.
danger of explosion of the battery gases.
7. If a booster battery is used, it must be a 12
IMPORTANT!
NEVER jump start the engine directly to the Volt battery. If a vehicle is used, it must have
starter or starter solenoid. Serious injury could a negative ground electrical system.
result from the crane moving forward or back
8. Connect the positive (+) jumper cable
and running over the person performing the
jump starting procedure. (usually red) to the positive (+) post on the
discharged battery. See Figure 3-32.
6. Disconnect the FIELD connection from the 9. Connect the end of the positive cable to the
alternator (Figure 3-31). The connection is positive (+) post on the booster battery.
generally marked with an “F”.
10. Connect one end of negative (–) jumper
cable (usually black) to the negative (–) post
02
on the booster battery.
11. Make the final connection to the engine block
0 3- or a ground point the furthest away from the
discharged battery.
12. Follow the steps under “Normal Starting”,
on page 3-16.
25
13. Remove the jumper cables in reverse order

FIELD
CONNECTION a0047 (i.e., negative ground cable first, etc.). If
removed, install the battery vent caps and
12
Figure 3-31. Field Connection the alternator field connection.
Positive Battery On Unit

Jumper Cable
Negative
Jumper Cable
Connects to Good
Ground on Frame
Booster Battery p0299
a0048
Figure 3-32. Connecting Jumper Cables
3-20
Model 5560B
1. Enter the operator’s cab, close the door, if

TRAVELING WITH THE equipped, and fasten the seat belt.
CRANE
2. Start the engine and disengage the parking
brake.
NOTICE!
To avoid damage to the parking brake and
crane, do not apply the parking brake while
traveling.
3. Select either the Forward (F) or Reverse (R)
travel position on the travel select lever. (See
Figure 3-33)
02
1100255
w0027
0 3-
IMPORTANT!
25
If travel sight is restricted, do not attempt to p0701

travel with the crane until a signalman gives a
signal that the crane is clear of obstacles in the Figure 3-33. Travel Select Lever
wheel path. Remove any blocking from the
12
wheel path before moving.

IMPORTANT!
To help inhibit accidents, use a “Slow Moving
Vehicle Sign and a flashing strobe light (where
legal) for traveling on highways or public roads.
1200143C
w0026
• The crane has no axle suspension. Traveling

at high speeds, especially on rough roads,
can create a bouncing effect that can result
w0003 in loss of control. Personal injury, death and
property damage could result. Reduce
speed if bouncing occurs.
a seat belt. Use this belt at all times
when operating the machine.
3-21
Model 5560B
4. Start out traveling from a stopped position in SHIFTING GEARS (TRAVEL

1st speed (Figure 3-34). Travel speed may
SPEEDS)
be shifted from 1st to 2nd, 2nd to 3rd, 3rd to
4th when the crane is moving. See “Shifting IMPORTANT!
Gears”, in the next column. Avoid operating The transmission used on this crane is not an
at too high of speed when moving a heavy automatic transmission. It is “Powershift”
load, as this may cause “lugging” on the transmission. The gears and clutches will not
engine. Use a lower gear when moving a shift automatically. Each gear range must be
heavy load; higher gear when moving a shifted manually.
lighter load. SELECTING THE CORRECT 1. Shifting to the next gear (travel speed) may
TRAVEL SPEED WILL PROLONG ENGINE be done at any engine speed, while the
LIFE. crane is in motion, but first ease up on the
accelerator pedal.
2. When downshifting, do not over-rev the
engine. Allow the crane to slow down before
shifting to the next lower gear.
02
3. The crane must come to a complete stop
when shifting between forward and reverse.
IMPORTANT!
3-
To avoid possible damage to the transmission ,
observe the following:
0
DO NOT attempt to start the engine by pushing
or towing with another vehicle. The power train
25
does not allow starting this way, and transmission

damage may occur.
Figure 3-34. Speed Positions
The following practices could result in transmission
12
failure:
NOTICE!
Check the instrument panel gauges frequently • Shifting between forward and reverse while
during operation. Any abnormal readings should the engine is at high speed or heavy throttle,
be investigated and corrected as soon a possible.
such as when driving wheels on ice --
CHANGING TRAVEL DIRECTION commonly called rocking.
• Shifting to reverse or forward while operating
1. Completely stop the crane travel.
the engine at high speed in neutral.
NOTICE!
Shifting the crane from forward to reverse or • Operating the transmission at or near “stall
reverse to forward when the crane in moving speed” for more than 10 seconds at a time.
will cause damage to the transmission. Always “Stall condition” is when the engine runs at
stop the crane before changing travel directions. high speed while the transmission is in forward
or reverse and the drive wheels are not
2. Move the travel select lever to the opposite moving. For example, when the wheels are in
travel direction. deep sand or mud, or when the crane is
against a fixed barrier.
• Down shifting at high speeds causing the
engine to over rev.
3-22
Model 5560B
STOPPING TRAVEL To Extend - (Figure 3-36) Run the

engine at idle speed (accelerator pedal
1. Apply the service brakes and downshift as released). Move the joystick control lever
necessary to slow the crane until it comes (Figure 3-35) to the left and hold it in
to a complete stop. position. Press the accelerator pedal to
increase the engine speed, which will
2. Place the travel select lever in Neutral (N)
accelerate the outward movement of the
and engage the parking brake.
outriggers. Release the accelerator
3. Turn the ignition switch to the OFF position pedal and the switch control lever when
to stop the engine. the outriggers are fully extended.
4. If the crane is parked and unattended,

remove the ignition key.
OPERATING THE
OUTRIGGER CONTROLS
TO EXTEND AND RETRACT THE a0570
02
OUTRIGGERS
The most common way of extending and
retracting the outriggers is to extend and retract
the four outriggers at the same time. Place both
3-
selector switches in the center ALL position.
0
IMPORTANT!
25
Each outrigger may be adjusted independently a0862

if required for clearance and leveling problems.
See Independent Outrigger Operation, on page Figure 3-36. Extending The Outriggers
12
3-23.
a0556
p0268
Figure 3-35. Outrigger Controls
3-23
Model 5560B
To Lower - (Figure 3-37) Pull back on

the joystick control lever and hold it in
position. Press the accelerator pedal to
accelerate the lowering speed of the
outriggers. Release the accelerator
pedal and the control lever when the
outriggers are fully lowered.
a0573
a0864
02
a0571 Figure 3-38. Raising The Outriggers
3-To Retract - (Figure 3-39) Run the

engine at idle speed. Move the joystick
control lever to the right and hold it in
0
a0863
25

accelerate the retraction of the
outriggers. When the outriggers are fully
12
raised, release the accelerator pedal

Figure 3-37. Lowering The Outriggers and the control lever.
IMPORTANT!
The outriggers can not be extended or retracted
when they are in the lowered position. Attempting
to do this will cause damage to the outriggers.
TO RAISE AND RETRACT THE

OUTRIGGERS a0572
To Raise - (Figure 3-38) Run the engine

at idle speed. Push forward on the
joystick control lever and hold it in
accelerate the raising of the outriggers.
When the outriggers are fully raised,
release the accelerator pedal and the a0865
control lever.
Figure 3-39. Retracting The Outriggers
3-24
Model 5560B
OPTIONAL INDEPENDENT
OUTRIGGER OPERATION
Each outrigger may be operated independent
of the others. This is accomplished by placing
the outrigger select switch (Figure 3-40) in
position for the outrigger that is to be operated.
For example; if the left front outrigger is to be
operated independently from the others, place
the top select switch in the LEFT FRONT
position. When the switch is placed in this
position the switch will illuminate, and all other
outrigger functions will cease to operate.
To operate the outrigger, operate the joystick p0477
control lever as indicated on pages 3-23 and
3-24. Figure 3-40. Select Switches
02
0 3-
25
12
3-25
Model 5560B
OPERATING THE BOOM BOOM SWING OPERATION

CONTROLS
Four levers in the operator’s cab control the
crane function. See Figure 3-1. These levers
are connected to the main control valves by
hydraulic pilot lines. The function of each control
is shown in Figure 3-41.
When operating each control, press the
accelerator pedal to increase the engine speed
to maximum rpm. Slowly move the control lever.
The further the control lever is moved the faster
the function will operate. To stop function
movement, move control lever to the neutral
position, then lower the engine speed to idle. 1100262 w0022
IMPORTANT!
• Before rotating the mast, be sure there is
02
The function speeds can also be controlled by enough clearance on all sides and that all
engine rpm. The slower the rpm the slower the persons are away from the area. A pinch point
function speed.
3-between the operator’s cab and mast can
cause injury or death.
0
25
12
a0577
Figure 3-41. Boom Controls
3-26
Model 5560B
TO ROTATE THE MAST RIGHT

TO ROTATE THE MAST TO THE (CLOCKWISE)
LEFT (COUNTERCLOCKWISE):
Press the accelerator pedal to increase the
Press the accelerator pedal to increase the engine speed to maximum rpm. Slowly push
engine speed to maximum rpm. Slowly pull back forward on the swing control lever (Figure 3-42)
on the swing control lever (Figure 3-42) until the until the desired swing speed is obtained. The
desired swing speed is obtained. The further the further the control is pulled back the faster the
control is pulled back the faster the mast will mast will rotate.
rotate.
NOTICE!
TO STOP ROTATION Never put side loads on the boom. Side loads
can damage the swing gearbox. Move the boom
Slowly move the control lever to the neutral so that it is directly above the load before lifting
position and decrease the engine speed to idle. the load.
02
0 3-
25
a0576
12
a0578
Figure 3-42. Boom Swing Control
3-27
Model 5560B
BOOM TELESCOPE OPERATION

IMPORTANT!
Always operate the winch control to unwind the
wire rope when extending the boom. Do not let
the drop block touch the boom head. An automatic
cutout device is equipped on this crane to inhibit
the drop block from being pulled into the boom
head. When the drop block touches the anti-
double blocking bracket (Figure 3-43), hanging
from the boom head, a switch is activated and p0496
the hydraulic flow to extend the crowd cylinder is
stopped. An alarm will sound, warning the operator Figure 3-43. Anti-Double Block Bracket
that the block has touched the bracket. The
operator must then lower the drop block to stop TO STOP EXTENSION
the alarm and allow for the extension of the Slowly move the control lever to the neutral
boom.
position and decrease the engine speed to idle.
The above information also pertains when a jib is
attached to the boom.
02
TO RETRACT THE BOOM
TO EXTEND THE BOOM
Press the accelerator pedal to increase the engine speed to maximum rpm. Slowly pull back
3-
engine speed to maximum rpm. Slowly push on the telescope control lever (Figure 3-44) until
forward on the telescope control lever (Figure the desired retract speed is obtained. The further
0
3-44) until the desired extend speed is obtained. the control is pulled back the faster the boom
The further the control is pushed forward the will retract.
25
faster the boom will extend.
WARNING
12
When lifting at high boom angles with an

extended boom, it is crucial to maintain proper
side slide pad adjustment. See page 6-7.
Visually check the lateral straightness of the
boom before raising the load. Lifting with a
boom which is not visually straight may cause
boom failure and could result in injury or death. a0579
a0687
Figure 3-44. Telescope Control
3-28
Model 5560B
BOOM LIFT OPERATION NOTICE!

Look for overhead obstructions before raising
the boom. Possible damage or possible
electrocution could occur if the boom comes in
contact with over head power lines.
TO RAISE THE BOOM
engine speed to maximum rpm. Slowly pull back
on the boom control lever (Figure 3-45) until the
w0030
desired raising speed is obtained. The further
the control is pulled back the faster the boom
1100254
• Know the capacity of the crane. The operator will raise.

must be familiar with the crane’s capacity chart
before lifting a load. See how to read the TO STOP BOOM MOVEMENT
capacity chart on page 4-1. A falling load or Slowly move the control lever to the neutral
machine tip-over can cause injury or death. position and decrease the engine speed to idle.
02
TO LOWER THE BOOM
3- engine speed to maximum rpm. Slowly push
forward on the boom control lever (Figure 3-45)
until the desired lowering speed is obtained. The
0
further the control is pushed forward the faster
25
w0028
the boom will lower.
WARNING
12
When lifting at high boom angles with an

extended boom, it is crucial to maintain proper
side slide pad adjustment. See page 6-7.
Visually check the lateral straightness of the
boom before raising the load. Lifting with a
boom which is not visually straight may cause
boom failure and could result in injury or death.
a0582
a0866
Figure 3-45. Boom Lift Operation
3-29
Model 5560B
WINCH HOIST OPERATION NOTICE!

When lifting a load, keep you eyes on the load at
all times. If you must look away, stop the movement
of the load first. A moving load can cause injury
or death.
NOTICE!
Always have a flagman give assistance if you
can not see a moving load. Be sure you can see
the flagman at all times. Agree in advance to
signals to be used (see page 2-14). A moving
load can cause injury or death and/or property
damage.
NOTICE!
Never put side loads on the boom. Side loads
can damage the swing gearbox. Move he boom
so that it is directly above the load before lifting
1200143A
the load.
02
• Before making a lift, be sure all persons are IMPORTANT!
clear of the load. A falling load can cause injury Do not let the drop block touch the boom head.
or death. An automatic cutout devise is installed on this
crane to inhibit the drop block from being pulled
3-
into the boom head. When the drop block touches
DANGER the anti-double blocking bracket (Figure 3-43),
hanging from the boom head, a switch is activated
0
and the hydraulic flow to raise the drop block is
25
stopped. An alarm will sound, warning the

operator that the drop block has touched the
bracket. The operator must then lower the drop
block to stop the alarm and allow for other boom
12
functions.
The above information also applies when a
boom extension is attached to the boom.
TO RAISE THE DROP BLOCK
engine speed to maximum rpm. Slowly pull back
on the hoist control lever (Figure 3-46) until the
desired raising speed is obtained. The further
the control is pulled back the faster the drop
block will raise.
TO STOP BOOM MOVEMENT
w0030
1100254
Slowly move the control lever to the neutral
• Know the capacity of the crane. The operator position and decrease the engine speed to idle.
must be familiar with the crane’s capacity
chart before lifting a load. See how to read the
capacity chart on page 4-1. A falling load or
machine tip-over can cause injury or death.
3-30
Model 5560B
TO LOWER THE BOOM

WARNING
engine speed to maximum rpm. Slowly push When lifting at high boom angles with
forward on the hoist control lever (Figure 3-46) an extended boom, it is crucial to
until the desired lowering speed is obtained. The maintain proper side slide pad
further the control is pushed forward the faster adjustment. See page 6-7. Visually
the drop block will lower. check the lateral straightness of the
boom before raising the load. Lifting with
a boom which is not visually straight may
cause boom failure and could result in
injury or death.
02
0 3-
25
a0584
12
a0868
Figure 3-46. Hoist Operation
3-31
Model 5560B
OPTIONAL CONTROLS
TO EXTEND THE WIRE ROPE
OPERATION
Push and hold the toggle switch up (Figure
AUXILIARY WINCH 3-47). Keep tension on the wire rope to inhibit
twisting of the wire rope on the winch drum. For
fast unwind, release the free spool lever on the
right side of the winch.
TO STOP THE WINCH
w0031
Release the toggle switch.
• Always keep hands and clothing clear of the
fairlead rollers and front opening while the TO RETRACT THE WIRE ROPE
winch is operating. Keep persons away from Pull the toggle switch down (Figure 3-47).
the area. Injury can be caused if the wire rope
breaks or the hook becomes disconnected.
02
Winch
3-
Out
0
25
12
Winch p0291
In
a0869
Figure 3-47. Auxiliary Winch Operation
3-32
Model 5560B
Operating Practices
HANDLING A LOAD C. The lift and swing path is clear of
obstructions.
The crane must not be loaded beyond the
specifications of the rated load chart. The load 2. Before starting to lift the load, the following
being lifted must be within the rated capacity of conditions should be noted:
the crane.
When loads which are not accurately known are
to be lifted, the operator of the crane shall
WARNING
ascertain that the weight of the load does not When lifting at high boom angles with
exceed the crane ratings at the radius at which an extended boom, it is crucial to
the load is being lifted. maintain proper side slide pad
adjustment. See page 6-7. Visually
ATTACHING THE LOAD check the lateral straightness of the
boom before raising the load. Lifting with
02
The hoist rope must not be wrapped around the a boom which is not visually straight may
load. cause boom failure and could result in
injury or death.
The load shall be attached to the hook by means
of slings or other devices of sufficient capacity.
3-
A. That the boom when extended, is laterally
0
HOLDING THE LOAD straight.
25
The operator must not leave the controls while B. That the hoist rope is not kinked.
a load is suspended. An exception to this is under
C. That multiple-part lines are not twisted
those circumstances where a load is to be held
around each other.
12
suspended for a period of time exceeding normal

lifting operations, the operator may leave the D. That the hook is brought over the load in
controls provided that, prior to that time, the such a manner as to minimize swinging.
appointed individual and operator establish the
requirements for restraining the boom hoist, E. If there is a slack condition, it must be
telescoping, load, swing and outrigger functions, determined that the rope is seated on
and provide notices, barricades or whatever the hoist drum and in the sheaves as
other precautions may be necessary. the slack is removed.
No person should be permitted to stand or pass F. The effect of ambient wind on the load
under a suspended load. and crane stability.
3. During lifting operations care must be taken
MOVING THE LOAD that:
1. The person directing the lift must see that: A. There is no sudden acceleration or
deceleration of the moving load.
A. The crane is level and where necessary,
blocked. B. Load, boom and other parts of the crane
do not contact any obstruction.
B. The load is well secured and balanced
in the sling or lifting device before it is
lifted more than a few inches.
3-33
Model 5560B
4. The load must not be lowered below a point ELEVATING PERSONNEL

where less than three full wraps of rope
remain on the hoist drum.
5. When two or more cranes are used to lift
one load, one designated person shall be
responsible for the operation. That person
must analyze the operation and instruct all
personnel involved in the proper positioning, 1100256
rigging the load and the movements to be w0029

made. Decisions such as the necessity to Generally, this crane should not be used to
reduce crane ratings, load positions, boom elevate personnel. But, should the need arise
location, ground support and speed of to elevate personnel with the crane, use ONLY
movement must be in accordance with this an approved work platform.
determination.
. When rotating the crane with a load, sudden
PREPARATION AND SETUP
starts and stops shall be avoided. Rotational NOTICE!
02
speed must be such that the load does not When using the crane for lifting personnel, the
swing out beyond the radius at which it can crane must be inspected daily for anything
be controlled. A tag or restraint line must be hazardous to the person(s) being lifted.
used when rotation of the load is hazardous. 3-
1. Be sure that the platform is securely
attached to the boom. Follow the
TRAVELING WITH A LOAD manufacturer’s instructions.
0
(PICK AND CARRY)
2. Ensure that the crane has a firm and level
25
IMPORTANT! footing.
Pick and carry is not allowed when the boom
extension is attached and used to lift the load. 3. Place the travel select lever in Neutral (N).
12
When traveling with a load, a designated person 4. Engage the parking brake.
must be responsible for the operation.
Decisions, such as the necessity to reduce 5. Extend and lower the outriggers.
crane ratings, load position, boom location,
ground support, travel route and speed of
LIFTING PERSONNEL
movement must be in accordance with that
person’s determination. Specified tire pressure
must be maintained. The boom should be carried
in line with the direction of travel. Sudden starts
and stops should be avoided. Tag and restraint
lines should be used to control swinging of the
load.
w0028
1. Before lifting, make sure there are no

overhead obstructions or electrical wires
above the platform.
3-34
Model 5560B
2. A trained crane operator must operate the MACHINE SHUTDOWN

controls from the operator’s cab. Using
extreme caution, lift and lower personnel 1. Park the crane on level ground.
smoothly and ONLY at their request. The
2. Place the travel select lever in Neutral (N)
operator should always alert personnel in
and engage the parking brake.
the platform, and in the work area, before
moving the platform up or down.
3. Always lower the platform to the travel

position (boom fully retracted and lowered)
before moving the crane.
IMPORTANT!
Make sure that required restraining items, such
as railings, chains, cables, body belts with
lanyards, etc. are in place and are properly
used. Never use railings, planks, ladders, etc.
on the platform for the purpose of achieving
additional reach or height.
02
IMPORTANT!
Refer to ASME B30.5 (Latest Edition) for additional
precautions and operating instructions for lifting 3-
personnel using a crane.
w0018
CAPACITY LIMITATIONS
0
25
The combined weight of the platform and

3. Lower any load to the ground and fully retract
personnel shall not exceed one-third the
and lower the boom.
capacity of the operating radius indicated on
the capacity chart, located on the right side wall
12
4. Turn the ignition switch to the OFF position

of the operator’s cab. Refer to “Using the and remove the key.
Capacity Chart”, on page 4-1.
TOWING A DISABLED
TURNING CLEARANCES MACHINE
The front end of the boom extends beyond the
If the crane becomes disabled and can not be
end of the frame . The operator must be aware
moved under engine power, the crane may be
of the maximum sweep of the boom when
towed for a distance of one mile (1.5 km) by
turning and allow for adequate clearance
another piece of equipment, which is designed
between boom and other objects.
for towing. Always use a rigid tow bar and ensure
that the travel select lever is in neutral (N).
Restrict travel to 15 mph (25 kmph).
If is necessary to tow the crane for a distance in
excess of one mile (1.5 km), the drive shafts
must be disconnected to inhibit damage to the
transmission system.
3-35
Model 5560B

Left Blank
02
0 3-
25
12
3-36
5500 Series Section 4 - Capacity Chart
Model 5560B
Section 4
Capacity Chart
Using The Capacity Chart
The capacity chart for this crane is located on LOCATING THE LIFT
the inside of the operator’s cab to the right of CAPACITY
the seat. The chart provides maximum loads
that can be safely lifted and give conditions under Locate on the Capacity Chart the Main Boom
which these maximum lifts can be made. Load Ratings. Find the 10 foot radius in the chart.
Always use the next highest radius if the radius
OPERATING BOOM measured is not on the chart. Read across the
RADIUS line to determine what can be lifted at that radius,
either with the outriggers extended and down,
02
Located on both sides of the boom is a indicator retracted and down or on rubber.
that gives the angle at which the boom is
positioned (Figure 4-1). The angle at which the DO NOT lift more than what the capacity chart
boom is positioned and the length at which the
boom is extended determines the lifting radius
3- states.
of the boom. For example, if the boom is at a THINGS TO OBSERVE

0
70° angle and is extended to 43.5 feet WHEN USING THE
25
(13.25 meters) the lifting radius is 12 feet CAPACITY CHART

(3.66 meters). See capacity chart.
1. The rated loads are the maximum lift
IMPORTANT!
12
capacities as determined by operating

To determine the exact lifting radius, use a tape
radius, boom length and boom angle. The
measure and measure the from the center of
rotation to the load line. operating distance from a projection of the
axis of rotation to the supporting surface,
before loading, to the center of the vertical
hoist line or tackle load applied.
2. The rated loads shown in the Capacity Chart
on Outriggers do not exceed 85% of actual
tipping. The rated loads shown on rubber
do not exceed 75% of actual tipping. These
ratings are based on freely suspended loads
with the crane leveled, standing on a firm,
p0264 uniform supporting surface. Practical
working loads depend on supporting surface,
operating radius and other factors affecting
stability. Hazardous surroundings, climatic
conditions, experience of personnel and
proper training must be taken into account
by the operator.
Figure 4-1. Boom Angle Indicator
4-1
Section 4 - Capacity Chart 5500 Series
Model 5560B
3. The weights of all load handling devices such PICK AND CARRY
as hooks, hook blocks, slings, jib boom, etc., RANGES
except the hoist rope, shall be considered
as part of the load. See paragraph 1. The Figure 4-2 illustrates the range of operation for
weights for these items is stated on the pick and carry loads. Do not pick and carry
capacity chart. outside of the specified ranges. The crane could
become unstable and tip over.
4. Rating on outriggers are for either outriggers
fully extended and down or fully retracted and
down. Ratings for outriggers fully retracted
and down will apply for any intermediate
outrigger setting.
5. Ratings on rubber depend on tire capacity,
condition of the tires and proper inflation
pressure of 120 psi (827 kPa). Loads on
rubber may be transported at a maximum
speed of 2.5 mph (4 km/h) on a smooth level
02
surface with the boom retracted to the
shortest length possible and centered over
the front. Do not use the jib crane on rubber.
6. For operating radius not shown on the
Capacity Chart, use load rating of the next
0 3-
larger radius.
25
7. With a load both on the boom (pick and carry)

and on the cranes’s deck the maximum
combined load is 16,000 lb.
(7258 kg). The maximum load that can be
12
place only on the deck with nothing attached

to the boom is 20,000 lb. (9072 kg).
8. Do not induce any external side loads to the
boom or the jib boom.
a0063
LIFTING WITH THE JIB
Figure 4-2. Pick And Carry Ranges
BOOM INSTALLED
To find the lifting capacity when using the jib
boom, observe the angle at which the main
boom is positioned (use the angle indicator on
the boom, see Figure 4-1). Find this angle on
the capacity chart. Read across the line to the
amount of offset on the jib boom. The capacity
given is the capacity that can be lifted.
DO NOT lift more than what the capacity chart
states.
4-2
5500 Series Section 4 - Capacity Chart
Model 5560B
02
FOR REFERENCE ONLY
Figure 4-3. Capacity Chart

3-
USE THE LOAD CHART IN
0
THE OPERATORS CAB
25
12
4-3
Section 4 - Capacity Chart 5500 Series
Model 5560B

Left Blank
02
0 3-
25
12
4-4
5500 Series Section 5 - Attachments
Model 5560B
Section 5
Attachments
Pivoting Boom Head
BOOM HEAD POSITIONS
The pivoting boom head can be adjusted to four
angle positions. Two of which are used when
there is no boom extension attached and two
when a boom extension is attached.
Positions When No Boom
Extension Is Attached
02
The plus 40° and plus 80° boom head positions
(Figure 5-1) can be used when there is low head
room clearance and a smaller profile boom head
is needed.
3-
Positions When boom Extension
0
a0924
Is Attached
25
Figure 5-1. Boom Head Positions - Without

The minus 15° and minus 30° boom angles Boom Extension
are used to offset the boom extension. See
Figure 5-2.
12
a0594
Figure 5-2. Boom Head Positions - With Offset Boom Extension
5-1
Section 5 - Attachments 5500 Series
Model 5560B
CHANGING THE BOOM 5. Position the pin hole in the boom head to
HEAD POSITION (NO align up with hole or the desired angle. Insert
the pivot lock pin (Figure 5-5) through the
BOOM EXTENSION) holes and install the lynch pin.
1. Lower and retract the boom.
2. Lower the block or ball to the ground to take
weight off of the wire rope and boom head.
3. Remove the lynch pin from the pivot lock
pin (Figure 5-3).
02
p0370
3- Figure 5-5. Installing The Pivot Lock Pin
6. Using the hoist control, raise the block or

0
hook ball off of the ground. Check that the
wire rope is engaged in all the sheaves in
25
p0368 the boom, hoist block and winch drum.
ADJUSTING THE BOOM

12
Figure 5-3. Removing The Lynch Pin

EXTENSION OFFSET
4. Remove the pivot lock pin (Figure 5-4).
WARNING
The boom extension is very heavy. Use
adequate support to hold the boom from
falling when the pivot anchor pin is
removed. A falling boom can cause
serious injury or death.
The boom extension offset is adjustable by

moving the boom head to a negative 15° or 30°.
With the boom attached it is necessary to both
raise or lower the jib boom and the boom head
simultaneously. The boom extension is very
p0369 heavy and must not be lifted and supported by
one person.
Figure 5-4. Removing The Pivot Lock Pin
5-2
Model 5560B
1. Lower the hook and ball to the ground.

2. Provide adequate support at the end of the
boom extension. If a mechanical hoist or
equivalent is available, use it to support the
boom extension. If no hoist is available, use
two or three persons to support the end
of the boom extension.
3. Remove the lynch pin (Figure 5-6) from the
pivot lock pin.
02
p0394
Figure 5-7. Removing The Anchor Lock Pin.

0 3- 5. Raise or lower boom extension until the
desired offset angle is achieved.
6. Install the pivot lock pin and lynch pin.
25
7. Raise the hook and ball

12
p0395
Figure 5-6. Removing The Lynch Pin.
4. With the boom extension supported, remove

the pivot lock pin (Figure 5-7) . It will be
necessary to remove the boom extension
weight on the pin in order to remove it.
5-3
Model 5560B
Hoist Block
REMOVING THE HOIST
BLOCK
Remove
1. Lower the hoist block to the ground to place Pins
slack in the wire rope.
2. Remove the pin (Figure 5-8) securing the
rope wedge socket to the boom head.
Remove the wire rope dead end socket.
02
0 3-
p0569
25
p0531
Figure 5-9. Typical Hoist Block

Figure 5-8. Typical Wire Rope Wedge Socket Pin
12
IMPORTANT! INSTALLING THE HOIST

When removing the hoist block to install the BLOCK
down haul weight, the wire rope dead end assem-
bly does not have to be disassembled 1 Remove the four pins and hook assembly
from the hoist block assembly. See Figure
3. Remove the three pins as indicated in Figure 5-9.
5-9.
2. Thread the wire rope through the hoist block
4. Pull the wire rope and dead end through the so it is under the hoist block sheave.
block.
3. Install the hook assembly and four pins to
5. Install the three pins. the hook block assembly.
4. Attach the wire rope wedge assembly to
boom head.
5. Lift the hoist block off of the ground. Be sure
the wire rope ins engaged in the sheave
grooves in both the boom head and hoist
block.
5-4
Model 5560B
Boom Extension
ATTACHING THE BOOM 5. Remove the pin from the boom extension
EXTENSION anchor bracket as shown in Figure 5-11.
To use the boom extension it must be positioned

and attached to the main boom. The boom
extension can be attached as follows:
1. Locate the crane on level ground. If this is
not possible, use the outriggers to level the
crane.
NOTICE!
The crane must be level to attach the boom
extension. If the crane is not level, there is a
possibility the boom extension could swing away
02
from the main boom as soon as it is released.
2. Completely retract and lower the booms.
3. Position the boom head angle at 0°. 3- p0371
4. Remove the four boom extension attaching

Figure 5-11. Removing The Anchor Bracket Pin.
0
pins from the boom extension, as shown in
Figure 5-10.
25
6. Swing the boom extension at the swing arm

pivot point and align the link holes with the
holes on the ears of the boom head (Figure
12
5-12).
p0372
Figure 5-12.
p0370
Figure 5-10. Removing The Jib Boom

Attaching Pins
5-5
Model 5560B
7. Install two of the link pins removed in Step 4

into the holes (Figure 5-13) to attach the
boom extension to the boom head. Be sure
to install the hair pins in the pins.
p0375
02
Figure 5-15. Installing The Link Pins
10. Install the pin removed in Step 7 as shown

p0373
3- in Figure 5-16. Be sure to install the hair pin.
Swing the swing arm back towards the
boom.
0
25
Figure 5-13. Installing The Link Pins
8. Remove the pin from the swing bracket, as

shown in Figure 5-14.
12
p0376
p0375
Figure 5-16. Swing Bracket Pin Installed
Figure 7-14. Removing The Swing Bracket Pin
9. Swing the boom extension fully to the front
and install the remaining two link pins. (Figure
5-15).
5-6
Model 5560B
11. Install the anchor bracket pin (Figure 5-17). 13. Connect the boom extension’s anti-double
block wire with the anti-double block wire on
the main boom (Figure 5-19).
p0379
Figure 5-19. Anti-Double Block Wires Connected
02
p0377
Figure 5-17. Anchor Pin Installed. 14. Remove the hook and ball from the storage
3- compartment on the crane and place it below
12. Remove the pin from the deflector sheave the end of the boom extension.
bracket. Flip up the deflector sheave bracket
to the upright position (Figure 5-18). Install 15. Remove the hoist block from the hoist wire
0
the pin. rope. Refer to page 5-5.
25
16. Remove the pin from top of the boom head

as shown in Figure 5-20. Remove the wire
rope from the boom head sheaves. Install
12
pin back into the top of the boom head.
p0378
Figure 5-18.
p0380
Figure 5-20.
5-7
Model 5560B
17. Remove the top pin from the deflector 19. Install the wire rope over the deflector
sheave (Figure 5-21). sheave (Figure 5-23) and install the pin.
p0383
p0381
02
Figure 5-23. Wire Rope Installed Over The
Deflector Sheave
Figure 5-21. Pin Removed From
Deflector Sheave
20. Place the wire rope over the end of the boom
3- extension as shown in Figure 5-24. Install
18. Remove the two retaining pins from the
the two pins.
boom extension head (Figure 5-22).
0
25
12
p0382 p0384
Figure 5-22. Pins Removed From Boom Head Figure 5-24. Wire Rope Installed over The
End Sheave
p0376
5-8
Model 5560B
21. Install the down haul weight to the wire rope. 7. Remove two of the pins from the link and
See Attaching Hook and Ball, on page 5-12. boom head, as shown in Figure 5-26.
ADJUSTING THE BOOM

EXTENSION ANGLE
See page 5-3, Adjusting The Jib Boom Offset.
STOWING THE BOOM

EXTENSION
To stow the boom extension, perform the
following procedure:
1. Make sure the offset angle is set at 0° before
attempting to stow the boom extension. See
page 5-2.
p0385
02
2. Make sure the crane is level before
attempting to stow the boom extension.
Figure 5-26.
3. Remove the down haul weight. See page 3-
5-11. 8. Remove the pins from the swing bracket
(Figure 5-27) and swing the bracket out.
4. Pull the wire rope from the boom extension,
0
through the deflector sheave.
25
5. Remove the pin from the deflector sheave

bracket and swing the deflector sheave
bracket to the left side of the boom. Attach
12
the deflector sheave to the side of boom

extension with the removed pin.
6. Disconnect the anti-double block wire
(Figure 5-25).
p0376
p0376
Figure 5-27. Swing Bracket Pin
p0386
Figure 5-25. Disconnecting The Anti-Double

Block Wire
5-9
Model 5560B
9. Remove the pin from the anchor bracket

(Figure 5-28).
02
p0377 p0373
Figure 5-28. Jib Anchor Bracket Pin. Figure 5-30. Removing the Attaching Pins
10. Swing the boom extension backward until it

3-
makes contact with swing bracket. Align the
0
swing bracket with the bracket on the boom
25
extension. Then push the boom extension

mounting bracket onto the swing bracket.
Install the pin (Figure 5-30).
12
p0371
Figure 5-31. Install the Anchor Pin
p0375 13. Install the pins removed in Steps 7 and 12

in the vacant holes in the jib link.
Figure 5-29. Installing The Swing Bracket Pin
14. Install pins that were removed in their
11. Remove the two pins (Figure 5-31) securing stowed positions.
the boom extension to the boom head. 15. Reeve the boom head. See page 5-13.
12. Push the boom extension onto the anchor 16. Install the drop block. See page 5-5.
bracket and install the pin (Figure 5-32).
5-10
Model 5560B
Down Haul Weight

INSTALLING THE DOWN INSTALLING THE DOWN
HAUL WEIGHT (UNITS HAUL WEIGHT (UNITS WITH
PRIOR TO S/N 124504-03) S/N 124504-03 AND AFTER)
1. Remove the hoist block from the wire rope. Whenever a single part line is used on a
See page 5-5. Carrydeck crane to lift a load, the load indicator
transmitter must be removed from the boom
2. Remove the pin (A, Figure 5-32) from the head and installed onto the down haul weight.
down haul weight. Without the transmitter installed and attached
3. Remove one of pins (B). to the load pin, the load indicator receiver in the
cab will not register the weight being lifted by
4. Insert the wire rope wedge socket, removed the single part line.
from boom head, in place in the hook and
ball assembly. To install the load indicator transmitter in the
down haul block perform the following steps:
02
5. Reinstall pin (A) into the hook and ball
assembly to secure the wire rope wedge 1. Disconnect the transmitter wire and load pin
socket to the link of the hook and ball wire (Figure 5-33) from the jumper wire.
assembly. 3-
6. Reinstall pin (B). Be sure the wire rope is
0
installed between the two pins
25
7. Adjust the boom head angle in the position

required for the lift operation. See page 5-1.
12
the wire rope is engaged in the sheave

block.
Figure 5-33.
2. Remove the transmitter from the boom head

by removing the transmitter mounting
hardware (bolts, lockwashers and flat
washers).
Figure 5-32. Down Haul Weight Installation
5-11
Model 5560B
3. Follow instructions on page 5-4 and remove REMOVAL OF DOWN HAUL

the hoist block. WEIGHT (UNITS WITH
4. Using the hardware removed when removing S/N 124504-03 AND AFTER)
the load indicator transmitter, install the
transmitter onto the down haul weight (See Whenever the down haul block is removed, the
Figure 5-34). load indicator transmitter must be removed from
the down haul block and installed onto the boom
head. Without the transmitter installed and
attached to the load pin, the load indicator
receiver in the cab will not register the weight
being lifted by the crane.
To install the load indicator transmitter to the
boom head perform the following steps:
1. Lower the down haul block to the ground.
2. Disconnect the transmitter load pin wire
02
(Figure 5-34) from the transmitter wire.
3. Remove the rope guide pin indicated in
Figure 5-34.
3-
4. Remove the lynch pin and the load pin from
down haul weight. Remove the wire rope
0
deadend socket. Install the rope guide pin in
the down haul weight.
25
Figure 5-34.
5. Remove the transmitter from the downhaul
5. Remove the rope guide pin indicated in weight. Retain the hardware.
12
Figure 5-34 from the down haul weight.

6. Install the transmitter to the boom head
6. Attach the wire rope deadend socket to the (Figure 5-33) using the existing hardware.
down haul weight using the load pin removed
when removing the hoist block. Install the 7. Install the hoist block using using instructions
lynch pin. on page 5-4. Install the load pin.
7. Install the rope guide pin. Be sure the wire 8. Connect the transmitter wire (Figure 5-33)
rope is placed between the two pins. and the load pin wire to the jumper wire.
8. Connect the transmitter wire to the load pin
wire.
9. Adjust the boom head angle in the position
required for the lift operation. See page 5-1.
the wire rope is engaged in the sheave
block.
5-12
Model 5560B
Wire Rope Wedge Socket

WARNING
Loads may fall if the wedge socket is
not properly installed. A falling load can
injure or kill.
1. Place the end of the wire rope through the

rope dead end socket (Figure 5-35). Align
the live end of the wire rope with the center
line of the mounting pin hole.
2. Wrap the wire rope around the wedge so at
least a minimum of six rope diameters , but
02
not less then 6 inches (152 mm) is extended
past the socket. Install the wedge into the
socket.
3. Secure the dead end of the wire rope with
3-
the cable clamp as shown in Figure 5-35. a0069
0
Tighten the nuts on the clamp to 95 lb-ft.
(129 Nm). Figure 5-35.
25
IMPORTANT!
DO NOT attach the dead end to the live end or
install the wedge backwards. The installation
12
must look like the illustration in Figure 5-35.

4. Use a soft hammer to seat the wedge and
rope as deep into the socket as possible
before applying the first load. Be careful not
to damage the wire rope.
5. Install the rope dead end socket to the boom
head
6. Apply a load to seat the wedge and wire rope
into the socket. The load should be of equal
or greater weight than loads expected to be
in use.
5-13
Model 5560B
Reeving
Reeving For 4-Part Line NOTE!
It may be easier to place the wire rope over the
Place the wire rope over the top sheave in the sheaves if you remove the hair cotter pins and
boom head and then down and over the lower wire rope retaining pins from the boom head and
left sheave. Thread rope through one of the hoist block. Install pins after the wire rope is
sheaves in the hoist block and then over the installed.
second lower sheave in the boom head.
Connect the loose end of the wire rope to the
Continue by threading the rope through the
ear on the crane side of the boom head with a
second sheave in the hoist block. See Figure
socket and wedge. See instructions on page
5-36.
5-13.
02
Top Sheave In
Boom Head
0 3-
Socket
(Connect to Ear
25
on Boom Head) Boom Sheaves In

Boom Head
12
Sheave In
Hoist block
a0136
Figure 5-36. Wire Rope Reeving
5-14
5500 Series Section 6 - Adjustments
Model 5560B
Section 6
Adjustments
Hydraulic System
Adjustments
TESTING THE RELIEF 2. Disconnect a hose from one of the elbows
installed in the hoist valve section. Cap the
VALVE SETTINGS elbow and plug the hydraulic hose.
PUMP SECTION NO. 1 RELIEF 3. Start the engine and accelerate the speed
VALVE TEST (MAIN WINCH to maximum rpm.
02
CIRCUIT) 4. When testing pump section No. 1, use the
1. With the engine shut off, install a 0-5000 psi main winch control to put the pump circuit
(0 - 34 450 kPa) pressure gauge on the over relief.
pump No. 1 quick-disconnect. See Figures
3- 5. Actuate the winch control lever to the
6-1. position that does not rotate the winch and
0
hold the control in this position.
25
12
Pump No. 1
Quick-Disconnect
Pump No. 2
Quick-Disconnect
Pump No. 3
Quick-Disconnect
Hoist Valve
Swing Valve Section
Boom Valve Telescope
Section Section Valve Section p0706
Figure 6-1. Quick Coupler and Valve Section Locations
6-1
Section 6 - Adjustments 5500 Series
Model 5560B
6. Read the pressure reading on the gauge 3. Start the engine and accelerate the speed
when the relief valve opens. It should be to maximum rpm.
3600 ± 50 psi (24 821 ± 345 kPa).
4. When testing pump section No. 3, use the
7. Release the control lever. main swing control to put the pump circuit
over relief.
8. If pressure reading is correct, shut off the
engine, disconnect the pressure gauge and 5. Actuate the swing control lever to the
connect the hose to the elbow on the valve position that does not rotate the turntable and
section. hold the control in this position.
9. If the pressure reading is not correct, adjust 6. Read the pressure reading on the gauge
the main relief valve. when the relief valve opens. It should be
2400 ± 50 psi (16 547 ± 345 kPa).
PUMP SECTION NO. 2 RELIEF
7. Release the control lever.
VALVE TEST (TELESCOPE AND
LIFT CIRCUITS) 8. If pressure reading is correct, shut off the
engine, disconnect the pressure gauge and
1. With the engine shut off, install a 0-5000 psi
02
connect the hose to the elbow on the valve
(0 - 34 450 kPa) pressure gauge on the section.
pump No. 2 quick-disconnect. See Figure
6-1. 9. If the pressure reading is not correct, adjust
2. Start the engine and accelerate the speed

3- the main relief valve.
to maximum rpm. PUMP SECTION NO. 4 RELIEF

0
3. Fully retract the lift cylinders. Continue to VALVE TEST (STEERING,
25
hold the control in position after the cylinder OUTRIGGER AND PILOT
rod has stopped. CIRCUITS)
12
4. Read the pressure indicated on the pressure Outrigger Circuit Relief Valve
gauge when the relief valve opens. It should
be 3600 ± 50 psi (24 821 ± 345 kPa). 1. To check the outrigger circuit relief pressure,
with the engine shut off, install a 0 - 5000 psi
5. Release the control lever. (0 - 34 450 kPa) pressure gauge to pump
6. If the pressure reading is correct, stop the section No. 4 quick-disconnect shown in
engine and remove the pressure gauge. Figure 6-2.
7. If the pressure reading is incorrect, adjust Pump No. 4

the pressure setting of the main relief valve. Quick-Disconnect

VALVE TEST (SWING CIRCUIT)
1. With the engine shut off, install a 0-5000 psi
(0 - 34 450 kPa) pressure gauge on the
pump No. 3 quick-disconnect. See Figures
6-1. p0708
2. Disconnect a hose from one of the elbows

p0708
Figure 6-2. Quick Coupler Location
installed in the swing valve section. Cap the
elbow and plug the hydraulic hose. Pump Section No. 4.
6-2
Model 5560B
2. Accelerate the engine to maximum rpm. gauge to pump section No. 4 quick-
disconnect shown in Figure 6-2.
3. Fully retract one of the outriggers all the way
in and then hold the outrigger switch in 2. Start the engine and read the pressure
position after the outrigger stops. gauge. The relief valve should open at
250 psi (1724 kPa).
4. Read the pressure indicated on the pressure
gauge when the relief valve opens. It should 3. If the pressure reading is correct, stop the
be 2500 ± 50 psi (17 230 ± 345 kPa). engine and remove the pressure gauge.
5. Release the outrigger switch. 4. If the pressure reading is incorrect, adjust
the pressure setting of the pilot circuit relief
6. If the pressure reading is correct, stop the valve.
engine and remove the pressure gauge.
7. If the pressure reading is incorrect, adjust ADJUSTING RELIEF
the pressure setting of the outrigger relief VALVE PRESSURE
valve.
PUMP SECTIONS NO. 1 (HOIST
Steering Circuit Relief Valve
02
CIRCUIT)
1. To check the steering circuit relief pressure,
1. If the reading on the pressure gauge is
with the engine shut off, install a 0 - 5000 psi
3- higher or lower than 3600 ± 50 psi
(0 - 34 450 kPa) pressure gauge to pump
(24 821 ± 345 kPa), remove the relief valve
section No. 4 quick-disconnect shown in
cartridge and check for foreign material and
Figure 6-2.
0
wear. Check that the relief valve is aligned
2. Start the engine and accelerate the speed with the seat in the inlet section of the valve.
25
to maximum rpm.
2. Again, follow the procedures to check the
3. With the steering selector switch set at relief valve pressure setting. If the reading
12
2-wheel steering, turn the steering wheel in on the pressure gauge is not correct, adjust
one direction until the front wheels will not as follows:
turn any further.
a. Loosen the jam nut on the relief valve
4. Read the pressure indicated on the pressure (Figure 6-3).
gauge when the relief valve opens. It should
be 2500 ± 50 psi (17 230 ± 345 kPa). Relief Valve
5. Release the outrigger switch.

6. If the pressure reading is correct, stop the
engine and remove the pressure gauge.
7. If the pressure reading is incorrect, adjust
the pressure setting of the steering relief
valve.
Pilot Circuit Relief Valve p0709
1. To check the pilot circuit, with the engine shut

off, install a 1000 psi (6895 kPa) pressure
Figure 6-3. Hoist Circuit Relief Valve
6-3
Model 5560B
b. With the pressure gauge installed and f. Check pressure reading again. If
the engine running at full rpm, actuate correct, shut down the engine and
the control lever to bring the valve over remove the pressure gauge. If incorrect,
relief. repeat the adjustment procedure.
c. Turn the adjusting screw to obtain the
correct pressure setting.
d. Release the control lever. Relief Valve
e. Tighten the jam nut against the adjusting

screw.
f. Check pressure reading again. If
correct, shut down the engine and
remove the pressure gauge. If incorrect,
repeat the adjustment procedure.
PUMP SECTIONS NO. 2 p0710
02
(TELESCOPE AND BOOM
CIRCUITS) Figure 6-4. Telescope and Boom
Circuit Relief Valve
1. If the reading on the pressure gauge is
higher or lower than 3600 ± 50 psi
3-
(24 821 ± 345 kPa), remove the relief valve VALVE SETTING (SWING
0
cartridge and check for foreign material and
CIRCUIT)
25
wear. Check that the relief valve is aligned

with the seat in the inlet section of the valve. 1. If the reading on the pressure gauge is
2. Again, follow the procedures to check the higher or lower than 2400 ± 50 psi
12
relief valve pressure setting. If the reading (16 547 ± 345 kPa), remove the relief valve
on the pressure gauge is not correct, adjust cartridge and check for foreign material and
as follows: wear. Check that the relief valve is aligned
with the seat in the inlet section of the valve.
a. Loosen the jam nut on the relief valve
(Figure 6-4). 2. Again, follow the procedures to check the
relief valve pressure setting. If the reading
b. With the pressure gauge installed and on the pressure gauge is not correct, adjust
the engine running at full rpm, actuate as follows:
the control lever to bring the valve over
relief. a. Loosen the jam nut on the relief valve
(Figure 6-5).
c. Turn the adjusting screw (Figure 6-5) to
obtain the correct pressure setting. b. With the pressure gauge installed and
the engine running at full rpm, actuate
d. Release the control lever. the control lever to bring the valve over
relief.
screw. c. Turn the adjusting screw (Figure 6-5) to
obtain the correct pressure setting.
d. Release the control lever.
6-4
Model 5560B

screw.
3. Check pressure reading again. If correct,
shut down the engine and remove the
pressure gauge. If incorrect, repeat the
adjustment procedure.
Relief Valve Location Steering Relief Valve
p0711
Figure 6-6. Steering Circuit Relief Valve
Outrigger Circuit Relief Valve

1. Loosen the jam nut (Figure 6-7).
02
2. With a pressure gauge installed and the
engine running at full rpm, actuate one of
Figure 6-5. Swing Circuit Relief Valve
3- the outrigger switches to retract one of the
outriggers. Hold the switch in position after
the outrigger is retracted all the way.
0
VALVE SETTING (STEERING, 3. Turn the adjusting screw (Figure 6-7) in or
25
out to obtain the correct pressure setting.

OUTRIGGER AND PILOT
CIRCUITS) 4. Release the outrigger switch.
12
Steering Circuit Relief Valve 5. Tighten the jam nut against the relief valve
body.
1. Loosen the jam nut on the steering relief
valve (Figure 6-6) 6. Check the pressure setting again to verify
proper setting.
engine running at full rpm, turn the steering
wheel in one direction to turn the wheels until
they can turn no further. Hold the steering
Jam Nut
wheel in position.
3. On the relief valve, turn the adjusting screw
p0223
Adjusting Screw
in or out to obtain the correct pressure
setting.
4. Release the steering wheel.
5. Tighten the jam nut against the relief valve
body.
p0166
6. Check the pressure setting again to verify
proper setting. Figure 6-7. Outrigger Relief Valve Adjustment
6-5
Model 5560B
Pilot Circuit Relief Valve

1. Loosen the jam nut on the pilot relief valve
(Figure 6-8).
engine running at idle speed, turn the
adjusting screw) in or out to obtain the
correct pressure setting.
3. Tighten the jam nut against the relief valve Pilot Circuit
Relief Valve
body.
4. Check the pressure setting again to verify p0711
proper setting.
Figure 6-8. Pilot Circuit Relief Valve
02
0 3-
25
12
6-6
Model 5560B
Boom Adjustments
BOOM SLIDE PAD 3. Tighten the adjustment screws until the
ADJUSTMENTS adjustment pads make contact with the
boom and the boom is centered. DO NOT
The boom side slide pads on the 1st, 2nd and OVERTIGHTEN. Back out each adjustment
3rd boom sections are adjustable to allow for screw 1 full turn.
wear on the pads.
4. Repeat steps 2 and 3 for the 2nd and 3rd
1. There are side slide pads located on the 1st, boom sections, except for the 3rd boom
2nd and 3rd boom sections (see Figure section jam nuts must be loosened before
6-9). Each slide pad is adjustable by turning the adjusting screws can be turned and then
the adjustment screw for each slide pad. tightened after adjustment is completed.
A. The 1st boom section has four slide 5. After the slide pads are adjusted, retract the
pads; two on each side of the boom. boom sections and visually check that the
booms are centered within each boom
B. The 2nd boom section has four slide
02
section and that there is no binding of the
pads; two on each side of the boom. boom sections. If a boom section is not
C. The 3rd boom section has two slide centered, adjust the slide pads until the
pads; one on each side of the boom. 3- boom is centered. If a boom binds while
retracting, loosen each slide slightly until the
2. Starting with the 1st boom section, position boom slides freely.
0
the boom at the tightest spot on the boom.
Wear marks will identify the tight spot on the
25
boom.
12
Figure 6-9. Adjustment Locations
6-7
Model 5560B
Swing Gear and Pinion

Adjustment
NOTE!
Be sure the swing gear and pinion are aligned High Point
at the high spot of the swing gear. Punch Mark
1. Slightly loosen the four bolts securing the

rotation gearbox (see Figure 6-10).
2. With a spanner wrench, turn the eccentric
ring to move the pinion until it contacts the
swing gear tooth (zero backlash).
Eccentric
3. Tighten the four bolts to the appropriate Ring
Swing Gearbox
torque. Mounting Bolts (4)
02
a0157
4. Install the swing pinion cover.
Figure 6-10. Swing Gear/Pinion Adjustment
0 3-
Parking Brake Adjustment
25
NOTICE! 4. Tighten the lock nut while holding the

12
It is necessary to climb under the crane to adjust adjusting screw with a wrench. Remove the
the parking brake. Be sure engine is shut off, the feeler gauge.
ignition key is removed and chock blocks are in
place before climbing under the crane. 5. Apply the parking brake and shut off the
engine.
1. With the engine running and the parking
brake released, loosen the lock nut (Figure
6-11) and the adjusting screw.
2. Place a 0.012 inch (0.30 mm) feeler gauge
between the brake disc and one of the
linings.
3. Tighten the adjusting screw until it is just
possible to remove the feeler gauge.
a0608
Figure 6-11. Adjusting The Parking Brake
6-8
5500 Series Section 7 - Maintenance
Model 5560B
Section 7
Maintenance
Introduction
NOTICE! SPARK ARRESTING
Do not use gasoline or other flammable fluids to
clean component parts. Fire or explosion may
MUFFLERS
occur causing bodily burns. IMPORTANT!
NOTICE! Codes of some states or provinces may require
Use eye protection when performing service or that this crane be equipped with a SPARK
maintenance tasks. Propelled and/or dropped ARRESTING MUFFLER. The State of
items can cause eye injury. California, as an example, is one state which
has such regulations for agricultural and forestry
02
NOTICE!
If maintenance or adjustments must be performed application, plus a regulation for construction
with the engine running, have a person at the applications in forest covered, brush covered,
controls while another person performs the work 3- or grass covered lands.
to inhibit accidental movement which could cause
injury or death. SAFETY LIST
0
Preventive maintenance is necessary to keep Inspect the following safety equipment daily:
25
the crane in good condition as long as possible.

Adjust the maintenance schedule to your SAFETY BELT - Check for frayed or cut
operation, according to the type of work, size of webbing, damaged buckles or loose mounting
loads, temperature conditions and frequency of hardware.
12
equipment use.
SAFETY DECALS - Check condition of decals.
The intervals in the Maintenance Schedule are Replace if worn, damaged or missing. See
for average operating conditions, and must be Section 2
understood as the MINIMUM maintenance
COVERS - Keep all protective covers in place.
necessary for the machine. Decrease these
intervals if the machine is operated in conditions PARKING BRAKE - Check operation. Have unit
that are below average (for example, in dust, in repaired if required.
high or low temperatures, with heavy loads or
frequent starting and stopping. ENGINE - Check operation. Remove all dirt or
debris, and all flammable materials before
Use the hourmeter and a calendar to make sure running engine.
that all necessary maintenance is done
according to the schedule.
NOTICE!
When performing service on the crane, put a
tag on the key switch or remove the key to
prevent operation of the crane.
7-1
Section 7 - Maintenance 5500 Series
Model 5560B
Lubricants
LUBRICANTS In various paragraphs in this maintenance
section, statements may be found, “use
It is not the policy of Shuttlelift, Inc. to publish (lubricant brand name) or equivalent.” This
lists of approved lubricants or guarantee statement does not constitute an unconditional
lubricant performance. The responsibility for the guarantee of performance of the brand of
quality of rest completely with the distributor or lubricant mentioned. It is intended only as a guide
manufacturer of the lubricant. to the type of lubricant recommended for a given
application.
Maintenance Records
02
Dated records must be kept for inspection of critical components such as, brakes, crane hooks, wire
ropes, hydraulic cylinders and relieve valve pressure settings. These records must be kept where they
can be easily obtained and reviewed.
3-
Special Maintenance
0
25
DELIVERY INSPECTION
Fuel Tank ..................................................................................... Fill with correct fuel. See page 7-11.
12
Engine ..................................................................................... Check oil in crankcase See page 7-11.

On diesel engines remove water
from fuel filters and sediment bowl. See page 7-12.
Cooling system ............................................. Check coolant level. Fill if level is low. See page 7-12.
Hydraulic Tank .......................................................... Check oil level. Fill if level is low. See page 7-13.
Drive Axles .............................................................................. Check axle housing lubricant level and
wheel hub lubricant level. Fill if levels are low. See page 7-27.
Winch Gearbox ........................................................ Check oil level. Fill if level is low. See page 7-28.
Tires ................................................................................... Check for correct air pressure. See 7-14.
Wire rope cable clamps and connections .............. Check for loose or missing parts. See page 7-10.
Anti-Double Blocking System .................. Check that the system is working properly. See page 7-10.
Controls ................................................. Check that all controls are working properly. See page 7-10.
7-2
Model 5560B
AFTER FIRST 50 HOURS OF OPERATION (NEW CRANES)

Engine ....................................................................... Change the engine oil and filter. See page 7-22.
Transmission.......................................................... Change the transmission oil filter. See page 7-29.
Swing Gearbox ..................................................... Check and tighten mounting bolts. See page 7-23.
Hoist Gearbox ....................................................... Check and tighten mounting bolts. See page 7-22.
Swing Gear Pinion and Swing Gear ............................................................ Lubricate. See page 7-21.
Grease Fittings ........................................................ Apply grease to all grease fittings. See page 7-6.
Boom Chains ........................................... Inspect chains for looseness and tighten. See page 7-19.
Boom Slides ................................................................................................ Lubricate. See page 7-16.
Wheel Mounting Nuts .......................................................................... Check Torque. See page 7-18.
CRANES NOT IN REGULAR USE
02
A crane which has been idle for a period of one month or more, but less than six months, it must be
given an inspection by a qualified person. This person should use the daily through monthly inspections.
3-
A crane which has been idle for a period of over 6 months must be given a complete inspection
covering all inspections through one year, by a qualified person.
0
Standby cranes must be inspected using the daily through monthly inspection, by a qualified person.
25
12
7-3
Model 5560B
Preventive Maintenance
MAINTENANCE SCHEDULE AND CHECKLIST
IMPORTANT!
Hour intervals in each maintenance chart show the correct time for service. The hourmeter located in
the operator’s cab indicates the total hours the Carrydeck crane has been running.
IMPORTANT!
In addition to the following scheduled maintenance, perform the scheduled maintenance suggested in
the engine manual furnished with the crane.
IMPORTANT!
When performing maintenance, do the required maintenance interval as well as all previous interval
maintenance. For example, when performing the 250 Hour (Monthly) maintenance interval, perform all
the tasks required for Daily, 50 Hour and 100 Hour maintenance.
*INTERVAL (Whichever Occurs First)
02
SERVICE/CHECK Daily 50 100 250 500 1000 2000 See
Before Hours Hours Hours Hours Hours Hours Page
Inspect The Anti-Double Blocking System

Operation
X
Weekly Two Weeks3- Monthly Three Months Six Months Yearly
7-10
Inspect The Wire Rope X 7-10
0
Inspect Reeving, Clamps and Connections X 7-10
25
Inspect The Lifting Hook X 7-10

Inspect Safety Devices X 7-10
Check Controls Operation X 7-10
12
Check Engine Crankcase Oil Level X 7-11

Check Transmission Oil Level X 7-11
Check Engine Coolant Level X 7-12
Check Fuel Level X 7-11
Check Tire Pressure X 7-14
Drain Water From Engine X 7-12
Fuel Filter
Check Air Cleaner Restriction Indicator X 7-13
Check Hydraulic Oil Level X 7-13
Inspect Wire Rope and Sheaves X 7-15
Apply Grease to All Lubrication Fittings X 7-16
Lubricate the Boom Slides X 7-16
Lubricate the Boom Chains X 7-17
Clean Air Cleaner Duct Cup X 7-15
Lubricate Parking Brake Fitting X 7-16
Inspect The Engine Fan Belts X 7-18
Check Wheel Nut Torque X 7-18
* Maintenance should be performed using either the hourly or calendar dates, whichever occurs first.
7-4
Model 5560B
Maintenance Schedule (Contd)
INTERVAL (Whichever Occurs First)
SERVICE/CHECK Daily 50 100 250 500 1000 2000 See

Before Hours Hours Hours Hours Hours Hours Page
Operation Weekly Two Weeks Monthly Three Months Six Months Yearly
Lubricate the Swing Gear and Pinion X 7-21

Lubricate the Wire Rope X 7-21
Inspect The Boom Chains X 7-19
Inspect All Hydraulic Hoses X 7-20
Replace Engine Crankcase Oil** X 7-22
Replace Engine Oil Filter** X 7-22
Clean Radiator Fins and Core X 7-21
Clean Battery and Connections X 7-20
Torque Critical Bolts X 7-22
Check Axle Wheel Hub Lubricant Level (4) X 7-27
02
Check Axle Housing Lubricant Level (2) X 7-27
Check Winch Gearbox & Brake
Lubricant Level X 7-28
Lubricate the Outrigger Slides
Add Grease to Swing Gearbox
3- X
X
7-26
7-27
Replace Fuel Filter Elements (Diesel) X 7-25
0
Inspect The Parking Brake Pads X 7-25
25
Inspect Tires for Damage X 7-25

Add Rust Inhibitor To Engine Cooling X 7-26
System
Replace The Air Cleaner Element** X 7-25
12
Clean and Adjust Spark Plug Gap X 7-26

(Gasoline Engine)
Check Swing Gear To Pinion Backlash X 7-34
Replace The Transmission Oil and Filter X 7-29
Replace The Axle Wheel Hub Lubricant (4) X 7-31
Replace The Axle Housing Lubricant (2) X 7-30
Replace The Winch Gearbox Lubricant X 7-31
Replace The Hydraulic Oil X 7-32
Replace The Hydraulic Oil Filter X 7-33
Replace L.P.G Inline Filter X 7-33
Replace In-Line Fuel Filters (Gasoline) X 7-35
Replace PVC Valve (Gasoline Engine) X 7-34
Clean PVC Hoses, Tubes and Fittings X 7-34
(Gasoline Engine)
Replace Spark Plugs (Gasoline Engine) X 7-34
Replace The Engine Coolant X 7-36
Inspect the Crane Structure and Booms X 7-36
for Damage
Test the Load Moment Indicator (LMI) X 7-36
- Optional
** Under extremely dusty conditions, the (*) items may require replacement more frequently.
7-5
Model 5560B
LUBRICATION POINTS
Apply grease to the following fitting after the first 20 hours of operation, thereafter every 50 hours of
operation, whichever occurs first. Use a Lithium Base, E.P. No. 2 bearing grease or equivalent. Apply
enough grease to remove the old grease.
Booms and Main Frame

LOCATION QTY
Mast Bearing (See Figure 7-1) 2
Boom Pivot (See Figure 7-2) 2
Retract Chain Rollers - 2nd Boom Section (See Figure 7-3) 2
Retract Chain Rollers - 3rd Boom Section (See Figure 7-4) 2
Boom Head Sheaves and Pivot (See Figure 7-5) 2
Secondary Crowd Assembly (See Figure 7-6) 2
Lift Cylinder Pivots (See Figure 7-7) 2
02
Drive Train
LOCATION QTY
Steering Knuckles - Front Axle (See Figure 7-8) 4
Steering Knuckles - Rear Axle (See Figure 7-9)
Steering Link - Front Axle (See Figure 7-10)
0 3- 4
2
Steering Link - Rear Axle (See Figure 7-11) 2
Steering Cylinder Pivot Ends - Front Axle (See Figures 7-12) 2
25
Steering Cylinder Pivot Ends - Rear Axle (See Figures 7-13) 2

Drive Shaft - Front Axle (See Figure 7-14) 2
Drive Shaft - Rear Axle (See Figure 7-15) 2
12
Rear Axle Pivot (See Figure 7-15A) 2
Optional Equipment and Accessories

LOCATION QTY
Drop Block (See Figure 7-16) 1
Jib Boom Head Sheave (See Figure 7-17) 1
Jib Boom Deflector Sheave (See Figure 7-18) 1
Two Fittings Located On

Inside Surface or Bearing
Ring
p0408 p0407
Figure 7-1. Mast Bearing Lubrication Point Figure 7-2. Boom Pivot Lubrication Points
7-6
Model 5560B
Both Sides
p0435
Both Sides
p0434
Figure 7-6. Secondary Crowd Assembly
Lube Points
Figure 7-3. Retract Chain Roller Lube Points
(2nd Boom Section)
02
Both Sides
0 3- Both Sides
25
12
Both Sides
p0433 p0390
Figure 7-4. Retract Chain Rollers Lube Points Figure 7-7. Lift Cylinder Pivots Lube Points
Location (3rd Boom Section)
Both Sides
p0389 p0417
Figure 7-8. Steering Knuckle Lube Points

Figure 7-5. Boom Head Sheaves
(Front Axle)
and Pivot Lube Points
7-7
Model 5560B
p0221
p0418
Figure 7-9. Steering Knuckle Lube Points
(Rear Axle) Figure 7-12. Steering Cylinder Pivot Ends Lube
Points (Front Axle)
02
Both Sides
0 3-
25
12
p0419
Figure 7-10. Steering Link Lube Points Figure 7-13. Steering Cylinder Pivot Ends Lube
(Front Axle) Points (Rear Axle)
Figure 7-14. Drive Shaft Lube Points

Figure 7-11. Steering Link Lube Points
(Front Axle)
(Rear Axle)
7-8
Model 5560B
p0315
Figure 7-15. Drive Shaft Lube Points Figure 7-17. Jib Head Sheave Lube Point
(Rear Axle)
02
0 3-
25
p0392
12
p0423
Figure 7-18. Jib Boom Deflector Sheave
Figure 7-15A. Rear Axle Pivot Lube Point Lube Point
p0391
Figure 7-16. Drop Block Lube Point
7-9
Model 5560B
SCHEDULED MAINTENANCE
DAILY (WALK-AROUND) INSPECTION
NOTICE! Inspect the terminal ends of the wire rope for
You must read and understand the warnings and damaged parts, loose clamps or wrong
basic safety rules, found in Section 2 of this installation.
manual, before performing any operation or
maintenance procedures.
For additional engine maintenance guidelines, WARNING
see the engine manual furnished with this crane.
Loads may fall if the wedge and socket
is not installed properly or has damage.
INSPECTIONS A falling load can injure or kill.
Inspecting The Anti-Double
Blocking System Do not operate the crane if any of the above are
02
Test the anti-double block system daily before found. Only after correcting the problem should
beginning operation to make sure it is functioning the crane be put back in service.
properly. 3-
Inspecting The Lifting Hook
WARNING
Raise the drop block until it hits the anti-double
blocking bracket under the boom head. An alarm
0
should sound and the raising of the hoist block
25
should stop.
Loads may fall if the lifting hook is
Lower the hoist block and the alarm will stop. damaged or loose. A falling load can
injure or kill.
12
If there is a malfunction in the system, DO NOT

operate the crane. Have the malfunction
corrected. Daily before beginning operation, inspect the
lifting hook for damage; cracks, deformation,
Inspect The Wire Rope loose retaining hardware, etc. If any damage is
Each day before beginning operation, visually found, DO NOT operate the crane until the
inspect the wire rope for damage. Refer to 50 damage is repaired.
Hour Maintenance on page 7-15, for examples
Inspecting All Safety Devices
of damage that can be visually inspected for. If
any damage is found, do not operate the crane. Daily before beginning operation, check all safety
The wire rope must be replaced with a new rope devices for proper operation. Examples of safety
before operation can resume. devices include, backup alarms, horn and
beacon lights.
Inspecting Reeving, Clamps and
Connections If any is found to be malfunctioning, correct the
problem before placing the crane in service.
Each day before beginning operation, inspect
for correct reeving of the boom and drop block. Checking Controls Operation
Each control should be checked for proper
operation after the above inspections have been
competed. Do not place the crane in service if
any control is not functioning properly.
7-10
Model 5560B
COMPONENT/SYSTEM Checking The Engine Crankcase

CHECKS Oil Level
Checking Fuel Level 1. Level the crane, engage the parking brake
and shut off the engine.
Check the fuel supply daily before operation.
Turn the ignition key to the ON position and view 2. Lift the engine compartment cover and
the fuel gauge on the instrument panel. If support in place using the furnished prop
necessary, fill the tank with recommended fuel. rod.
Engine fuel is flammable and can cause a fire 3. Remove the engine oil dipstick and check
and/or explosion. Avoid personal injury or death oil level. Oil should be present within the
by keeping sparks, open flames, and smoking crosshatched mark area on the dipstick.
materials away from the crane and fuel during
refueling or fuel system servicing. Know the 4. If the oil is low, add recommended oil to bring
location of the fire extinguishers on the job site the level up to the crosshatch area of the
and how to use them. dipstick. When full, install the dipstick and
close the engine compartment cover.
WARNING
02
Checking the Transmission Oil
Level
3- IMPORTANT!
When checking the transmission oil level, also
check the indicator (Figure 7-20) on the
0
FIRE HAZARD transmission filter. If the indicator is in the red
Engine fuel is flammable and can area, the filter must be changed. See Changing
25
cause a fire or explosion. Death

The Oil Filter on page 7-29.
Do not put fuel in tank with engine
running.
Keep open flames away.
12
Do not use smoking materials during

w0015
Maintain control of the hose nozzle when filling

the fuel tank. Do not allow fuel to spill. Clean up
spilled fuel immediately. Dispose of clean up
materials properly.
Figure 7-20. Transmission Filter Indicator

w0033
Location
1. Check the oil level when the oil is cold. Level

the crane, engage the parking brake and shut
off the engine.
Do not fill the fuel tank to capacity. Allow room
for fuel expansion.
Tighten the fuel cap securely. If the cap is lost,
replace only with original equipment.
7-11
Model 5560B
2. Open and support the engine cover. Remove 2. Check that the overflow bottle (Figure 7-22)
the dipstick (Figure 7-21) and check the oil is at least half full. If coolant is low, fill the
level. Oil should be visible on the dipstick overflow bottle half way with a 50/50 mixture
between the minimum and maximum marks of glycol antifreeze and water. Do not add
with the oil cold. only water as this could cause rust to form
in the radiator and engine.
3. If oil is low, add recommended oil to bring
the level between the marks. DO NOT 3. If the bottle is empty, BE SURE THE
OVERFILL. Install the dipstick. Close the ENGINE IS COOL (Below 120° F [50° C]),
cover. then slowly loosen the radiator cap to the
first stop. Allow all pressure to release.
Remove the radiator cap and check the fluid
level. Coolant should be visible in the
radiator.
4. If level is low, add a 50/50 mixture of glycol
antifreeze and water, do not add only water
as this could cause rust to form in the
02
radiator and engine.
p0317
IMPORTANT!
For more details on proper radiator checking and
p0397
0 3-
maintenance procedures, refer to the engine
manual furnished with the crane.
Figure 7-21. Transmission Level Dipstick
and Filter
25
Checking Engine Coolant Level

12
WARNING
HOT COOLANT
can scald.
Check and service
cooling system
only when cool.
1100259
w0020
p0437
• Never remove the radiator cap while the
cooling system is hot. Check coolant level only Figure 7-22. Overflow Bottle
when the coolant temperature is below
120° F (50° C). The system is under pressure Drain Water From Engine Fuel
and the coolant can cause severe burns or Filter (Diesel Engine)
eye injury. Wear protective clothing and safety
glasses. Always turn the cap slowly to the first 1. Shut off the engine and engage the parking
stop and allow the pressure to escape before brake.
removing the cap completely.
2. Refer to the engine manual furnished with
1. Level the crane, engage the parking brake the crane and follow the water draining
and shut off the engine. instructions.
7-12
Model 5560B
Checking The Air Cleaner

Checking Hydraulic Oil Level Restriction Indicator
If the hydraulic oil constantly low, check for leaks The air cleaner is equipped with a filter restriction
in the hydraulic system. indicator (Figure 7-24). The air cleaner element
needs cleaning or replacing if the indicator’s
colored piston has popped out and is visible
1. Be sure the boom is fully when the engine is running at high idle.
retracted and lowered
and the outriggers are To check the visual indicator the engine must
retracted and up. be running. The filter restriction indicator is
visible through the rear cab window.
2. Level the crane, engage
the parking brake and Don’t remove the element for inspection. Such
shut off the engine. a check always does more harm to your engine
than the good your inspection can do. Ridges of
dirt on the gasket sealing surface can drop on
the clean filter side when the gasket is released.
02
3. Visually check the oil level on the hydraulic
oil level sight gauge (Figure 7-23). The
hydraulic oil should be visible in the sight
gauge. If low, fill tank with clean
3-
recommended hydraulic oil.
0
25
12
p0409
Figure 7-24. Air Cleaner Restriction Indicator
REMOVING THE ELEMENT

NOTICE!
p0396 Service the air cleaner only with the engine shut
down. Dirt and debris can enter the engine and
Figure 7-23. Hydraulic Oil Sight Gauge cause damage if the engine is operated with the
air cleaner element removed.
1. Remove the housing cover.
2. Remove the wing nut securing the air
cleaner element to the air housing. Remove
the element as gently as possible until you
get it outside of housing. Accidently bumping
it while it is still inside the housing means
7-13
Model 5560B
dropped dirt and dust that may contaminate 2. Direct the air inside the element and then
the clean side of the air cleaner housing, move the nozzle up and down while rotating
before the new or cleaned filter element has the element.
a chance to do its job.
INSTALLING THE ELEMENT
3. Remove the wing nut securing the safety
element to the air housing. Remove the 1. Install the safety element over the stud in
safety element. the housing and slide it all the way in.
4. Clean the inside of the housing carefully. Any 2. Install and tighten the wing nut. Hand tighten
dirt left inside the housing could cause it only. Install the element over the stud in
damage to the engine. Use a clean, water- the housing and slide it all the way in.
dampened cloth to wipe every surface clean. 3. Make sure the gasket is seating evenly. If
Check it visually to make sure it is clean you don’t feel the gasket is seating evenly
before installing a cleaned or new element. for a perfect seal, you won’t have protection.
5. Always clean the gasket sealing surfaces Recheck to see if the sealing surface in the
of the housing. An improper gasket seal is housing is clean, or if the element is the
one of the most common causes of engine right model number. If may be too short for
02
contamination. Make sure that all hardened the housing. Install and tighten the wing nut.
ridges are completely removed, both on the Hand tighten only.
bottom and top of the housing. 4. Install the air cleaner housing cover and the
INSPECTING THE ELEMENT
3- wing nut.
5. Reset the air cleaner restriction indicator by
0
1. Don’t be fooled by the appearance of the
element, it should look dirty. pushing in the reset button (Figure 7-24).
25
2. Check the element for uneven dirt patterns. 6. If a cleaned air cleaner element was
The dirty element is a valuable clue to dust installed, start the engine and run at high idle.
If the air cleaner restriction indicator’s
12
leakage of gasket sealing problems. A dust

trail or pattern on the element clean side is colored piston pops out and is visible again,
a sign that the element was not firmly sealed shut down the engine and replace the air
or that a dust leak exists. Make sure the cleaner element with a new element.
cause of the leak is identified and rectified
before replacing the element. CHECKING TIRE
CLEANING THE ELEMENT
PRESSURE
NOTICE! Check the air pressure in the crane’s four tires.

To prevent personal injury, always wear safety Correct pressure is 120 psi (828 kPa).
glasses when using compressed air. Also, check for broken studs, rim damage, loose
IMPORTANT! nuts, cracks and other tire damage.
Air cleaner elements must be replaced after six
cleanings, every three months or after every 500
hours of operation, whichever occurs first.
1. Clean the filter element with compressed air.
Use compressed air with 30 psi (205 Nm)
maximum pressure at the nozzle.
7-14
Model 5560B
50 Hours of Operation
NOTICE! • It indicates if you are using the most suitable
You must read and understand the warnings and type of rope.
basic safety rules, found in Section 2 of this
manual, before performing any operation or • It makes possible the discovery and correction
maintenance procedures. of faults in equipment or operation that can
cause costly accelerated rope wear.
For additional engine maintenance guidelines,
see the engine manual furnished with this crane. INSPECTION
Inspections should be carried out by a person
CLEAN THE AIR CLEANER who has learned through special training or
DUST CUP practical experience what to look for, and who
knows how to judge the importance of any
Squeeze the dust cup (Figure 7-25) to remove
abnormal conditions they may discover. It is the
any accumulation of dust or debris.
inspector’s responsibility to obtain and follow
02
proper inspection criteria for each application
inspected.
3- If you are not familiar with wire rope inspection,

information on how to inspect wire rope, sheaves
and drums is available from your Shuttlelift
0
dealer. Order Wireco Report No. 107.
25
General Inspection
NOTICE!
Always wear gloves when working with wire
12
rope to inhibit hand injuries.

1. Wire Rope - Inspect for damage, rust or
wear to the wire rope. Keep a record of each
Figure 7-25. Dust Cup inspection. Replace the wire rope if any of
the conditions in Figure 7-26 are present.
WIRE ROPE INSPECTION
2. Sheaves - Inspect sheaves for damage and/
All wire ropes wear out eventually and lose work or wear. The sheave grooves must be
capability throughout their service life. That’s why smooth and a little larger than the wire rope.
period inspections are critical. SAE J959, Lifting Use a sheave gauge to check the size of
Crane, Wire-Rope Strength Factors, requires the sheave groove. Rough edges, narrow
that a thorough inspection be performed and or worn grooves will cause damage to the
recorded on the wire rope not less often than wire rope. Replace any worn or damaged
weekly when the crane is in continuous service. sheaves.
Regular inspection of wire rope and equipment IMPORTANT!

should be performed for three good reasons: As a sheave wears, the groove for the wire rope
becomes smaller. The tracks on the sheave are
• It reveals the rope’s condition and indicates caused by the wire rope. Yet, the wire rope will
the need for replacement. continue to engage these tracks, for example a
chain engages a sprocket. As the wire rope
7-15
Model 5560B
REDUCTION FROM NORMAL EVIDENCE OF HEAT DAMAGE

DIAMETER OF 9/16” (14 MM) OF FROM ANY CAUSE
MORE THAN 1/32” (0.8 MM)
KINKING, CRUSHING, OR
DISTORTION OF ROPE
STRUCTURE
6 BROKEN WIRES IN ANY ONE

LAY OR 3 BROKEN WIRES IN
ONE STRAND IN ANY LAY
WEAR GREATER THAN 1/3 DIAMETER OF

MORE THAN 1 BROKEN WIRE AT A
02
OUTSIDE INDIVIDUAL WIRES
DEAD-END CONNECTION
a0590
3-
Figure 7-26. Wire Rope Inspection Criteria
0
turns and twists on the sheave, the wire rope will
25
move out of the worn track. This will cause 5. Align the boom access holes (Figure 7-27)
increase wear on the wire rope. to gain access to the chain roller bracket
and slide pad at the end of the boom
GREASE FITTINGS
12
telescope cylinder.
Refer to page 7-6 and lubricate all points 6. Apply bronze anti-seize, or equivalent, to the
indicated under the heading “Lubrication Points”. inner boom surface in front of and behind
the slide block. Only use a small amount of
LUBRICATING THE BOOM lubricant for best results. Extend and retract
SLIDES the booms to distribute the lubricant along
the slide path.
1. Lower the boom and then extend it to its
maximum out position. LUBRICATE PARKING
2. Engage the parking brake and shut off the BRAKE
engine.
Apply grease to the fitting on the parking brake.
3. Clean the old lubricant from the booms. See page 7-6 for grease type.
4. Apply bronze anti-seize, or equivalent, to the

boom sliding surfaces (Figure 7-27) on the
boom sections. Only use a small amount of
lubricant for best results.
7-16
Model 5560B
Extend the booms until the slide

pads are accessible through the
access holes in the boom sections.
Apply Lubricant (Bronze Anti-Seize).
Both Sides
APPLY LUBRICANT
(Bronze Anti-Seize)
NOTE: Lubricate on both sides of the booms
02
a0140
3-
Figure 7-27. Boom Slide Lubrication
0
LUBRICATING THE BOOM Apply ample lubricant to each pin, between the
CHAINS inner and outer side plates and between the inner
25
side plates and roller. DO NOT, under any

IMPORTANT! circumstances apply grease lubricant to the
One of the most important, but overlooked chain. Grease will not penetrate to the pin
12
factors causing premature wear of breakage of bearings. Lack of lubricant in the pin bearings is
chains is inadequate lubrication. In addition to usually indicated by squealing or groaning
reducing internal friction, maintaining a film of sounds when the boom is extended or retracted.
lubricant on all chain surfaces will inhibit rust
IMPORTANT!
and corrosion.
Under normal operating conditions, especially
The boom retract chain is lubricated through the in dusty environments, lubricated chains will
access holes in the boom. Align the holes to accumulate a paste-like buildup of grime. This
buildup should never be permitted to accumulate
expose sections of the boom chain. Each sufficiently to seal off the clearances, thereby
section must be lubricated as directed below. restricting the lubricant to the bearing surfaces.
Whenever the buildup is excessive, the buildup
IMPORTANT!
must be removed by cleaning and chain
Use a good grade of spray chain lubricant. If immediately lubricated. DO NOT steam clean
none is available, use preheated oil (60° to or use degreasers; use a suitable solvent.
100° F [50° to 122° C]) to provide a better
penetration of oil to the chain joints.
7-17
Model 5560B

NOTICE!
You must read and understand the warnings and Lengthwise Cracks,
Intersecting Cracks,
basic safety rules, found in Section 2 of this or Belt Damage
manual, before performing any operation or NOT OK.
maintenance procedures. REPLACE BELT
Cracks
see the engine manual furnished with this crane. Across
Width OK
INSPECTING THE FAN
BELTS
Keep the engine and accessory belts properly
tensioned for maximum engine performance and
fuel economy. Proper belt tension minimizes a0019
02
slippage and increases belt life.
Figure 7-28. Ribbed Belt Inspection - General
3-
Any ribbed belt showing signs of wear or that
has material missing should be replaced. When
a belt is replaced, check its tension again after
0
30 minutes of operation. New belts will stretch
with use.
25
c CHECKING WHEEL NUT

12
TORQUE
Check the torque on each wheel nut in
crisscross pattern. Wheel nut torque should be
500 lb-ft. (680 Nm).
w0021
1100264
A belt that is too loose will see excessive vibration

and increased wear. A belt that is too tight
produces wear on the belt and the bearings of
the pulleys it travels around.
Check ribbed belts for intersecting cracks.
Cracks across the belt are acceptable. Cracks
along the length of a ribbed belt are not
acceptable. Ribbed belts with cracks along their
length should be replaced. See Figure 7-28.
7-18
Model 5560B

NOTICE! B. Distortion or spreading of an outside link
You must read and understand the warnings and plate, evidenced by increasing clearance
basic safety rules, found in Section 2 of this between overlapping link plates, or
manual, before performing any operation or between the inner link plates and the
maintenance procedures. roller. This indicates a hidden break in a
For additional engine maintenance guidelines, pin (Figure 7-30).
INSPECTING THE BOOM

CHAINS
1. Place the booms in the fully lowered position.
2. Extend the booms to expose all of the side
02
access holes. Link Plate
Distortion a0159
3. Visually inspect the chains through the
access holes. A light may be needed to see Figure 7-30.
most of the chain. Look for any damage to
the chains.
0 3- C. Looseness between the riveted ends of
a chain pin and the outer link plates. If a
NOTICE! pin is broken, the normal rigid riveting
25
If chain damage is found during the inspection, may loosen, leaving a visible clearance
DO NOT USE THE CRANE. Cease operation around the exposed ends of the pin
and replace the damaged chain before placing (Figure 7-31).
the crane back in service. A damaged chain
12
could break, causing boom to not function

properly. Personal injury or property damage
could result.
4. Damage could be any of the following:
A. A crack or complete break of a link plate,
particularly an outer plate on either side Clearance At
of the chain (Figure 7-29) Riveted Chain Pin
a0160
Cracked Plates
(Fatigue) Figure 7-31.
D. The pin head rivets should be examined

to determine if the V-flats are still in the
correct alignment. Chain with rotated or
displaced heads or abnormal protrusion
(Figure 7-32) should be replaced
a0158 immediately.
Figure 7-29.
7-19
Model 5560B
Turned Pin
a0161
Figure 7-32.
INSPECTING HYDRAULIC
HOSES
w0017
Inspect hydraulic hose assemblies for leaks,
damaged fittings and worn exterior. Do not use
your hands to check for hydraulic leaks. Hydraulic CLEANING BATTERY AND
CABLES
02
oil under pressure can cause serious injury or
possible death. Use a piece of cardboard or other
1. Open the battery compartment cover (Figure
material as a deflector to detect leaks. Replace
7-33).
any problem hose before beginning work. 3-
0
25
12
1100263
p0299
w0019
a0591
p0399
Figure 7-33. Battery Location
7-20
Model 5560B
2. Tighten all battery hardware to keep the LUBRICATING THE SWING

battery securely in place. GEAR AND PINION
3. Disconnect the battery cables.
1. Engage the parking brake and shut off the
4. Sprinkle the batteries with baking soda to engine.
neutralize the acid. Rinse with water. Be
2. Remove the guard covering the swing pinion.
careful not to get water inside the battery.
5. Coat the battery posts with petroleum jelly
and reinstall the battery cables.
6. Close the battery box cover.
CLEANING THE
RADIATOR
NOTICE!
To inhibit personal injury, always wear safety
02
glasses when using compressed air.
Clean the radiator fins by using compressed air
or a water hose to remove all foreign materials. 3-
If these materials are not removed, the engine
1100262 w0022
may over heat due to blocked air through the
0
radiator fins and core. • Rotating gears can cause injury. Keep hands
clear of rotating pinion and gear while the mast
25
LUBRICATE THE WIRE is rotating.

ROPE 3. Using a brush, apply open gear lube to the
12
Apply lubricant to the hoist wire rope to inhibit pinion and swing gear teeth (Figure 7-34).
rust, corrosion and wear.
1. Unwind the wire rope from the hoist drum.
Use A Brush To
Apply Lubricant
2. Be sure the wire rope is clean and dry before To Gear Teeth
applying the lubricant.
3. Apply a good grade spray wire rope lubricant
to the entire length of the wire rope. If a wire
rope lubricant is not available, a light weight
engine oil may be used. Use brush or cloth
to apply the oil.
IMPORTANT!
Be sure the lubricant enters the strands of the
wire rope for proper lubrication. Do not use
grease to lubricate the wire rope.
Figure 7-34. Swing Gear and Pinion Lubrication
7-21
Model 5560B
4. Start the engine and rotate the mast until a 6. Fill the new filter with clean recommended
non-lubricated portion of the swing gear is lubricating oil (Refer to engine operator’s
exposed. Keep hand away from rotating manual furnished with the crane).
pinion and gear.
7. Apply a small amount of clean engine oil to
5. Shut off the engine. the gasket of the new oil filter. Turn the filter
clockwise to tighten it until the gasket makes
6. Using a brush, apply open gear lube to the contact. Then, tighten the filter 1/2 to 3/4 turn
swing gear teeth. to get correct seal.
7. Repeat steps 4, 5 and 6 until the complete 8. Fill the engine crankcase with clean
swing gear is lubricated. recommended lubricating oil.
9. Operate the engine at idle and inspect for
REPLACING THE leaks at the filter and drain plug
CRANKCASE OIL AND
FILTER TORQUING CRITICAL
Change the engine oil more frequently if BOLTS
02
operating under difficult conditions, for example
NOTICE!
in high or low temperatures, dusty surroundings
Maintain correct torque on all bolts. Failure to do
or frequent starting and stopping.
so may result in severe damage to the machine.
3-
NOTICE! HOIST WINCH GEARBOX
If it is necessary to climb under the crane to
change the engine oil and replace the engine oil MOUNTING BOLTS
0
filter, be sure engine is shut off, the ignition key Torque the 3/4” mounting bolts (4) to 280 lb-ft.
25
is removed and chock blocks are in place before (380 Nm). See Figure 7-35.
climbing under the crane.
IMPORTANT!
12
Drain the engine oil only when it is hot and the

contaminants are in suspension.
NOTICE!
Hot oils can cause personal injury.
1. Operate the engine until the water
temperature reaches 140° F (60° C).
2. Shut off the engine
Four Bolts
3. Place a suitable container under the engine
drain plug. Remove the oil drain plug.
4. Clean the area around the engine oil filter
head. Figure 7-35. Hoist Gearbox Mounting Bolts
5. Remove the filter and clean the gasket

surface of the filter head.
IMPORTANT!
The o-ring can stick on the filter head. Make sure
it is removed before installing the new filter.
7-22
Model 5560B
SWING GEARBOX MOUNTING MAST MOUNTING BOLTS

BOLTS Because of the cyclic loading on the mast bolts,
Torque the 3/4” gearbox mounting bolts (4) to it is important that these bolts be checked at
200 lb-ft. (272 Nm). See Figure 7-36. If the bolts regular intervals.
are loose, check gear backlash Make a record of any loose bolts. If any bolt does
not hold to correct torque after the second check,
remove and replace the bolt. A loose bolt
indicates possible failure of the bolt.
The correct torque on each outside bolt (mast
to swing bearing) should be 282 lb-ft. (384 Nm).
The correct torque on each inside bolt (swing
bearing to frame) should be 158 lb-ft. (215 Nm).
Use the torque sequence shown in Figure 7-37
when checking the torque on the bolts.
02
Four Bolts
Figure 7-36. Swing Gearbox Mounting Bolts

0 3-
25
12
THE BEARING TO MAST BOLTS ARE

ACCESSIBLE THROUGH THE ACCESS
HOLE IN THE MAST PLATE.
Figure 7-37. Mast Bolt Torquing Sequence
7-23
Model 5560B
NOTICE! FRONT AXLE MOUNTING

Use only special Grade 8 for replacement of
BOLTS
the mast bolts. Order the bolts from your
Shuttlelift dealer, see you parts manual. Torque the 1” axle mounting bolts (8) to
575 lb-ft. (782 Nm). See Figure 7-38.
IMPORTANT!
If a broken bolt is found, replace the bolt and
also replace the bolt on each side of the broken
bolt.
IMPORTANT!
The proper bolt torque will not be obtained
without the hardened steel washers under the
bolt heads on the outer (mast) bolt circle.
02
p0424
3- Figure 7-38. Front Axle Mounting Bolts

0
25
12
7-24
Model 5560B

NOTICE! REPLACING FUEL FILTER
You must read and understand the warnings and (DIESEL ENGINE)
basic safety rules, found in Section 2 of this
manual, before performing any operation or Refer to the engine operator’s manual furnished
maintenance procedures. with the crane and follow the replacement
procedures.
see the engine manual furnished with this crane. IMPORTANT!
If the filter is not filled with fuel prior to installation,
INSPECT THE TIRES the engine will not start due to air in the fuel
system. The fuel system will have to be bled as
Inspect the tires for any signs of damage, such instructed in the engine operator’s manual
as cracks, large gouges, deterioration, etc. If furnished with the crane.
damage is found, it must be carefully analyzed
to determine if the tire is safe to use. Replace
02
all tires that are unsafe. REPLACING AIR CLEANER
ELEMENT
INSPECT PARKING 3- NOTICE!
BRAKE PADS
Service the air cleaner only with the engine shut
NOTICE! down. Dirt and debris can enter the engine and
0
It is necessary to climb under the crane to check cause damage if the engine is operated with the
the parking brake pads. Be sure engine is shut
25
air cleaner element removed.

off, the ignition key is removed and chock blocks
are in place before climbing under the crane. 1. Remove the housing cover.
12
Inspect the thickness of the brake pads (Figure 2. Remove the wing nut securing the air
7-39). Replace the brake pads if they are cleaner element to the air housing. Remove
0.028 inches (0.71mm) thick or less. the element as gently as possible until you
get it outside of housing. Accidently bumping
Check the surface condition of the brake disc. it while it is still inside the housing means
Replace the disc if badly warped, pitted or out dropped dirt and dust that may contaminate
of tolerance. the clean side of the air cleaner housing,
before the new element has a chance to do
its job.
3. Clean the inside of the housing carefully. Any
dirt left inside the housing could cause
damage to the engine. Use a clean, water-
dampened cloth to wipe every surface clean.
Check it visually to make sure it is clean
before installing a cleaned or new element.
Both Sides
Of Disc
p0329
Figure 7-39. Parking Brake Pads
7-25
Model 5560B
4. Always clean the gasket sealing surfaces ADDING RUST INHIBITOR

of the housing. An improper gasket seal is TO ENGINE COOLING
one of the most common causes of engine
contamination. Make sure that all hardened
SYSTEM
ridges are completely removed, both on the
bottom and top of the housing. WARNING
HOT COOLANT
5. Install the new element over the stud in the
can scald.
housing and slide it all the way in.
Check and service
6. Make sure the gasket is seating evenly. If cooling system
only when cool.
you don’t feel the gasket is seating evenly 1100259
for a perfect seal, you won’t have protection. w0020

Recheck to see if the sealing surface in the
For maximum protection of the engine cooling
housing is clean, or if the element is not the
system, add a corrosive inhibitor to the radiator.
right model number. If may be too short for
When the engine is cold, remove the radiator
the housing.
cap and pour the inhibitor in the radiator
7. Install and tighten the wing nut. Hand tighten reservoir, following manufacturer’s instructions.
02
only.
LUBRICATING THE
8. Install the air cleaner housing cover and the
OUTRIGGER SLIDES
3-
wing nut. Only hand tighten the wing nut.
1. Extend and lower the outriggers.
9. Reset the air cleaner restriction indicator by
0
pushing in the reset button (Figure 7-40). 2. Clean the slide beams, top and bottom, with
a suitable solvent.
25
3. Apply Mobil EP grease, or equivalent, to the

areas shown in Figure 7-41. Do not over
12
lubricate by applying to complete outside of

sliding beam. During extend and retract, the
beams slide only on two surfaces.
APPLY LUBRICANT
ACROSS END OF
SLIDING BEAM
p0411
Figure 7-40. Resetting The Indicator Button.
SPARK PLUG GAP APPLY LUBRICANT

ON SLIDE BLOCKS
(GASOLINE ENGINE)
a0141
Thoroughly clean the spark plugs, including the
threads. Check the electrode gap with a Figure 7-41. Outrigger Lubrication
0.035 inch (0.90 mm) feeler gauge. If not correct,
reset the gap.
7-26
Model 5560B
ADDING GREASE TO THE 1. Clean around the axle housing fill/check plug
SWING GEARBOX (Figures 7-43 and 7-44) and remove the
plug.
NOTICE!
It is necessary to climb under the crane to add
grease to the swing gearbox. Be sure engine is
shut off, the ignition key is removed and chock
blocks are in place before climbing under the
crane.
The grease fitting for adding grease to the swing

gearbox can only be reached from under the
crane. It will be necessary to use a light to see p0331
the fitting.
p0429
02
Figure 7-43. Fill/Check Plug - Front Axle
Housing
0 3-
25
Check Plug
Location
12
Figure 7-42. Swing Gearbox Grease Fitting

engine. Remove the ignition key.
p0430
2. Clean the grease fitting and check plug
(Figure 7-42).
Figure 7-44. Fill/Check Plug - Rear Axle Housing
3. Remove the check plug.
2. Check the lubricant level, which should be
4. Apply Lithium Base, E.P. No. 2 bearing
even with the bottom of the fill/check hole.
grease to the fitting. Fill gear box until grease
exits the check plug hole. Install the check 3. If necessary, add Mobil Fluid 424 to fill the
plug. housings until oil is level with the bottom of
the fill/check hole.
CHECKING THE AXLE
HOUSING LUBRICANT CHECKING THE WHEEL
LEVEL HUB LUBRICANT LEVEL
It is necessary to climb under the crane to check 1. Using the outriggers, raise the tires slightly
the axle housing lubricant.. Be sure engine is off of the ground.
shut off, the ignition key is removed and chock
blocks are in place before climbing under the
crane.
7-27
Model 5560B
2. Place the transmission in neutral and

release the parking brake.
3. Turn one of wheel hubs until the fill/check
plug is horizontal with the ground (Figure
7-45).
p0412
Figure 7-46. Brake Breather
Breather Check Plug

Location
02
p1385
Figure 7-45. Fill/Check Plug -Wheel Hub
4. Clean around the plug and then remove it.

3-
0
even with the bottom the hole.
25
6. If necessary, add Mobil Fluid 424 to fill the

hub to the recommended level. p1250
p0415
Figure 7-47. Fill/Check Plug
12
7. Repeat Steps 1 through 4 for the other wheel

hubs. 7. Check the lubricant level which should be
level with the bottom of the breather hole.
CHECKING WINCH p0413
GEARBOX AND BRAKE

LUBRICANT LEVELS WARNING
1. Lower the boom to its lowest position.
Do not use EP type gear lubes in the
2. Engage the parking brake and shut off the brake section of this winch. EP lubes
engine. may prevent the clutch from locking up,
causing the load to fall and resulting in
3. Clean around the fill/check plug (Figure
property damage, personal injury or
7-46) and then remove the plug.
death.
to the bottom of the fill hole. 8. If necessary, add SAE 20-20W motor oil
through breather hole until oil is level with
5. If necessary, add SAE 90 EP gear lube to fill the hole.
requirements.
9. Install the breather and check plug
6. Clean around the area of the brake breather
(Figure 7-47). Remove the breather.
7-28
Model 5560B

NOTICE! 3. Place a suitable container under the drain
You must read and understand the warnings and plug and remove the drain (Figure 7-47).
basic safety rules, found in Section 2 of this Drain any oil left in the transmission into the
manual, before performing any operation or container. Install the drain plug.
IMPORTANT!
Before removing the strainer, be sure you have
a new strainer gasket. The old strainer gasket
will be damaged during removal of the strainer,
REPLACING THE and if it is installed with the strainer, leakage will
TRANSMISSION OIL AND occur. It is recommended that three gaskets be
FILTER kept in supply at all times. This will cover a years
maintenance and one for emergency
NOTICE! maintenance.
It is necessary to climb under the crane to drain
02
the transmission oil. Be sure engine is shut off, 4. Clean the strainer in a suitable solvent.
the ignition key is removed and chock blocks
are in place before climbing under the crane. 5. Install the cleaned strainer and new gasket.

3- Tighten the strainer mounting bolts to a
torque of 7.4 lb-ft. (10 Nm).
engine. Remove the ignition key.
0
6. Remove the transmission oil filter by
2. Place the container capable of holding 4 unscrewing it from the filer head (Figure
25
gallons under the strainer (Figure 7-48). 7-49). Properly discard the filter element.
Remove the strainer and gasket and drain
the oil into the container. Discard the gasket.
12
Strainer
Drain
Plug
p0425
p0428 Figure 7-49. Transmission Filter

Figure 7-48. Transmission Drain Plug and
Strainer
NOTICE!
When the strainer is removed, oil will gush out.
Keep to one side when you remove the strainer.
7-29
Model 5560B
6. Coat the seal of the new filter with clean

transmission oil, or equivalent.
Fill Plug
7. Screw on the transmission filter until it
touches the filter head. Then, turn the filter
another 3/4 of a turn to seat the seal.
8. Fill the transmission with Mobil ATF 210, or Drain Plug
equivalent, transmission fluid to full mark on
the dipstick (approximately 4 gallons
[15.1 liters]).
9. Start the engine and let it run at idle speed
p0430
for approximately five minutes. This allows
the oil to fill the transmission filter, torque
Figure 7-51. Axle Housing Drain and Fill Plugs
converter and hoses.
(Rear Axle)
10. Stop the engine, wait approximately one 3. Clean the front axle breather (Figure 7-52)
minute and then check oil level. If low, add with a suitable solvent. If the breather is
02
oil to the full mark on the transmission. DO removed, be sure that the hole in the breather
NOT OVERFILL. tube is facing toward the axle hub (toward
the right).
REPLACING THE AXLE 3-
HOUSING LUBRICANT
0
NOTICE!
It is necessary to climb under the crane to drain
25
the axle housing oil. Be sure engine is shut off,

are in place before climbing under the crane.
12
1. Clean around the fill plug in the axle housing

(Figures 7-50 and 7-51). Remove the plug.
2. Place a container under the axle housing
drain plug (Figures 7-50 and 7-51). Remove
p0431
the drain plug and drain the fluid into the
container. Install the drain plug.
Figure 7-52. Axle Housing Breather
(Front Axle)
Fill Plug 4. Fill the axle housing with recommended

lubricant through the fill plug hole. Fill until
the oil reaches the bottom of the fill hole.
Drain Plug 5. Install the fill plug.
p0429
Figure 7-50. Axle Housing Drain and Fill Plugs
(Front Axle)
7-30
Model 5560B
REPLACING AXLE WHEEL 5. Turn the wheel hub until the drain hole is
HUB LUBRICANT horizontal (Figure 7-54).
6. Fill the wheel hub with the recommended
lubricant through the fill hole until the oil
reaches the bottom of the hole.
7. Install the plug.
8. Repeat the above procedure for the other
three wheel hubs.
REPLACING THE WINCH

GEARBOX AND BRAKE
LUBRICANT
p0416 Winch Gearbox
1. Lower the boom to lowest position, engage
02
Figure 7-53. Drain Plug Location the parking brake. Leave the engine running.
2. Rotate the drum until the drain plug is visible
1. Using the outriggers, raise the tires slightly in the hole in the side of the mounting bracket.
off of the ground. 3-
2. Place the transmission in neutral and
0
release the parking brake. Breather
25
3. Turn one of the front axle wheel hubs until Fill/Check

the drain plug is located at the bottom of the Plug
wheel hub (Figure 7-54). Drain Plug
12
4. Clean around the drain plug and then

remove it. Drain the wheel hub oil into a
suitable container.
Install 1”
Pipe Nipple
Here
Figure 7-55. Plug Locations
3. Clean around the gearbox breather and the

fill/check plug hole. Remove the gearbox
breather (Figure 7-55) and clean it in a
suitable solvent. After it is cleaned, install the
breather.
4. Clean around the fill/check plug (Figure
7-54) and remove the plug.
5. Place a suitable container under the drain
p0415
plug.
Figure 7-54. Fill Position
7-31
Model 5560B
6. Screw a 1 inch pipe nipple into the hole in NOTICE!

the mounting bracket (Figure 7-55). Using a It is necessary to climb under the crane to drain
ratchet wrench with an extension and a 3/8” the hydraulic oil. Be sure engine is shut off, the
hex wrench attached, remove the drain plug ignition key is removed and chock blocks are in
through the pipe nipple. Allow the fluid to place before climbing under the crane.
drain into the container. Examine the oil for
4. Level the crane, engage the parking brake,
signs of significant metal particles. If any
shut off the engine and remove the ignition
particles are found, the gearbox may require
key.
disassembly and repair.
5. Place a suitable container under the
7. Install the drain plug and remove the nipple.
hydraulic tank drain ports (Figure 7-56).
8. Fill the gearbox through the fill hole until the
fluid is even with the bottom of the fill hole.
Fill with SAE 90 EP gear lube.
9. Install the fill/check plug.
02
REPLACING THE
HYDRAULIC OIL
IMPORTANT!
ISO (International Standards Organization)
3-
#46/68 Hydraulic Oil (Mobil Fluid #424) is
0
recommend for year-round use in the hydraulic p0426
25
system.
Figure 7-56. Hydraulic Tank Drain Ports.
In very cold temperatures, SAE 5W or SAE
5W-20 oils can be used if the viscosity of the oil
12
will not be less than 60 SUS (Saybolt Universal

Seconds) at maximum operating temperature.
It may be necessary to use a pre-heater and a
longer than normal warming period at low
operating speed to heat the oil to operating
temperature. p0413
To change the hydraulic oil:

1. Fully retract and lower the booms.
2. Retract all outriggers.
3. Operate the hydraulic system until the p0427
hydraulic oil is warm.
Figure 7-57. Tank Hoses and Suction Strainer
7-32
Model 5560B
6. When the tank is empty, disconnect the two NOTICE!

hydraulic lines from the rear of the hydraulic It is necessary to climb under the crane to
oil tank (Figure 7-57). Remove the suction replace the hydraulic oil filter. Be sure engine is
strainer from the suction port and clean it in shut off, the ignition key is removed and chock
a suitable solvent. blocks are in place before climbing under the
crane.
7. Clean the inside of the hydraulic tank and
remove any sediment. 2. Locate the hydraulic oil filter under the
machine (Figure 7-58).
8. Install the fill strainer, suction strainer,
suction hose and return line to the hydraulic 3. Remove the filter:
tank. A. Using a filter wrench, turn the filter
9. Replace the hydraulic oil filter. See counterclockwise to loosen and remove
“Replacing The Hydraulic Oil Filter.” the filter. Properly discard the removed
filter.
10. Fill the hydraulic tank with Mobil Fluid 424
hydraulic oil to the level sight glass. B. Clean the mounting surface on the filter
head for the filter.
02
11. After the tank is filled, start the engine and
operate each function until all the cylinders 4. Install the filter:
and lines are filled. A. Apply a small amount of clean hydraulic
12. Fully retract and lower the boom and retract
the outriggers. Check the hydraulic oil level.
3- oil to the gasket of the new hydraulic filter.
Install the filter. Install the filter to the filter
Oil must be to the level sight glass. Add head by turning it clockwise until the filter
0
hydraulic oil if necessary. gasket makes contact. Then, tighten the
25
filter 1/2 to 3/4 turn to achieve a tight seal.

13. Visually check for leaks.
B. Start the engine and check for leaks
REPLACING THE around the filter.
12
HYDRAULIC OIL FILTER REPLACE L.P.G. INLINE

FILTER
WARNING
Before disconnecting any L.P.G lines and
fittings, be sure the gas supply is shut
off at the tank. L.P.G. gas is explosive
and can cause serious personal injury
or death.
WARNING
p0432
Figure 7-58. Hydraulic Filter

Keep flames from the surrounding area
1. Engage the parking brake and shut off the when disconnecting L.P.G. lines. L.P.G.
engine. gas is explosive and can cause serious
personal injury or death.
7-33
Model 5560B
Shut off the L.P.G. supply at the tank and slowly

loosen the hose at the bottom of inline swivel HIGH POINT
until all gas has escaped. Then, disconnect the PUNCH
MARKS
hose and remove the inline filter. Install a new
filter and attach the hose. Open the L.P.G. supply
and check for leaks, using a soap and water
solution. Bubbles will appear if leaks are
present. Do not operate the crane with gas leaks.
Tighten any loose connections.
CHECKING SWING
GEAR/PINION BACKLASH
1. Remove the cover to expose the swing
pinion and ring gear.
7-59. Swing Gear Backlash Check
02
CLEANING THE PVC
VALVE (GASOLINE
ENGINE)
3-
Remove the PVC valve from the engine and
0
clean in a suitable solvent. If the valve does not
rattle after cleaning, replace the valve.
25
1100262
w0032
CLEANING THE PVC
• Rotating gears can cause injury. Keep hand TUBING AND FITTINGS
12
clear of rotating pinion and gear while the (GASOLINE ENGINE)

mast is rotating.. Start the engine and
Clean all tubes and fitting connecting to the PVC
rotate the mast until the high point on the
valve in a suitable solvent.
swing gear is in alignment with the pinion.
The high point is punch-marked on the mast
plate (Figure 7-59). REPLACING THE SPARK
PLUGS (GASOLINE
2. Using a feeler gauge, check the backlash
between the gear and pinion. There should
ENGINE)
be no clearance between the swing gear Disconnect one spark plug wire at a time and
tooth and the pinion tooth. If there is any then replace the old spark plug with a new plug.
clearance, adjust the backlash. See Section Correct spark plug as AC R42LTS spark plug.
6, Adjustments. The spark plug gap should be 0.035 inches
(0.90 mm). Connect the spark plug wire and then
remove the next wire.
7-34
Model 5560B
REPLACING THE IN-LINE Replacing the Fine Fuel Filter

FUEL FILTERS (GASOLINE
1. Remove the tiewrap securing the fine fuel
ENGINE) filter (Figure 7-61) in place.
The fuel system for the gasoline engine has a 2. Remove the clamps securing the fuel lines
course fuel filter and a fine fuel filter installed in to the fine filter. Disconnect the fuel lines and
the circuit. The course filter is installed before remove the fuel filter.
the fuel pump and fine filter is installed before
the fuel injectors. 3. Connect the fuel lines to the filter and secure
with clamps.
Replacing the Course Fuel Filter
4. Using a tiewrap, secure the fuel filter in
NOTICE! place.
It is necessary to climb under the crane to
change the fuel filter Be sure engine is shut off,
are in place before climbing under the crane.
02
engine.
2. Disconnect the two clamps and remove the
course filter (Figure 7-60).
3-
3. Install a new filter between the hoses and
0
secure it in place with the two clamps.
25
p0705
Figure 7-61. Fine Fuel Filter

12
p0704
Figure 7-60. Course Fuel Filter
7-35
Model 5560B

NOTICE! 2. Inspect for cracked or broken welds. Do not
You must read and understand the warnings and operate the crane if a critical weld is cracked
basic safety rules, found in Section 2 of this or broken until the weld is repaired. Contact
manual, before performing any operation or your Shuttlelift distributor.
3. Inspect for missing or unreadable warning
For additional engine maintenance guidelines, decals. Replace if necessary.
4. Inspect for excessive rust or corrosion on
REPLACING THE ENGINE crane structure and booms. Paint any areas
COOLANT with excessive rust or corrosion.
5. Inspect for missing items. Replace if
necessary.
WARNING
6. Inspect the crane for any damage that might
02
HOT COOLANT inhibit safe operation of the crane. Repair
can scald. any damage.
Check and service 3-
cooling system TESTING THE LOAD
only when cool. MOMENT INDICATOR
0
(OPTIONAL)
1100259
w0020
25
1. Open and prop in place the engine Refer to the Load Moment Indicator manual
compartment cover. furnished with this crane and test the indicator
according to instructions in the manual.
12
2. BE SURE THE ENGINE IS COOL and

follow the cooling system draining and filling
procedures in the Engine Operation and
Maintenance Manual furnished with the
crane.
3. After the coolant is replaced, close the
engine compartment cover.
INSPECT THE CRANE

STRUCTURE AND BOOMS
FOR DAMAGE
Thoroughly inspect the crane structure and
booms for the following:
1. Inspect for loose mounting hardware.
Tighten any loose hardware.
7-36
Model 5560B
Miscellaneous Maintenance
When the voltmeter on the instrument panel
BATTERIES/CHARGING
indicates a low battery charge, attach a battery
SYSTEM charger and increase the battery charge.
NOTICE! Charging the Battery
Lead -acid batteries produce flammable and
Under normal conditions, the engine’s alternator
explosive gases. To avoid personal injury, when
will have no problem keeping a charge on the
checking, testing or charging batteries:
batteries. The only condition in which the
• DO NOT use smoking materials near battery(s) may cause a problem is when they
batteries. have been completely discharged for a long
period of time. Under this condition the alternator
• Keep arcs, sparks and flames away from may not be able to recharge the battery(s) and
batteries. a battery charger will be required for charging
• Provide ventilation and wear safety glasses. the battery(s).
02
• Never check battery charge by placing a metal Before using a battery charger, an attempt can
object across the posts. The sparks could be made to recharge the battery using the
engine alternator by first jump starting the crane
explode battery gases and cause injury or
death. Use a voltmeter or hydrometer.
0 3- (See Jump Starting, in Section 3) and letting the
engine run.
DO NOT charge a frozen battery; it may explode
25
and cause injury. Let the battery warm up before

attaching a charger.
Charging rates between 3 to 50 amperes are
12
satisfactory if no excessive gassing or spewing

1100263 of electrolyte occurs or the battery does not feel
w0019 excessively warm (over 125° F [52° C]). If
spewing or gasing occurs or temperatures
Checking The Charging System exceed 125° F (52° C), the charging rate must
Check the voltmeter reading on the instrument be reduced or temporarily stopped to permit
panel. Normal voltmeter readers are as follows: cooling.
Replacing The Battery
Normal Operating Ranges
NOTICE!
Engine above idle - 14 to 16 volts The fluid in electric storage batteries contains
Engine stopped - 10 to 14 volts sulfuric acid, which is POISON and can cause
SEVERE CHEMICAL BURNS. Avoid all
A reading of less than 10 volts with the contact of fluid with eyes, skin or clothing. Use
engine at low indicates a low battery charge. proper protective gear when handling batteries.
DO NOT tip any battery beyond a 45° angle in
A reading of less than 14 volts with the
any direction. If fluid contact does occur, follow
engine speed above low idle indicates a
the First Aid suggestions below.
problem in the charging system. The system
should be checked out by an qualified
service technician.
7-37
Model 5560B
Keep fuel in an outside location. Use a shelter

BATTERY ELECTROLYTE FIRST AID
to keep the fuel as cool as possible. The water
• External Contact - Flush with water. from condensation must be removed at regular
• Eyes - Flush with water for at least 15 intervals from the storage tank.
minutes and get immediate medical FUSE REPLACEMENT
attention.
• Internal - Drink large quantities of Ten fuses are located on a fuse block behind
water. Follow with Milk of Magnesia, the instrument panel. To access the fuses,
beaten egg or vegetable oil. Get remove the outside cover (Figure 7- 62) from
immediate medical attention. the front of the cab.
The table on page 7-39 gives the fuse location,
IMPORTANT! rating and circuit number.
In case of internal contact, DO NOT give
fluids that would induce vomiting.
Remove the battery very carefully to avoid
spillage of battery fluid. Properly dispose of the
battery.
02
FUEL SYSTEM
3-
WARNING
0
25
12
Figure 7-62. Fuse Cover Location
FIRE HAZARD
Engine fuel is flammable and can
cause a fire or explosion. Death
Do not put fuel in tank with engine
running.
Keep open flames away.
Do not use smoking materials during
w0015
Fuel Storage
Storage of fuel for an extended period causes
accumulation of sediment, dirt, water and other
foreign materials in the fuel. Many engine
problems are caused by dirty fuel and long
storage periods.
7-38
Model 5560B
Table 7-1. Fuse Chart
F G J A B C
D E H
02
FUSE
A
RATING
15 amp
3-
FUNCTION CIRCUIT
Heater/defroster, strobe light, gauges
B 15 amp Windshield wiper
0
C 15 amp Horn, parking brake
D 15 amp Outrigger control, winch control
25
E 15 amp Brake lights, fuel shut-off (diesel

engine) or spark ignition coil
(gasoline engine), alternator
12
F 20 amp Anti-double blocking

G 20 amp Warning lights, turn signal lights and
flasher
H 15 amp Backup alarm, transmission
I 20 amp Steering Circuit
J 20 amp Head and tail lights, dash lights,
boom lights
7-39
Model 5560B

Left Blank
02
0 3-
25
12
7-40
5500 Series Section 8 - Specifications
Model 5560B
Section 8
Specifications
Lubricants And Capacities
IMPORTANT!
The following list of lubricants does not constitute an unconditional guarantee of the performance of the
lubricant mentioned. It is intended solely as a guide to the type of lubricant recommended for a given
application.
COMPONENT CAPACITY LUBRICANT/FLUID
Engine Crankcase - Gasoline Engine
02
Without Filter Change 4.5 qts. (4.3 liters) See Page 8-3
With Filter Change 5.5 qts. (5.2 liters)
Engine Crankcase - Diesel Engine

Without Filter Change
With Oil Filter Change
3-
10.0 qts. (9.5 liters)
11.5 qts. (10.9 liters)
0
See Page 8-2
Fuel Tank 40 gal. (151.4 liters) See Page 8-3

25
Cooling System 23 qts. (21.9 liters) 50/50 Mixture of Glycol Antifreeze & Water
Hydraulic Tank 40 gal. (151.4 liters) Mobil Fluid 424 or equivalent (ISO 46/68)
12
Very Cold Temperatures: SAE 5W or SAE

5W-20 oil if the viscosity will not be less
than 60 SUS at maximum operating
temperature.
Transmission 4 gal. (15.1 liters) Mobil ATF 210 or equivalent
Front Axle Housing 6.1 gal. (23.0 liters) Mobil Fluid 424 or equivalent (ISO 46/68)
Front Axle Wheel Hubs (2) 1.65 qts. (1.5 liters) Mobil Fluid 424 or equivalent (ISO 46/68)
Rear Axle Housing 4.8 gal. (18.0 liters) Mobil Fluid 424 or equivalent (ISO 46/68)
Rear Axle Wheel Hubs (2) 1.9 qts. (1.7 liters Mobil Fluid 424 or equivalent (ISO 46/68)
Swing Gearbox As Required Multipurpose EP Lithium Base grease or

equivalent
Hoist Winch Gearbox 1-1/2 - 2 qts. SAE 90 EP gear lubricant or equivalent

(1.4 - 1.9 liters)
Hoist Winch Brake 1/2 - 1 pt. SAE 20-20 motor oil

(.2 - .5 ) liters
Swing Gear Pinion As Required Open gear lube
8-1
Section 8 - Specifications 5500 Series
Model 5560B
ENGINE OIL VISCOSITY GRADES

SPECIFICATIONS Arctic Operation
Diesel Engine: IMPORTANT!
SAE 5W viscosity grade synthetic oil may be
Oil Performance Recommendations used when operating the engine in ambient
temperatures below -10° F (-23° C) provided
CC/SF for use in naturally aspirated engines and
they meet the minimum viscosity at 212° F
in engines that operate in light duty service (100° C).
including standby and emergency operation
(equivalent to MIL-L-2104B). When there is no provision to keep the engine
warm when operating in ambient temperatures
Sulfated Ash Limit of 1.85% by weight is consistently below -10° F (-23° C), use a
recommended. Oils with higher ash count may lubricating oil that meets the following
produce deposits on valves that can progress requirements:
to guttering and valve burning.
Do not use “break-in” lubricating oils in new or Parameter
(Test Method) Specification
rebuilt engines. Use lubricating oils specified for
02
normal engine operation. Performance API Classification CC
- Naturally Aspirated
Oil Viscosity Recommendations API Classification CC/
3- CD - Turbocharged
The use of a multigrade lubricating oil improves
oil consumption control and improves engine Viscosity 10,000 mPa°s
Maximum at -31° F
0
cranking in cold temperatures while maintaining
(-35° C) 0.16 inch
lubrication at high operating temperatures. A (4.1 mm) Squared
25
multigrade oil is therefore recommended with Minimum at 212° F

the viscosity grades shown in the following chart. (100° C)
The use of single grade lubricating oils is not
Pour Point (ASTM D-97) Maximum of 41° F
12
recommended, except for synthetic oils used in

(5° C) Below the
Arctic conditions. Lowest Expected
Ambient Temperature
Sulfated Ash Content Maximum of 1.85% by
weight (ASTM D-874)
Figure 8-1. Diesel Engine Oils
8-2
Model 5560B
Gasoline Engine: Recommended SAE Viscosity Grades.

The lubricating oil recommendation is based 5W20 +20° to -25° F
upon engine design, type of service and the 10W30 +104° to -15° F
atmospheric temperature prevailing. High quality 15W40 +122° to +14° F
oils are required to ensure maximum 20W40 +122° to +25° F
performance, long engine life, and minimum
cost of operation. 10W +40° to -25° F
20W +75° to +32° F
The recommended oil to be used in the GMC 30W +104° to +45° F
4.3L V-6 Gasoline Engine must have the following 40W +122° to +60° F
classifications.
API, SAE ASTM Classification

SG/CD, SF/CC
Do not use SD or SC API classification oils.
These oils do not provide adequate protection
02
against oil oxidation, high temperature oil
deposits, rust and corrosion.
Fuel Types 3-
0
DIESEL FUEL IMPORTANT!
The use of gasoline with a lower octane than 87
25
The Cummins Diesel Engine operates most AKI (91 RON) octane will result in serious
efficiently with No. 2 diesel fuel in temperatures damage to the engine. Engine damage resulting
above 32° F (0° C). When operating in from use of a low octane gasoline is considered
12
temperatures below 32° F (0° C), use No. 1 misuse of the engine and will void the engine
diesel fuel, or a blend of No. 1 and No. 2 diesel warranty and the Shuttlelift warranty.
fuels, most commonly known as “Winterized”
No. 2 diesel. Use ASTM No. 2 diesel fuel with a Many types of gasoline being sold today contain
minimum Cetane number of 40. No. 2 diesel alcohol. Two commonly used alcohol additives
fuel gives the best economy and performance are Ethanol and Methanol.
under most operating conditions. Fuels with
The GMC gasoline engine may be operated
Cetane numbers higher than 40 may be needed
using gasoline blended with no more than 10%
in high altitudes or extremely low ambient
Ethanol meeting the minimum octane
temperatures to prevent misfires and excessive
specifications. DO NOT use any gasoline which
smoke.
contains METHANOL.
GASOLINE
The GMC gasoline engine operates only on lead-
free gasoline with the following minimum or
higher octane ratings:
Anti-Knock Index Number (AKI) — 87
Research Octane Number (RON) — 91
8-3
Model 5560B
Relief Valve Settings

RELIEF VALVE PRESSURE SETTING
Hoist Circuit 3600 ± 50 psi (24 821 ± 345 kPa)
Telescope and Boom Circuits 3600 ± 50 psi (24 821 ± 345 kPa)
Swing Circuit 2400 ± 50 psi (16 547 ± 345 kPa)
Outrigger Circuit 2500 ± 50 psi (17 225 ± 345 kPa)
Pilot Control Circuits 250 ± 5 psi (1724 ± 34 kPa)
Steering Circuit 2500 ± 50 psi (17 225 ± 345 kPa)
02
Telescope Port Relief Valve (In Only) 1800 ± 50 psi (12 402 ± 345 kPa)
3-
General Specifications
0
25
ENGINE
Diesel:
Make and model ..................................................................... Cummins 4B3.9-C110 diesel
12
Type of Aspiration ................................................................... Turbocharged

Horsepower ............................................................................ 110 hp @ 2500 rpm
Low idle speed ........................................................................ 800 rpm
Maximum engine speed .......................................................... 2500 rpm
Gasoline/L.P.G.:
Make and model ..................................................................... GMC 4.3 L gasoline
Horsepower ............................................................................ 110 hp @ 2500 rpm
Low idle speed ........................................................................ 700 rpm
Maximum engine speed .......................................................... 2500 rpm
TIRES
Size .............................................................................................. 385/65R22.5
Type .............................................................................................. Radial
Air pressure .................................................................................. 120 psi (828 kPa)
Wheel nut torque ........................................................................... 500 lb-ft. (680 Nm)
ELECTRICAL SYSTEM
Rating ........................................................................................... 12 VDC negative ground
Number and type of batteries:
Standard: ................................................................................ One - maintenance free
With optional cold weather start .............................................. Two
Battery rating ................................................................................ 90 amp/hr
Alternator ...................................................................................... 63 amps
8-4
Model 5560B
General Specifications (Contd)
BOOM
Reach (from center line of rotation) ................................................ 15 ft. - 51 ft. (4.57 m - 15.54 m)
Type of boom ................................................................................ Telescopic, 4 section
Boom Extension (optional ............................................................. 15 ft. (4.57 m)
WIRE ROPE
Size .............................................................................................. 1/2" (12.7 mm) 6 x 19 Bright EIPS-IWRC
Length ........................................................................................... 300 ft. (91.44 m)
HYDRAULIC SYSTEM
Filters ........................................................................................... 10 micron return line filter
30 mesh suction filter in tank
WEIGHT
Crane ............................................................................................ 30,000 lb. (13 608 kg)
TRAVEL SPEEDS
Two-wheel steer
02
1st gear .................................................................................. 4 mph (6.4 km/hr)
2nd gear ................................................................................. 7 mph (11.3 km/hr)
3rd gear .................................................................................. 13 mph (21 km/hr)
4th gear .................................................................................. 21 mph (34 km/hr)
OPERATING DIMENSIONS
3-
Two-wheel steer:
0
Outside turning radius (center line outside tires) ..................... 21' 6 " (6.55 m)
Minimum aisle space for 90° turn
25
(center line inside tires) ......................................................... 12' 10" (3.91 m)

Four-wheel steer:
Outside turning radius (center line outside tires) ..................... 12' 4" (3.76 m)
12
Minimum aisle space for 90° turn ............................................ 6' 0" (1.83 m)
Boom angle:
Maximum ............................................................................... 80°
Minimum ................................................................................. 0°
8-5
Model 5560B
Dimensions
02
0 3-
25
12
Figure 8-2. Crane Dimensions
8-6
Model 5560B
02
0 3-
25
12
8-7
Model 5560B
02
0 3-
25
12
8-8
Model 5560B
02
0 3-
25
12
8-9
BLANK
12
25
03-
02
January 1, 2003
NEW MACHINE WARRANTY

— CARRYDECK CRANE —
1. Shuttlelift, Inc. warrants that it will repair or replace, with new or remanufactured parts, without charge F.O.B. its
Factory, any material in its equipment which, within twelve (12) months or 2,000 hours, whichever occurs first,
after the date of delivery to the original retail purchaser is proven to the satisfaction of Shuttlelift, Inc., to have
been defective at the time it was sold, provided that, if so requested, all parts claimed defective shall be returned,
properly identified, to the Company’s factory, charges prepaid. THIS WARRANTY IS LIMITED TO REPAIR OR
REPLACEMENT OF THE PART OR PARTS NOT COVERED BY ANOTHER MANUFACTURER’S WARRANTY.
See paragraph 4 below.
1a. Shuttlelift, Inc. further warrants that it will repair or replace, with new or re-manufactured parts, without
charge F.O.B. its factory, any structural steel member within sixty (60) months or 4000 hours (whichever occurs
first) after the date of delivery to its original purchaser, that has been proven to the satisfaction of Shuttlelift, Inc. to
have failed because of defect.
Structural steel members include: main frame, outriggers, mast and boom sections as noted in the machine parts
manual.
The structural steel extended warranty does not include items of failure caused by unit overload conditions or by
02
rust, corrosion, neglect, abuse or any part that may have been altered or repaired in any manner not authorized
by seller.
Attaching parts will be covered under paragraph 1.
2.
3-
Shuttlelift, Inc., makes no warranties either express or implied except as herein provided. No warranty other than
title and description has been made or exists either expressly or by implication, all other statutory and implied
0
warranties, including warranties as to merchantability, being hereby expressly waived and excluded from this
transaction, and the Company’s liability in connection with this transaction is expressly limited to the repair or
replacement of defective parts. All other damages direct or consequential, arising under statute, through
25
negligence or otherwise, being hereby expressly denied.
3. This warranty applies only to new and unused equipment which after shipment from the Factory of the Company,
has not been altered, changed, repaired, or damaged by improper use, accident, other casualty or negligence or
12
by operation beyond rated capacity. No warranty of any kind, statutory, implied, or otherwise, relating to
merchantability, fitness or other qualities shall apply to trade accessories, attachments, tools, or implements not
manufactured by Shuttlelift, Inc., or to second-hand equipment, or to new and unused equipment, which, after
shipment from the Factory, has been altered, changed, repaired, or treated in any manner whatsoever, and no
attempt to repair, or promise to repair, or improve the equipment covered by this contract by any representative of
Shuttlelift, Inc., shall waive any consideration of the contract or change or extend this warranty in any manner
whatsoever.
4. Items covered by the standard warranty of another manufacturer are excluded from Shuttlelift, Inc.’s, warranty;
such items are tires, batteries, electrical, engine and accessories. Also excluded from the Shuttlelift, Inc. warranty
is normal maintenance service, repair and replacement of filters, belts, or parts used in normal maintenance
service.
GOOD MAINTENANCE INSURES GOOD PERFORMANCE
49 E. Yew St., Sturgeon Bay, WI, U.S.A. 54235

02
0 3-
25
12
SHUTTLELIFT, INC.
P.O. Box 66
Shuttlelift, Inc. reserves the right to alter specifications 49 E. Yew Street
and designs without obligation. Sturgeon Bay WI 54235

Om 5560B Operators 1006266

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Om 5560B Operators 1006266

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5500 Series

BEFORE STARTING THE ENGINE, DO THE

1. READ THIS OPERATOR'S MANUAL.

LEARN AND PRACTICE SAFE USE OF THE

MACHINE CONTROLS IN A SAFE, CLEAR

It is your responsibility to observe pertinant

Safety Decals ............................................ 2-11 The Capacity Chart .......................... 4-1

Pick And Carry Ranges ......................... 4-2

Table Of Contents (Contd)

250 Hours Of Operation ....................... 7-19

Miscellaneous Maintenance ................ 7-37

Figure 1-2. Crane Nomenclature

1. Counterweights Location 10. 4th Boom Section

This symbol means “Attention! Become Alert!

to safety messages found on safety decals and

TRAINED OPERATORS NEW OR ADDITIONAL

equipment. start the engine.

operating the crane. Be especially careful of

• engage the parking brake, EXHAUST FUMES CAN BE FATAL.

flames, and smoking materials away

job site and how to use them.

DO NOT jump off the crane.

• If anyone is injured by, or if any

CAUSE SEVERE BURNS. Wait for

Keep sparks, flames, and lit cigarettes

6. Falling Load and Boom Hazard OPERATIONAL

3-Know the location and function of all machine

engaged before starting the engine.

2. Work Site If a failure that causes loss of control, such

hand signals for controlling crane operations.

area in which overhead power lines, overhead

ELECTRICAL CONDUCTOR CLEARANCE CHART

Minimum Vertical Minimum Lateral Clearance From

50,000 V or less 10' (3.1 m) 10' (3.1 m) 4' (1.3 m)

Over 345,000 V 16' (4.9 m)

DO NOT exceed the rated lift capacity of the

place the load on the crane’s deck. Travel

DO NOT side-pull with the boom, either by

11. Slopes 14. Ventilation

12. Falling Load Hazard

3- EXHAUST FUMES CAN BE FATAL.

the crane until the obstruction clears, and

DO NOT modify, alter or permit anyone to

Figure 2-6. Safety Decals In Engine

Standard Hand Signals

TRAVEL (Both Tracks): Use both

TRAVEL (One Track Only): Lock

Wire Rope Safety

core, and (3) the core, which forms a foundation

Figure 2-8. Wire Rope

4. The Nominal Strength of a wire rope IF IN DOUBT, REPLACE THE ROPE. An

of a wire rope when it is manufactured. The

• Kinks permanently damage a wire rope

This Page Intentionally

Controls, Switches, Gauges

Figure 3-1. Cab Controls

OUTRIGGER CONTROLS STEERING SELECT CONTROL

ACCELERATOR PEDAL TRAVEL SELECT LEVER

A reading of less than 14 volts with the engine

Table Of Contents (Contd)

TRAINED OPERATORS NEW OR ADDITIONAL